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Harris Platinum Z16HD+ Preliminary Manual

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PRELIMINARY MANUAL
888-2586-001
Platinum Z16HD+
IBOC FM Transmitter
Platinum Z16HD+
IBOC FM Transmitter
Printed: May 2006
T.M. No. 888-2586-001
Rev A
© Copyright Harris Corporation 2006
All rights reserved

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Summary of Contents for Harris Platinum Z16HD+

  • Page 1 PRELIMINARY MANUAL 888-2586-001 Platinum Z16HD+ IBOC FM Transmitter Platinum Z16HD+ IBOC FM Transmitter Printed: May 2006 T.M. No. 888-2586-001 Rev A © Copyright Harris Corporation 2006 All rights reserved...
  • Page 2 HARRIS Service Parts Department. Telephone 217/222-8200 to contact the service parts department or address correspondence to Service Parts Department, HARRIS CORPORATION, Broadcast Systems Division, P.O. Box 4290, Quincy, Illinois 62305-4290, USA. The HARRIS factory may also be contacted through a FAX facility (217/221-7096). NOTE: The # symbol used in the parts list means used with (e.g.
  • Page 3 Manual Revision History Platinum Z16HD+ Technical Manual REV. DATE Pages Affected Preliminary 2/03/2006 Created 9/15/06 888-2586-001 MRH-1 WARNING: Disconnect primary power prior to servicing.
  • Page 4 MRH-2 888-2586-001 9/15/06 WARNING: Disconnect primary power prior to servicing.
  • Page 5 • In the ten digit part numbers, if the last three numbers are 000, the item is a part that Harris has pur- chased 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.
  • Page 6 9/15/06 888-2586-001 MRH-1 WARNING: Disconnect primary power prior to servicing.
  • Page 7 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.
  • Page 8 viii 888-2586-001 9/15/06 WARNING: Disconnect primary power prior to servicing.
  • Page 9 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.
  • Page 10 888-2586-001 9/15/06 WARNING: Disconnect primary power prior to servicing.

  • Page 11: Table Of Contents

    Grounding ......2-20 Harris HDx-FM™ Exciter ....1-4 Low Voltage Power Supply and Blower .
  • Page 12 Table of Contents Fault Logging ......3-8 IPA Monitoring ......4-13 Air Flow Sensing .
  • Page 13 Table of Contents PA Controller Faults ..... . . 4-53 Reflected Power Calibration ....5-18 Power Supply Controller Boards .
  • Page 14 Table of Contents PA_ISO Resistor and Thermistor Test ..6-21 PA_ISO_SW, Fault ......6-36 PA RF Switch Test .

  • Page 15: Introduction/Specifications

    Introduction/ Specifications Introduction This technical manual describes the Harris Platinum Z16HD+™ In Band On Channel (IBOC) solid-state radio transmitter, and contains information needed to install, operate and service the transmitter. This model represents the 16 PA module version of the ZHD+ series.
  • Page 16 • Section 5: Maintenance/Alignments, lists and explains alignments and adjustments which might be required once the transmitter leaves the Harris Broadcast factory. • Section 6: Troubleshooting, is included as a servicing aid, to be used along with Sec- tions 4 and 5 by qualified service personnel to identify and correct an equipment mal- function.

  • Page 17: Features/Benefits

    Available for single or three phase mains power (3 or 4 wire), 50/60Hz. operation General Description The Harris Platinum ZHD+ series is a family of highly-functional, cost-effective IBOC radio transmitters designed using a concept called Z-Axis 3-dimensional electronic design. The Z-axis approach arranges the system RF components such as dividers, combiners and amplifiers in three dimensions, to permit the most efficient possible signal paths between them.
  • Page 18 HDx-FM exciter, or a BoostPro amplifier output. Or, in FM backup mode it may begin with any one of several Harris FM exciters. To simplify terminology this RF origination will be called RF Source by the controller, and throughout this manual. However, there may be times when text discussing certain circuitry may still use the original term exciter.

  • Page 19: Boostpro™ Amplifier

    Section 1 Introduction/Specifications Platinum Z16HD+ • The ¼VGA touch screen GUI for intuitive control and realtime monitoring • Direct proprietary ZHD+ transmitter interface for dedicated control and status between the exciter and transmitter • Adaptive Correction: The exciter uses real-time adaptive correction (RTAC), non-lin- ear adaptive correction for HD, FM+HD, and SLC performance •...

  • Page 20: Rf Combining

    Section 1 Introduction/Specifications Platinum Z16HD+ modules are “hot-pluggable” and can be removed and inserted into an operating transmitter without removing plugs and cables. The IPA consists of 2 standard PA Modules, with only one side active at a time to provide the required drive for the two PA Power Blocks.

  • Page 21: Directional Rf Sample Port

    Section 1 Introduction/Specifications Platinum Z16HD+ Display, permits extensive viewing of internal voltages, temperatures and a detailed Fault Log to easily pin-point problems. Long-life LED fault and status indicators and reliable membrane switches provide local control and selection for the transmitter. 1.3.5 Directional RF Sample Port Platinum ZHD+ transmitters provide an RF sample port with 30dB or greater directivity...
  • Page 22 Section 1 Introduction/Specifications Platinum Z16HD+ NOTE: Specifications subject to change without notice. 888-2586-001 9/15/06 WARNING: Disconnect primary power prior to servicing.

  • Page 23: Installation & Initial Turn-On

    The contents of the shipment should be as indicated on the packing list. If the contents are incomplete or if the unit is damaged electrically or mechanically, notify the carrier and HARRIS CORPORATION, Broadcast Systems 2.2.1...

  • Page 24: Returns And Exchanges

    HARRIS Order Number or Invoice Number. Air Cooling Requirements Harris transmitters are designed to operate in an unobstructed environment with a maximum inlet air temperature of 45°C. This means that the transmitter air system is designed to supply sufficient air at the required static pressure to cool the transmitter only.

  • Page 25: Z16Hd+ Transmitter Installation

    Section 2 Installation & Initial Turn-On Platinum Z16HD+ Z16HD+ Transmitter Installation Prior to installation, this Technical Manual and the appropriate Exciter Technical Manuals should be carefully studied to obtain a thorough understanding of the principles of operation, circuitry and nomenclature. This will facilitate proper installation and initial checkout.

  • Page 26: Removal Of Pallet Bolts

    Section 2 Installation & Initial Turn-On Platinum Z16HD+ 2.5.1.1 Removal of Pallet Bolts There are 4 bolts which must be removed in order to take the transmitter off the wooden pallet, 2 toward the front of the cabinet and 2 toward the rear. Location of these bolts can be verified by looking for the bolt heads underneath the pallet.

  • Page 27: Exciter Remounting

    HDx-FM exciter, or a BoostPro amplifier output. Or, in FM backup mode it may begin with any one of several Harris FM exciters. To simplify termi- nology, this RF origination will be called RF Source by the controller, and throughout this manual.

  • Page 28: Digit Cd Fm Exciter

    Section 2 Installation & Initial Turn-On Platinum Z16HD+ 2.5.3.2 DIGIT CD FM Exciter If the DIGIT CD exciter(s) were removed for shipping, there are three cables which will need to be hooked up (not counting the audio inputs) for each. See DIGIT technical manual and Exciter rack wiring diagrams for complete details.

  • Page 29: Add-On Installation

    Section 2 Installation & Initial Turn-On Platinum Z16HD+ Carefully slide exisiting exciter or IP1D/IP2D out of cabinet STEP 6 Use existing rails to slide new unit into cabinet STEP 7 Refer to "2.5.4.4 BoostPro Connections" on page 2-7 STEP 8 2.5.4.3 Add-on Installation If being installed as an addition, remove blank panels of the Z...
  • Page 30 Be sure to allow extra cable length to accomodate devices that slide out on rack rails. Terminal 1 Terminal 2 Terminal 3 CANL CANH Shield (shown at IN position) Figure 2-2 CAN Buss Adaptor (Harris #901-0207-271) 888-2586-001 9/15/06 WARNING: Disconnect primary power prior to servicing.
  • Page 31 Section 2 Installation & Initial Turn-On Platinum Z16HD+ Secure the cable to the adaptor using the screw terminals as follows: STEP 3 • CANL: Clear-jacketed conductor(s) to terminal 1 • CANH: Blue-jacketed conductor(s) to terminal 2 • Shield wire(s) to terminal 3 If two CAN cables will be connected to a single adaptor, twist and lightly solder the like conductors together before attaching to adaptor.

  • Page 32: Phase Power Supply Installation

    Section 2 Installation & Initial Turn-On Platinum Z16HD+ 2.5.4.4.4 PLAT Z SERIAL N+1 communication path between ZHD+ transmitter and HDx-FM exciter (via the CAN buss). 2.5.4.4.5 USER REMOTE See Table 2-4 on page 2-41 for parallel interface connections. CAUTION: ANY REMOTE OR EXTENDED CONTROL CONNECTIONS SHOULD BE CONNECTED ONLY AFTER THE TRANSMITTER SYSTEM IS CHECKED OUT AND FULLY OPERATIONAL.

  • Page 33: Power Supply Connections

    Section 2 Installation & Initial Turn-On Platinum Z16HD+ power supply access panel on the front of the transmitter and rolling out the power supply (this is only if the transmitter was shipped with the power supply installed). 2.5.5.2 Power Supply Connections First, remove the front cover panel from the power supply compartment at the bottom of the transmitter.
  • Page 34 Section 2 Installation & Initial Turn-On Platinum Z16HD+ Figure 2-3 3 Phase Power Supply Top View The following cables will need to be connected: a. There are 4 ribbon cables and one power cable hanging on the right side of the power supply compartment.
  • Page 35 Section 2 Installation & Initial Turn-On Platinum Z16HD+ 2. Next, connect W212 to J4 on PS4, then roll the power supply in about half way or at least far enough to connect W211 to PS3. Be extremely careful when pushing the power supply into the cabinet that none of the cables get caught or stretched.

  • Page 36: Single Phase Power Supply Installation

    Section 2 Installation & Initial Turn-On Platinum Z16HD+ inside the Wago block and the wire can be inserted. Be very careful not to let the wire ends fray. The wire insulation should actually extend just inside the Wago block hole. Release the screwdriver to clamp the wire. d.

  • Page 37: Power Transformer Tapping

    Section 2 Installation & Initial Turn-On Platinum Z16HD+ Figure 2-5 Single Phase Power Supply Component Locations and Interconnects 2.5.6.1 Power Transformer Tapping The power transformers are tapped at the factory for the primary AC voltage specified by the customer. This voltage should be documented in the factory test data accompanying the transmitter.
  • Page 38 Section 2 Installation & Initial Turn-On Platinum Z16HD+ They must be placed in the proper cabinet. They are marked or tagged for shipping as to which cabinet they belong in. However, if there is any doubt, PS3 and PS4 have the longer orange cables, marked 680, 681, 652 and 752.

  • Page 39: Installing Ps1 And Ps2

    Section 2 Installation & Initial Turn-On Platinum Z16HD+ c. The cable 2A1P2, (gray connector with discrete wire) on the front left corner, is not connected for this power supply tray (PS3 and PS4). d. AC input wires #1 and #2 (large orange cables tied up on the left side of the power supply compartment) connect to the gray Wago block, 2A17TB1, on the front left side of the power supply tray.
  • Page 40 Section 2 Installation & Initial Turn-On Platinum Z16HD+ a. There is one control cable and two ribbon cables on the right side of the power supply compartment, W21, W11 and W12. See Figure 2-5 for connection loca- tions. Connect W12 to J4 on PS2. Pull the AC input and blower wires out of the cabinet where they are out of the way of the power supply tray and can be easily reached later.

  • Page 41: Auxiliary Cabinet

    A customer supplied AC primary power disconnect or means to completely de-energize the transmitter primary circuit for servicing is necessary. Harris does not recommend using circuit breakers for this transmitter. The recommended fuse type is class RK5, a dual element time delay fuse. Examples are the Bussmann FRN-R (250V), FRS-R (600V), Littelfuse FLNR (250V), FLSR (600V), and Ferraz gG fuses.

  • Page 42: Information Concerning Some 360 To 416 Volt Systems

    Please consult with an electrician if this applies to your installation. If applicable, the phase-to-earth 275 volt MOVs in the RV7 through RV13 and RV20 positions may be replaced with 510 volt MOVs (Harris part number 5600042000, quantity 8).

  • Page 43: Three Phase Ac Connection

    Section 2 Installation & Initial Turn-On Platinum Z16HD+ 2.5.7.2 Three Phase AC Connection AC connections are made to the top of the AC mains contactor K1. K1 is on the top right side in the rear of the cabinet. There is also a large standoff located near the main contactor for the NEUTRAL connection in 380VAC (342-432Vac) 4-wire WYE systems.
  • Page 44 Section 2 Installation & Initial Turn-On Platinum Z16HD+ it to the building ground. This strap can be removed from the bottom and used at the top. A grounding stud is also provided near the AC input connections in the upper portion of the Platinum Z transmitter.

  • Page 45: Low Voltage Power Supply And Blower

    Section 2 Installation & Initial Turn-On Platinum Z16HD+ of non-shielded wire makes a very efficient antenna for RF and transient energy. If RF is allowed into the audio equipment, it can be rectified and may show up as noise or feedback.

  • Page 46: Failsafe Interlock Connection

    Section 2 Installation & Initial Turn-On Platinum Z16HD+ 2.5.9.2 Failsafe Interlock Connection To use the failsafe interlock connection, remove the jumper between TB1-8 to TB1- 10(GND), then connect failsafe interlock wires. A contact closure allows the transmitter to operate. The Failsafe connection can be used for any application which requires muting the transmitter RF output.

  • Page 47: Initial Turn-On

    Section 2 Installation & Initial Turn-On Platinum Z16HD+ Initial Turn-on CAUTION: ANY REMOTE OR EXTENDED CONTROL CONNECTIONS SHOULD BE CONNECTED ONLY AFTER THE TRANSMITTER SYSTEM IS CHECKED OUT AND FULLY OPERATIONAL. Each transmitter is thoroughly checked out during factory final test but adjustment may be required during installation due to shipping, variations in primary power, antenna systems, or transmission line differences.
  • Page 48 Section 2 Installation & Initial Turn-On Platinum Z16HD+ Figure 2-8 Z16HD+ Default Diagnostics Display Press the PA VOLTS button on the front panel of the controller. STEP 4 Press the LOW power ON button on the front of the controller, but be STEP 5 ready to quickly press the off button if necessary.
  • Page 49 Section 2 Installation & Initial Turn-On Platinum Z16HD+ placed in the same positions as during factory testing. The module serial number tag should be on top of the module when inserted into the transmitter. CAUTION: EACH MODULE HAS TWO CAPTIVE THUMBSCREWS WHICH MUST BE TIGHTENED TO ASSURE PROPER MODULE OPERATION.
  • Page 50 Section 2 Installation & Initial Turn-On Platinum Z16HD+ Figure 2-10 PA Compartment Rear View IPA Module configuration - The Platinum Z16HD+ has two IPAs active STEP 8 at any given time, one for each Power Block. For the standard dual IPA configuration, the IPA modules (each has 2 IPAs) will be identical to any of the PA modules and may be plugged in with either side up in the IPA slot.
  • Page 51 Section 2 Installation & Initial Turn-On Platinum Z16HD+ Log to find the active fault(s) and refer to Section VI, Troubleshooting for information on how to track down the problem. NOTE: The HDx-FM exciter will NOT generate HD carriers unless one of the two following condtions is met: 1.
  • Page 52 Section 2 Installation & Initial Turn-On Platinum Z16HD+ Press the HIGH power ON button on the front panel of the controller. If STEP 12 there are no faults, again verify all of the transmitter display readings against those in the factory test data sheet. This is optional, as it simply makes the transmitter FWD PWR % meter STEP 13 read 100% at the customer specified Transmitter Power Output (TPO),...

  • Page 53: Remote Connections

    Section 2 Installation & Initial Turn-On Platinum Z16HD+ Remote Connections The Platinum Z16HD+ Transmitter may be operated by remote control by installing a remote control system. If the transmitter is to be remotely controlled, it is important to initiate thorough inspection and maintenance procedures at the transmitter location. Installation of equipment to monitor temperature and humidity at the remote transmitter site is also recommended.

  • Page 54: Remote/Extended Control And Status Connections

    Section 2 Installation & Initial Turn-On Platinum Z16HD+ 2.7.1 Remote/Extended Control and Status Connections Input control lines are standard ground switching inputs. The inputs can be operated by relay contact or transistor switching. See Figure 2-12. Grounds are provided on TB1 for use as common.
  • Page 55 Section 2 Installation & Initial Turn-On Platinum Z16HD+ NOTE: Maximum status line current is 25 mA. If the output is used to drive a small printed circuit board type relay, check current requirements for relay coil and be sure to install a circuit protection diode across the coil. A 1N4004 or equivalent will work.

  • Page 56: Extended Metering

    Section 2 Installation & Initial Turn-On Platinum Z16HD+ 2.7.1.1 Extended Metering Extended metering can also be connected to TB1 terminals. See Figure 2-15 for extended metering connections. Figure 2-15 Extended Metering 2.7.2 UPS/RFSOURCE Select: Configurable Input The remote input at TB1-9 is a software configurable input which is set via the Diagnostics Display Menu.

  • Page 57: Using A Ups Or Generator

    Section 2 Installation & Initial Turn-On Platinum Z16HD+ Figure 2-16 Configurable Input Select [HOME, MORE, CONFIGURATION, A, A] Using a UPS or Generator If the transmitter is backed up with a UPS or generator to keep it operating during an AC power failure, then the logical thing to do is to lower the transmitter power to conserve the UPS for as long as possible.

  • Page 58: Setting The Low Power Alarm

    Figure 2-18 Remote Low Power Alarm Set [HOME, MORE, CONFIGURATION, B, A, C] 2.10 Jumper Settings for Installation of a Harris Exciter The following is for installing an exciter other than the one (or two) which came with the transmitter. Any exciter tested and shipped with the transmitter will have already been configured properly for the transmitter and should not require any jumper changes.
  • Page 59 Section 2 Installation & Initial Turn-On Platinum Z16HD+ • DIGIT CD Exciter with 994-XXXX-004 part number. • DIGIT Exciter with 994-XXXX-002 part number. 9/15/06 888-2586-001 2-37 WARNING: Disconnect primary power prior to servicing.
  • Page 60 Section 2 Installation & Initial Turn-On Platinum Z16HD+ Table 2-1 TB1 Remote Control Interface Connections 2-38 888-2586-001 9/15/06 WARNING: Disconnect primary power prior to servicing.
  • Page 61 Section 2 Installation & Initial Turn-On Platinum Z16HD+ Table 2-2 TB1 Remote Control Interface Connections (continued) 9/15/06 888-2586-001 2-39 WARNING: Disconnect primary power prior to servicing.
  • Page 62 Section 2 Installation & Initial Turn-On Platinum Z16HD+ Table 2-3 Jumper Settings for Installing a Harris Exciter 2-40 888-2586-001 9/15/06 WARNING: Disconnect primary power prior to servicing.
  • Page 63 Section 2 Installation & Initial Turn-On Platinum Z16HD+ Table 2-4 BoostPro Rear Panel USER REMOTE Connections 9/15/06 888-2586-001 2-41 WARNING: Disconnect primary power prior to servicing.

  • Page 64: Power Distribution For Optimum

    This section is applicable to the three phase supplies only, as well as other three phase equipment. For many years HARRIS engineers have recommended that the three phase power distribution system should be either a closed delta or WYE configuration to provide better radio and television transmitter performance by helping prevent line unbalance.

  • Page 65: Phase Delta Distribution Transformers

    For this reason, along with their inherent susceptibility to transients, Harris does not recommend the use of open delta systems. Figure 2-19 3 Phase Closed Delta vs. Open Delta...

  • Page 66: Phase Wye Distribution Transformers

    Section 2 Installation & Initial Turn-On Platinum Z16HD+ Many transmitters are located at the end of a long transmission line which is highly susceptible to transient phenomena. Devices such as Metal Oxide Varistors are inexpensive and very effective in reducing over voltage spikes. These units are limited in the amount of energy that can be dissipated, but will handle, if designed properly, very large currents.
  • Page 67 Section 2 Installation & Initial Turn-On Platinum Z16HD+ Today, many transformers are supplied with all of the primary terminals available so that either a delta or WYE connection can be made. Table 2-5 shows the different line- to-line voltages that are available with this configuration. Table 2-5 Typical Line Voltages, Delta or WYE Delta Connected...
  • Page 68 Section 2 Installation & Initial Turn-On Platinum Z16HD+ 2-46 888-2586-001 9/15/06 WARNING: Disconnect primary power prior to servicing.

  • Page 69: Operator Guide

    HDx-FM exciter, or a BoostPro amplifier output. Or, in FM backup mode it may begin with any one of several Harris FM exciters. To simplify termi- nology this RF origination will be called RF Source by the controller, and throughout this manual.

  • Page 70: Transmitter Controls

    Section 3 Operator Guide Platinum Z16HD+ Transmitter Controls The transmitter controls are mostly on the right half of the controller front panel at the top of the transmitter, See Figure 3-1. These controls and their function are listed below. OFF - Used to turn the transmitter off. ON HIGH - Turns the transmitter on to the previous HIGH setting which is set by pressing the POWER Up/Down buttons.

  • Page 71: Forward Power (Fwd Pwr) Units Of Measure

    Section 3 Operator Guide Platinum Z16HD+ 3.3.1 Forward Power (FWD PWR) Units of Measure The default unit of measure for the forward power reading is percentage, with 100% representing the nominal power output for the station. This percentage can be calibrated to any power level using the Configuration controls in the Diagnostics System.

  • Page 72: Home

    Section 3 Operator Guide Platinum Z16HD+ hardware and software Testing of the controller. A good working knowledge of the diagnostic system is crucial to proper transmitter maintenance and operation. Familiarization with the display and its operation should be quick and easy. Simply press the HOME key and follow the menus.

  • Page 73: Back

    Section 3 Operator Guide Platinum Z16HD+ • Software Revision Figure 3-3 Home Menu Page 1 Figure 3-4 Home Menu Page 2 3.4.2 BACK BACK takes you to the previous layer in the menu tree, not necessarily to the previous screen. As an example, if you were to press HOME and then choose STATUS you would now be in layer 2 of the STATUS menu.

  • Page 74: More

    Section 3 Operator Guide Platinum Z16HD+ Figure 3-5 Status Layer 2, Page 1 3.4.3 MORE MORE is a menu item which is used when there are more menu items on a layer than will fit on one screen. It will take you to the next screen in the same layer. When you have reached the last screen in that layer, pressing MORE again will take you back to the first screen in that layer.

  • Page 75: Asterisk And Pound Signs (*, #)

    Section 3 Operator Guide Platinum Z16HD+ Figure 3-6 PA Temperature Metering [HOME, METERING, D, B, C] Example 2 You want to check or possibly change the Maximum High Power Setting. This falls under the category of CONFIGURATION, but this menu item only shows up on the second screen of the HOME layer.

  • Page 76: Fault Logging

    Section 3 Operator Guide Platinum Z16HD+ 3.4.6 Fault Logging The Fault Log is located under “Fault” in the Main Menu. Pressing Fault will take you to the screen shown in Figure 3-8. This screen gives you a choice of resetting the transmitter faults and fault log (and clearing any red indicators) or viewing the Fault Log.

  • Page 77: Boostpro Boost Amplifier

    Section 3 Operator Guide Platinum Z16HD+ BoostPro Boost Amplifier Figure 3-10 BoostPro Front Panel 3.5.1 GUI Screen Software-driven, 4-line LCD for metering and diagnostics textual display. 3.5.2 METER, POWER, INFO Menu Switches Pressing one of these three buttons will take you to the next layer of menus for extensive metering, status information, and configurable parameters.

  • Page 78: Boostpro Operation

    Section 3 Operator Guide Platinum Z16HD+ 3.5.5 BoostPro Operation The following graphic is the entire menu structure for the front panel GUI on the BoostPro. 3-10 888-2586-001 9/15/06 WARNING: Disconnect primary power prior to servicing.
  • Page 79 Section 3 Operator Guide Platinum Z16HD+ &2175$67 02'8/$7,21 6(783 68%0(18 23(5 02'( %67 $03 5) 67$786 67$786 68%0(18 7; 7<3( = +' 087( 67$786 )$8/7 68%0(18 087( 32/ +,*+ )$67 087( &21752/ 68%0(18 )$67 087( 32/ ,1)2 )$8/7 675,.( &$1 &200/266 RU 2. $3&...

  • Page 80: Emergency Operating Procedures

    Section 3 Operator Guide Platinum Z16HD+ Emergency Operating Procedures WARNING: THE EXCITER MAY BE POWERED THROUGH AN UNINTERRUPTIBLE POWER SUP- PLY (UPS). AC POWER WILL STILL BE PRESENT AT THE EXCITER AFTER THE INPUT VOLTAGE HAS BEEN SHUT OFF. ELECTRICAL SHOCK IS POSSIBLE. 3.6.1 No Front Panel LEDs or GUI 1.

  • Page 81: Interlock Led Illuminated

    Section 3 Operator Guide Platinum Z16HD+ CAUTION: DO NOT REPEATEDLY HIT THE HIGH POWER BUTTON. THIS COULD CAUSE DAMAGE TO TRANSMITTER. 4. Investigate and repair the condition causing the foldback before pressing the HIGH power button to resume normal operation The operator may refer to "3.4.6 Fault Logging"...

  • Page 82: Boostpro Response

    Section 3 Operator Guide Platinum Z16HD+ HD Carriers: ENABLED Exgine Input: INTERNAL Exgine Output: PATTERN IMPORTANT: It is very important to note that once the HDE-100 Exporter is properly connected and configured, the following HDx-FM settings on the Output Setup page 1/4 must be made for normal HD operation.

  • Page 83: Manual Ipa Switching

    Section 3 Operator Guide Platinum Z16HD+ 3.6.9 Manual IPA Switching The IPAs operate in pairs. IPA_AB1 and IPA_CD2 operate together as do IPA_AB2 and IPA_CD1. The active IPA pair can be switched manually from the IPA Status menu in the Diagnostics Display. To manually switch the active IPA pair press [HOME, STATUS, A, C].
  • Page 84 Section 3 Operator Guide Platinum Z16HD+ 3-16 888-2586-001 9/15/06 WARNING: Disconnect primary power prior to servicing.

  • Page 85: Overall System Theory

    Platinum Z16HD+ Section 4 Overall System Theory Introduction This section contains theory of operation and circuit descriptions of the Platinum Z16HD+ IBOC Broadcast Transmitter. As mentioned in the introduction section of this manual, the Z16HD+ has hundreds of possible configurations depending on the hardware options and mode of operation (modulation format).
  • Page 86 Section 4 Overall System Theory Platinum Z16HD+ Figure 4-1 RF Flow Block Diagram - Z16HD+ (shown with optional 2nd RF Source) 888-2586-001 9/15/06 WARNING: Disconnect primary power prior to servicing.

  • Page 87: Rf Flow Block Diagram Description

    HDx-FM exciter, or a BoostPro amplifier output. Or, in FM backup mode it may begin with any one of several Harris FM exciters. To simplify terminology this RF origination will be called RF Source by the controller, and throughout this manual. However, there may be times when text discussing certain circuitry may still use the original term exciter.

  • Page 88: Z-Plane Divider Board

    Section 4 Overall System Theory Platinum Z16HD+ outputs from the IPA_AB Backplane board drive the inputs to Z-Planes A and B. The 2 outputs from the IPA_CD Backplane Board drive the inputs to Z-Planes C and D. 4.2.2.2 The Z16HD+ PA can be broken down into several levels. First, there are two Power Blocks, each Power Block contains two Z-Planes, each of which could be considered Power Blocks.

  • Page 89: 5Kw" Hybrid Combiner

    Section 4 Overall System Theory Platinum Z16HD+ allowing greater redundancy. This also allows the PA Modules to be HOT- PLUGGABLE, meaning that a PA module may be removed while the transmitter is operating. If a module is removed, the short interlock pins disconnect first, causing a 120mS system mute.

  • Page 90: Boostpro Circuit Descriptions

    Section 4 Overall System Theory Platinum Z16HD+ BoostPro Circuit Descriptions Refer to Figure 4-2 on page 4-7 for the following descriptions. The BoostPro boost amplifier can be divided into three parts for sake of circuit discussion: Control, amplification, and display. The control portion handles the communication, phase adjustment, and the power control of the RF signal.
  • Page 91 Section 4 Overall System Theory Platinum Z16HD+ Figure 4-2 BoostPro Block Diagram 9/15/06 888-2586-001 WARNING: Disconnect primary power prior to servicing.

  • Page 92: Signal Descriptions

    Section 4 Overall System Theory Platinum Z16HD+ One of the requirements of the Boost Amplifier is to have adjustable phase for aligning multiple cabinets. For this reason, the controller board features a 90° hybrid in a voltage controlled phase shifter circuit. The phase shifter has the capability of adjusting the phase of the RF from 0º...

  • Page 93: A To D Converter

    Section 4 Overall System Theory Platinum Z16HD+ 4.3.2 A to D Converter For monitoring the power amplifier, a 12-bit eight channel analog-to-digital converter is used: TLV2548 from Texas Instruments. This converter is used to monitor the PA’s forward power, reflected power, voltage, current, and temperature. 4.3.3 Power Supplies There are two separate power supplies for the Boost Amplifier.

  • Page 94: Detailed Rf Theory Of Operation

    HDx-FM exciter, or a BoostPro amplifier output. Or, in FM backup mode it may begin with any one of several Harris FM exciters. To simplify termi- nology this RF origination will be called RF Source by the controller, and throughout this manual.

  • Page 95: Ipa

    Section 4 Overall System Theory Platinum Z16HD+ The RF Source divider configuration involves placing JP1 and JP2 in position 2-3 and plugging RF source 1 output and RF source 2 output into J3A and J4A respectively. K3 now becomes the RF Source Select RF switch and is controlled by the Relay_Select signal at J7-19.

  • Page 96: Manual Ipa Switching

    Section 4 Overall System Theory Platinum Z16HD+ 4.4.2.1 Manual IPA Switching The on-air IPA pair can be selected manually using the Diagnostics Display. The IPA select screen is located in the IPA Status menu. For exact location, refer to the “Diagnostics Display Menu Tree”...

  • Page 97: Main/Alternate Ipa Switching

    Section 4 Overall System Theory Platinum Z16HD+ The IPA modules plug into the IPA Backplane Boards. This board interfaces all inputs and outputs for the IPA module. It is also responsible for: • Main/Alternate IPA switching (active with standard, dual IPA configuration) For IPA Status press [STATUS A,B].

  • Page 98: Air Flow Sensing

    Section 4 Overall System Theory Platinum Z16HD+ • IPA Forward Power (IPA FWD PWR). A sample of the IPA forward power is taken by the directional coupler (shown right after K3 on the schematic) and detected by CR1. The DC voltage at TP1 will therefore be relative to the IPA output. This is sent to the controller for monitoring and main/alternate IPA switching.

  • Page 99: 8-Way Divider

    Section 4 Overall System Theory Platinum Z16HD+ Each Z-Plane assembly contains: • Edge connectors for 8 PA amplifier boards (4 in front and 4 in the rear). These con- nectors are labeled J1-J8. • An 8 way Wilkinson Divider, driven by the IPA, which feeds RF drive to each of the 8 PA amplifiers.
  • Page 100 Section 4 Overall System Theory Platinum Z16HD+ IPA_CD1 IPA_CD2 IPA_AB1 IPA_AB2 Figure 4-4 PA Compartment Front View Figure 4-5 PA Compartment Rear View 4-16 888-2586-001 9/15/06 WARNING: Disconnect primary power prior to servicing.

  • Page 101: Pa Modules

    Section 4 Overall System Theory Platinum Z16HD+ 4.4.4 PA Modules Each of the 16 PA Modules contain two PA Amplifier boards mounted on opposite sides of the PA Module heat sink. The modules are numbered 1 through 8 with the top module in the front being #1 and counting to #4 at the bottom.
  • Page 102 Section 4 Overall System Theory Platinum Z16HD+ The gate control voltage (Vg) is -18V to turn the amplifier off (or mute), and 0V to turn the amplifier fully on. In the Backup FM (using an analog exciter) mode, the variable APC voltage is applied to the IPA gates for power level control.

  • Page 103: 8-Way Combiner

    Section 4 Overall System Theory Platinum Z16HD+ Maximum RF output per PA is 350W peak, with typical output of 250Wavg at nameplate TPO. The power module is designed for single amplifier field replacement. In the event an RF power MOSFET fails, field replacement is not practical due to the cost of components, time and test equipment involved in repair and alignment of phase, gain and response.

  • Page 104: 5Kw" 3 Db Hybrid Combiners

    Section 4 Overall System Theory Platinum Z16HD+ the isolation resistor for the 2-way Wilkinson combiner. Each Isolation Board has a pair of ID jumpers, JP1 and JP2, which have to be set to designate into which Z-Plane that particular Isolation Board is plugged. Proper setting for each Z-Plane is on the schematic and silk-screened on the PC board.

  • Page 105: 10Kw" Final Hybrid Combiner

    Section 4 Overall System Theory Platinum Z16HD+ hybrid, just above the Z-Planes. These reject loads are called ISO_AB and ISO_CD to note which Z-Planes they are attached to. These are considered System ISO loads and their temperature is monitored by both the Master Controller and the PA Controllers. The Master Controller monitors these for power foldback purposes while the PA Controllers monitor for protection if the Master Controller is not operational.

  • Page 106: Power Supply Block Diagram Description

    Section 4 Overall System Theory Platinum Z16HD+ Power Supply Block Diagram Description There are two different types of power supplies in the transmitter, the PA Power Supply and the Low Voltage Power Supply. 4.5.1 PA Power Supply There are three power supply configurations available for the Z16HD+ transmitter: •...
  • Page 107 Section 4 Overall System Theory Platinum Z16HD+ Figure 4-7 Power Supply Locations, Top View Figure 4-8 shows a simplified diagram of one of the 3-Phase PA power supply transformers (for the 3 phase, 4 wire connection, the primary would be re-configured as WYE).
  • Page 108 Section 4 Overall System Theory Platinum Z16HD+ NOTE: Each power supply is connected to the same PAs as its corresponding PA Con- troller. For example, PS1 powers the same PAs that are controlled by PA Control- ler 1. These are listed in Table 4-1 at the end of this section. Figure 4-8 Simplified 3-Phase Power Supply 4.5.1.1.1 Soft Start During transmitter turn on, a fifth set of SCRs is activated, see Figure 4-9.

  • Page 109: Single Phase Power Supply

    Section 4 Overall System Theory Platinum Z16HD+ when the transmitter is turned off. When the discharge circuit is active, it disables the SCRs to prevent the supply from trying to turn on during a discharge cycle. Figure 4-9 Simplified 3-Phase PA Power Supply Soft-Start and Discharge 4.5.1.2 Single Phase Power Supply The Z16HD+ single phase transmitter uses four main power transformers working in...
  • Page 110 Section 4 Overall System Theory Platinum Z16HD+ Figure 4-10 Single Phase Power Supply Locations and Interconnects Refer to the Overall System Block Diagram in the schematic package and Figure 4-11 for the following discussion. Each of the four power transformers has a single, center tapped full wave rectified secondary.
  • Page 111 Section 4 Overall System Theory Platinum Z16HD+ Figure 4-11 Simplified Single Phase Power Supply 4.5.1.2.1 Soft Start A simplified diagram of the Soft-Start and Discharge circuits is shown in Figure 4-12. During transmitter turn on, a fifth set of SCRs is activated (these are located on the Rectifier Boards).

  • Page 112: Low Voltage Power Supply

    Section 4 Overall System Theory Platinum Z16HD+ Figure 4-12 Single Phase PA Power Supply Simplified Soft-Start and Discharge 4.5.1.2.2 PA Power Supply Discharge The PA Power Supply Discharge circuit also uses the Soft Start resistor to discharge the 52Vdc PA supply. The discharge circuit is activated when the transmitter is turned off. To discharge the power supply, the 52Vdc supply output is connected to the discharge resistor through a pair of MOSFET switches.

  • Page 113: Detailed Power Supply Descriptions

    Section 4 Overall System Theory Platinum Z16HD+ • -20Vdc • +10Vdc These voltages are sent to the Rectifier boards where they are regulated before being sent on to the controller boards. The board contains 3 relays, A19K1, A19K2 and A19K3. When the transmitter is turned on, A19K1 activates the main contactor (simply called K1) which then applies 3 phase AC to the PA power Supplies, while A19K2 applies AC to turn on the exciter(s).
  • Page 114 Section 4 Overall System Theory Platinum Z16HD+ a different secondary tap. The taps closest to the center will provide the least amount of secondary turns in circuit and will therefore give the lowest DC output voltage. This means that the taps which are furthest from the center will give the highest DC output voltage due to more active turns in the secondary.
  • Page 115 Section 4 Overall System Theory Platinum Z16HD+ Figure 4-13 Simplified 3-Phase Transformer Secondary 9/15/06 888-2586-001 4-31 WARNING: Disconnect primary power prior to servicing.

  • Page 116: Rectifier Board Circuit Description

    Section 4 Overall System Theory Platinum Z16HD+ 4.6.1.2 Rectifier Board Circuit Description Refer to the Rectifier Board schematic and Figure 4-13 for the following. The Rectifier Boards perform three primary functions: • Dynamic secondary tap switching using SCRs, to maintain a relatively constant sup- ply voltage and thus maintain constant transmitter power output despite fluctuations in the 3 phase AC line voltage.
  • Page 117 Section 4 Overall System Theory Platinum Z16HD+ connections). Note that both the “A” and “B” side SCRs have selected the same relative (lowest voltage) taps on each of the two transformer secondaries. 4.6.1.2.2 PA Power Supply Soft-Start Soft-Start is used to limit the surge current during transmitter turn on. The Soft Start and PA Power Supply Discharge circuits are able to use the same resistor, R48 since only one or the other will be active at any one time.

  • Page 118: Single Phase Pa Power Supply

    Section 4 Overall System Theory Platinum Z16HD+ Figure 4-14 Power Supply Tap Status [HOME, STATUS, A, B, C, D] 4.6.1.2.5 IPA Supply Voltage Each IPA in the Z16HD+ is fed from 2 of the power supplies. IPA_AB is fed from PS1 and PS2 and IPA_CD is fed from PS3 and PS4.

  • Page 119: Rectifier Board

    Section 4 Overall System Theory Platinum Z16HD+ 4.6.2.1 Rectifier Board The SCRs for the single phase are required to carry a much larger amount of current than the 3-Phase counterparts and are therefore much larger. They are mounted on large heatsinks on top of the transformers.
  • Page 120 Section 4 Overall System Theory Platinum Z16HD+ The DRIVE_1 signal is used to activate the 48Vdc tap on T1 and T2 secondaries. This tap is designated TAP 1 in the Diagnostics Display. When active (HIGH) it causes the output of U2-17 to go low. This turns on Q1 which applies 20VB-SS, now called DRIVE_1, to R16.

  • Page 121: Power Supply Id Jumpers

    Section 4 Overall System Theory Platinum Z16HD+ b. Second, it allows the base of Q9 to pull high, shutting it off. R62 will then pull the gates of Q6, Q7, Q12 and Q13 low, turning them on. Q6, Q7, Q12 and Q13 are switches which tie the 52Vdc to R48, and the supply is discharged.

  • Page 122: Low Voltage Power Supply Board

    Section 4 Overall System Theory Platinum Z16HD+ check the IDs so they know to which power supply they are connected. The controllers will also not allow 2 IDs to be the same. The jumper table below is also located on the Rectifier Board schematic. PS#1 PS#2 PS#3...

  • Page 123: Relays

    Section 4 Overall System Theory Platinum Z16HD+ 4.6.4.1 Relays There are three mechanical relays on the Low Voltage Power Supply Board assembly A19. They are A19K1, A19K2 and A19K3. The relays are powered by +12Vdc from the Life Support Board in the controller. •...

  • Page 124: Control System Description

    Section 4 Overall System Theory Platinum Z16HD+ Control System Description The control system is a multiple micro-controller based system. It monitors over 100 operating functions in the transmitter and can make intelligent operating decisions based on operating conditions. The system has the standard parallel remote connections.

  • Page 125: Master Controller

    Section 4 Overall System Theory Platinum Z16HD+ 4.8.1 Master Controller The Master Controller is responsible for primary transmitter control and is the summary point for all of the information gathering. It controls and/or receives information from the PA Controllers, Power Supply Controllers, and Life Support Board, and takes action appropriate to the operating conditions of the transmitter.

  • Page 126: Apc, Automatic Power Control

    Section 4 Overall System Theory Platinum Z16HD+ • Forward Factor - 0.015393 • Reflect Factor - 0.000613 • Cal Frequency - 98MHz • Operating Frequency - 98MHz • Cal APC Factor - 15.15 • TPO 100% - 07.00kW • Max High - 07.30kW •...
  • Page 127 Section 4 Overall System Theory Platinum Z16HD+ NOTE: This controller number can be checked by pressing [HOME, MORE, CONFIGU- RATION, C, B]. The actual DAC_APC_REF output voltage APC_REF can be metered at TP8 or in the Diagnostics Display by pressing [METERING, C, B]. The output at U5-7 is the difference between the forward power sample and the APC_REF voltage.

  • Page 128: Calibration Factors And A/D Values

    Section 4 Overall System Theory Platinum Z16HD+ transmitter at 25% of rated power. Proper setting of R25 requires an external wattmeter and is covered in Section V, Maintenance under “Setting Life Support Power Level.” CAUTION: IN LIFE SUPPORT MODE THERE IS LIMITED OVERLOAD PROTECTION AND NO FOLDBACK FUNCTIONS.

  • Page 129: Dac_Apc_Ref

    Section 4 Overall System Theory Platinum Z16HD+ Table 4-1 Default Cal Factors for All ZHD+ Transmitters Z4HD+ Z6HD+ Z8HD+ Z12HD+ Z16HD+ Forward Factor 0.003079 0.005388 0.007697 0.011545 0.015393 Reflect Factor 0.000123 0.000225 0.000306 0.000460 0.000613 Cal APC Factor 3.03 5.30 7.58 11.36 15.15...

  • Page 130: Forward Factor And A/D_Fwd_Pwr

    Section 4 Overall System Theory Platinum Z16HD+ which controls the APC loop discussed earlier in this section. The correct APC_REF voltage for a specific DAC_APC_REF number can be calculated from the formula: APC_REF voltage = DAC_APC_REF * 0.004803 Example: For the nominal DAC_APC_REF value of 660, APC_REF Voltage = 660 * 0.004803 = 3.17V ±0.1V and can be measured at TP8 on the Master Controller.

  • Page 131: Apc Factor

    Section 4 Overall System Theory Platinum Z16HD+ 4.8.2.3 APC Factor APC_Factor is also calculated during the Forward power calibration. APC_Factor allows the micro to calculate the necessary DAC_APC_REF number to obtain any specific power level. For the Z16HD+, APC_Factor is calculated as Forward calibration power divided by the DAC_APC_REF number or: APC_Factor = FWD PWR (kW) / DAC_APC_REF APC_Factor = 7000W / 660 = 10.61...
  • Page 132 Section 4 Overall System Theory Platinum Z16HD+ • UPS SET Screen [HOME, MORE, CONFIGURATION, B, A, B] Then choose the desired modulation format to set the power level when the transmitter is operating on a backup UPS or generator AC supply. Once the operator has set a power level in kW in these screens, the controller uses the OP_APC_Factor to find the DAC_APC_REF that would represent each of the power levels and sets that number as the power level limit.

  • Page 133: Reflect Factor And A/D_Rfl_Pwr

    Section 4 Overall System Theory Platinum Z16HD+ 4.8.2.5 Reflect Factor and A/D_RFL_PWR Reflect Factor is a calibration factor that is calculated during reflected power calibration. To check the Reflect Factor press [HOME, MORE, CONFIGURATION, C, A, C]. All Z16HD+ transmitters are factory calibrated by reversing the reflected coupler (it now measures forward power) and adjusting for a reflected sample voltage of 2.1V at 210W, as measured at TP18 on the Life Support Board.

  • Page 134: Master Controller Faults

    Section 4 Overall System Theory Platinum Z16HD+ turn will reduce the reflected coupler output and the clamp will be removed from the APC Voltage and the power will try to come back to normal. Since this is happening extremely fast, once the reflected coupler output voltage exceeds the VSWR_FB_LVL, the new APC loop will try to keep the 2 inputs to U7 the same, preventing the reflected power from exceeding 115W.

  • Page 135: Pa Controller Boards

    Section 4 Overall System Theory Platinum Z16HD+ c. Strike 3 - A third fault detected within this 10 seconds will cause the transmitter to be muted until the operator gives the transmitter an ON command (High or Low), locally or by remote. If the cause of the fault is still present, the transmitter will simply repeat the 3 strikes and mute again.

  • Page 136: Control Distribution And Controller Failure

    Section 4 Overall System Theory Platinum Z16HD+ Whenever a defective PA is to be shut off or MUTED, all of the PAs will be MUTED for 120mS while the defective PA is disconnected from the combiner by the isolation switch. The rest of the PAs are then turned back on. 4.8.5.2 Control Distribution and Controller Failure Each PA Controller controls (8) of the PAs on either Z-Planes A and B or Z-Planes C...

  • Page 137: Crossover (Xover) Protection

    Section 4 Overall System Theory Platinum Z16HD+ • PA ISO Resistor Temperatures - VTEMP PA1 through VTEMP PA8 -Each ISO resis- tor has a thermistor, used as a temperature sensor, attached to it for metering and fault monitoring. To check the ISO resistor temperatures press [METERING, D, D then selecting the desired Z-Plane].

  • Page 138: Power Supply Turn On

    Section 4 Overall System Theory Platinum Z16HD+ • All power supply monitoring and fault detection. These include voltage, current, tem- perature and status. 4.8.6.1 Power Supply Turn On The primary function of the PS Controller is to turn the power supplies on and off. The on/off signal is called PS_DISABLE and comes in on J3-13.

  • Page 139: Pa Power Supply Discharge

    Section 4 Overall System Theory Platinum Z16HD+ 4.8.6.2 PA Power Supply Discharge When the PS_DISABLE signal goes high, all of the SCR taps are disabled and the DISCHARGE signals at J1-7 and J2-7 go low. This activates the PA discharge circuits on the rectifier boards, which allows a quick and safe discharge of the PA supply.

  • Page 140: Watchdog Timer

    Section 4 Overall System Theory Platinum Z16HD+ of the SCR taps and shutting off the supply. This also activates the DISCHARGE(BAR) signal which then bleeds off the supply. 4.8.6.6 Watchdog Timer The watchdog timer, U4 is basically looking for two things. First, it must receive a pulse from the micro-controller every 1.0mSec.

  • Page 141: Normal Operational Mode

    Section 4 Overall System Theory Platinum Z16HD+ 1. Normal Operational Mode. The Life Support Board basically acts as an interface and summing point between the Master Controller and various parts in the transmitter when the Master Controller is functioning properly. 2.
  • Page 142 Section 4 Overall System Theory Platinum Z16HD+ up to full power. If a fault returns, the transmitter will simply revert back to the previous fault condition. NOTE: Pressing an ON command will not erase any faults from the Diagnostics Fault Log.
  • Page 143 Section 4 Overall System Theory Platinum Z16HD+ initial 100mSec turn on pulse from U4-10 is gone, the CLR input to U4 will also go low, holding the Q output low whether the ON button is pressed or not. This prevents U8-10 from generating a 3 second mute command for no reason, since the Master Controller is not working and cannot be initialized (if the Master was working, MSTR-NORMAL 1 at U33-13 would be high removing the clear from U4-13).
  • Page 144 Section 4 Overall System Theory Platinum Z16HD+ the U25-10 input. The remote off command is then tied in to the same off command circuitry discussed earlier. Failsafe The Failsafe input can be used basically for any purpose which requires muting of the transmitter output, such as failure of the remote control, or for external RF switching systems.
  • Page 145 U27 inverters and is inverted to an active low by U28-1 or U28-2, again depending on the position of K1. For proper positioning of these and other related jumpers, refer to “Jumper Settings for Installation of a Harris Exciter” in Section II, Installation.
  • Page 146 Section 4 Overall System Theory Platinum Z16HD+ 4.8.7.1.5 RF Source Select RF Source Select is only applicable if the transmitter is configured with a backup RF source. RF Source select is software controlled by the Master Controller. It can be switched manually or will switch automatically if the active source fails (no RF output).
  • Page 147 Section 4 Overall System Theory Platinum Z16HD+ 4.8.7.1.7 Power Control: HDx-FM Exciter or BoostPro The transmitter power output is determined by the RF drive to the PAs from the IPA output. The IPA output level is controlled by the RF drive generated by the RF Source, based on the signal APC which is an analog voltage (variable DC).

  • Page 148: Life Support Mode

    Section 4 Overall System Theory Platinum Z16HD+ VDP which is the PA voltage plus 4 volts and VDN which is the PA voltage minus 4 volts. Basically U22 is a small switching supply providing a floating +/-supply for the op-amps U18 and U21. 4.8.7.1.10 Forward Power Sample The forward power sample from the directional coupler enters the Life Support Board at J2.
  • Page 149 Section 4 Overall System Theory Platinum Z16HD+ go low and Q_NOT will go high. The low signal from the Q output is inverted at U16- 13, and pulls the MASTER_NORMAL(BAR) signal high (this signal is normally low when the Master Controller is working). The high Q_NOT signal at U4-7 is inverted at U16-14 and U16-15.
  • Page 150 Section 4 Overall System Theory Platinum Z16HD+ SAFE become active due to the signal MASTER_NORMAL(BAR) going high when Life Support is initiated. This is discussed in the paragraphs labeled MASTER_NORMAL(BAR). d. MSTR_NORMAL 1 applies a low to AND gate U25-2. This inhibits the Master Controller from initiating a SYSTEM_MUTE which would mute the exciters and the IPA.
  • Page 151 Section 4 Overall System Theory Platinum Z16HD+ 5 will be low and the REM_ON_LOW(BAR) command is inhibited. When Life Support Mode is initiated, U32-5 and therefore U26-5 is forced high enabling the REM_ON_LOW(BAR) command. c. MASTER_NORMAL(BAR) applies a high to the CLEAR line of U8-3. This enables U8-6, the Q output, to apply a 3 second SOFTSTART_MUTE after a power failure.
  • Page 152 Section 4 Overall System Theory Platinum Z16HD+ is sent to AND gate U6-1. U6-2 is connected to the MASTER_NORMAL line. This line will be high only if the Master Controller has failed, which is the case here for Life Support Mode. Therefore the LS_SYST_FAULT will cause U6-3 to go high. Next, OR gates U33-3 and U33-6 will also go high, making U16-10 output high.
  • Page 153 Section 4 Overall System Theory Platinum Z16HD+ Table 4-3 PA Control Distribution PA Designations on PA Controller Schematics PA Designations on Related Related Combiner and Isolation Isolation Designations Divider Schematics Relay # Resistor # PA8 (J8) PA7 (J7) PA6 (J6) PA5 (J5) Z-PLANE A PA1 (J1)
  • Page 154 Section 4 Overall System Theory Platinum Z16HD+ 4-70 888-2586-001 9/15/06 WARNING: Disconnect primary power prior to servicing.

  • Page 155: Maintenance And Alignment

    Platinum Z16HD+ Section 5 Maintenance and Alignment Introduction This section provides maintenance and alignment information, for the purpose of routine maintenance and replacement of PC boards and other major components of the Platinum Z16HD+ IBOC BROADCAST TRANSMITTER. Routine Maintenance Routine maintenance of the Platinum Z series transmitter basically consists of regular cleaning and monitoring of temperatures, currents, voltages and faults.

  • Page 156: Record Keeping

    Section 5 Maintenance and Alignment Platinum Z16HD+ 5.2.2 Record Keeping The importance of keeping station performance records cannot be over-emphasized. Logbooks should be maintained for all operation and maintenance activities. These records can provide data for predicting potential problem areas and analyzing equipment malfunctions.

  • Page 157: Cleaning

    Section 5 Maintenance and Alignment Platinum Z16HD+ SYSTEM ELAPSED TIME Total transmitter time on. NAME OF REPAIRMAN Person who actually made the repair. STATION ENGINEER Indicates chief engineer noted and approved the transmitter repair. 5.2.3 Cleaning Proper airflow is essential in keeping the transmitter in top working condition. If outside air is brought into the building it should be well filtered to keep dirt out of the building and the transmitter.

  • Page 158: Cleaning The Power Supply

    Section 5 Maintenance and Alignment Platinum Z16HD+ 5.2.3.3 Cleaning the Power Supply WARNING: DISCONNECT AND LOCKOUT PRIMARY POWER AT THE AC SOURCE PRIOR TO PERFORMING ANY CONNECTIONS, REPAIRS, OR MAINTENANCE INSIDE THE TRASNMITTER. The power supply can either be cleaned with a vacuum cleaner or compressed air or both.

  • Page 159: Adding A Boostpro

    Section 5 Maintenance and Alignment Platinum Z16HD+ Adding a BoostPro If a BoostPro amplifier has been added to an HD+ transmitter, the following procedure may need to be performed for the initial setup. On the ZHD+ control panel, press the HIGH power button then press STEP 1 and hold the power LOWER button for 30 seconds which will set the DAC REF APC value to zero, as well as lower the power to zero.
  • Page 160 Section 5 Maintenance and Alignment Platinum Z16HD+ Navigate to EXT APC GAIN. Change to 3000 for the initial value, and STEP 11 leave this screen showing on GUI. Set the Flexstar HDx-FM Exciter Aux Power Level to 90% by accessing STEP 12 page 3 of the Output Setup screen.

  • Page 161: Routine Annual Tests

    Section 5 Maintenance and Alignment Platinum Z16HD+ Routine Annual Tests These tests should be used as part of a routine maintenance program at least once a year. It should also be done if major combiner components are removed and/or replaced, such as a Z-Plane or Isolation Board or if cabling is disconnected and re-connected to the Z- Planes or Isolation Boards.

  • Page 162: System Test

    Section 5 Maintenance and Alignment Platinum Z16HD+ 5.4.2 System Test CAUTION: SYSTEM TEST WILL CHANGE THE POWER LEVEL TO APPROXIMATELY ¼ OF THE RATED POWER. BE AWARE THAT THE SYSTEM TEST WILL REPEATEDLY MUTE THE TRANSMITTER WHICH WILL INTERUPT NORMAL PROGRAMMING. The purpose of the SYSTEM test is to check the combiner configuration, cabling and integrity.

  • Page 163: Pa Replacement

    PC board itself. The isolation resistors all have thermistors attached to them with epoxy for temperature sensing. Therefore the resistors and thermistors must be obtained from Harris, pre- assembled. De-soldering on the Isolation Board requires a lot of heat due to the large amount of ground plane.

  • Page 164: Isolation Board Removal

    Section 5 Maintenance and Alignment Platinum Z16HD+ 5.6.1.1 Isolation Board Removal a. There are 2 ribbon cables connecting to each Isolation assembly. The cables should be disconnected from the RFI filter boards. They can be removed from the Isolation Board once it is removed from the transmitter. It does make a difference where these re-connect.

  • Page 165: Installation Of Isolation Assembly

    Section 5 Maintenance and Alignment Platinum Z16HD+ CAUTION: BE VERY CAREFUL WHEN DESOLDERING ANY OF THE RESISTORS AS A LARGE AMOUNT OF HEAT IS REQUIRED. DO NOT PULL VERY HARD OR THE FEED THROUGH HOLES ON THE PC BOARD COULD BE DAMAGED. NOTE: The resistors should be ordered as an assembly, with the thermistor already attached as this is very critical to proper transmitter operation.

  • Page 166: Directional Coupler Removal And Replacement

    Section 5 Maintenance and Alignment Platinum Z16HD+ top of the transmitter. Slide it up enough to get to the Isolation Boards and tighten the top clamp to hold it in place. If there is not enough room to raise the harmonic filter very far, then the STEP 5 back section of the upper PA deck plate can be removed and the harmonic filter can be raised just until the bottom clears the lower PA...

  • Page 167: Maximum Power Settings

    Section 5 Maintenance and Alignment Platinum Z16HD+ • Forward Couplers: 48.8dB @ 88MHz to 47dB @ 108MHz • Reflected Couplers:43.8dB @ 88MHz to 42dB @ 108MHz (Typical tolerance is +/- 0.1dB at 108MHz, but is not guaranteed) For frequencies between 88 and 108MHz the actual coupling ratio can be extrapolated linearly.

  • Page 168: Setting Fwd Pwr To Display 100

    Section 5 Maintenance and Alignment Platinum Z16HD+ Press Raise to make sure the power level will not go above the new STEP 3 MAX LOW setting. The MAX LOW setting in Step 2 can be adjusted slightly to get the exact desired power level. Repeat steps above for all desired modulation formats.

  • Page 169: Forward Power Calibration

    Section 5 Maintenance and Alignment Platinum Z16HD+ Adjust R25, Manual PWR Reference on the Life Support Board for 25% STEP 3 of the default rated power (of your primary modulation format) on the external meter. Switch S1-9 to OFF and the transmitter should return to your normal STEP 4 TPO.
  • Page 170 Section 5 Maintenance and Alignment Platinum Z16HD+ Z16HD+ Figure 5-3 Forward Factor Calibration Screen [HOME, MORE, CONFIGURATION, C, A, B] Press [HOME, MORE, CONFIGURATION, C, A, A, D]. This should STEP 5 take you to the screen in Figure 5-4. Set the CAL_APC_FACTOR to 15.15.
  • Page 171 Section 5 Maintenance and Alignment Platinum Z16HD+ Desired TPO divided by 15.15 = DAC APC REF EXAMPLE: Desired TPO of primary modulation format = 4600W 4600 ‚ 15.15 = 304 Figure 5-5 DAC_APC_REF Screen [HOME, MORE, CONFIGURATION, C, B] NOTE: The following adjustment will be sensitive, so be careful not to go too fast.

  • Page 172: Reflected Power Calibration

    Section 5 Maintenance and Alignment Platinum Z16HD+ press the [BACK] key to the left of the display to calibrate the FWD power and save the new information. The display will flash “Calibration Done” very quickly at the bottom of the Diagnostics Display.
  • Page 173 Section 5 Maintenance and Alignment Platinum Z16HD+ On the Diagnostics Display, check the VSWR fault and foldback STEP 3 settings. Press [HOME, MORE, CONFIGURATION, B, A, D, C]. If necessary, set it to 1.70. Press [BACK] to update the information. Press [D], to go to the VSWR Foldback screen.
  • Page 174 Section 5 Maintenance and Alignment Platinum Z16HD+ primary modulation method, to determine the Reflected Power Calibration values: 0.03 · EXAMPLE: Desired TPO of primary modulation format = 4600W 4600 x 0.03 = 138W for the RFL PWR CAL Press [HOME, MORE, CONFIGURATION, C, B]. This will take you to STEP 9 the screen in Figure 5-8.
  • Page 175 Section 5 Maintenance and Alignment Platinum Z16HD+ Z16HD+ Figure 5-9 Reflected power CAL Screen [HOME, MORE, CONFIGURATION, C, D] Shut the transmitter off and return the Reflected Power Directional STEP 11 Coupler back to its normal position. Press [HOME, MORE, CONFIGURATION, B, A, D, D]. This takes you STEP 12 to the VSWR Foldback Set screen.

  • Page 176: Pc Board Replacement Procedures

    There are 7 jumpers on the Life Support Board. JP1 and JP2 select the main and alternate exciter mute as active HIGH or LOW. Table 2-2 (in Section II) shows the proper settings for a Harris exciter.

  • Page 177: Replacing The Power Supply Controller Board

    Section 5 Maintenance and Alignment Platinum Z16HD+ Setting the +5V REF - with a digital voltmeter, check TP4, the +5V REF STEP 7 (reference). The voltage should be 5.00V, +/- 0.01V. If not, adjust R28 to make it so. IPA Current Fault Adjustment - this adjustment only affects operation in STEP 8 Life Support Mode.

  • Page 178: Replacing A Pa Controller Board

    Section 5 Maintenance and Alignment Platinum Z16HD+ a. For PSC #1 - All switches OFF b. For PSC #2 - S1-1 = ON, all other switches OFF c. JP1 pins 1-2 (Both Controllers) d. JP2 pins 1-2 (Both Controllers) 5.14.3 Replacing a PA Controller Board Replacement of a PA Controller Board requires no analog adjustments.

  • Page 179: Replacing Eeprom U39

    Section 5 Maintenance and Alignment Platinum Z16HD+ 5.14.4.1 Replacement Using EEPROM U39 From the Old Board If the Master Controller needs to be replaced, but EEPROM U39 can be swapped from the old board, then proceed as follows: Shut the transmitter off and remove AC power from the transmitter. STEP 1 Remove the defective Master Controller Board.
  • Page 180 Section 5 Maintenance and Alignment Platinum Z16HD+ Shut the transmitter off and remove AC power from the transmitter. STEP 1 Remove the Master Controller Board. If only the EEPROM U39 is being STEP 2 replaced then replace U39 with the new one, reinstall the Master Controller Board and skip to Step 6.
  • Page 181 Section 5 Maintenance and Alignment Platinum Z16HD+ Table 5-1 EEPROM U39 Default Parameter Checklist Platinum Z16HD+ Transmitter Parameter FM+HD Mode HD Mode Default Settings Default Settings Forward Factor 0.015393 Reflect Factor 0.000613 CAL Frequency Set to your frequency (Default = 98MHz) Operating Frequency Set to your frequency (Default = 98MHz)

  • Page 182: System Configuration And Calibration

    Section 5 Maintenance and Alignment Platinum Z16HD+ 5.15 System Configuration and Calibration System configuration and calibration is mainly for setting the transmitter up for the first time by factory personnel. The procedures contained here should NOT be done as part of a routine maintenance or adjustment schedule.

  • Page 183: Calibration

    Section 5 Maintenance and Alignment Platinum Z16HD+ Press [MORE] and then continue below. STEP 3 • INTLK LOG - ON or OFF (ON if you want interlock faults to be entered into the Diagnostics Display Fault Log, OFF if you do not want the interlock faults entered into the Fault Log).

  • Page 184: Removing/Replacing Firmware Ics

    Section 5 Maintenance and Alignment Platinum Z16HD+ WARNING: REFLECTED POWER CALIBRATION MUST BE COMPLETED FIRST TO PROVIDE VSWR PROTECTION DURING THE FORWARD POWER CALIBRATION PROCE- DURE. THIS REQUIRES THE USE OF AN EXTERNAL WATT METER CAPABLE OF READING 300 WATTS. 5.16 Removing/Replacing Firmware ICs Each of the controller boards, with the exception of the Life Support Board, have 2 Firmware ICs which contain the software for the microcontrollers.

  • Page 185: Firmware Ic Installation

    Section 5 Maintenance and Alignment Platinum Z16HD+ Before removal, notice that the IC has one corner which is bevelled and STEP 4 the IC socket has a pointer etched in the top which is pointing to the bevelled corner. See Figure 5-10. Figure 5-10 Top View of Firmware IC Socket The manufacturers do make a special extraction tool for these type of STEP 5...

  • Page 186: Combiner Removal (3-Phase Supply)

    Section 5 Maintenance and Alignment Platinum Z16HD+ 5.17 Combiner Removal (3-Phase Supply) WARNING: DISCONNECT AND LOCKOUT PRIMARY POWER AT THE AC SOURCE PRIOR TO PERFORMING ANY CONNECTIONS, REPAIRS, OR MAINTENANCE INSIDE THE TRASNMITTER. The following procedure is for the removal of the hybrid in the Z16HD+ transmitter equipped with a 3-phase power supply.
  • Page 187 Section 5 Maintenance and Alignment Platinum Z16HD+ Locate A1J2 and A1P2 on the left hand side of the chassis between the STEP 10 transformers and disconnect. Slowly roll the power supply approximately 3/4 of the way out being STEP 11 careful not to snag any wiring or ribbon cables.

  • Page 188: Combiner Removal (Single Phase Supply)

    Section 5 Maintenance and Alignment Platinum Z16HD+ 5.18 Combiner Removal (Single Phase Supply) WARNING: DISCONNECT AND LOCKOUT PRIMARY POWER AT THE AC SOURCE PRIOR TO PERFORMING ANY CONNECTIONS, REPAIRS, OR MAINTENANCE INSIDE THE TRASNMITTER. The following procedure is for the removal of the hybrid in the Z16HD+ transmitter equipped with a single phase power supply.
  • Page 189 Section 5 Maintenance and Alignment Platinum Z16HD+ Remove the orange DC ground cables numbered 52, 152, 652, and 752 STEP 9 from the ground studs located under the front top lip of the power supply compartment. Remove the orange DC output cables from their respective feed through STEP 10 capacitors: 681 from C8, 680 from C7, 81 from C4, and 80 from C3.
  • Page 190 Section 5 Maintenance and Alignment Platinum Z16HD+ Table 5-2 Default Power Levels for All ZHD+ Transmitters FM 100% TPO Set 02.00 03.50 05.00 07.50 10.00 FM MAX HIGH Set 02.10 03.68 05.25 07.88 10.50 FM MAX LOW Set 01.00 01.75 02.50 03.75 05.00...
  • Page 191 Section 5 Maintenance and Alignment Platinum Z16HD+ Table 5-3 Z16HD+ Recommended Minimum Log Readings 9/15/06 888-2586-001 5-37 WARNING: Disconnect primary power prior to servicing.
  • Page 192 Section 5 Maintenance and Alignment Platinum Z16HD+ 5-38 888-2586-001 9/15/06 WARNING: Disconnect primary power prior to servicing.

  • Page 193: Troubleshooting

    Platinum Z16HD+ Section 6 Troubleshooting Introduction In order to assist in the troubleshooting of the Platinum Z16HD+ transmitter this section will concentrate in the following areas: • Using the Diagnostics Display System, concentrating on the Fault Log. • Defining all of the transmitter fault indications, their origin, and their effect on the transmitter.

  • Page 194: Power Amplifier Repair

    REV]. This will bring up the screen shown in Figure 6-1. The Firmware part number is printed on a label attached to the ICs on the individual controller boards. Before calling Harris Technical Support personnel it is a good idea to get the software part number and revisions for each of the controller boards.

  • Page 195: System Reset - Tx_Restart

    Section 6 Troubleshooting Platinum Z16HD+ Figure 6-1 Software Revision Screen System Reset - TX_RESTART Pressing the ON (LOW or HIGH) button on the transmitter will issue the TX_RESTART command and try to return the transmitter to normal operation after any fault has occurred.

  • Page 196: Diagnostics Display Menu Tree

    Section 6 Troubleshooting Platinum Z16HD+ • Strike 1 - When any of the above fault conditions is met, the transmitter output is muted (DAC_APC_REF is brought to zero) for 3 seconds (6 seconds for transmitters with a Single Phase power supply). At the end of the 3 (or 6) seconds the transmitter power is slowly ramped back up and a 10 second timer is started.

  • Page 197: Fault Log

    Section 6 Troubleshooting Platinum Z16HD+ Fault Log The Fault Log is in the “FAULT” menu of the Diagnostics Display. To access the Fault Log press [MORE, FAULT, D]. This should bring up the screen shown in Figure 6-2. This screen shows the latest of a possible 32 faults (the maximum number of faults which can be stored in the log) as designated by “LOG No.

  • Page 198: Abbreviations Used In Fault Reporting

    Section 6 Troubleshooting Platinum Z16HD+ Figure 6-3 Fault Reset Screen 6.7.3 Abbreviations Used In Fault Reporting The following is a listing of abbreviations used in the Fault Log. • AMB - Ambient • INTLK - Interlock • RFL - Reflected •...

  • Page 199: Fault Listing

    Section 6 Troubleshooting Platinum Z16HD+ • OV - Over Voltage • UV - Under Voltage • TAP# - Power Supply SCR TAP # (TAP1, TAP2, TAP3, or TAP4) 6.7.4 Fault Listing Table 6-2, Table 6-3, and Table 6-4 provide a quick reference, containing a complete listing of all of the faults which can show up on the Diagnostics Display Menu, including their effect on transmitter operation and a brief comment explaining the fault.

  • Page 200: Boostpro Faults

    Section 6 Troubleshooting Platinum Z16HD+ BoostPro Faults The BoostPro front panel LED will illuminate red if a fault condition is detected. Press INFO, then FAULT SUBMENU to view a listing of statuses where the malfunction would be indicated by the word FAULT. To reset the fault, press INFO, then CONTROL SUBMENU, move cursor to point to RESET FAULT.

  • Page 201: Boostpro Diagnostics/Programming

    Section 6 Troubleshooting Platinum Z16HD+ 24V, 15V, 12V, -15V, -12V, 8V, 5V, 3V (Low Voltage Power Supplies): All on-board low voltage supplies thresholds are +/-20% - Warning only. VSWR FOLDBACK: Indication of a foldback condition, where the threshold levels are based on the TX type and modulation defined in the master configuration file. The foldback circuit will cancel the foldback state, and automatically restore power to the previous level, once the condition causing the high VSWR stops.
  • Page 202 Section 6 Troubleshooting Platinum Z16HD+ • Flow Control = None • Emulation = VT100 Call, or hit "Enter" twice to initiate handshake STEP 5 To navigate around the VT100 screens: • Left/Right arrows to page back/forward • Up/Down arrows to move cursor within page To edit a numerical entry: Type the line number or letter in parenthesis - do NOT hit "Enter"...

  • Page 203: Vt100

    Section 6 Troubleshooting Platinum Z16HD+ 6.9.2 VT100 - Page 1 Operational statuses and system information. Each line of the VT100 screen is listed below. The parameter in bold, followed by possible statuses in parenthesis. Figure 6-4 VT100 - Page 1 OPERATIONAL STATUS: RF On: (ON/OFF) Status of the RF output, when “ON”...
  • Page 204 Section 6 Troubleshooting Platinum Z16HD+ Class A Class AB Class A Class A Flexstar Frequency: Current frequency of HDx-FM exciter. This is information obtained via the CAN bus from the HDx-FM exciter. Check Exciter Flexstar Sum Fault: (OK/FAULT) FAULT if there is a fault condition in the exciter. This information is obtained via the CAN bus from the Flexstar exciter.
  • Page 205 Section 6 Troubleshooting Platinum Z16HD+ 6.9.3 VT100 - Page 2 Configuration and Setting / Faults. Each line of the VT100 screen is listed below. The parameter in bold, followed by possible statuses in parenthesis. Figure 6-5 VT100 - Page 2 CONFIGURE &...
  • Page 206 Section 6 Troubleshooting Platinum Z16HD+ (f) Fault Reset: Typing f will reset the Fault Strike Status. (r) RF Mute/Unmute: Typing r will mute (or unmute) the RF depending on the current state. (CTRL-z) Lock/Unlock: This will allow the user to unlock the current configuration settings so that they can be adjusted.

  • Page 207: Vt100

    Section 6 Troubleshooting Platinum Z16HD+ 6.9.4 VT100 - Page 3 Build-in Test page. (CTRL-bit) to run test. Figure 6-6 Build-in Test: Passed Figure 6-7 Build-in Test: Failed 9/15/06 888-2586-001 6-15 WARNING: Disconnect primary power prior to servicing.

  • Page 208: Vt100

    Section 6 Troubleshooting Platinum Z16HD+ 6.9.5 VT100 - Page 4 Z Serial information: Commands: (l) Loopback: Typing l will initiate a serial communication test. Figure 6-8 VT100 - Page 4 6-16 888-2586-001 9/15/06 WARNING: Disconnect primary power prior to servicing.

  • Page 209: Vt100

    Section 6 Troubleshooting Platinum Z16HD+ 6.9.6 VT100 - Page 5 Remote Output/Remote Input: The information displayed on this page is the digital data the micro-module is receiving and send- ing. Figure 6-9 VT100 - Page 5 9/15/06 888-2586-001 6-17 WARNING: Disconnect primary power prior to servicing.

  • Page 210: Vt100

    Section 6 Troubleshooting Platinum Z16HD+ 6.9.7 VT100 - Page 6 Analog-to-Digital and Digital-to-Analog Converters: The information on the left side of the screen is data coming from an external analog-to- digital converter. (The internal analog-to-digital converter is being used to sample the voltages on the controller board.) Also on the left side, bottom, of the screen is the data showing that a power cal has been done.

  • Page 211: Self Diagnostics

    Section 6 Troubleshooting Platinum Z16HD+ 6.10 Self Diagnostics The Z Series transmitter is equipped with a set of TEST menus for testing various internal systems. To access the TEST menus press [HOME, MORE, TEST]. This brings you to the screen in Figure 6-4. This screen gives you 2 choices: •...

  • Page 212: Pa Muting Test

    Section 6 Troubleshooting Platinum Z16HD+ the SYSTEM test press [HOME, MORE, TEST, C]. This will bring up the screen in Figure 6-5. Press [D] to run the test or [C] to go back to the previous menu. NOTE: Due to operational variables, it is possible to get false indications which place a fault in the log and abort the test.

  • Page 213: Pa_Iso Resistor And Thermistor Test

    Section 6 Troubleshooting Platinum Z16HD+ 6.10.1.2 PA_ISO Resistor and Thermistor Test If the PA Muting Test is passed, the PA_ISO resistors and thermistors will be checked. These first two tests are actually done at the same time. With the PA muted, the ISO resistor temperature for that PA should increase within a few seconds.
  • Page 214 Section 6 Troubleshooting Platinum Z16HD+ Figure 6-13 Hardware Test Menu a. LCD/LED Test - This is a test of all of the LCD segments and LEDs on the front panel to make sure the overlay indicators are operational. Pressing [B] will active the test.

  • Page 215: General Troubleshooting Tips

    Section 6 Troubleshooting Platinum Z16HD+ 6.11 General Troubleshooting Tips 6.11.1 Foldback Conditions The Master Controller is responsible for transmitter power foldback conditions, however a foldback condition by itself will not cause a fault to be registered in the Fault Log. Foldback limits in the transmitter are always set lower than the actual fault limit. This allows the transmitter to stay on the air at some maximum power level without shutting off, but since the actual fault level was not reached, no fault will be logged.

  • Page 216: Asterisk And Pound Signs(*, #)

    Section 6 Troubleshooting Platinum Z16HD+ IMPORTANT: It is very important to note that once the HDE-100 Exporter is properly connected and configured, the following HDx-FM settings on the Output Setup page 1/4 must be made for normal HD operation. HD Carriers: ENABLED Exgine Input: EXPORTER Exgine Output: NORMAL 6.11.3 Turning the Transmitter ON with No Power Output...

  • Page 217: Troubleshooting For A Thermistor Fault

    Section 6 Troubleshooting Platinum Z16HD+ reading. If the thermistor circuit becomes open, the detector input goes high which gives a cold temperature reading. This leaves the device to which the thermistor is connected, unprotected from an over-temperature condition. Once this fault is detected it will stay active in the log until the Fault Log is reset.

  • Page 218: Eeprom_Def, Eeprom U39 Default Load

    Section 6 Troubleshooting Platinum Z16HD+ c. If the thermistor is not open, turn the low voltage back on and check to see if there is voltage across the thermistor. No voltage to the thermistor means an open between the controller and the thermistor. Trace the connection back to the con- troller board.

  • Page 219: Rfl_Pwr, Reflected Power Fault

    Section 6 Troubleshooting Platinum Z16HD+ 6.12.5 RFL_PWR, Reflected Power Fault This fault is activated when the VSWR overload trip point is exceeded. This fault will only show up if there is a large and quick change in the transmitter load impedance or if the VSWR foldback setting is too close to the overload setting.

  • Page 220: Power_Fail, Fault

    Section 6 Troubleshooting Platinum Z16HD+ 6.12.8 POWER_FAIL, Fault This fault is activated as a result of an AC power failure. This fault is detected by monitoring the +20Vdc supply on the Life Support Board (IC U37). If the +20Vdc supply drops below the power fail threshold (approximately 12V) the POWER_FAIL signal is sent to the Master Controller telling it to save the time and ignore certain types of faults which will obviously be present during a power failure.

  • Page 221: Cplr_Nc, Coupler Cable Not Connected

    Section 6 Troubleshooting Platinum Z16HD+ AFTER THE INPUT VOLTAGE HAS BEEN SHUT OFF. ELECTRICAL SHOCK IS POS- SIBLE. 6.12.11 CPLR_NC, Coupler Cable Not Connected This fault is active anytime the sample cable from the Forward power directional coupler to the Life Support Board is disconnected. The fault immediately mutes the transmitter until the cable is re-connected due to the effect this would have on the Automatic Power Control (APC) loop.

  • Page 222: Ipa_Load, Fault

    Section 6 Troubleshooting Platinum Z16HD+ 6.12.17 IPA_LOAD, Fault To check for bad RF Cables, the Master Controller checks Z-Plane currents for proper IPA load balance. If a severe imbalance is found, the transmitter is muted. 6.12.18 PSC#_COMM, Fault This fault means there is a communication failure between the Power Supply Controller and the Master Controller.

  • Page 223: System Iso Foldback

    Section 6 Troubleshooting Platinum Z16HD+ • ISO_AZ, BZ, CZ AND DZ - These 4 are the ISO loads located in the middle of the Isolation Boards. Their component designation is R9 on the Isolation Board sche- matic. • ISO_AB and ISO_CD - These 2 are the ISO (reject) loads on the hybrids which are combining the outputs of the respective Z-Planes.

  • Page 224: Rfsource#_Low, Fault

    Section 6 Troubleshooting Platinum Z16HD+ the IPAs and the exciter and the PA Controllers will mute the PAs. At this point an ISO_Load fault will be reported in the fault log and the transmitter will mute momentarily. The possible faults are: •...

  • Page 225: Pa Controller Faults

    Section 6 Troubleshooting Platinum Z16HD+ schematics for each of these boards must apply to any position, the labeling is also generic. For instance, the PA Controllers have the ability to control and monitor 8 amplifiers. These lines to and from the amplifiers are labeled PA1-PA8 on the PA Controller schematic.

  • Page 226: A, B, C Or D#_Oc, Pa Over-Current Fault

    Section 6 Troubleshooting Platinum Z16HD+ 6.14.2 A, B, C or D#_OC, PA Over-Current Fault The PA Current overload threshold for each PA is nominally 14.0 amps, provided there are no failed PAs. If an individual PA exceeds this current, the PA will be muted and the Combiner isolation switch will disconnect the associated isolation resistor from the combiner and apply a ground to the PA output.

  • Page 227: A, B, C Or D#_Ot, Pa Over-Temperature

    Section 6 Troubleshooting Platinum Z16HD+ 6.14.5 A, B, C or D#_OT, PA Over-Temperature The temperature of each PA is sensed by thermistor, RT1 (located on each individual amplifier board). If the temperature reaches 100°C, the transmitter will mute and disconnect the problem PA via the isolation switch. If one of the thermistors or its wiring is shorted the temperature indication will be 155°C or higher.

  • Page 228: Pa_Iso_Ot

    Section 6 Troubleshooting Platinum Z16HD+ 6.14.8 PA_ISO_OT This is a general over-temperature fault which will shut the transmitter off if one of the PA Isolation resistors in the combiner physically reaches 150°C (no prediction). This protects against a failure in the combiner system where the Isolation resistor does not get switched out of circuit.

  • Page 229: Pac#_Ref, +5V Reference Fault

    Section 6 Troubleshooting Platinum Z16HD+ Controllers will mute all of the PAs. The system can be reset by pressing an ON button. This fault will only show up if the Master Controller is not operational or if the ISO APC Foldback routine initiated by the Master Controller fails to reduce the temperature of the ISO load.

  • Page 230: Pac#_Volts, Power Supply Fault

    Section 6 Troubleshooting Platinum Z16HD+ 6.14.13 PAC#_VOLTS, Power Supply Fault This fault is activated if the supply voltage to the PAs under the control of an individual PA Controller is under 30Vdc or over 65Vdc. All PAs under that controller (and power supply) will be muted and switched out.

  • Page 231: Power Supply Controller Faults

    Section 6 Troubleshooting Platinum Z16HD+ 6.15 Power Supply Controller Faults The following paragraphs give a detailed description of all faults associated with the PS Controller Boards. A quick reference of these faults is given in Table 6-4 on page 6-50. There are two types of power supply faults: •...

  • Page 232: Ps#_Start, Soft Start Circuit Fault

    Section 6 Troubleshooting Platinum Z16HD+ normally. Due to the distribution of voltage to the PAs, this will affect all of the PAs associated with one of the PA Controllers. Therefore the effect is the same as the loss of a PA Controller and the transmitter will have a maximum power out- put of about 30% of nominal.

  • Page 233: Psc#+20V, Fault

    Section 6 Troubleshooting Platinum Z16HD+ frequency should be 300 or 360Hz) is interpreted as an indication of a transformer primary fault or line loss. The filter as a whole is implemented in software via the microcontroller, hence not requiring any further adjustment. Note that a major voltage imbalance between one or more phases could also trigger this fault.

  • Page 234: Ps#_Jump

    Section 6 Troubleshooting Platinum Z16HD+ 6.15.2.7 PS#_JUMP If a power supply tap fails and the next one available is two or more taps away, a JUMP fault is triggered and the supply will be shut off and discharged. The only situations where this could happen are: •...
  • Page 235 Section 6 Troubleshooting Platinum Z16HD+ Table 6-1 Power Supply Tap Troubleshooting Chart 3 Phase Power Supply Single Phase Supply Rectifier Board "A" Rectifier Board "B" SCRs Fuses SCRs Fuses SCRs Fuses TAP 1 TAP 2 TAP 3 TAP 4 Soft Start There are no Soft Start SCRs on Rectifier Board "A"...
  • Page 236 Section 6 Troubleshooting Platinum Z16HD+ Figure 6-14 3 Phase Power Supply Component Locator Top View 6-44 888-2586-001 9/15/06 WARNING: Disconnect primary power prior to servicing.
  • Page 237 Section 6 Troubleshooting Platinum Z16HD+ Figure 6-15 Single Phase Power Supply Rectifier Assembly Component Locator, Top View 9/15/06 888-2586-001 6-45 WARNING: Disconnect primary power prior to servicing.
  • Page 238 Section 6 Troubleshooting Platinum Z16HD+ Table 6-2 Master Controller Related Faults FAULT COMMENT ACTION MSTR_REF +5V reference fault. Indicates +5V Mute XMTR (IPA & Exciter, Power supplies) reference is < 4.6V REF_WARNING Indicates Reference Reports fault in Log without shutting down tolerance at the Master Controller Board the PAs.
  • Page 239 Section 6 Troubleshooting Platinum Z16HD+ Table 6-2 Master Controller Related Faults FAULT COMMENT ACTION IPA_LOAD Z-Plane currents are checked during Mute XMTR startup to determine if IPA load is balanced. Most likely caused by bad RF cable. ISO_AB Reject Load ISO_AB, on the AB 3dB Will follow the 3 Strike Routine (described in Section 6) hybrid, is >...
  • Page 240 Section 6 Troubleshooting Platinum Z16HD+ Table 6-2 Master Controller Related Faults FAULT COMMENT ACTION THERMISTOR Protection against a temperature-sensor Indication of fault (no other action taken) circuit open AMB_WARNING Switch Fan to high speed Ambient Temperature Warning > 40 degree AMB_TEMP Ambient temperature critical >...
  • Page 241 Section 6 Troubleshooting Platinum Z16HD+ Table 6-3 PA Controller Related Faults FAULT COMMENT ACTION A#_UC Designated Power Amplifier’s current is Mute XMTR 120ms, switch out the PA and less than 10% of the Foursome’s avg. release the mute on the other PAs. B#_UC current.
  • Page 242 Section 6 Troubleshooting Platinum Z16HD+ Table 6-4 Power Supply Controller Related Faults FAULT COMMENT ACTION PSC# +20V +20V DC supply to PSC failed Shut Power Supply OFF and discharge. PS#_DSCHG A failure of the discharge circuit has been Transmitter is shut off detected PS#_START Supply voltage did not reach 40V during...
  • Page 243 Section VII Parts List Replaceable Parts List Index Table 7-1 ! XMTR, Z16HD+, FORMAT - - - - - - - - - - - - - - 995 0034 016 (D) Table 7-2 FLEXSTAR BOOST AMP - - - - - - - - - - - - - - - 971 0027 006 (F) Table 7-3 POWER BLOCK, RF, Z16HD+- - - - - - - - - - - - - 992 9522 811 (B) Table 7-4...
  • Page 244 Section VII Parts List Platinum Z16HD+ Table 7-1 ! XMTR, Z16HD+, FORMAT - 995 0034 016 (D) Harris PN Description Qty UM Reference Designators 570 0329 000 *CONTACTOR 90A 3-POLE 60HZ 0 EA UNIT 1 K1,UNIT 2 K1 570 0372 000...
  • Page 245 CHASSIS, BOOST AMP 1 EA 952 9239 012 ASSY, CABLE FLEXSTAR BOOST AMP 1 EA Table 7-3 POWER BLOCK, RF, Z16HD+ - 992 9522 811 (B) Harris PN Description Qty UM Reference Designators 026 6010 002 GROMMET STRIP, 0.090 1.500 FT...
  • Page 246 Section VII Parts List Platinum Z16HD+ 917 2435 951 PKG, 5KW JUMPER 1 EA 917 2435 987 CABLE PKG Z16+ 1.0 EA 917 2558 080 PATENT LABEL - FM XMTRS 1 EA 922 1260 023 SIDE, LEFT, DUCT 1 EA 922 1260 024 SIDE, RIGHT, DUCT 1 EA...
  • Page 247 A4,A20A5,A20A8,A20A9 992 9803 001 ASSY, DIRECTIONAL COUPLER DB 1 EA Table 7-5 CONTROLLER,TX, Z12HD+ & Z16HD+ - 992 9515 701 (B) Harris PN Description Qty UM Reference Designators 299 0015 000 TAPE, PVC VINYL CLOSED 0.033 RL 358 2105 000...
  • Page 248 1 EA 917 2435 039 STANDOFF, LCD DISPLAY 4 EA 4/XDS1 Table 7-7 PWA, LIFE SUPPORT - 992 9992 141 (C) Harris PN Description Qty UM Reference Designators 300 1485 000 SCR, 4-40 X 5/16 1 EA 1/U10 304 0087 000...
  • Page 249 Platinum Z16HD+ Section VII Parts List Table 7-8 PWA, BACKPLANE, IPA - 992 9541 001 (S) Harris PN Description Qty UM Reference Designators 2520420000A *WIRE, RIBBON 5 X 100 MIL 0.170 FT 254 0001 000 WIRE, BUS CU 22AWG 0.320 FT 358 2684 000 PC BD STANDOFF 4-40X.125...
  • Page 250 Section VII Parts List Platinum Z16HD+ Table 7-10 ASSY., AIR 2 SPEED - 992 9719 003 (F) Harris PN Description Qty UM Reference Designators 299 0014 000 TAPE, PVC VINYL CLOSED 0.050 RL 350 0100 000 PREF PRT IS 350-0105-000 23.00 EA...
  • Page 251 4 EA A17A1,A17A2,A17A3,A17A4 992 8553 001 PWA, MOV-AC 198-250 VAC 1 EA Table 7-14 ASSEMBLY, RECTIFIER, 3PH - 992 9719 006 (C) Harris PN Description Qty UM Reference Designators 2520006000A *WIRE, STRD 14AWG BLU 1.260 FT 2/R048 296 0262 000 TUBING, SHRINK 1/4 WHITE 0.160 FT 2/R048...
  • Page 252 Section VII Parts List Platinum Z16HD+ 14,Q015,Q016,Q017,Q018,Q019,Q020,Q 021,Q022,Q023,Q024,Q034,Q035,Q036 386 0082 000 ZENER, 1N4744A 15V 1W 5% ESD 1 EA CR026 398 0518 000 FUSE, 30A, 125V FAST CART 24 EA F001,F002,F003,F004,F005,F006,F007,F 008,F009,F010,F011,F012,F013,F014,F0 15,F016,F017,F018,F019,F020,F021,F02 2,F023,F024 402 0199 000 CLIP, 1/4 DIA FUSE 48 EA 404 0766 000 SOCKET, DIP, 18 PIN (DL)
  • Page 253 Platinum Z16HD+ Section VII Parts List Table 7-15 PWA, MOV-AC 198-250 VAC - 992 8553 001 (E1) Harris PN Description Qty UM Reference Designators 2960345000A *TUBING, SHRINKABLE 3/4 1 FT 560 0111 000 MOV, 275WVAC, 140J, 20MM DISC 12 EA...
  • Page 254 PWB, MOV-AC PROTECTOR, 1 EA 999 2711 002 WIRE/TUBING LIST 0 EA Table 7-18 AUX P/S, CAB, 1 PHASE - 992 9719 019 (H) Harris PN Description Qty UM Reference Designators 026 6010 003 GROMMET STRIP, 0.125 3.500 FT 358 3466 000...
  • Page 255 992 9762 001 PWA, P/S RECTIFIER, 1 PH 2 EA A17A1A1,A17A2A1 Table 7-20 AC MAINS, AUX 1PH - 992 9719 020 (D) Harris PN Description Qty UM Reference Designators 354 0223 000 CONNECTOR 70 AMP 1 EA 424 0016 000 GROMMET 1-1/8 MTG D.
  • Page 256 Section VII Parts List Platinum Z16HD+ Table 7-21 P/S, 10KW, 480VAC, 3PH, 3W - 992 9719 032 (A2) Harris PN Description Qty UM Reference Designators 2520006000A *WIRE, STRD 14AWG BLU 16 FT 2960003000A *PLASTIC TUBE 20AWG 0.500 FT 299 0014 000 TAPE, PVC VINYL CLOSED 0.016 RL...
  • Page 257 1 EA 992 9992 021 PWA, PA, IBOC 2 EA A1,A2 Table 7-24 PWA, PA, IBOC - 992 9992 021 (G) Harris PN Description Qty UM Reference Designators 055 0100 005 *THERMAL COMPOUND, 8OZ JAR 2 EA #Q001,#Q002 086 0004 054 SOLDER, SN63/PB37, 0.032"...
  • Page 258 ASSY, ISO RESISTOR, 70.7 OHM 1 EA 922 1272 675 ASSY, LOAD, 10KW COMBINER 1.0 EA Table 7-26 ! KIT,Z4HD+,Z8HD+,Z16HD+ BOARDS - 992 9992 206 (B) Harris PN Description Qty UM Reference Designators 917 2572 092 KIT,FRMWR, 1PH, Z4HD+, SPARE 0 EA...
  • Page 259 POSISTOR 1.1 AMP 60VDC DISC 1 EA 560 0121 015 POSISTOR 1.6 AMP 60VDC DISC 2 EA Table 7-28 *KIT, ZHD+, 3PH SEMICOND,FUSE - 992 9992 209 (A) Harris PN Description Qty UM Reference Designators 380 0190 000 XSTR, PNP 2N3906 ESD 1 EA...
  • Page 260 Section VII Parts List Platinum Z16HD+ 560 0049 000 MOV, 275WVAC, 75J, 14MM DISC 6 EA 560 0111 000 MOV, 275WVAC, 140J, 20MM DISC 6 EA 560 0121 010 POSISTOR 0.9 AMP 60VDC DISC 2 EA 560 0121 015 POSISTOR 1.6 AMP 60VDC DISC 2 EA 7-18 888-2586-001...

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