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Harris DiamondCD Series Technical Manual

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TECHNICAL MANUAL
888-2463-001
DiamondCD Series™
ATSC UHF Transmitter
DiamondCD Series™
ATSC UHF Transmitter
Printed - March 6, 2008
T.M. No. 888-2463-001
Rev: F2
© Copyright Harris Corporation 2008
All rights reserved

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  • Page 1 TECHNICAL MANUAL 888-2463-001 DiamondCD Series™ ATSC UHF Transmitter DiamondCD Series™ ATSC UHF Transmitter Printed - March 6, 2008 T.M. No. 888-2463-001 Rev: F2 © Copyright Harris Corporation 2008 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 DiamondCD Series™ REV. DATE Pages Affected 8/10/2001 Document Page 5-16 - Updated Driver Setup procedure (Specifically Change only 5.7.1 Setting Bias for Preamp and Driver) 4/17/02 47994 Title Page, MRH-1/MRH-2 and all of Section VII 7/11/02 All. Updates for software and hardware changes.
  • Page 4 MRH-2 888-2463-001 3/6/08 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 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.
  • Page 7 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 888-2463-001 3/6/08 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 11: Table Of Contents

    Table of Contents Section 1 PA Cabinet Connections ....2-11 Interlocks ......2-14 Introduction Determining Cabinet Style .
  • Page 12 Table of Contents (continued) GUI Computer ......4-6 PA Cabinet Power Samples ....4-19 Transmitter Control and Monitoring .
  • Page 13 Table of Contents (continued) Hybrids In Attenuators....4-34 AC FAIL Set Point..... .5-35 Replacing the Cabinet Controller Board .
  • Page 14 Table of Contents (continued) AC Fault ......6-11 AC Ground ......B-3 LVPS A or B Fault .

  • Page 15: Purpose Of This Manual

    Diamond Series™ Section 1 Introduction Purpose of This Manual This technical manual contains the information pertaining to the Diamond CD™ Series UHF solid-state DTV transmitter. The various sections of this technical manual provide the following types of information. • Section 1 Introduction, provides general manual layout, frontispiece, equipment description, block diagram.

  • Page 16: General Description

    Section 1 Introduction Diamond Series™ General Description This section contains a general description of the Diamond CD™ series television transmitters. Included in this section will be descriptions of the Control cabinet, Power Amplifier cabinet, block diagrams of the different models and system specifications. The Diamond HD™...

  • Page 17: Diamond Transmitter Models

    Section 1 Introduction Diamond Series™ 1.2.1 Diamond Transmitter Models There are 10 different Diamond Transmitter Models (power levels) available not including Dual Transmitter configurations. The available models are listed below in Table 1-1. Table 1-1 Diamond Transmitter Models and Power Levels Model # # of PA Modules Peak Power...

  • Page 18: New Style Pa Cabinet

    Section 1 Introduction Diamond Series™ 1.2.2 New Style PA Cabinet Figure 1-2(a) shows the original cabinet with the original style combiner and 8 way detectors located at the top and bottom of the cabinet. This shows a 16 way combiner. A 12 way combiner uses the top 12 modules, the 8 way uses only the top 8 modules while the 4 way uses only the top 4 modules.

  • Page 19: System Block Diagrams

    Section 1 Introduction Diamond Series™ 1.2.3 System Block Diagrams The following figures contain System block diagrams showing the basic signal flow and configuration for each Diamond Transmitter Model. PA Cabinet Control Cabinet *D D-1 D river is not required. Exciter output is sufficient to drive the PA Cabinet Exciter Exciter...
  • Page 20 Section 1 Introduction Diamond Series™ PA Cabinet Control Cabinet Exciter Driver Exciter Exciter Select SMPTE-310M Filter Filter Data Input Exciter Driver Exciter 2 Cabinet Combiner SMPTE-310M Data Input Optional CAB 2 CAB 2 Control Meters Remote Figure 1-5 DHD20P1, DHD45P2 System Block Diagram PA Cabinet Control Cabinet Exciter...

  • Page 21: Control Cabinet

    The Main Controller has three RS232 serial ports, one is connected directly to a com port on the GUI and the other two are Harris protocol to the Main Controller which can be used for serial remote control. These are in addition to the parallel remote control connections to the Life Support and Main Controller boards.
  • Page 22 Section 1 Introduction Diamond Series™ NOTE: For more information about Remote GUI operation , software installation and upgrades and modem connections refer to the "Diamond Software Manual" - 888-2470-001. The Life Support board is the backup control system. This board uses a CPLD and a parallel interconnect bus to provide basic transmitter functions in the event of a Main Controller failure.

  • Page 23: Graphical User Interface

    1.2.4.3 In-System Programming (ISP) Using the Harris ISP software, the firmware (embedded software) on the Main Controller, Cabinet Controller and all PA Module controllers can be updated (if necessary) using the GUI computer or an external pc and a serial connection to either the System I/O board or the Cabinet controller.

  • Page 24: Pa Cabinet(S)

    Section 1 Introduction Diamond Series™ 1.2.5 PA Cabinet(s) The PA Cabinet can operate as a stand alone unit. The only required external input to the cabinet control system is an interlock closure. ON/OFF operation at the PA cabinet can be done via push buttons on the Cabinet Controller board. The Cabinet Controller is microprocessor based with a discrete logic back up (life support) like the Control Cabinet but on a smaller scale.

  • Page 25: Pa Modules

    Section 1 Introduction Diamond Series™ 1.2.5.1 PA Modules The Power Amplifier modules use LDMOS FETs for amplification. See Figure 1-7. The amplifiers use a palletized approach to provide a means of module repair at the pallet level. Six output pallets provide up to 600 watts RMS DTV power, a seventh pallet is used as a driver for the output pallets.

  • Page 26: Power Supplies

    Section 1 Introduction Diamond Series™ 1.2.5.2 Power Supplies Up to eight 32 volt power supplies are used to provide the DC voltage to the PA modules within each PA cabinet. Each power supply provides power to two PA modules. The power supplies are designed to allow removal and insertion of one unit while the remaining power supplies are operating.

  • Page 27: 8-Vsb Exciters

    There are 2 exciters available for use wtih the DiamondCD series transmitters: • The CD-1A DTV Exciter - The Harris CD-1A, 8 VSB exciter can be used with any ATSC DTV UHF or VHF transmitter. This exciter is described in a separate instruction book.
  • Page 28 Section 1 Introduction Diamond Series™ 1-14 888-2463-001 3/6/08 WARNING: Disconnect primary power prior to servicing.
  • Page 30 Section 1 Introduction Diamond Series™ 1-16 888-2463-001 3/6/08 WARNING: Disconnect primary power prior to servicing.

  • Page 31: Installation

    Diamond Series™ Section 2 Installation Introduction This section contains information necessary to install and perform initial checkout procedures on Diamond™ Series television transmitters. Drawings identified here may be found in the drawing package accompanying this manual. Installation Planning The information in this section is intended to be used only as a general guideline in planning installation.

  • Page 32: Weights

    Section 2 Installation Diamond Series™ 2.2.2 Weights Weights are listed below each cabinet on the Transmitter Outline drawing. Be sure to include this information in your planning for the building and verify that the structure is capable of safely supporting the total weight of the transmitter and its peripheral equipment.

  • Page 33: Electrical Power

    1000 feet above sea level). Service Bulletin VHF-140 contains general information on air handling and some tips for analyzing typical problems in air systems. To obtain a copy of this bulletin, contact Harris Field Service department. 2.2.5 Electrical Power The transmitter is designed to operate from 208/240/480 volts, 50/60 Hz.

  • Page 34: Unpacking And Equipment Inventory

    The contents of the shipment should be as indicated on the packing lists. If the contents are incomplete, or if the unit is damaged electrically or mechanically, notify the Harris Customer Service Department by phone at 217-222-8200, or at the following address: Harris, Broadcast Communications Division P.O.

  • Page 35: Factory Test Data Sheets

    Section 2 Installation Diamond Series™ 2.3.1.2 Factory Test Data Sheets A set of factory test data is supplied with each transmitter. It lists parameters for operation of the transmitter at your power level and channel. These readings were recorded during factory testing. Locate the test data, copy, and file the original so that copies may be made as needed.

  • Page 36: Grounding

    Section 2 Installation Diamond Series™ • If equipment is not available to lift the cabinet off the skid, you may want to remove the back door to lighten the cabinet. The door may be set aside and rollers (pipe) and a ramp used to remove the cabinet from the skid.

  • Page 37: Rf Output Coax

    Section 2 Installation Diamond Series™ RF Output Coax CAUTION: WHEN INSTALLING RF TRANSMISSION LINE OR AIR SYSTEM WIRING, DO NOT STEP ON THE CONNECTORS OR THE ALUMINUM COVER PLATES ON TOP OF THE CABINETS. Because almost every station is different, refer to the Outline Drawings in Section 700 of the drawing package for information on location of hybrids, loads, couplers etc.

  • Page 38: Inter-Cabinet Wiring

    Section 2 Installation Diamond Series™ Tuning probes, used for fine matcher construction, are provided with the installation kit. Four probes are installed at 1/8 wavelength intervals along the length of a short section of line. The distance for 1/8 wavelength is calculated using the formula: spacing (inches) = 1476/F .

  • Page 39: Control Cabinet Connections

    Section 2 Installation Diamond Series™ • RF Drive Cable - The RF output from the Control Cabinet comes from RF Output Directional Coupler DC1 in a single PA Cabinet system. This RF output will connect to the RF Input Directional Coupler in the PA Cabinet. In a multiple PA Cabinet sys- tem, the Control Cabinet RF output comes from the Output RF Splitter and again connects to each RF Input Directional Coupler.

  • Page 40: Keyboard Connections

    Section 2 Installation Diamond Series™ • For systems with an APEX exciter, a PA output RF sample is also required and con- nects to J30 on the Customer I/O panel. This sample should come from a point in the RF system after any combiners but before the High Power Filter (HPF). •...

  • Page 41: Pa Cabinet Connections

    Section 2 Installation Diamond Series™ Figure 2-2 PS2 Keyboard Adaptor Connection PA Cabinet Connections Refer to the "PA Cabinet Wiring Diagram" in Section 500 of the Schematic Package and/or the AC Power Flow Diagram in Section 700. WARNING: DISABLE AND LOCK OUT STATION PRIMARY POWER BEFORE PRIMARY POWER CABLES ARE CONNECTED TO THE EQUIPMENT.
  • Page 42 Section 2 Installation Diamond Series™ 240Vac 480Vac Figure 2-3 Tapping for T1, LVPS Stepdown Transformer • Forward/Reflected RF cables - After the Directional Coupler line section is attached to the RF output of the PA Cabinet, connect the forward (or incident) sample to J8 and the reflected sample to J9 (connectors located on top of the PA Cabinet).
  • Page 43 Section 2 Installation Diamond Series™ • 3 phase AC input - The 3-phase AC input connects to the PA Cabinet at TB1 in the lower rear compartment. The three wires connect to pins 7, 13, and 19 of TB1, as shown in Figure 2-4.

  • Page 44: Interlocks

    S3-2 PA Cabinet Switch Caution: The standard VSWR Trip point should be used unless instructed Reflected Combinations otherwise by Harris Personnel. S3-3 Power Trip shown at right S3-2 (OFF) and S3-3 (OFF) = Standard 178 Watt Trip Point Adjust S3-2 (ON) and S3-3 (OFF) = 215 Watts...

  • Page 45: Determining Cabinet Style

    Section 2 Installation Diamond Series™ 2.8.2 Determining Cabinet Style As of Mid year 2002, PA cabinets started to have the new new style PA module combiner installed in place of the old style combiner. This is more of a hardware change than electrical and in no way changes or effects performance.

  • Page 46: Installing Pa Modules

    Section 2 Installation Diamond Series™ 2.8.4 Installing PA Modules The PA Modules should be placed in the transmitter at this time, but not plugged in all the way. It is important to place the modules back into the module slots in which they were tested to maintain the module phasing adjustments set at final test.

  • Page 47: Initial Turn On

    Section 2 Installation Diamond Series™ Initial Turn on 2.9.1 PA Cabinet AC Voltage Check WARNING: ENSURE ALL PRIMARY AC VOLTAGE HAS BEEN REMOVED FROM TRANSMITTER AND A GROUNDING STICK IS USED TO GROUND ALL POINTS WHERE AC OR RF POWER HAS BEEN APPLIED BEFORE PROCEEDING WITH THE FOLLOWING PRO- CEDURE.

  • Page 48: Check The Pa Cabinet Lvps Dc Voltage

    Section 2 Installation Diamond Series™ Apply AC voltage to the PA Cabinet from the primary disconnect. STEP 3 Turn on the Blower breaker and verify that the phase indicator light on STEP 4 the phase loss detector (orange box) in the lower rear of the cabinet is illuminated.

  • Page 49: Control Cabinet Ac Voltage Check

    Section 2 Installation Diamond Series™ Activate power supply “B” by turning OFF LVPS A breaker and turning STEP 4 ON LVPS B breaker. Verify the DC voltages again on each pin of J7. The supplies are diode STEP 5 or’ed together. This verifies that both supplies are operating. Turn OFF circuit breakers to both Low Voltage Power Supplies.

  • Page 50: Control Cabinet Lvps Dc Voltage Check

    Section 2 Installation Diamond Series™ 2.9.4 Control Cabinet LVPS DC Voltage Check Unplug J7, the DC output of the LVPS assembly in the Control Cabinet. STEP 1 Activate power supply “A” by turning ON the LVPS A circuit breaker on STEP 2 the front of the Control Cabinet.

  • Page 51: Power-Up And Alignment

    TRANSMITTER HAS BEEN RUNNING, ESPECIALLY IN HIGH AMBIENT TEMPERA- TURE ENVIRONMENTS. SPECIAL GLOVES HAVE BEEN PROVIDED IN THE REAR OF THE CONTROL CABINET OR CAN BE OBTAINED FROM HARRIS, PART #0990006483 OR GRAINGER ITEM #4JF36. Turn ON all of the Control Cabinet circuit breakers except for Driver A STEP 1 and Driver B (to prevent rf drive to the modules at this time).

  • Page 52: Bringing Up Rf Output: Individual Pa Cabinets2-22

    Section 2 Installation Diamond Series™ Repeat this process again for each module in each cabinet until all STEP 4 communications have been verified. Leave all modules plugged in. Shut OFF all of the PA Power Supply circuit breakers. STEP 5 2.9.7 Bringing Up RF Output: Individual PA Cabinets Turn OFF the circuit breakers on all but the first PA Cabinet (if more...
  • Page 53 Section 2 Installation Diamond Series™ Power Supply 1 Power Supply 3 Power Supply 5 Power Supply 7 Supplies Modules Supplies Modules Supplies Modules Supplies Modules 5 and 6 1 and 2 9 and 10 13 and 14 Power Supply 2 Power Supply 4 Power Supply 8 Power Supply 6...
  • Page 54 Section 2 Installation Diamond Series™ power for the cabinet should be very low. Verify that the combiner and filter system are okay (no hot spots). Connect the power meter to a precision directional coupler in the system STEP 9 and reset the meter offset to equal the coupling value of the coupler. As power is slowly raised, the Forward and Reflected power and Module STEP 10 Phasing should be closely monitored.

  • Page 55: Bringing Up Rf Output: Multiple Pa Cabinets

    Section 2 Installation Diamond Series™ Compare the PA Module currents and voltages against the factory test STEP 12 data. Major discrepancies should be investigated before proceeding. Next, compare the external power meter (connected to a precision STEP 13 coupler in the cabinet output line) to the GUI cabinet output power reading.

  • Page 56: Parallel Remote Control Connections

    Section 2 Installation Diamond Series™ Slowly increase the transmitter output power while monitoring the reject STEP 5 load power, the RF output power and the upper and lower RF sidebands on the spectrum analyzer. If the sidebands increase to within -20dB of the in-band signal, stop and troubleshoot the system.

  • Page 57: Transmitter Control Functions, J1

    Section 2 Installation Diamond Series™ 2.10.1 Transmitter Control Functions, J1 All control inputs use opto-isolators for surge protection. The opto-isolators can be powered by an internal +15Vdc which is considered "Half Isolation" or can be powered by an external customer supplied source from 10 to 24Vdc which is considered "Full Isolation".

  • Page 58: Remote Status Outputs, J2

    Section 2 Installation Diamond Series™ 2.10.2 Remote Status Outputs, J2 All of the remote status outputs are open collector and will sink 200mA at up to +24Vdc to provide an indication status is active. The supply voltage or pull up voltage for the status indications can be supplied via J2 or can be supplied by an external voltage source.

  • Page 59: Remote Power Metering, J3

    Section 2 Installation Diamond Series™ 2.10.3 Remote Power Metering, J3 Each analog metering output will provide 0-4Vdc output into a 400 ohm load. By squaring this voltage in the remote control equipment, a voltage proportional to the RF power it represents can be obtained. The connections for J3 are listed in Table 2-4. Table 2-4 J3, System I/O Board, Remote Power Metering Connection...
  • Page 60 Section 2 Installation Diamond Series™ 2-30 888-2463-001 3/6/08 WARNING: Disconnect primary power prior to servicing.

  • Page 61: Operation

    Diamond Series™ Section 3 Operation Operation, Controls and Indicators This section only contains a brief explanation of the hardware controls and indicators on the front of the Control Cabinet of the DiamondCD™ Transmitter. Primary transmitter control is intuitive through a high-resolution color monitor and a touch screen serving as a Graphical User Interface or GUI.

  • Page 62: Light Bar

    Section 3 Operation Diamond Series™ Light Bar The illuminated light bar above the GUI screen indicates the presence of any summary fault. The color of the light indicates the overall transmitter operating condition. • Green - Normal operation, no faults. •...

  • Page 63: Theory Of Operation

    Section 4 Theory of Operation Introduction This section of the technical manual presents the detailed, technical description of the operation of the cabinets in the transmitter. This section is organized by transmitter cabinet. The sub-assemblies in each cabinet will be detailed here. Control Cabinet The Control Cabinet can control up to 5 PA cabinets (actual transmitter model numbers and basic transmitter block diagrams are contained in Section 1, Introduction).

  • Page 64: Exciter

    Section 4 Theory of Operation Diamond Series™ WARNING: THE GUI EQUIPMENT IS POWERED THROUGH AN UNINTERRUPTABLE POWER SUPPLY (UPS). AC POWER WILL STILL BE PRESENT AT THE GUI AFTER THE INPUT VOLTAGE HAS BEEN SHUT OFF. ELECTRICAL SHOCK IS POSSIBLE. 4.2.2 Exciter For detailed descriptions of the circuits contained in the exciter, please refer to the...

  • Page 65: Cabinet Splitter

    Section 4 Theory of Operation Diamond Series™ 4.2.5 Cabinet Splitter For transmitters utilizing multiple PA Cabinets, a cabinet splitter is used. The cabinet splitter takes a single output of the Driver Module and splits it for each PA cabinet. Up to five PA Cabinets can be supplied.

  • Page 66: Main Controller

    Section 4 Theory of Operation Diamond Series™ the PA Cabinet controller refer to the PA Cabinet paragraph in this section. For information on the Module Controller refer to the Power Amplifier Module section in this manual. 4.3.1 Main Controller The Main Controller is a microprocessor based control system that receives commands from the Graphical User Interface (GUI)/overlay local controller, parallel remote control input or RS232 remote control inputs.

  • Page 67: Life Support

    Section 4 Theory of Operation Diamond Series™ e. Module strike - If a module is faulty and it has been shut down, the Module con- troller will send two successive ON commands to try to restart the module to avoid a false shut-down mode. This will eliminate nuisance faults without dis- playing them.

  • Page 68: Gui User Interface

    Section 4 Theory of Operation Diamond Series™ 4.3.5 GUI User Interface The GUI is a touch screen based operator interface that allows local control, status and metering of the overall transmitter. This operator interface has various screens that can be accessed to give control/status of different subsystems of the transmitter. Most of the system configuration, calibration, set-up and software upgrading is done through the GUI.

  • Page 69: Transmitter Control And Monitoring

    Section 4 Theory of Operation Diamond Series™ 4.3.6 Transmitter Control and Monitoring The Main Controller uses a Controller Area Network or CAN bus for PA Cabinet control and monitoring. The CAN bus is a bi-directional serial network line that is daisy chained to all PA Cabinets and PA Modules.

  • Page 70: Detectors

    Section 4 Theory of Operation Diamond Series™ 4.4.3 Detectors The PA Cabinet utilizes RF detector circuits to monitor power levels in various parts of the cabinet. These circuits rectify an RF signal sample, turning it into a DC voltage. The square of this voltage is proportional to the RF sample level.

  • Page 71: Pa Cabinet Rear Door Interlock Configuration

    Section 4 Theory of Operation Diamond Series™ 4.4.4.1 PA Cabinet Rear Door Interlock Configuration Since there are no dangerous voltages exposed, the rear door of the PA Cabinet may be opened briefly while the cabinet is ON without affecting the on-air signal. When the door is opened, the rear door fan stops, disabling the cooling system.

  • Page 72: 32Vdc Power Supplies

    Section 4 Theory of Operation Diamond Series™ 4.4.5 32VDC Power Supplies The +32VDC on-air serviceable Switching Power Supplies for the PA Modules are located in the lower front part of the PA Cabinet. One Power Supply serves two PA modules, and is removable while staying on the air with only two modules OFF. The Power Supply is removable after the Power Supply Breaker located on the front panel of each Power Supply assembly is turned OFF.

  • Page 73: Control Cabinet Detailed Circuit Description

    Section 4 Theory of Operation Diamond Series™ Control Cabinet Detailed Circuit Description 4.6.1 Main Controller The Main Controller consists of programming in a 32-bit micro processor chip. The control functions are divided into six parallel processes. Some of these processes also have sub-processes under them.

  • Page 74: External Interlocks

    Section 4 Theory of Operation Diamond Series™ 4.6.2.2 External Interlocks All interlocks are dealt with at the cabinet level and enter through J1, 6-9 and J1-11. LEDs located on the Life Support board will illuminate, and a summary fault is sent to the CPLD.

  • Page 75: U10 Cpld

    Section 4 Theory of Operation Diamond Series™ Equalization Reset and Hold is normally activated from the Main Controller. When the Main Controller fails, the Equalization Reset and Hold will be activated on the off-air Exciter only. JP1 selects between Reset and Hold. 4.6.2.6 U10 CPLD The main function of the Life Support board is contained in the CPLD (complex...

  • Page 76: Watch Dog

    Section 4 Theory of Operation Diamond Series™ 4.6.2.10 Watch Dog The Watch Dog circuit receives 1ms pulses from the Main Controller through J6-26. The One-shot is configured with a 100ms output pulse, much longer than the input. The supplied input pulses are much quicker than the time-out of the one-shot. This keeps the one-shot in the unstable state as long as the input pulses are present.

  • Page 77: Exciter Fold Back References

    Section 4 Theory of Operation Diamond Series™ The reflected Power sample is also sent to a comparator U44, which has an adjustable set point. The set point is set for the overload point at R134. When this level is exceeded, pulse stretcher U21 will send a one second pulse to the CPLD to indicate VSWR.

  • Page 78: Driver Pallet

    Section 4 Theory of Operation Diamond Series™ As AGC voltage from the Driver Controller is applied to the PIN diodes, their resistance goes from high to low and the overall termination of T2 is lowered from it’s nominal 50 ohms. This reduces the attenuation between the hybrids input (6) and output (3) ports.

  • Page 79: Bias Control

    Section 4 Theory of Operation Diamond Series™ 4.6.3.3.1 Bias Control Both the PA pallet current and Preamp current circuits work the same, only the PA Pallet circuit will be discussed here. The PA Pallets are adjusted for an open loop current of 5 amps.

  • Page 80: Driver System Control

    Section 4 Theory of Operation Diamond Series™ 4.6.3.3.4 Driver System Control The control of the Driver is centered around CPLD U11 which handles remote fault reporting and ON/OFF control. External inputs for enable/disable which come from the system are opto-coupled at U12. Local control with on-board ON/OFF switches are also available.

  • Page 81: Cabinet Controller

    Section 4 Theory of Operation Diamond Series™ 4.7.2 Cabinet Controller 4.7.2.1 Reject Power Samples The Reject Power samples from the reject loads enters the Cabinet Controller at J1 and J2. This signal is a DC voltage proportional to the amount of reject power to indicate the amount of phase imbalance, filtered to remove any noise and applied to U16 multiplex chip.

  • Page 82: Pa Cabinet Configuration

    Section 4 Theory of Operation Diamond Series™ run timer is closed the cabinet will shut off immediately when the rear door is opened. If S3-8 is open, then the PA cabinet fan will shut off when door is opened and the PA cabinet will continue to run for 2 minutes before turning off.

  • Page 83: Rs-232/Rs-485 Interface

    Section 4 Theory of Operation Diamond Series™ 4.7.2.7 RS-232/RS-485 Interface To allow a personal computer to be connected at the Cabinet Controller for control of the transmitter a separate RS-232 line is provided. The Cabinet Controller and the Module Controllers serial interface output is converted to RS-485 for use in the transmitter.

  • Page 84: Eprom U22

    Section 4 Theory of Operation Diamond Series™ OFF locally in the event of a GUI failure. This logic-L command is inverted and becomes the MASTER ON/OFF-H pulse to the output driver U36 to enable/disable the Modules. The MASTER ON/OFF also goes through the CPLD (complex programmable logic device) U39 to create the system level command to turn on the fans and power supplies.

  • Page 85: Analog Voltage Reference

    Section 4 Theory of Operation Diamond Series™ 4.7.2.14 Analog Voltage Reference The reference voltage for the DAC on this board need an accurate voltage reference which is regulated by U13. Using a precision volt meter on TP 50, adjust R97 for 4.999 VDC to 5.003 VDC.

  • Page 86: On/Off

    Section 4 Theory of Operation Diamond Series™ remain operational and the Controller will readjust the output power to eliminate signal quality degradation. The Module Controller will still acknowledge the problem to the Main Controller via the CAN bus, so the problem can be fixed at the next possible time. The Module Controller stores data on the PA Module’s frequency response allowing the controller to readjust the AGC reference voltage to maintain the same gain of the module over all operating frequencies.

  • Page 87: Gain Vs. Freq Compensationa/Calibration

    Section 4 Theory of Operation Diamond Series™ 4.8.1.1.4 Gain Vs. Freq Compensationa/Calibration This function stores the module’s frequency response and automatically compensates the module’s gain for all operating frequencies. Frequency selection is through main controller’s command or bench test PC’s command. 4.8.1.2 Monitor and Protection To monitor the module’s working condition the Controller uses a 1ms time base.

  • Page 88: No Load" Fault Protection

    Section 4 Theory of Operation Diamond Series™ • Over Drive • AGC unlocked • VSWR fault 4.8.1.3 “No Load” Fault Protection In case a PA module is not properly positioned in the slot or a circulator does not work, the Module Controller will turn the PA OFF and indicate a VSWR failure. 4.8.1.4 DC Switch The DC voltage supplied to the PA Pallets is controlled by the DC switch circuit.

  • Page 89: Driver Pallet

    Section 4 Theory of Operation Diamond Series™ 4.8.3 Driver Pallet The RF Module Driver Pallet provides for further gain of the RF signal. It delivers about 20 watts average of the 8 VSB signal to the input of a 6-way power splitter. The Driver Pallet’s structure is similar to the PA pallet and contains two push-pull amplifiers that are being fed from or through a 90 degree power splitter on the pallet.

  • Page 90: Pa Module Detailed Circuit Description

    The Controller Area Network (CAN) interface consists of the CAN Controller U41 and CAN Driver U40. Asynchronous communication is through RS485 driver U38. The protocol is a Harris protocol and data rate is 9600 baud. 4.9.1.2 DC Switch Circuit Description +32Vdc at E1 and E2 is applied to the drain of Q1 and Q2.

  • Page 91: Watchdog Circuits

    Section 4 Theory of Operation Diamond Series™ The output power sample enters at J6 and reports the power out to the micro. Three sections of U3 (pins 1, 7 and 10) are for the fast protection of the output of the module. The Output Overdrive signal is NOR’ed with other fault signals at U30 to create the fault interrupt request-L to the micro which will turn the module OFF.

  • Page 92: I And Q Vectors

    Section 4 Theory of Operation Diamond Series™ • 2-disables AGC • 3-disables normal fault strike (so 1 fault=OFF) • 4-store default enable-configuration • 5-NA • 6-NA • 7-NA • 8-reset microprocessor 4.9.1.6 I and Q vectors The 12 bit digital to analog convertor, U21, sends analog voltages to the phase and gain board to adjust the RF modules’...
  • Page 93 Section 4 Theory of Operation Diamond Series™ With no current in PIN diodes CR2 and CR3 or CR4 and CR5, R24 and R26 and R30 and R32 provide a nominal impedance termination for T2 and T3 ports 1 and 4 and therefor a minimum of signal transmission from the input (6) to the isolated (3) port.

  • Page 94: Pallet Circuit Description

    E1, 0-4.5v will represent 0 - 90 degrees of phase shift. Initial set up is 2.25 volts for 45 degrees of shift. 4.9.3 Pallet Circuit Description The Harris UHF MRF183-based PA pallet consists of 3 different sections. The description and operation of these sections will be detailed below. 4.9.3.1 Input Circuit The input circuit is formed by: a.

  • Page 95: Push-Pull Pairs

    Section 4 Theory of Operation Diamond Series™ 4.9.3.2 Push-Pull Pairs The amplification is performed by common-source push-pull pair of LDMOS MRF- 183 transistors. There are two push-pull pairs, Q1/Q3 and Q2/Q4, in the UHF PA pallet, making a total of 4 RF transistors. For proper operation, isolation between each push- pull pair is needed.

  • Page 96: Splitting

    Section 4 Theory of Operation Diamond Series™ The rules for the operation of 3 dB quadrature hybrids are listed below. Rules number 4 and beyond may be derived from the first three. Other types of hybrids follow similar sets of rules. 4.9.4.1 Splitting a.
  • Page 97 Section 4 Theory of Operation Diamond Series™ An adjustable attenuator can be made from a 3 dB hybrid and two 50 ohm rheostats or variable resistors ganged together. Power is input to port 1, and ports 2 and 3 are each terminated with one section of the rheostat, so that each sees the same impedance (see Figure 4-1).
  • Page 98 Section 4 Theory of Operation Diamond Series™ In our applications, PIN diodes in parallel with 50 ohm resistors are used instead of rheostats. The amount of bias current through the diodes controls their RF impedance. The impedances seen at ports 2 and 3 are the parallel combination of the 50 ohm and PIN diode impedances.

  • Page 99: Maintenance And Alignments

    PERATURE. DO NOT TOUCH THE MODULES WITH BARE HANDS AFTER THE TRANSMITTER HAS BEEN RUNNING, ESPECIALLY IN HIGH AMBIENT TEMPERA- TURE ENVIRONMENTS. SPECIAL GLOVES HAVE BEEN PROVIDED IN THE REAR OF THE CONTROL CABINET OR CAN BE OBTAINED FROM HARRIS, PART #0990006483 OR GRAINGER ITEM #4JF36. Routine Mechanical Maintenance 5.2.1...

  • Page 100: Check Connections

    Section 5 Maintenance and Alignments Diamond Series™ Printed circuit board edge connectors may be cleaned using a commercial cleaner such as Cramolin. Apply a small amount of the cleaner to the contacts, then remove it with a clean, lint-free cloth. Do not use a pencil eraser to clean contacts, as gold or silver contact plating will be removed.

  • Page 101: Rf Power Measurements

    Section 5 Maintenance and Alignments Diamond Series™ 5.2.4 RF Power Measurements The easiest and most accepted method for measuring DTV average power is using precision directional couplers calibrated for your particular frequency along with a Digital power meter and power sensor. A precision coupler for this application is defined as one in which the Coupling Ratio has been set at a specific operating frequency.
  • Page 102 Section 5 Maintenance and Alignments Diamond Series™ Jumpers are located behind the front panel. Figure 5-1 PA Power Supply Strapping 888-2463-001 3/6/08 WARNING: Disconnect primary power prior to servicing.

  • Page 103: Pa Modules

    TRANSMITTER HAS BEEN RUNNING, ESPECIALLY IN HIGH AMBIENT TEMPERA- TURE ENVIRONMENTS. SPECIAL GLOVES HAVE BEEN PROVIDED IN THE REAR OF THE CONTROL CABINET OR CAN BE OBTAINED FROM HARRIS, PART #099- 0006-483 OR GRAINGER ITEM #4JF36. Thermal Gloves have been provided in the rear of the Control Cabinet for handling of the PA Modules.

  • Page 104: Pa Module Pallet Replacement

    TRANSMITTER HAS BEEN RUNNING, ESPECIALLY IN HIGH AMBIENT TEMPERA- TURE ENVIRONMENTS. SPECIAL GLOVES HAVE BEEN PROVIDED IN THE REAR OF THE CONTROL CABINET OR CAN BE OBTAINED FROM HARRIS, PART #099- 0006-483 OR GRAINGER ITEM #4JF36. Using the protective gloves, remove the PA module from the STEP 1 Transmitter.
  • Page 105 Section 5 Maintenance and Alignments Diamond Series™ Unsolder the brown DC power wire from the bad pallet, and stretch it up. STEP 4 NOTE: Be sure to properly identify the failed pallet prior to removal. Figure 5-2 can be used to verify pallet location. The pallets are numbered 1 through 6 with pallet number 1 being closest to the front of the module.
  • Page 106 Section 5 Maintenance and Alignments Diamond Series™ per clamps can be used to finish removal of the board with less pressure required. Remove the thermal pad from the heat sink and discard. These pads STEP 7 should not be reused. Wipe off any thermal grease or other residue from the heat sink using the STEP 8 cotton cloth and alcohol.

  • Page 107: Power Calibration Procedures

    Section 5 Maintenance and Alignments Diamond Series™ Power Calibration Procedures There are basically 4 calibration procedures that could be required in the field: • Forward Power - For PA Cabinet and Total System Forward power calibration. • Reflected Power - For PA Cabinet and Total System Reflected power calibration. •...

  • Page 108: Forward Power Calibration

    Section 5 Maintenance and Alignments Diamond Series™ 5.5.1 Forward Power Calibration The PA Cabinet forward power and total system forward power RF detectors are set up to provide approximately 4 Vdc output at nominal operating power. The GUI will then be calibrated to this voltage to indicate the proper power reading.

  • Page 109: Reflected Power Calibration

    Section 5 Maintenance and Alignments Diamond Series™ NOTE: If the voltage drops to zero while you are attempting to calibrate, the cabinet's RF power has probably turned off (as per the 2 minute door timer). If that happens, close the cabinet door, press the transmitter On button, then open the cabinet door and resume calibration (does not apply to Control Cabinet).
  • Page 110 Section 5 Maintenance and Alignments Diamond Series™ Check the detector voltage reading on the GUI calibration screen for the STEP 5 stage you are calibrating. If it is 4V (+/- 0.1V) the rf detector requires no adjustment and you can continue with the next step to finish the software calibration.

  • Page 111: Drive Output Calibration

    Section 5 Maintenance and Alignments Diamond Series™ 5.5.3 Drive Output Calibration This reading is the Drive output of the Control Cabinet (before the Control Cabinet splitter in multiple cabinet transmitters). Start with the transmitter operating at your nominal power level as STEP 1 measured at the test load.

  • Page 112: Pa Cabinet Combiner Reject Calibration

    Section 5 Maintenance and Alignments Diamond Series™ 5.5.4 PA Cabinet Combiner Reject Calibration For transmitters with 2 or more PA Cabinets, there will be 1 or more reject loads on the combiner. RF samples from these loads are sent to the detector in the Control Cabinet. These detectors are calibrated for 4Vdc output when the reject load is dissipating maximum power.

  • Page 113: Module Combiner Reject Load Rf Detectors

    Section 5 Maintenance and Alignments Diamond Series™ 5.5.5 Module Combiner Reject Load RF Detectors The RF Detectors for the circulator reject loads in the PA Module combiner are set up in the factory and require no further adjustment. This means they can be replaced without any adjustment or calibration.

  • Page 114: Old Style Reject Load Detector Calibration

    Section 5 Maintenance and Alignments Diamond Series™ New Detector Located behind Heatsink Old Style Detector (a) Old Style Combiner (b) New Style Combiner Figure 5-4 Cabinet Comparison 5.5.5.1 Old Style Reject Load Detector Calibration Loosen the hardware holding the STEP 1 detector in the cabinet and turn it over.
  • Page 115 Section 5 Maintenance and Alignments Diamond Series™ Move the cable from the power sensor to the detector input to be STEP 6 calibrated. On the GUI display, go to the screen shown in Figure 5-5. It is under STEP 7 Main Menu, Maintenance, Calibrate Meter, Reject Load Calibrations.
  • Page 116 Section 5 Maintenance and Alignments Diamond Series™ Figure 5-5 PA Module Reject Load Calibration Screen 5-18 888-2463-001 3/6/08 WARNING: Disconnect primary power prior to servicing.

  • Page 117: New Style Reject Load Detector Calibration

    Section 5 Maintenance and Alignments Diamond Series™ 5.5.5.2 New Style Reject Load Detector Calibration Loosen the thumbscrews holding the reject load heatsinks in place. The STEP 1 detectors are located behind the 2nd and 3rd heatsinks from the top. The heatsink will basically just lean out and hang by the large coaxial cables coming from the circulators as shown in Figure 5-6.
  • Page 118 Section 5 Maintenance and Alignments Diamond Series™ voltage is OK but does not read 100%, go to STEP 8. If not, continue with the next step. If necessary adjust the trim pot for 4 VDC, as read on the GUI screen. To STEP 7 access the trim pots, remove the 6 cap nuts holding the cover plate.

  • Page 119: Rf Detector Adjustment

    Section 5 Maintenance and Alignments Diamond Series™ 5.5.6 RF Detector Adjustment This procedure is meant to be used in conjunction with the Forward and Reflected and Drive power calibration procedures. It provides the steps necessary to perform the hardware calibration of the 4 way detector in the PA Cabinet or the 4 way detector in the Control Cabinet (The Control Cabinet will have an 8 way detector if you have 3 or more PA Cabinets).

  • Page 120: Main Controller Vswr Foldback

    Section 5 Maintenance and Alignments Diamond Series™ Main Controller VSWR Foldback This adjustment will set the association between reflected voltage from the RF detector and the exciter foldback power for a CD-1A exciter only. NOTE: This procedure is not required for APEX exciters. For APEX exciters this fold- back setting is set via software and adjustment is not required.

  • Page 121: Driver Set-Up

    Section 5 Maintenance and Alignments Diamond Series™ Driver Set-up Complete set-up of the DD-1 Driver consists of several short procedures. Each of the procedures should be read and understood before starting. 5.7.1 Setting Bias for the Preamp The following procedure should be used when replacing the Driver Preamp Board or to simply re-bias the preamp as part of a complete DD-1 Driver tune up.
  • Page 122 Section 5 Maintenance and Alignments Diamond Series™ If this happens the following procedure should be performed to re-bias the pallet. If the proper bias currents cannot be achieved, then the pallet should be replaced. Shut off AC power to the driver with the ac switch on the rear of the STEP 1 driver.
  • Page 123 Section 5 Maintenance and Alignments Diamond Series™ Adjust one of the Pallet bias pots (R7 or R10) for an indication of STEP 7 25mVdc across R42 (25mV = 2.5amps) on the Driver Control Board. Then adjust the other pot for an indication of 50mVdc across R42 (50mV = 5amps).

  • Page 124: Driver Agc Set-Up

    Section 5 Maintenance and Alignments Diamond Series™ Place JP9 in the 2-3 position and JP12 in the 1-2 position. STEP 10 Turn ON the Driver by pressing S1 on the Driver Control Board. STEP 11 On the Driver Control Board, turn RF Amp Bias Adjust R59 CW until STEP 12 the voltage across R42 is now 40mVdc.

  • Page 125: Temperature And Overcurrent Alarm Set-Up

    Section 5 Maintenance and Alignments Diamond Series™ 5.7.5 Temperature and Overcurrent Alarm Set-up The following adjustments are made with the AC supply turned ON and the Driver not activated. a. Adjust R52 for 0.975 Vdc at TP10 for the overtemp threshold. b.

  • Page 126: Module Phasing

    Section 5 Maintenance and Alignments Diamond Series™ c. Turn on the transmitter and very slowly increase the exciter output until the digi- tal power meter reads 3 watts. If your sensor is rated at less than the normal 3.5W then simply increase the driver output to within 0.5W of its maximum rating for the calibration or use an attenuator.

  • Page 127: Pa Module Manual Phasing

    Section 5 Maintenance and Alignments Diamond Series™ 5.8.2 PA Module Manual Phasing This will only need to be done if the Auto phasing procedure does not work or to optimize a particular module. Note that module reject power is strongly coupled as pairs (module 1 and 2 effect each other the most, 3 and 4 effect each other the most...).

  • Page 128: Cabinet Phase And Gain

    Section 5 Maintenance and Alignments Diamond Series™ When decreasing reject power for a module, reduce it a small amount, STEP 3 then reduce the other in it’s pair a small amount and repeat until the pair reaches a minimum. Also try to maintain a balance for groups of 4 modules (1-4, 5-8, 9-12 and 13-16).
  • Page 129 Section 5 Maintenance and Alignments Diamond Series™ Figure 5-11 Cabinet Phase and Gain Screen 4.3 3/6/08 888-2463-001 5-31 WARNING: Disconnect primary power prior to servicing.

  • Page 130: Board Change Procedures

    Section 5 Maintenance and Alignments Diamond Series™ 5.10 Board Change Procedures It is possible to change either the Main Controller Board or the Life Support Board without turning the power off in the Control Cabinet and without shutting the transmitter off. The critical requirement here is that the cables be removed and replaced in the proper order.
  • Page 131 Main Controller Board Connector Locations RS-232 to RS-232 to (Connector Side) Exciter B Exciter A GUI Interface Harris Protocol Drive Change Remote I/O Mode Control LVPS/Parallel To Life Support LS Discrete From Life Support Figure 5-12 Main Controller Connector Locations...

  • Page 132: Life Support Board Hot-Swap

    Section 5 Maintenance and Alignments Diamond Series™ 5.10.2 Life Support Board Hot-Swap Go to the Transmitter Control screen and set the following: a. Set Drive Control to MANUAL and EXCITER A. b. Select REMOTE CONTROL - DISABLED. WARNING: BE SURE TO USE AN ANTI-STATIC WRIST STRAP WHEN HANDLING PC BOARDS OR IC’S TO PREVENT DAMAGE TO THE COMPONENTS.

  • Page 133: Ac Ok Set Point

    Section 5 Maintenance and Alignments Diamond Series™ 5.10.2.1 AC OK Set Point The AC OK set point is adjusted with R122 and measured at TP31. The voltage at this test point is determined by calculating a ratio of the DC voltage at TP33 (the actual AC voltage sample) to the measured AC line voltage and multiplying that ratio by the AC mains voltage at which the transmitter can again turn on (95V).

  • Page 134: Replacing The Cabinet Controller Board

    Section 5 Maintenance and Alignments Diamond Series™ 5.10.3 Replacing the Cabinet Controller Board The Cabinet Controller board at the top of the PA Cabinet has several switch settings which should most likely be set the same as the board being replaced. Table 5-2, Table 5-3, and Table 5-4 are provided here for quick reference for all of the switch settings of S1, S3 and S6.
  • Page 135 PA Cabinet Switch Caution: The standard VSWR Trip point should be used unless instructed Reflected Power Combinations otherwise by Harris Personnel. S3-3 Trip Adjust shown at right S3-2 (OFF) and S3-3 (OFF) = Standard 178 Watt Trip Point S3-2 (ON) and S3-3 (OFF) = 215 Watts...
  • Page 136 Section 5 Maintenance and Alignments Diamond Series™ Table 5-3 S1, Cabinet ID Switch Settings S1 Switch Cabinet Position Position Table 5-4 Dipswitch S6, AC Fail/External Interlock Settings S6 Switch Position Function AC_FAIL reporting to Control Cabinet. Set to ON For Cabinet #1 (Otherwise OFF) AC_FAIL reporting to Control Cabinet.
  • Page 137 Section 5 Maintenance and Alignments Diamond Series™ Figure 5-14 Cabinet Controller Component Locator 3/6/08 888-2463-001 5-39 WARNING: Disconnect primary power prior to servicing.

  • Page 138: In-System Programming (Isp) Procedures

    The software loaded into each of the transmitters controllers can be updated in the field using the ISP or In-System Programming feature. Detailed instructions on using the ISP applications are contained in the DiamondCD™ Software Manual, Harris part # 888-2470-001.

  • Page 139: Troubleshooting

    Diamond Series™ Section 6 Troubleshooting Controller Failure Modes 6.1.1 Module Controller The RF amplifier is self contained and protects itself from external and internal failures. Due to the number of modules in each PA Cabinet, redundancy is not necessary. The Module Controllers fail OFF and the pass FET requires an active micro to operate.

  • Page 140: Life Support Controller

    Section 6 Troubleshooting Diamond Series™ remaining on the air with the Life Support Board providing transmitter control. The procedure for Hot-Swap of the Main Controller Board is contained is Section 5, Maintenance. 6.1.4 Life Support Controller If the Life Support board failed, control would be from the Main Controller only, which is the normal control.

  • Page 141: Fault Listings

    Section 6 Troubleshooting Diamond Series™ which will interface directly into the Main Controller in the event of a GUI failure. Disconnect ribbon cable W29 from J7 on the back side of the Main Controller and connect the PC’s COM port to J7. A laptop loaded with the GUI program can also be connected to J6 or J35 on the Customer Interface Board if the local GUI fails.

  • Page 142: Exciter Fault

    Section 6 Troubleshooting Diamond Series™ 6.2.1.2 Exciter Fault RF present fault generated by the exciters. For CD-1A exciters, this fault is factory adjusted to trip when the rf level drops below 50%. However, this adjustment can be set to any level at the customers discretion via a pot in the exciter. For dual exciter/driver transmitters, (provided the other drive chain has no errors) the transmitter will switch to the alternate drive chain when this fault occurs.

  • Page 143: Driver Power Supply Over Current

    Section 6 Troubleshooting Diamond Series™ 6.2.2.3 Driver Power Supply Over Current Too much current drawn from +28volt supply. The current draw for the preamp and amplifier pallet in the Driver are summed together for this fault. Most likely fault is a shorted FET on the preamp or amplifier pallet but could also be caused by misadjustment of the over-current threshold.

  • Page 144: Rf Output Fault

    Section 6 Troubleshooting Diamond Series™ 6.2.2.6 RF Output Fault Driver RF output is lower than set minimum. Non-latching. Just a warning. Will cause switch to alternate Exciter/Driver if available. This level is user adjustable, see "5.7.4 RF OK indication set-up" on page 5-26. 6.2.3 Power Amplifier Module 3.1.2 The following is a listing of all faults internal to the PA Modules.

  • Page 145: Reference

    Section 6 Troubleshooting Diamond Series™ 6.2.3.3 Reference +5V reference voltage on the Module Control board is not within tolerance. Warning only. This effects module calibration. The module should be sent in for repair. 6.2.3.4 +12V Fault +12V not in tolerance on the Module Control board. Warning only. (Other problems likely to result).

  • Page 146: Pallet Over-Current

    Section 6 Troubleshooting Diamond Series™ 6.2.3.6 Pallet Over-current Too much current drawn by pallet. Latching fault. Threshold is 12 Amps for DHD and 8 amps for DCD. The module should be sent in for repair due to the fact that this fault is rarely caused by the pallet itself and usually requires bench troubleshooting (under power) to repair.

  • Page 147: Under Voltage

    Section 6 Troubleshooting Diamond Series™ • If the power supply is ruled out and this is the only module with this fault, the module should be swapped with another to rule out the slot into which the module is plugged. If the fault follows the module then it should be sent in for repair.

  • Page 148: Over Drive

    Section 6 Troubleshooting Diamond Series™ 6.2.3.14 Over Drive Input RF is too high. Trip point set to 1.9dB above nominal or approximately 23mW (15mW = nominal for DHD = ADC reading of 800 determined by pot in module). Modules does 3-strike. 6.2.3.15 Low Input Input RF is too LOW.

  • Page 149: Ac Mains Fault

    Section 6 Troubleshooting Diamond Series™ 6.2.4.1 AC Mains Fault AC power dropped below threshold (hardwired threshold on LVPS). Configuration saved to micro, and micro resets itself. Latching. Transmitter will automatically turn back on as soon as AC power returns. 6.2.4.2 AC Fault This is the fault output of the 3 phase ac monitor in the bottom of the PA Cabinet.

  • Page 150: External Interlock

    Section 6 Troubleshooting Diamond Series™ 6.2.4.6 External Interlock External interlock (cab or sys level) open. RF turns off. Depending on dipswitch settings on the Cabinet Controller(s), the transmitter may or may not come back on when fault goes away. If S3-6 on the Cabinet Controller is OFF, (Auto Restart mode) then the cabinet will automatically come back on when the interlock is closed again.

  • Page 151: Failsafe

    6.2.5.7 Com Fail There are 3 possible com failures that could show up on this screen: a. TCP/IP b. Harris Protocol RS-232 c. GUI 3/6/08 888-2463-001 6-13 WARNING: Disconnect primary power prior to servicing.

  • Page 152: Power Supplies 3.2

    Section 6 Troubleshooting Diamond Series™ 6.2.6 Power Supplies 3.2 Fault - +32V not present at module (module is the detector). Attached modules will not have RF output, and will 3-strike and report errors. This fault could also be caused by power supply over-temperature.

  • Page 153: Parts List

    Section 7 Parts List Replaceable Parts List Replaceable Parts List Index Table 7-1 CABINET, BASIC CONTROL, HP, AR - - - - - - - - - 992 9896 005 Table 7-2 RF LOAD ASSEMBLY - - - - - - - - - - - - - - - - 922 1179 001 Table 7-3 PWA, SYSTEM I/O - - - - - - - - - - - - - - - - - - 992 9906 001 Table 7-4...
  • Page 154 Diamond Series™ Section 7 Parts List Table 7-34 KIT, SPARE PALLET (547-638MHZ) - - - - - - - - - 994 9782 005 7-16 Table 7-35 ASSY, PWR SUPPLY, 240VAC, 5KW - - - - - - - - - 992 9900 007 7-16 Table 7-36 ASSY, PWR SUPPLY, 480VAC, 5KW - - - - - - - - - 992 9900 008...
  • Page 155 Diamond Series™ Section 7 Parts List Table 7-1 CABINET, BASIC CONTROL, HP, AR - 992 9896 005 Harris PN Description Qty UM Reference Designators (G) 041 1310 025 RUB SILICONE SPONGE 0.0 RL #A014, CUT INTO (2) 12" LG PIECES 041 1310 030 GASKET, RUBBER 11.0 FT #REAR FLANGE #EXCITER...
  • Page 156 917 2518 356 CABLE, CONTROL CABINET, MISC, 1.0 EA 917 2518 357 CABLE, DETECTOR 1.0 EA 917 2518 365 CABLE, HARRIS ISP, RS-232 1.0 EA HARRIS ISP, RS-232 CABLE 917 2518 372 CABLE, CTLR CAB, (APEX COMPAT) 1.0 EA 922 0900 366 FOAM, DOOR LOWER 1.0 EA FOR REAR DOOR...
  • Page 157 992 9908 002 CONTROL UNIT, DIAMOND HP 1.0 EA A012 992 9919 001 ASSEMBLY, LOW VOLTAGE SUPPLY 1.0 EA A004 Table 7-2 RF LOAD ASSEMBLY - 922 1179 001 Harris PN Description Qty UM Reference Designators (A) 055 0100 005 *THERMAL COMPOUND, 8OZ JAR 0.0 EA 302 0054 000 SCR, 4-40 X 3/8 2.0 EA...
  • Page 158 922 1177 001 COVER PLATE 1.0 EA 922 1178 001 RESISTOR HOUSING 1.0 EA Table 7-3 PWA, SYSTEM I/O - 992 9906 001 Harris PN Description Qty UM Reference Designators (P) 086 0001 010 *SEALANT GLYPTOL 0.0 QT 357 0033 000 SCREW 4-40 X .375 BHMS 40.0 EA 2/J001 2/J002 2/J003 2/J004 2/J005 2/...
  • Page 159 Diamond Series™ Section 7 Parts List Table 7-5 PWA, MAIN CONTROLLER - 992 9904 001 Harris PN Description Qty UM Reference Designators (P) 055 0100 005 *THERMAL COMPOUND, 8OZ JAR 0.0 EA 086 0001 010 *SEALANT GLYPTOL 0.0 QT 300 1485 000 SCR, 4-40 X 5/16 1.0 EA 1/XU054...
  • Page 160 939 8210 048 COVER, LV BOARD 1.0 EA #A001 992 9918 001 PWA, LOW VOLTAGE DISTRIBUTION 1.0 EA A001 Table 7-9 PWA, LOW VOLTAGE DISTRIBUTION - 992 9918 001 Harris PN Description Qty UM Reference Designators (K) 300 1485 000 SCR, 4-40 X 5/16 2.0 EA 1/CR003 1/CR004...
  • Page 161 Diamond Series™ Section 7 Parts List Table 7-10 DRIVER, 470 TO 550 MHZ, DD1 - 992 9914 001 Harris PN Description Qty UM Reference Designators (E) 992 9914 010 DRIVER, BASIC, DD1 1.0 EA 992 9975 001 PWA, PALLET, BAND ’A’...
  • Page 162 992 9926 001 PWA, DRIVER CONTROL 1.0 EA A004 992 9927 001 PWA, OUTPUT 1.0 EA A003 Table 7-15 PWA, DRIVER PREAMP - 992 9925 001 Harris PN Description Qty UM Reference Designators (G) 302 0052 000 SCR, 4-40 X 1/4 5.0 EA 5/PCB 302 0401 000 SCR, 4-40 X 1/4 2.0 EA 2/Q001...
  • Page 163 Diamond Series™ Section 7 Parts List Table 7-18 ASSY, 8 SECTION RF DETECTOR - 992 9916 002 Harris PN Description Qty UM Reference Designators (F) 308 0009 000 .25 FLAT WASHER BRS 8.0 EA USED ON J1-J8 358 1214 000 SCREWLOCK, FEMALE 1.0 EA...
  • Page 164 Diamond Series™ Section 7 Parts List 448 0920 000 HINGE, CONCEALED, 120 DEG 3.0 EA (FOR REAR DOOR) 548 2400 209 RES 121 OHM 1/2W 1% 0.0 EA (POSITIVE QTY 1 ON CONTROL CABINET B/M, TO BE INSTALLED IN LAST ’PA’ CABINET- END TERMINATION OF CAN BUS) R001 556 0142 000 ATTENUATOR FIXED SMA 4DB...
  • Page 165 992 9980 021 ASSY, DETECTOR, 8 WAY 1.0 EA 2ND UNIT A35, IF NEEDED CALLED OUT ON XMTR FORMAT BOM A034 Table 7-21 CONTROLLER, CABINET - 992 9899 001 Harris PN Description Qty UM Reference Designators (E) 448 0815 000 HINGE ADJUSTABLE BLACK 2.0 EA 943 5494 145 COVER CABINET CONTROLLER 1.0 EA...
  • Page 166 917 2515 165 FIRMWARE, CABINET CHIP CODE 1.0 EA U024 U034 992 9903 002 *PWA, CABINET CONTROLLER, SMT 1.0 EA Table 7-23 PWA,AMPLIFIER MODULE BACKPLANE - 992 9915 001 Harris PN Description Qty UM Reference Designators (G) 516 0790 000 CAP NTWK 1000PF 10% 50V 11.0 EA C001 C002 C003 C004 C005 C006...
  • Page 167 1.0 EA 943 5494 284 BRACKET, CIRCUIT BREAKER 4.0 EA #CB001 CB002 CB003 CB004 Table 7-27 PA MODULE, 600W, 470-550MHZ, - 992 9898 005 Harris PN Description Qty UM Reference Designators (H) 817 2416 242 PA MODULE SPEC, BAND A, 600W 0.0 EA...
  • Page 168 Section 7 Parts List 992 9980 001 COMBINER 636-860MHZ HP ASSBLY 1.0 EA A014 Table 7-30 PA MODULE, 600W 736-806MHZ - 992 9898 008 Harris PN Description Qty UM Reference Designators (G) 817 2416 245 PA MODULE SPEC, BAND D, 600W 1.0 EA...
  • Page 169 Diamond Series™ Section 7 Parts List Table 7-36 ASSY, PWR SUPPLY, 480VAC, 5KW - 992 9900 008 Harris PN Description Qty UM Reference Designators (C) 606 0990 000 CIRCUIT BREAKER, 20A 2P 480VAC 1.0 EA CB001 736 0354 000 *PSU, SW, 32VDC 240/480VAC 5KW 1.0 EA PS001...
  • Page 170 Diamond Series™ Section 7 Parts List Table 7-40 KIT, SINGLE EXCITER - 994 9746 002 Harris PN Description Qty UM Reference Designators (A) 700 1263 000 RF LOAD, 50 OHM 3.0 EA 1R3, #1SP1 939 8210 093 PANEL, BLANK, DRIVER 2.0 EA 1 USED FOR DRIVER, 1 USED FOR...
  • Page 171 Section 7 Parts List 943 5494 395 GND STRAP, EXTERNAL AIR 1.0 EA Table 7-43 KIT, (4) MODULE SUPPORT - 994 9783 018 Harris PN Description Qty UM Reference Designators (E) 357 0089 001 GUIDE MODULE 8.0 EA #A001 - A016 404 0902 000 HEATSINK, CIRCULATOR 4.0 EA...
  • Page 172 Diamond Series™ Section 7 Parts List ANDREW PPP IS SPECIFIED) LAST TWO DIGITS OF PART NUMBER INDICATES CHANNEL, XX = US CHANNELS 14-69 484 0535 000 FILTER, UHF DTV; (REFLECTIVE) 0.0 EA (1 REQ’D) (USED WHEN STF "COOL FUEL" AND VENDOR DIELECTRIC IS SPECIFIED) LAST TWO DIGITS OF PART NUMBER INDICATES CHANNEL, XX = US...
  • Page 173 Diamond Series™ Section 7 Parts List 943 5510 303 6-1/8 TEST LOAD LINE KIT-DIE 0.0 EA (OPTION, 1 REQ’D IF DIELECTRIC RF COMPONETS ARE REQUESTED); SUFFICIENT QUANTITIES TO CONNECT FROM THE PA CABINETS TO THE DTV MASK FILTER 943 5510 500 KIT,RF(MYAT),DIAMOND,5-PA 0.0 EA (OPTION, 1 REQ’D IF MYAT RF COMPONETS ARE REQUESTED);...

  • Page 174: Kit, Spare Pallet (547-638Mhz)

    Diamond Series™ Section 7 Parts List 992 9914 002 DRIVER, 547 TO 638 MHZ, DD1 0.0 EA OPTION, THIS FREQUENCY (ONE REQUIRED "1A8" WITH SINGLE EXCITER) (TWO REQUIRED "1A8", "1A9" WITH DUAL EXCITER) 992 9914 003 DRIVER, 636 TO 741 MHZ, DD1 0.0 EA OPTION, THIS FREQUENCY (ONE REQUIRED "1A8"...
  • Page 175 Diamond Series™ Section 7 Parts List Table 7-45 KIT, XMTR INSTALL, 5 P.A. CAB - 994 9751 005 Harris PN Description Qty UM Reference Designators (D) 003 4010 045 CU, STRAP .020 X 2" 140.0 FT #GROUND SYSTEM 252 0003 000 WIRE, STRD 20AWG WHT 100.0 FT...
  • Page 176 Diamond Series™ Section 7 Parts List INDICATES CHANNEL, XX = US CHANNELS 14-69 484 0532 000 FILTER, UHF DTV, (REFLECTIVE) 0.0 EA (1 REQ’D) (USED WHEN STF "COOL FUEL" AND VENDOR ANDREW PPP IS SPECIFIED) LAST TWO DIGITS OF PART NUMBER INDICATES CHANNEL, XX = US CHANNELS 14-69 484 0535 000 FILTER, UHF DTV;...

  • Page 177: Kit, Rf (Myat), Diamond, 4Pa

    Diamond Series™ Section 7 Parts List REQUESTED); SUFFICIENT QUANTITIES TO CONNECT FROM THE PA CABINETS TO THE DTV MASK FILTER 943 5510 400 KIT, RF (MYAT), DIAMOND, 4PA 0.0 EA (OPTION, 1 REQ’D IF MYAT RF COMPONETS ARE REQUESTED); SUFFICIENT QUANTITIES TO CONNECT FROM THE PA CABINETS TO THE DTV MASK FILTER...

  • Page 178: Kit, Xmtr Install, 4 P.a. Cab

    0.0 EA OPTION, ORDER 1 OR 2 EXCITERS AS REQUIRED. (1APEX W/ 1 CD1A PERMISSIBLE) Table 7-47 KIT, RF (MYAT), DIAMOND, 4PA - 943 5510 400 Harris PN Description Qty UM Reference Designators (D) 618 0378 000 LINE XMISSION 3-1/8 4.0 EA...
  • Page 179 2.0 EA 994 8442 005 KIT, PROBE (1.125); 3-1/8 LINE 4.0 EA Table 7-48 KIT, RF (DIE), DIAMOND, 4-PA - 943 5510 401 Harris PN Description Qty UM Reference Designators (E) 618 0633 000 XMSN LN 6-1/8 20FT 50 OHM 1.0 EA...
  • Page 180 Diamond Series™ Section 7 Parts List OF PART NUMBER INDICATES CHANNEL, XX = US CHANNELS 14-69 484 0509 000 FILTER, UHF DTV; (ABSORBATIVE) 0.0 EA (1 REQ’D) (USED WHEN VENDOR PASSIVE POWER IS SPECIFIED) TO BE ORDERED FROM SCHEDULE ’A’. LAST TWO DIGITS OF PART NUMBER INDICATES CHANNEL, XX = US CHANNELS 14-69...

  • Page 181: Kit, Rf (Myat), Diamond, 3Pa

    Diamond Series™ Section 7 Parts List 620 2957 006 CIRCULATOR, UHF 1000W 0.0 EA (48 REQ’D FOR 596-704 MHZ) 2CIR1 - 2CIR16, 3CIR1 - 3CIR16, 4CIR1 - 4CIR16 620 2957 007 CIRCULATOR, UHF 1000W 0.0 EA (48 REQ’D FOR 701-860 MHZ) 2CIR1 - 2CIR16, 3CIR1 - 3CIR16, 4CIR1 - 4CIR16 620 3065 001 SPLITTER, POWER 16-WAY...

  • Page 182: Kit, Xmtr Install, 3 P.a. Cab

    Diamond Series™ Section 7 Parts List 992 8553 001 PWA, MOV-AC 198-250 VAC 0.0 EA (3 REQ’D THIS VOLTAGE) 2A17A1, 3A17A1, 4A17A1 992 8553 005 PWA, MOV-AC 384-552VAC 0.0 EA (3 REQ’D THIS VOLTAGE) 2A17A1, 3A17A1, 4A17A1 992 9896 005 CABINET, BASIC CONTROL, HP, AR 1.0 EA UNIT #1 992 9897 020 CABINET, BASIC H.P., ’PA’...
  • Page 183 0.0 EA OPTION, ORDER 1 OR 2 EXCITERS AS REQUIRED. (1APEX W/ 1 CD1A PERMISSIBLE) Table 7-51 KIT, RF (MYAT), DIAMOND, 3PA - 943 5510 300 Harris PN Description Qty UM Reference Designators (D) 618 0378 000 LINE XMISSION 3-1/8 3.0 EA...
  • Page 184 Diamond Series™ Section 7 Parts List Table 7-53 KIT, XMTR INSTALL, 3 P.A. CAB - 994 9751 003 Harris PN Description Qty UM Reference Designators (D) 003 4010 045 CU, STRAP .020 X 2" 120.0 FT #GROUND SYSTEM 252 0003 000 WIRE, STRD 20AWG WHT 100.0 FT...
  • Page 185 Diamond Series™ Section 7 Parts List INDICATES CHANNEL, XX = US CHANNELS 14-69 484 0530 000 FILTER, UHF DTV, (REFLECTIVE) 0.0 EA (1 REQ’D) (USED WHEN STF "COOL FUEL" AND VENDOR ANDREW PPP IS SPECIFIED) LAST TWO DIGITS OF PART NUMBER INDICATES CHANNEL, XX = US CHANNELS 14-69 484 0533 000 FILTER, UHF DTV;...

  • Page 186: Kit, Rf (Myat), Diamond, 2Pa

    Diamond Series™ Section 7 Parts List LOAD THROUGH THE PATCH PANEL OR COAX SWITCH 943 5510 103 3-1/8 TEST LOAD LINE KIT-DIE 0.0 EA (OPTION, 1 REQ’D IF DIELECTRIC RF COMPONETS ARE REQUESTED); SUFFICIENT QUANTITIES TO CONNECT THE OUTPUT OF THE DTV MASK FILTER TO THE TEST LOAD THROUGH THE PATCH PANEL OR COAX SWITCH...

  • Page 187: Kit, Xmtr Install, 2 P.a. Cab

    0.0 EA OPTION, ORDER 1 OR 2 EXCITERS AS REQUIRED. (1APEX W/ 1 CD1A PERMISSIBLE) Table 7-55 KIT, RF (MYAT), DIAMOND, 2PA - 943 5510 200 Harris PN Description Qty UM Reference Designators (E) 618 0378 000 LINE XMISSION 3-1/8 2.0 EA...
  • Page 188 843 5510 200 LAYOUT, RF EQUIPMENT, DHD60P2 0.0 EA 994 8442 005 KIT, PROBE (1.125); 3-1/8 LINE 3.0 EA Table 7-56 KIT, RF (DIE), DIAMOND, 2-PA - 943 5510 201 Harris PN Description Qty UM Reference Designators (F) 618 0635 000 LINE, XMSN 3-1/8" 2.0 EA 618 0696 000 LINE, XMISSION 1-5/8 1.0 EA...
  • Page 189 Diamond Series™ Section 7 Parts List SCHEDULE ’A’. LAST TWO DIGITS OF PART NUMBER INDICATES CHANNEL, XX = US CHANNELS 14-69 484 0511 000 FILTER, UHF DTV; (REFLECTIVE) 0.0 EA (1 REQ’D) (USED WHEN VENDOR DIELECTRIC IS SPECIFIED) TO BE ORDERED FROM SCHEDULE ’A’.
  • Page 190 Diamond Series™ Section 7 Parts List 620 3035 000 COMBINER, 3DB HYB 636-860MHZ 0.0 EA (1 REQ’D FOR 636-860MHZ, COMBINES 2 PA CABINETS RF OUTPUT PORTS) 620 3065 001 SPLITTER, POWER 16-WAY 0.0 EA (2 REQ’D FOR 470-638MHZ) 2A31, 3A31 620 3065 002 SPLITTER, POWER 16-WAY 0.0 EA (2 REQ’D FOR 636-860MHZ) 2A31, 3A31...
  • Page 191 Diamond Series™ Section 7 Parts List 992 7256 000 FILTER, LOW PASS DTV IN-SYSTEM 0.0 EA (2 REQ’D) LAST TWO DIGITS OF PART NUMBER INDICATES CHANNEL, XX = US CHANNELS 14-69 992 8553 001 PWA, MOV-AC 198-250 VAC 0.0 EA (2 REQ’D THIS VOLTAGE) 2A17A1, 3A17A1 992 8553 005 PWA, MOV-AC 384-552VAC 0.0 EA (2 REQ’D THIS VOLTAGE)

  • Page 192: Upgrade Kit, (4) Mod & P/S

    0.0 EA OPTION, ORDER 1 OR 2 EXCITERS AS REQUIRED. (1APEX W/ 1 CD1A PERMISSIBLE) Table 7-59 KIT, (4) BLANK MOD & P.S. - 994 9783 002 Harris PN Description Qty UM Reference Designators (K) 357 0103 001 MODULE FRONT CLAM SHELL 4.0 EA (PART OF BLANK MODULE...
  • Page 193 QTY 2 FOR 8 WAY, ORDER QTY 3 FOR 12 WAY, ORDER QTY 4 FOR 16 WAY) Table 7-61 TRANSMITTER, DHD30P1 - 994 9813 001 Harris PN Description Qty UM Reference Designators (U) 484 0505 000 FILTER, UHF DTV, (REFLECTIVE) 0.0 EA (1 REQ’D) (USED WHEN VENDOR...
  • Page 194 Diamond Series™ Section 7 Parts List 484 0508 000 FILTER, UHF DTV; (ABSORBATIVE) 0.0 EA (1 REQ’D) (USED WHEN VENDOR PASSIVE POWER IS SPECIFIED) TO BE ORDERED FROM SCHEDULE ’A’. LAST TWO DIGITS OF PART NUMBER INDICATES CHANNEL, XX = US CHANNELS 14-69 484 0511 000 FILTER, UHF DTV;...

  • Page 195: Kit, Rf (Myat), Diamond, 1Pa

    Diamond Series™ Section 7 Parts List 740 1059 000 MON, PH 430-480V 3PH 0.0 EA (1 REQ’D THIS VOLTAGE) 2A17 740 1139 000 PHASE MONITOR 208V-240V 0.0 EA (1 REQ’D THIS VOLTAGE) 2A17 917 2515 348 CABLE PACKAGE, HELIAX 1PA 1.0 EA 939 8210 092 SCH LIST, BASIC DIAMOND HP 0.0 EA (COMMON DOCUMENTATION...

  • Page 196: Kit, Xmtr Install, 1 P.a. Cab

    Diamond Series™ Section 7 Parts List 992 9900 007 ASSY, PWR SUPPLY, 240VAC, 5KW 0.0 EA 2A18- 2A25 (8 REQ’D THIS VOLTAGE) 992 9900 008 ASSY, PWR SUPPLY, 480VAC, 5KW 0.0 EA 2A18-2A25 (8 REQ’D THIS VOLTAGE) 992 9914 001 DRIVER, 470 TO 550 MHZ, DD1 0.0 EA OPTION, THIS FREQUENCY (ONE REQUIRED "1A8"...
  • Page 197 0.0 EA OPTION, ORDER 1 OR 2 EXCITERS AS REQUIRED. (1APEX W/ 1 CD1A PERMISSIBLE) Table 7-62 KIT, RF (MYAT), DIAMOND, 1PA - 943 5510 100 Harris PN Description Qty UM Reference Designators (D) 618 0378 000 LINE XMISSION 3-1/8 1.0 EA...
  • Page 198 Diamond Series™ Section 7 Parts List TO BE ORDERED FROM SCHEDULE ’A’. LAST TWO DIGITS OF PART NUMBER INDICATES CHANNEL, XX = US CHANNELS 14-69 484 0511 000 FILTER, UHF DTV; (REFLECTIVE) 0.0 EA (1 REQ’D) (USED WHEN VENDOR DIELECTRIC IS SPECIFIED) TO BE ORDERED FROM SCHEDULE ’A’.

  • Page 199: Kit, Rf Line, Diamond, 1-Pa

    Diamond Series™ Section 7 Parts List 700 1422 019 LOAD, 50 OHM, 1/2W 4.0 EA FOR UNUSED PORTS ON 16-WAY SPLITTER 740 1059 000 MON, PH 430-480V 3PH 0.0 EA 2A17 K2, (1 REQ’D THIS VOLTAGE) 740 1139 000 PHASE MONITOR 208V-240V 0.0 EA 2A17 K2, (1 REQ’D THIS VOLTAGE) 917 2515 348 CABLE PACKAGE, HELIAX 1PA...
  • Page 200 Diamond Series™ Section 7 Parts List 992 9898 005 PA MODULE, 600W, 470-550MHZ, 0.0 EA (12 REQ’D, THIS FREQUENCY) 2A1-2A12 992 9898 006 PA MODULE, 600W, 547-638MHZ 0.0 EA 12 REQ’D, THIS FREQUENCY) 2A1-2A12 992 9898 007 PA MODULE, 600W, 636-741MHZ 0.0 EA (12 REQ’D, THIS FREQUENCY) 2A1-2A12 992 9898 008 PA MODULE, 600W 736-806MHZ...

  • Page 201: Upgrade Kit, (8) Mod & P.s

    0.0 EA OPTION, ORDER 1 OR 2 EXCITERS AS REQUIRED. (1APEX W/ 1 CD1A PERMISSIBLE) Table 7-66 KIT, RF LINE, DIAMOND, 1-PA - 943 5503 100 Harris PN Description Qty UM Reference Designators (B) 618 0378 000 LINE XMISSION 3-1/8 1.0 EA...
  • Page 202 Diamond Series™ Section 7 Parts List 484 0524 000 FILTER, UHF DTV; (ABSORBATIVE) 0.0 EA (1 REQ’D) (USED WHEN STF "COOL FUEL" AND VENDOR ANDREW PPP IS SPECIFIED) LAST TWO DIGITS OF PART NUMBER INDICATES CHANNEL, XX = US CHANNELS 14-69 484 0527 000 FILTER, UHF DTV;...
  • Page 203 Diamond Series™ Section 7 Parts List 943 5510 101 KIT, RF (DIE), DIAMOND, 1-PA 0.0 EA (OPTION, 1 REQ’D IF DIELECTRIC RF COMPONETS ARE REQUESTED); SUFFICIENT QUANTITIES TO CONNECT FROM THE PA CABINET TO THE DTV MASK FILTER 943 5510 102 3-1/8 TEST LOAD LINE KIT-MYAT 0.0 EA (OPTION, 1 REQ’D IF MYAT RF COMPONETS ARE REQUESTED);...
  • Page 204 0.0 EA OPTION, ORDER 1 OR 2 EXCITERS AS REQUIRED. (1APEX W/ 1 CD1A PERMISSIBLE) Table 7-68 UPGRADE KIT, (8) MOD & P.S. - 994 9783 004 Harris PN Description Qty UM Reference Designators (F) 055 0100 005 *THERMAL COMPOUND, 8OZ JAR 1.0 EA USED WITH CIRCULATORS AND...
  • Page 205 STRIPLINE COMBINER, ORDER QTY 3 FOR 12 WAY, ORDER QTY 4 FOR 16 WAY UPGRADE) Table 7-69 TRANSMITTER, DHD8P1 - 994 9810 001 Harris PN Description Qty UM Reference Designators (Z) 484 0505 000 FILTER, UHF DTV, (REFLECTIVE) 0.0 EA (1 REQ’D) ( USED WHEN VENDOR...
  • Page 206 Diamond Series™ Section 7 Parts List DIGITS OF PART NUMBER INDICATES CHANNEL, XX = US CHANNELS 14-69 484 0511 000 FILTER, UHF DTV; (REFLECTIVE) 0.0 EA (1 REQ’D) (USED WHEN VENDOR DIELECTRIC IS SPECIFIED) TO BE ORDERED FROM SCHEDULE ’A’. LAST TWO DIGITS OF PART NUMBER INDICATES CHANNEL, XX = US CHANNELS 14-69...
  • Page 207 Diamond Series™ Section 7 Parts List 620 3065 003 LOW BAND SPLITTER, 4-WAY 0.0 EA (1 REQ’D FOR 470-638MHZ) 2A31 620 3065 004 HIGH BAND SPLITTER, 4-WAY 0.0 EA (1 REQ’D FOR 636-860MHZ) 2A31 620 3175 000 ADAPTER, SMA JACK TO SMA JACK 2.0 EA (2 REQ’D THESE ARE ONLY REQ’D ON THE DHD8P1 XMTR.) 740 1059 000 MON, PH 430-480V 3PH 0.0 EA , (1 REQ’D THIS VOLTAGE)
  • Page 208 Diamond Series™ Section 7 Parts List 992 9896 005 CABINET, BASIC CONTROL, HP, AR 1.0 EA UNIT #1 992 9897 020 CABINET, BASIC H.P., ’PA’ 1.0 EA UNIT #2 992 9898 005 PA MODULE, 600W, 470-550MHZ, 0.0 EA (4 REQ’D, THIS FREQUENCY) 2A1-2A4 992 9898 006 PA MODULE, 600W, 547-638MHZ 0.0 EA (4 REQ’D, THIS FREQUENCY)
  • Page 209 0.0 EA OPTION, ORDER 1 OR 2 EXCITERS AS REQUIRED. (1APEX W/ 1 CD1A PERMISSIBLE) Table 7-70 UPGRADE KIT, (12) MOD & P.S. - 994 9783 005 Harris PN Description Qty UM Reference Designators (D) 055 0100 005 *THERMAL COMPOUND, 8OZ JAR 1.0 EA USED WITH CIRCULATORS AND...
  • Page 210 Diamond Series™ Section 7 Parts List 7-58 888-2463-001 7/08/03 WARNING: Disconnect primary power prior to servicing.

  • Page 211: Appendix A Cutting And Soldering Transmission Line

    Diamond Series™ Appendix A Cutting and Soldering Transmission Line Suggested Procedure For Cutting And Soldering Transmission Line 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.
  • Page 212 Power Band Saw (can be rented) and Extra Blades Crowbar Silver Solder 1/16 inch diameter, 30%-45%, Hard Stay-Silv Rope #45, Aladdin #45, HARRIS part number 099 0002 238 Paste flux (Engelhard Ultra-Flux 1 lb jar) HARRIS part Saw Horses or Cutting Table number 086 0004 046...
  • Page 213 Appendix A Cutting and Soldering Diamond Series™ Figure A-1 Outer Conductor Measurements 3/6/08 888-2463-001 WARNING: Disconnect primary power prior to servicing.
  • Page 214 Appendix A Cutting and Soldering Diamond Series™ Figure A-2 Measurements When Elbows Are Used Figure A-3 Measurements for Cutback of Inner Conductor Figure A-4 Guide for Use with Hand Hack Saw 888-2463-001 3/6/08 WARNING: Disconnect primary power prior to servicing.
  • Page 215 Appendix A Cutting and Soldering Diamond Series™ Figure A-5 Cutting with Hand Band Saw 3/6/08 888-2463-001 WARNING: Disconnect primary power prior to servicing.
  • Page 216 Appendix A Cutting and Soldering Diamond Series™ Figure A-6 Swing Arm Band Saw Cutting Tips 888-2463-001 3/6/08 WARNING: Disconnect primary power prior to servicing.
  • Page 217 Appendix A Cutting and Soldering Diamond Series™ Figure A-7 Crimped Cut (Exaggerated) Figure A-8 Bevel and Remove Burrs Figure A-9 Torch Aiming Location 3/6/08 888-2463-001 WARNING: Disconnect primary power prior to servicing.

  • Page 218: Cutting The Transmission Line

    Appendix A Cutting and Soldering Diamond Series™ Cutting the Transmission Line A square smooth cut is required. Several methods may be used with the choice depending on tools and labor available. a. METHOD #1. A hand hack saw and cast iron cutting guide are a good combina- tion 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.

  • Page 219: Soldering Procedure

    Appendix A Cutting and Soldering Diamond Series™ 1.4.1 Soldering Procedure a. The line should be free of burrs. The outer corner may be beveled slightly to make assembly of flange easier. See Figure A-8. b. Emery cloth should be used to clean the outside of the line where it will meet the flange.

  • Page 220: Cleaning The Soldered Joint

    Appendix A Cutting and Soldering Diamond Series™ 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.

  • Page 221: Alternate Cleaning Method

    Appendix A Cutting and Soldering Diamond Series™ 1.5.1 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 •...
  • Page 222 Appendix A Cutting and Soldering Diamond Series™ A-12 888-2463-001 3/6/08 WARNING: Disconnect primary power prior to servicing.

  • Page 223: Surge, Lightning And Grounding Considerations

    Diamond Series™ Appendix B Surge, Lightning and Grounding Considerations Surge and Lightning Protection A lightning storm can cause transients in excess of 2 kV to appear on power or field signal lines. The duration of these transients varies from a few hundred nanoseconds to a few microseconds.

  • Page 224: System Grounding

    Appendix B Surge, Lightning and Diamond Series™ 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.
  • Page 225 Appendix B Surge, Lightning and Diamond Series™ B.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.
  • Page 226 Appendix B Surge, Lightning and Diamond Series™ B.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.
  • Page 227 Appendix B Surge, Lightning and Diamond Series™ 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.
  • Page 228 Appendix B Surge, Lightning and Diamond Series™ 888-2463-001 3/6/08 WARNING: Disconnect primary power prior to servicing.
  • Page 229 Diamond Series™ Appendix C Pioneer Power Supply Manual This section contains the Pioneer Magnetics 32 Vdc power supply manual. It contains information regarding power supply installation, maintenance, and repair. 3/6/08 888-2463-001 WARNING: Disconnect primary power prior to servicing.
  • Page 230 Appendix C Pioneer Power Supply Diamond Series™ 888-2463-001 3/6/08 WARNING: Disconnect primary power prior to servicing.
  • Page 231 Appendix C Pioneer Power Supply Diamond Series™ Instruction Manual Model PM33215F- 8 Type Number 32D157-156A 240/480VAC Single Phase Strappable PM33215F-8 Instructional Manual, Rev 3, 4/23/2007 3/6/08 888-2463-001 WARNING: Disconnect primary power prior to servicing.
  • Page 232 This manual is the proprietary property of Pioneer Magnetics. It is submitted under a confidential relationship with Harris Corporation for the purpose of including this material into their Diamond Transmitter Documentation. Further, this document shall not be disclosed to any unauthorized person, be incorporated in other projects, be reproduced in whole or part, or become the basis for a manufactured product without prior written consent from Pioneer Magnetics, Inc.
  • Page 233 Appendix C Pioneer Power Supply Diamond Series™ Table of Contents Page Section 1 Incoming Inspection Section 2 Installation Cautions Section 3 Environmental Section 4 Installation Procedure Section 5 Description Series and Parallel Configurations Working Block Diagram Theory of Operation Section 6 Specifications Section 7 Outline Drawing and Mounting...

  • Page 234: Incoming Inspection

    Six inches of clearance (front and rear) is recommended to maintain adequate forced Air Cooling. Refer to Harris transmitter manual for your transmitter. Section 5.3.2 for Diamond transmitter and Section 5.4 for Ranger transmitter. Note replacement power supply input is selectable for 240 or 480VAC.

  • Page 235: Description

    Appendix C Pioneer Power Supply Diamond Series™ Section 5 Description Model PM33215F-8 Front End PFC Switching Power supply is specifically designed for applications that require either 240VAC or 480VAC Single Phase AC Input. The AC Input connection is strappable for either 240VAC or 480VAC as shown in Fig 1 below. N L G NPUT WIRING INPUT WIRING...
  • Page 236 Appendix C Pioneer Power Supply Diamond Series™ 888-2463-001 3/6/08 WARNING: Disconnect primary power prior to servicing.

  • Page 237: Theory Of Operation

    Appendix C Pioneer Power Supply Diamond Series™ Theory of Operation The unit is made up of two separate converters boards called the Master Board and the Slave Board. The two PCBs are identical. The difference is how the two boards are populated with components.
  • Page 238 Appendix C Pioneer Power Supply Diamond Series™ The pulses from Z101 are fed to a driver U101 which drives both the drive transformer(T102) in the master board and the slave board. An option hybrid Z102 is configured to allow the output to be inhibited by external signal provided by the customer on the DB25 pin option connector.

  • Page 239: Specifications

    Appendix C Pioneer Power Supply Diamond Series™ Section 6 Specifications Key Features: Power Factor Correction – 0.99, Single Phase 0 C to +50 C at Full Load Standard 5” x 8” x 14” Case Output Fully Floating Over Current Protection Over Voltage Protection Remote Sense Over Temperature Protection...
  • Page 240 Appendix C Pioneer Power Supply Diamond Series™ Environmental: Over Temp Protection: The power supply is built with a thermal switch mounted on the heat sink with switching FETs. The trip automatically shuts down and latches the unit off. The recommended cooling time is 2 to 5 minutes.
  • Page 241 Appendix C Pioneer Power Supply Diamond Series™ 3/6/08 888-2463-001 C-13 WARNING: Disconnect primary power prior to servicing.

  • Page 242: I/O Interface Connections

    Appendix C Pioneer Power Supply Diamond Series™ Section 8 I/O Interface Connections ATTENTION: The following Procedure Must Be Carried Out By An Electrically Competent Person Using Appropriate ESD and Soldering Procedures. “Electrically Competent Person” as defined in the IEC-60215 Safety Standard Option Connector DB25: (-156A) Pin 1...
  • Page 243 “Electrically Competent Person” as defined in the IEC-60215 Safety Standard A. Fan Failure Detection in Harris Transmitter: In Harris transmitters, the power supply is installed in a removable tray assembly. The power supply is connected to the AC mains power via a circuit breaker on the power supply assembly front panel.
  • Page 244 Appendix C Pioneer Power Supply Diamond Series™ C. Standalone Power Supply Bench Test: Precautions: Use a test bench with proper ESD protection An ESD area is recommended to place the power supply AC Input souce must be brought in via variac to the power supply AC input terminal block with the on/off switch in off position on the variac Electronic load is recommended instead of resistive load...
  • Page 245 Appendix C Pioneer Power Supply Diamond Series™ Test Procedure: 1. Apply AC slowly using the variac till input voltage reaches 240V. 2. Check if the fan is running. If yes, go to step 3 If no, go to section 10 to check and replace input fuses If problem persist, go to section 13 3.

  • Page 246: Replacing Ac Input Fuses

    Appendix C Pioneer Power Supply Diamond Series™ Section 10 Replacing AC Input Fuses Step 1: To Remove the Top cover, follow the instructions below. Top Cover Remove the six screws on one side at the marked locations. The screws marked 1 and 6 are covered by the Warranty labels.
  • Page 247 Appendix C Pioneer Power Supply Diamond Series™ Step 3: Lift the top cover and remove it. Step 4: To pull Front Panel out follow the instructions as shown below: Remove both vertical bus bars by removing the four bolts Remove the two AC wires from the top AC terminal block only Pull out the front panel carefully as shown Do not detach or remove any wire assemblies...
  • Page 248 Appendix C Pioneer Power Supply Diamond Series™ Step 5: Looking from the top , the fuse F1 on the Master Board is shown as indicated. Remove the fuse and replace it with the spare one (not provided). See section 12 for order information Fuse F1 on the Master Board 20A, 250V 3AB Normal Blo Fuse...

  • Page 249: Replacing Fan Assembly

    Appendix C Pioneer Power Supply Diamond Series™ Section 11 Replacing Fan Assembly Step 1: To Remove the Top cover, follow the instructions below. Top Cover Remove the six screws on one side at the marked locations. The screws marked 1 and 6 are covered by the Warranty labels. Remove these screws w/o removing the labels.
  • Page 250 Appendix C Pioneer Power Supply Diamond Series™ Step 1: To remove the fan panel, follow the instruction below Remove this screw holding the fan panel to the bottom chassis on one side Note screw size and location Remove this screw holding the fan panel to the bottom chassis on the other side Note screw size and location...
  • Page 251 Appendix C Pioneer Power Supply Diamond Series™ Step 2: Unplug the fan cable assembly as shown Unplug the fan wire assembly here Fan wire assembly Step 3: Remove the fan assembly by pulling it out and replace it with the spare One, following steps 2 and 1 in the reverse order.
  • Page 252 Appendix C Pioneer Power Supply Diamond Series™ Section 12 Ordering parts for Field Repairs PMI Part # Description 533033 Fuse F1, 20A, 250V, 3AB Normal Blo 124664-1 Complete Fan Assembly Including Labor 124203 Fan Panel 429006 Fan Guard 4.5” 8 ring 466044-0075 Screw Pan Hd Phil 4-40X3/4 471115...
  • Page 253 Appendix C Pioneer Power Supply Diamond Series™ 3/6/08 888-2463-001 C-25 WARNING: Disconnect primary power prior to servicing.

  • Page 254: Return Units To The Factory For Repair Or Refurb

    Appendix C Pioneer Power Supply Diamond Series™ Section 13 Return Units to the Factory for Repair or Refurbishment Contact Information to return unit: Customer Service Manager Tel: 310 883 6210 Fax: 310 829 1026 E-mail: mneff@pioneermagnetics.com Step 1: Call Customer Service and request a RMA# Step 2: If serial number available, provide at the time of getting of requesting the RMA#...
  • Page 255 Appendix C Pioneer Power Supply Diamond Series™ – PMI Service Programs – Fix & Ship Refurbish Modify Verify Verify Verify Visual & Test Procedures Visual & Test Procedures Visual & Test Procedures Verify Verify Verify Customer's Concerns. Customer's Concerns. Customer's Concerns. Trouble Shoot Trouble Shoot Trouble Shoot...
  • Page 256 Appendix C Pioneer Power Supply Diamond Series™ C-28 888-2463-001 3/6/08 WARNING: Disconnect primary power prior to servicing.

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