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Nautel XR6 Operation And Maintenance Manual

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XR6/XR3 Transmitter
Operations and Maintenance
Manual
Document: NHB-XR3-XR6-OPS
Issue:
3.1 2013-03-14
Status:
Standard

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  • Page 1 XR6/XR3 Transmitter Operations and Maintenance Manual Document: NHB-XR3-XR6-OPS Issue: 3.1 2013-03-14 Status: Standard...
  • Page 3 The comparisons and other information provided in this document have been prepared in good faith based on publicly available information. The reader is encouraged to consult the respective manufacturer's most recent published data for verification. © Copyright 2013 NAUTEL. All rights reserved.

  • Page 5: Table Of Contents

    XR6/XR3 Operations and Maintenance Manual Table of contents Contents About this manual About Safety Electrical Hazards 1-xi Lightning Hazards 1-xii RF Hazards 1-xii Toxic Hazards 1-xii Other Hazards 1-xii Safety Precautions xiii Personal Safety 1-xiii Site Safety 1-xiv Equipment Safety...
  • Page 6 XR6/XR3 Operations and Maintenance Manual Table of contents Viewing digital meters 2-14 Setting the clock 2-16 Viewing software version information 2-19 Adjusting screen contrast 2-20 Changing hardware settings 2-20 Using the event log Viewing the event log Clearing the event log...

  • Page 7: About This Manual

    XR6/XR3 Operations and Maintenance Manual About this manual This manual provides technical information needed when operating, maintaining and troubleshooting an XR6/XR3 transmitter. This manual is intended for use by transmitter operators and field technicians. Using this manual If you are responsible for configuring or operating a transmitter, see Section 2, “Operating the...
  • Page 8 Tip: When you have completed a task or a step, put a checkmark beside the step number. Technical support Nautel offers technical support to customers over the Internet and by telephone. Nautel’s customer support team will answer your questions and work with you to identify and resolve problems.
  • Page 9 The Nautel website provides useful resources to keep you up to date on your XR6/XR3. Nautel User Group (NUG) The website includes a special section that customers can log into in order to access the Nautel customer newsletter, product manuals, frequently asked questions (FAQ), information sheets, and information about field upgrades.
  • Page 10 XR6/XR3 Operations and Maintenance Manual Page x Issue 3.1 2013-03-14...

  • Page 11: About Safety

    XR6/XR3 OPERATIONS AND MAINTENANCE MANUAL About Safety All Nautel transmitters are designed to meet the requirements of EN60215, Safety Requirements for Radio Transmitters. The philosophy of EN60215 is that the removal of any cover or panel that can only be opened using a tool is a maintenance activity, and that any person performing a maintenance activity is expected to be trained for that activity.

  • Page 12: Lightning Hazards

    XR6/XR3 OPERATIONS AND MAINTENANCE MANUAL Lightning Hazards Before opening the transmitter and touching internal parts, remove and solidly ground the antenna connection. WARNING: IT IS NOT ENOUGH TO GROUND THE ANTENNA TERMINAL WITH THE ANTENNA STILL CONNECTED. EVEN A SMALL IMPEDANCE IN THE GROUND STRAP WILL RESULT IN LETHAL VOLTAGES DURING A LIGHTNING STRIKE.

  • Page 13: Safety Precautions

    Personnel must be familiar with the transmitter, so that they can avoid physical danger, and be aware of hazards to themselves and the equipment. Nautel offers a number of training courses covering the basic fundamentals of RF systems and transmitters, and the operation and maintenance of the transmitter. For more information about available courses and schedules, go to the Nautel website at http://www.nautel.com/Training.aspx, or...

  • Page 14: Site Safety

    Operation of safety interlocks (if installed) First Aid Nautel does not offer first aid training, since the hazards associated with high voltage and RF energy are not specific to the transmitter. However, the customer should provide first aid training to all personnel who have access to the transmitter site.
  • Page 15 XR6/XR3 OPERATIONS AND MAINTENANCE MANUAL Marking Hazards Place warning signs close to any hazardous areas or systems (e.g., the feedline or the antenna system). Make the signs large enough that they cannot be missed. Provide signage in all languages used in the region.

  • Page 16: Equipment Safety

    (and to protect the rest of your site equipment and your personnel). For detailed information about lightning protection, see the Nautel Site Preparation Manual, available from your Nautel sales agent, or online from the Nautel website.
  • Page 17 XR6/XR3 OPERATIONS AND MAINTENANCE MANUAL Physical Protection Consider physical hazards to equipment at your site, including the transmitter. Ensure that equipment is protected from weather (e.g., rain or flooding), even during extreme weather events. Place equipment so that it is not in the path of swinging doors or high-traffic areas. Do not allow wheeled items like office chairs or tables with wheels in the transmitter room, as these may damage equipment if accidentally pushed or knocked over.
  • Page 18 XR6/XR3 OPERATIONS AND MAINTENANCE MANUAL PAGE XVIII VERSION 3.1 2013-03-14...

  • Page 19: Description

    RF output filter (includes combiner) • Control/monitor stage XR6/XR3 electrical schematics The descriptions in this section all refer to the XR6/XR3 electrical schematics located at the end of the XR6/XR3 Troubleshooting Manual. Redundancy The XR6/XR3 features redundancy in all key systems: •...
  • Page 20 312 V, 190 V, and 115 V. In three-phase XR3 transmitters there are two such levels: 220 V and 115 V. In single-phase XR6 transmitters there are four B+ dc voltage levels that are automatically selected to provide optimum performance: 315 V, 196 V, 115 V and 69 V.
  • Page 21 XR6/XR3 Operations and Maintenance Manual Description Figure 1.1: Exciter Stage PDM 1 To Power Modules PDM 2 & System Control F PDM Remote Audio Alarms Interface Driver Exciter Drive Interface Driver Drive Power Supply +24 V dc RF Drive RF Drive...
  • Page 22 XR6/XR3 Operations and Maintenance Manual Description Interphase PDM Driver PWBs The interphase PDM driver PWBs (A2A3 and A2A5) generate the required interphase PDM drive signals for the modulator assemblies in the RF power modules. These PDM drive signals determine the transmitter output power level as well as the output modulation level.

  • Page 23: Rf Output Filter

    RF Sample RF 2 (B) Forward Power Sample Reflected Power Sample RF Current Sample NOTE: The XR6/XR3 has one (optionally two) RF power modules. Each RF power module has two parallel inductors in the combiner. Issue 3.1 2013-03-14 Page 1-5...

  • Page 24: Control/Monitor Stage

    XR6/XR3 Operations and Maintenance Manual Description Control/monitor stage See electrical schematics SD-1 and SD-5 through SD-8 . The control/monitor stage monitors critical signal samples and status/alarm signals from the exciter stage, RF power stage, and ac/dc power stage. For example, RF power monitoring and RF power stage status information is applied to the control/monitor stage.
  • Page 25 XR6/XR3 Operations and Maintenance Manual XR Series Transmitter Block Diagram AC/DC POWER STAGE RF POWER STAGE EXCITER STAGE B+ P/S SYNTHESIZER PWB A RF DRIVE BUFFER RF POWER RF Power Module 2 VOLTAGE DC BLOCK is Optional SUPPLIES SYNTHESIZER 1 of 2: XR6/XR3...

  • Page 26: Operating The Transmitter

    XR6/XR3 Operations and Maintenance Manual Operating the transmitter Section 2: Operating the transmitter This section provides information about operating the XR6/XR3 transmitter: • Graphic user interface - see page 2-2 • Viewing alarm status - see page 2-7 • Changing automation settings - see page 2-9 –...

  • Page 27: Graphic User Interface

    Operating the transmitter Graphic user interface The XR6/XR3’s graphic user interface (GUI) is an LCD display panel mounted on the front of the transmitter. The GUI provides information about transmitter’s status and settings, and includes a set of buttons that let you use menus to select commands and options.
  • Page 28 XR6/XR3 Operations and Maintenance Manual Operating the transmitter • Fax: +1.902.823.3183 • Email: support@nautel.com 2. If the transmitter’s GUI functions normally when the power is turned on, and then the CHECKSUM error screen appears while changes are being made using the GUI, then it may...
  • Page 29 XR6/XR3 Operations and Maintenance Manual Operating the transmitter Table 2.1: GUI Pages GUI Page Function See Page Automation Control Turn automatic functions on and off. page 2-9 Change Meter Groups Choose the digital meters to display in the GUI. page 2-14 Software Version View software version information.
  • Page 30 XR6/XR3 Operations and Maintenance Manual Operating the transmitter Using GUI pages Each GUI page provides information about a specific transmitter function. The status bar at the top of every page shows the time, the current power, the Preset Scheduler status (M for manual or A for automatic), the current preset number, the current B+ level, the active power module, the power module transfer function status, the active exciter, and the exciter transfer function status.
  • Page 31 XR6/XR3 Operations and Maintenance Manual Operating the transmitter Navigating from page to page You can navigate from page to page using the MainMenu page. Use the Up and Down buttons to highlight the desired option, then press the Select button to select the highlighted option.

  • Page 32: Viewing Alarm Status

    XR6/XR3 Operations and Maintenance Manual Operating the transmitter Viewing alarm status If an alarm is present, a Status button appears as Soft Key 2 on many of the GUI pages. Press the Status button to go to the Status page. The Status page shows any active faults.

  • Page 33: Controlling Power Modules

    XR6/XR3 Operations and Maintenance Manual Operating the transmitter Controlling power modules Figure 2.3: Power Modules page 10:18 10:18 0.00kW M-1 B+1 PM:A 0.00kW M-1 B+1 PM:A Man Ex:A Man Man Ex:A Man Transfer Mode: Manual Transfer Mode: Manual Desired Config: A enabled, B standby...

  • Page 34: Changing Automation Settings

    XR6/XR3 Operations and Maintenance Manual Operating the transmitter Changing automation settings You can control the power scheduler and the auto exciter transfer functions using the Automation Control page. To view the Automation Control page, select Automation Control from the Main Menu.

  • Page 35: Changing General Settings

    Controlling presets The Preset Control page lets you see and edit the power level, power module Selecting presets. setting and exciter setting for each of the XR6/XR3’s six presets. To view the Preset Control page, select Preset from the Meters page.
  • Page 36 XR6/XR3 Operations and Maintenance Manual Operating the transmitter Figure 2.6: Preset Control page 10:18 10:18 0.00kW M-1 B+1 PM:A 0.00kW M-1 B+1 PM:A Man Ex:A Man Man Ex:A Man Power Power Exc PM Exc PM # Power Exc PM # Power Exc PM 0.00kW A...
  • Page 37 XR6/XR3 Operations and Maintenance Manual Operating the transmitter Holding down the Up or Down button while changing a setting will cause the rate of change to increase. Press the Back button to return to the Preset Control page. Note: You cannot increase the power level from 0 if RF Off is selected.
  • Page 38 XR6/XR3 Operations and Maintenance Manual Operating the transmitter Figure 2.8: Power Preset Schedule page 10:18 10:18 0.00kW A-1 B+1 PM:A 0.00kW A-1 B+1 PM:A Man Ex:A Man Man Ex:A Man Month: All Months Month: All Months 0:05 0:05 1:00 1:00...

  • Page 39: Viewing Digital Meters

    XR6/XR3 Operations and Maintenance Manual Operating the transmitter Changing meter groups The XR6/XR3 provides meter groups of three parameters and allows you define the meters being viewed to make the digital meters more convenient. The meters are displayed on the Meters page - see page 2-15.
  • Page 40 XR6/XR3 Operations and Maintenance Manual Operating the transmitter • PA voltage • B+ voltage • RF drive P/S voltage • Fan P/S voltage • +24 V P/S voltage • +15 V P/S voltage • +5 V P/S voltage • -15 V P/S voltage •...

  • Page 41: Setting The Clock

    Operating the transmitter Setting the clock The XR6/XR3’s internal clock has a backup battery, and maintains accurate time even during power outages. However, you need to reset the clock when the transmitter is first installed, or if the backup battery has failed. (Until the clock is set, the clock display will show an incorrect time or ‘garbage’...
  • Page 42 XR6/XR3 Operations and Maintenance Manual Operating the transmitter Figure 2.12: Calibrate Clock page 10:18 10:18 10:18 10:18 0.00kW M-1 0.00kW M-1 B+1 PM:A 0.00kW M-1 0.00kW M-1 B+1 PM:A PM:AB Man Ex:A Man PM:AB Man Ex:A Man Man Ex:A Man...
  • Page 43 2-16) according to a selected independent time standard. 2. After 30 days, compare the XR6/XR3’s clock time to the same independent time standard. Note the time difference. 3. In the Calibrate Clock page, adjust the Current RTC Calibration value until the Delta 30-day...

  • Page 44: Viewing Software Version Information

    XR6/XR3 Operations and Maintenance Manual Operating the transmitter Viewing software version information You can view the version of the software installed on the transmitter itself, or version information about components installed in the transmitter with the Software Version page. To view the Software...

  • Page 45: Adjusting Screen Contrast

    Operating the transmitter Adjusting screen contrast The XR6/XR3’s LCD screen (used to display the GUI) is set by default to a contrast suitable for most locations. The XR6/XR3 also adjusts the contrast setting automatically to compensate for changes in temperature. However, depending on your preferences and light conditions, you may wish...
  • Page 46 XR6/XR3 Operations and Maintenance Manual Operating the transmitter Figure 2.16: Hardware Settings menu 10:18 10:18 0.00kW M-1 B+1 PM:A 0.00kW M-1 B+1 PM:A Man Ex:A Man Man Ex:A Man HARDWARE SETTINGS HARDWARE SETTINGS Calibration Settings Calibration Settings Set B+ Switching...
  • Page 47 If required, you can use the Set Thresholds page - see Figure 2.17 to adjust the thresholds used to control and protect the XR6/XR3 transmitter. WARNING: These settings are adjusted at the factory and should not require any adjustment. These settings affect critical system protections.
  • Page 48 XR6/XR3 Operations and Maintenance Manual Operating the transmitter To change a threshold, select the threshold and press the Edit button. Press the Up and Down buttons to change the threshold value. For future reference, record the threshold value before and after making a change.
  • Page 49 Note: The transmitter is calibrated at the factory. Do not change calibration settings unless absolutely required. Calibrating analog meter You can recalibrate the XR6/XR3’s analog forward power meter, if necessary, using the Calibrate Analog Meter page. Notes: The transmitter is calibrated at the factory. Do not change calibration settings unless absolutely required.
  • Page 50 Calibrate B+ Thresholds and Switching Points page. You can also determine the points at which the XR6/XR3 B+ voltage switches between levels 0 (low), 2 (medium) and 3 (high) for 3-phase XR6; levels 0 (low) and 3 (high) for 3-phase XR3; or levels 0 through 3 for 1-phase XR6/XR3.
  • Page 51 Figure 2.21): CAUTION: Do not calibrate B+ thresholds unless specifically instructed by Nautel personnel. Decreasing the Recon. (reconnect) level can damage the transmitter. 1. Use the Up and Down buttons to select the appropriate Discon. (disconnect) level, noting it is in the left-hand B+ Thresholds column. Press the Edit button, then press the Up and Down buttons, to adjust the threshold (in volts) as desired.
  • Page 52 The XR6/XR3 transmitter uses multiple B+ voltage levels [0 Calibrate B+ switching points. (low) and 3 (high) for three-phase XR3s; 0 (low), 2 (medium) and 3 (high) for three-phase XR6; four levels (0, 1, 2 and 3) for single-phase XR3s and XR6s] to optimize transmitter performance. These levels are automatically switched as pre-defined minimum and maximum limits are reached.
  • Page 53 XR6/XR3 Operations and Maintenance Manual Operating the transmitter Figure 2.22: High Power Lockout page 10:18 10:18 0.00kW M-1 B+1 PM:A 0.00kW M-1 B+1 PM:A Man Ex:A Man Man Ex:A Man High Power Lockout: Enabled High Power Lockout: Enabled High Pwr Lock Carrier Limit:...
  • Page 54 XR6/XR3 Operations and Maintenance Manual Operating the transmitter Restoring factory settings You can restore the factory settings, discarding all settings made to the transmitter, including meter calibration settings, threshold settings, LCD contrast, meter groups, preset schedules and preset settings. To view the Factory Settings menu, select Settings from the...
  • Page 55 XR6/XR3 Operations and Maintenance Manual Operating the transmitter Press the Cancel button to cancel the request, leaving your transmitter settings intact, or press the Confirm button to restore the factory settings. CAUTION: This action cannot be undone Page 2-30 Issue 3.1 2013-03-14...
  • Page 56 XR6/XR3 Operations and Maintenance Manual Operating the transmitter Configuring NxLink (optional) You can configure the NxLink Ethernet interface module, if installed, using the NxLink Configuration page. To view the NxLink Configuration page, select Settings from the MAINMENU page. Next, select...
  • Page 57 XR6/XR3 Operations and Maintenance Manual Operating the transmitter Page 2-32 Issue 3.1 2013-03-14...

  • Page 58: Using The Event Log

    Section 3: Using the event log This section provides information about using and interpreting the XR6/XR3’s event log. The event log records key information such as setting changes, faults, and commands. You may wish to review the event log to check the transmitter’s status, perform troubleshooting, or review recent changes to transmitter controls.
  • Page 59 Shutback active at time of event: Yes/No • B+ switching level: 1, 2 or 3 in XR6 transmitters or 1 or 2 in XR3 transmitters • Preset setting: Preset number (A-1 to A-6 or M-1 to M-6). The A- or M- prefix indicates the...
  • Page 60 XR6/XR3 Operations and Maintenance Manual Using the event log Figure 3.2: View Event Page 1 10:18 10:18 0.00kW M-1 B+1 PM:A 0.00kW M-1 B+1 PM:A Man Ex:A Man Man Ex:A Man 001 24Oct06 10:48:43 LVPS Fault 001 24Oct06 10:48:43 LVPS Fault...
  • Page 61 XR6/XR3 Operations and Maintenance Manual Using the event log Figure 3.4: View Event Page 3 10:18 10:18 0.00kW M-1 B+1 PM:A 0.00kW M-1 B+1 PM:A Man Ex:A Man Man Ex:A Man 001 24Oct06 10:48:43 LVPS Fault 001 24Oct06 10:48:43 LVPS Fault...
  • Page 62 XR6/XR3 Operations and Maintenance Manual Using the event log Figure 3.6: View Event Page 5+ 10:18 10:18 0.00kW M-1 B+1 PM:A 0.00kW M-1 B+1 PM:A Man Ex:A Man Man Ex:A Man 001 24Oct06 10:48:43 LVPS Fault 001 24Oct06 10:48:43 LVPS Fault...
  • Page 63 XR6/XR3 Operations and Maintenance Manual Using the event log Clearing the event log If you entered the Events Log screen and one or more logs were present, a Clear Log button appears on the Main Menu. To clear the entire contents of the Events Log, press the Clear Log button. A warning screen will appear.
  • Page 64 XR6/XR3 Operations and Maintenance Manual Using the event log Event log messages Table 3.1: Event messages Event Log Messages Explanation Softstart Complete B+ relays have closed. Cmd. Auto Exciter Automatic Exciter changeovers have been enabled. Cmd. Man Exciter Automatic Exciter changeovers have been disabled.
  • Page 65 XR6/XR3 Operations and Maintenance Manual Using the event log Page 3-8 Issue 3.1 2013-03-14...

  • Page 66: Routine Maintenance

    “Replacing air filters” on page 4-2. 2. Clean the XR6/XR3 using a vacuum cleaner and a soft-bristle brush to remove loose dirt. Clean, damp rags should be used to remove dirt that cannot be removed with a vacuum cleaner. Never use compressed air to clean the XR6/XR3.

  • Page 67: Replacing Air Filter

    XR6/XR3 Operations and Maintenance Manual Routine maintenance Checking hardware All hardware must be checked at least once a year. Thermal cycling from turning the XR6/XR3 on and off will require more frequent checks. • To prevent damaging the hardware, ensure that the proper sized tools are used. In most cases, hardware is metric.

  • Page 68: Performing On-Air Checks

    XR6/XR3 Operations and Maintenance Manual Routine maintenance 3. Remove the old filter. 4. Insert the new air filter into the brackets. Check the air filter markings or instructions to ensure proper orientation, noting air flows into the back of the transmitter.

  • Page 69: Inspecting Lightning Protection Systems

    Routine maintenance Interval Every 12 months. Parts and tools Replacement battery. 3 V lithium coin cell, 20 mm (Nautel Part # BBLT01, Panasonic # Panasonic CR2032). Procedure Perform the following steps to replace the battery: 1. Ensure ac power is being applied to the transmitter.
  • Page 70 XR6/XR3 Operations and Maintenance Manual Routine maintenance Procedure Perform the following steps to test the lightning protection systems: 1. Test the continuity between ground available at your lightning arrestor and ground available on various pieces of equipment connected to the transmitter. Ensure that there is no resistance (0 ohms).
  • Page 71 XR6/XR3 Operations and Maintenance Manual Routine maintenance Page 4-6 Issue 3.1 2013-03-14...

  • Page 72: Test And Adjustment

    Section 5: Test and adjustment This section contains test and adjustment procedures for the XR6/XR3 transmitter. The test procedures use integral meters and precision test/monitoring equipment. The test procedures contain routine adjustment instructions to bring the parameter being tested within defined limits, where appropriate.

  • Page 73: Standard Adjustments

    XR6/XR3 Operations and Maintenance Manual Test and adjustment 3. Connect the XR6/XR3's RF output to a precision 50 Ω dummy load that is able to accurately display the RF power being applied to it. WARNING: If a jumper is placed between interlock inputs TB1-1/TB1-2 on the remote interface board, safety features controlled by the external interlocks will be disabled.
  • Page 74 XR6/XR3 Operations and Maintenance Manual Test and adjustment 3. Select the highest preset RF power level and verify that the RF output, displayed on the RF KILOWATTS meter, is the desired forward power level. 4. Verify that an audio signal generator is connected between TB2-1 (+) and TB2-3 (-) on the remote interface PWB, and that its output is preset to 1,000 Hz at a zero output level (turned off).

  • Page 75: Non-Standard Adjustments

    XR6/XR3 Operations and Maintenance Manual Test and adjustment Non-standard adjustments Complete the following non-standard adjustments only as directed by a troubleshooting or replacement procedure in the XR6/XR3 Troubleshooting Manual: • RF drive symmetry • Exciter Gain • Modulation Peak Limiting...
  • Page 76 1. Select exciter A as the active exciter. 2. Turn on the XR6/XR3 and select the highest preset RF power level and verify that the RF output, displayed on the RF KILOWATTS meter, is the desired forward power level.
  • Page 77 XR6/XR3 Operations and Maintenance Manual Test and adjustment Figure 5.1: Chopper Control Waveform Audio = 30Hz (AC Coupled) Page 5-6 Issue 3.1 2013-03-14...

  • Page 78: List Of Terms

    List of terms Section 6: List of terms This section defines some of the terms that are used in Nautel documentation. Audio Engineering Society/European Broadcasting Union (AES/EBU) is the name of a AES-EBU. digital audio transfer standard. The AES/EBU digital interface is usually implemented using 3-pin XLR connectors (the same type connector used in professional microphones).
  • Page 79 Preset. day and date basis. Exciters can be configured on a preset for a specific operating mode (for example, Exciter A - conventional AM, and Exciter B - IBOC). The XR6/XR3 allows you to pre-program up to six presets. A complete loss of RF output power, caused by any one of a variety of faults, including Shutback.

  • Page 80: Index

    XR6/XR3 Operations and Maintenance Manual Index Control/monitor stage, functional descrip- Index tion Ac/dc power stage, functional description Digital meters, viewing 2-14 Distribution PWB, functional description Adjusting screen contrast 2-20 Adjustment, exciter gain Adjustment, modulation limiting Event log messages Adjustments, non-standard...
  • Page 81 XR6/XR3 Operations and Maintenance Manual Index RF output filter, functional description RF power blocks, functional description Inspecting lightning protection systems RF power stage, functional description RF Synthesizer PWB, functional description Interphase PDM Driver PWB, functional de- scription Scheduled maintenance Lightning protection systems, inspecting...
  • Page 83 Phone: +1.902.823.3900 or Fax: +1.902.823.3183 Nautel Inc. 201 Target Industrial Circle Bangor, Maine USA 04401 Phone: +1.207.947.8200 Fax: +1.207.947.3693 Customer Service (24-hour support) +1.877.628.8353 (Canada & USA only) +1.902.823.5100 (International) Email: support@nautel.com Web: www.nautel.com © Copyright 2013 NAUTEL. All rights reserved.

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