Table of Contents
Troubleshooting
Related Manuals for Harris ZX10
Summarization of Contents
Technical Assistance and Services
Technical Assistance Details
Information on obtaining technical and troubleshooting support from Harris.
Replaceable Parts Service
Procedures for ordering replacement parts from Harris Service Parts Department.
Unpacking and Returns
Guidance on unpacking equipment and procedures for returns and exchanges.
Safety Precautions and First Aid
General Safety Precautions
Critical safety warnings regarding electrical hazards and equipment handling.
Treatment of Electrical Shock
Procedure for administering first aid in case of electrical shock.
First Aid Procedures for Burns
Guidelines for treating electrical burns, including extensive and less severe cases.
Section 1 Introduction
1.1 Manual Contents
Overview of the technical manual's sections and scope.
1.2 Features and Benefits
Highlights the key features and advantages of the Harris ZX Series transmitters.
1.3 General Product Description
Provides a general overview of the ZX series transmitters and their main components.
1.3.1 Exciter Description
Details the function and types of exciters used in the ZX series transmitters.
1.3.2 Amplifier Description
Explains the role of the amplifier chassis in amplifying RF signals.
1.4 Transmitter Nomenclature
Explains how ZX transmitters are named based on exciter and amplifier configuration.
1.5 Tri-mode Operation
Describes the three operating modes: FM, FM+HD, and HD.
1.6 ZX Transmitter General Construction
Discusses the solid-state construction and hot-pluggable modules of the ZX transmitter.
1.7 Simplified Block Diagrams
Presents simplified block diagrams of the amplifier and transmitter models.
1.8 Major Subassemblies
Identifies and describes key subassemblies within the ZX series amplifier.
1.9 Transmitter Accessories
Details various optional add-on accessories for the ZX transmitter system.
1.9.1 Customized Rack Integration
Explains options for integrating transmitters into equipment racks.
1.9.2 AC Distribution & Signal Monitor Chassis
Describes the AC distribution and signal monitoring chassis accessory.
1.9.3 Directional Coupler or Wattmeter
Details the on-board directional coupler and optional wattmeter accessory.
1.9.4 Dual-Drive / Main-alternate Switcher
Describes the dual-drive and main-alternate switcher accessory for exciters.
1.10 Specifications
Provides detailed technical specifications for the ZX transmitter family.
Section 2 Installation
2.1 Field Services
Options for professional installation and commissioning services from Harris.
2.1.1 Installation Services
Details required information for on-site transmitter installation services.
2.1.2 Commissioning Services
Describes operational check-outs and proof-of-performance services.
2.2 Unpacking and Documentation
Steps for unpacking and retaining essential documentation like manuals and test data.
2.3 Returns and Exchanges Policy
Outlines the procedure and conditions for returning or exchanging equipment.
2.4 Transmitter Documentation Overview
Emphasizes the importance of studying the technical manual, test data, and drawings.
2.4.1 Installation and Outline Drawings
Identifies key installation drawings provided with the transmitter shipment.
2.5 Site Selection Criteria
Guidelines for choosing a suitable installation location to ensure longevity and reliability.
2.6 AC Mains Requirements
Details the AC power input requirements and configurations for the transmitters.
2.6.1 Transmitters with AC Distribution Chassis
Explains AC mains connection for transmitters equipped with an AC distribution chassis.
2.6.2 Transmitters without AC Distribution Chassis
Describes AC mains connection for transmitters that lack an AC distribution chassis.
Power Connection Warnings and Cautions
Critical warnings and cautions regarding external circuit protection and neutral connections.
2.7 Surge Suppression Devices
Recommends the use of surge protection devices for incoming AC mains lines.
2.8 Ground Requirements
Outlines the necessity of AC safety ground and RF earth ground connections.
2.8.1 Overview of RF Grounding Practices
Provides a brief overview of proper RF grounding systems and lightning protection.
2.9 Cooling System Requirements
Details the forced air cooling system and its requirements for optimal operation.
2.10 Personnel and Equipment Protection
Recommendations for enhancing personnel safety during installation and operation.
2.10.1 Safety Circuits
Describes the built-in safety connections like RF mute and external interlocks.
2.11 Remote Control Installation
Explains how to install remote control interfaces for transmitter operation.
Exciter Connections and Interface
Details the RF drive coaxial cable and logic control connections for exciters.
Exciter Cable Connection Caution
Important caution regarding the correct orientation and use of exciter interface cables.
2.12 System Bus Connections
Describes the system bus port for connecting multiple PA chassis in parallel.
2.13 Initial Start-up Procedure
Step-by-step guide for the first-time power-on and initial setup of the transmitter.
Section 3 Operation
3.1 Introduction to Operation
Overview of the transmitter's operational information and basic procedures.
3.2 Controls and Indicators
Details the controls, indicators, and meters on the transmitter.
3.2.1 Front Panel Controls
Describes the basic controls and indicators on the front panel of the amplifier chassis.
3.2.2 Controller Board Controls
Explains the additional controls on the controller board for maintenance personnel.
3.2.3 Internal LEDs Status
Describes the internal LEDs that indicate the operational status of the transmitter.
3.3 System Metering Assembly
Details the system metering panel for displaying output power.
3.4 Basic Operational Procedures
Step-by-step guides for common transmitter operations.
3.4.1 ON/OFF Procedure
Steps for powering the transmitter on and off.
3.4.2 Power Raise/Lower Procedure
Procedure for adjusting the transmitter's output power level.
3.4.3 Switch Operating Mode Procedure
Steps for changing the transmitter's operating mode, e.g., FM, FM+HD.
3.4.4 Basic Functional Check Procedure
Procedure for assessing the transmitter's operational status.
Section 4 Theory of Operation
4.1 Introduction to Theory of Operation
Overview of the in-depth operational discussion provided in this section.
4.2 RF Interconnect Wiring Diagram
Explains the RF signal path from the exciter through the amplifier stages.
4.3 Output Assembly Theory
Details the function of the output assembly, including combiner, filter, and ballast loads.
4.4 AC-DC Interconnect Wiring Diagram
Describes the AC power input and DC power distribution within the chassis.
4.5 PA Backplane Functionality
Explains the support functions of the PA backplane, including alarm detection.
4.5.1 PA Reverse Power Alarm
Describes the circuit and conditions for the PA reverse power alarm.
4.5.2 PA Temperature Alarm
Explains the PA module temperature alarm detection circuit.
4.5.3 PA Current Alarm
Details the PA module current alarm sensing and reporting.
4.5.4 Socket Interlock Module Fault Sensor
Describes the fault detection related to module socket interlocks.
4.6 IPA Backplane Functionality
Explains the IPA backplane's role and fault detection mechanisms.
4.7 I/O Filter PCB Functionality
Describes the I/O filter board as the main interface point for various connections.
4.8 8X PS Interface PCB Functionality
Explains the PS interface board's role in power supply distribution and fan control.
4.9 5X Fan Monitor PCB Functionality
Details the fan monitor PCB for 50V distribution and fault checking.
4.10 16X Load PCB Functionality
Describes the 16X load board's monitoring of ballast load temperatures.
4.11 PA, IBOC PCB Functionality
Explains the PA module's RF signal amplification and bias control.
4.12 Transmitter Controller PCB Functions
Outlines the major functions of the transmitter controller board.
4.12.1 On/Off Control Logic
Describes how the transmitter's on/off state is managed by the controller.
4.12.2 APC Circuit and Power Level Adjust
Explains the Automatic Power Control circuit and how power levels are adjusted.
4.12.3 Operating Mode and Bias Level Control
Details how operating modes affect bias levels and transmitter operation.
4.12.4 Metering Data Interpretation
Explains how front panel meters display various operating parameters.
4.12.5 Fault and Status Signaling
Describes how faults and operational status are indicated by LEDs.
4.13 System Metering Assembly Functionality
Explains the system metering assembly for larger transmitters.
4.14 System Interconnect (multi-PA chassis transmitters)
Describes how multiple amplifier chassis are interconnected for parallel operation.
4.14.1 Command Sharing
Explains how on/off and power commands are shared across multiple chassis.
4.14.2 Power Control Sharing
Details how APC circuits share power control responsibilities in multi-chassis systems.
Section 5 Maintenance and Alignments
5.1 Introduction to Maintenance
Overview of maintenance information for qualified technical personnel.
Basic Maintenance Procedures
Routine maintenance tasks for operators or first-level technicians.
Power Amplifier (PA) Module Swap Procedure
Step-by-step guide for safely swapping PA modules.
PA Module Handling Warning
Critical warning regarding the high temperatures of PA modules.
Power Supply (PS) Module Swap Procedure
Procedure for replacing PS modules, which are hot-pluggable.
Air Filter Replacement Procedure
Instructions for replacing the front door air filter when it becomes dusty.
PA Module Cleaning Procedure
Guidelines for cleaning PA module heatsinks to remove dust buildup.
PA Module Cleaning Caution
Caution regarding cleaning PA modules while installed in the transmitter.
Advanced Maintenance Procedures
Procedures for chief engineers and lead technicians requiring advanced skills.
Advanced Functional Check
Detailed assessment of transmitter operational status beyond basic checks.
APC Power Level Set Procedure
Procedure for setting the Automatic Power Control (APC) power level.
Forward Power Meter Calibration
Steps to calibrate the forward power meter readings.
Reverse Power Meter Calibration
Procedure for calibrating the reverse power meter.
Set Transmitter Power Level (Case 1: Internal APC)
How to set power level using internal transmitter APC control.
Transmitter Power Level Adjustment Caution
Caution regarding improper adjustment of the transmitter power level circuit.
Set Transmitter Power Level (Case 2: Exciter APC)
How to set power level using exciter APC control with FlexStar HDX.
APC Setup for Multiple PA Chassis
Procedure for setting APC power control for ZX7.5 and higher power models.
Set User Reverse Power Foldback Threshold
How to set the user-defined reverse power foldback threshold.
RF Power Disconnection Warning
Warning against disconnecting RF power cables while the transmitter is producing RF power.
Set User Reverse Power Foldback Threshold (ZX7.5, ZX10)
Procedure for setting reverse power foldback threshold on larger transmitter models.
Periodic Cleaning and Inspection
Guidelines for periodically inspecting and cleaning the transmitter chassis.
Service one PA chassis while transmitter is on air (ZX7.5/ZX10)
Safe procedure for servicing a PA chassis while the transmitter remains operational.
Check balance by disconnecting load (ZX7.5/ZX10)
Procedure to check phase and gain balance between PA chassis.
5.5 Special Part Replacement Notes
Notes on replacing major ZX subassemblies.
PA Module (992-9992-041G or otherwise)
Notes regarding the replacement of PA modules, including hot-plugging.
PA Amplifier Assembly (PWA, PA) (992-9992-021G or otherwise)
Guidance on replacing the PA amplifier board or assembly.
Beryllium Oxide Handling Warning
Warning regarding the handling, use, and disposal of products containing Beryllium Oxide.
PS Module (736-0445-000)
Notes for replacing PS modules, including hot-plugging and fan behavior.
Transmitter Controller PCB (901-0203-541)
Notes for replacing the transmitter controller PCB, including jumper settings.
PA Backplane PCB (901-0203-381)
Notes for replacing the PA backplane PCB, including access and dipswitch settings.
IPA Backplane PCB (901-0203-581)
Notes for replacing the IPA backplane PCB, which has no dipswitch programming.
PS Interface PCB (901-0203-531)
Notes for replacing the PS interface PCB, with no user adjustments required.
RF Output Assembly (971-0023-026/027/028)
Procedure for replacing the entire output assembly as a module.
Output Assembly Ballast Load (700-1225-000)
Procedure for checking and replacing ballast loads in the output assembly.
RF Splitter (901-0203-511/561/571)
Notes regarding RF splitter installation and cable connections.
I/O Filter PCB (901-0203-551)
Notes for replacing the I/O filter PCB, including access and header care.
Web Remote PCB (901-0203-391T)
Notes for installing the Web Remote PCB and its setup requirements.
Fan Monitor PCB (901-0203-441)
Notes for replacing the Fan Monitor PCB, ensuring jumper settings are maintained.
Cooling Fans (430-0458-000)
Guidance on replacing cooling fans, including finger guard and door assembly.
Front Panel Multimeter (632-1201-000)
Notes for replacing the front panel multimeter, emphasizing ribbon cable alignment.
AC Mains Filter (476-0528-000 or 609-0125-000)
Notes for AC Mains Filter replacement; not field repairable.
Front Panel Filter (943-5567-408)
Notes for replacing the front panel filter, ensuring it is not installed wet.
2X IPA Splitter (901-0203-591)
Notes for replacing the 2X IPA Splitter.
Input 3dB Attenuator (971-0023-050)
Notes for replacing the Input 3dB Attenuator, including thermal compound application.
System Metering Assembly
Notes for replacing the System Metering Assembly, including calibration.
Output Combiner (3dB Hybrid)
Notes for replacing the Output Combiner, potential recalibration needed.
2.5 kW RF Load
Notes for replacing the 2.5 kW RF Load, including resistance checks.
Section 6 Troubleshooting
6.1 Contacting Harris Service
Information on how to contact Harris for technical support and service.
6.2 Troubleshooting Table
A table providing common symptoms and their causes and solutions.
Section 7 Parts List
7.1 ZX5000 Replaceable Parts List
A list of replaceable parts for the ZX5000 model transmitter.
7.2 ZX10 Replaceable Parts List
A list of replaceable parts for the ZX10 model transmitter.
Appendix A - FM Web Remote Option
A.1 Introduction to FM Web Remote
Introduction to the Harris FM Web Remote purchase option for ZX transmitters.
A.1.1 General Product Description
Overview of the FM Web Remote's capabilities for monitoring and control via web browser.
A.2 FM Web Remote Installation
Procedures for installing the FM Web Remote hardware and software.
A.2.1 Internet Security Considerations
Guidance on securing the web remote in a LAN or internet environment.
A.2.2 FM Web Remote Installation Procedure
Step-by-step instructions for installing the FM Web Remote hardware upgrade.
A.3 FM Web Remote Operation
How to access and use the FM Web Remote interface for monitoring and control.
A.3.1 Accessing the Main Page
Steps to access the primary web interface page of the FM Web Remote.
A.4 FM Web Remote Theory of Operation
Explanation of the FM Web Remote's hardware and software components and their function.
A.5 FM Web Remote Maintenance
Procedures for maintaining the FM Web Remote, including resets and clock calibration.
A.5.1 Access Configuration Page
Steps to access the web remote's configuration settings using the expert password.
A.5.2 Perform Simple Reset
Procedure for performing a simple reset of the web remote's microprocessor.
A.5.3 Perform Expert Reset
Procedure for resetting web remote IP address and password to factory defaults.
A.5.4 Change Clock Battery
Steps for replacing the on-board 3V Lithium battery for the real-time clock.
A.5.5 Calibrate Clock Speed
Procedure to fine-tune the on-board clock speed for accuracy.
A.5.6 Use Microchip Discoverer Utility
Instructions for using the Microchip Ethernet Discoverer utility to locate the web remote.
A.6 Web Remote Troubleshooting
Common issues and solutions for the FM Web Remote interface.
USB Flash Drive Contents
Lists the files provided on the USB flash drive accompanying the FM Web Remote.
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