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Platinum Z5CD™
FM Transmitter Manual
888-2408-002
Platinum Z5 CD™
FM Transmitter Manual
June 9, 2003
T.M. No. 888-2408-002
Rev C.
© Copyright Harris Corporation 2000, 2001
All rights reserved

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Summary of Contents for Platinum Z5 CD

  • Page 1 Platinum Z5CD™ FM Transmitter Manual 888-2408-002 Platinum Z5 CD™ FM Transmitter Manual June 9, 2003 T.M. No. 888-2408-002 Rev C. © Copyright Harris Corporation 2000, 2001 All rights reserved...
  • Page 2 Returns And Exchanges Damaged or undamaged equipment should not be returned unless written approval and a Return Authorization is received from HARRIS CORPORATION, Broadcast Systems Division. Special shipping instructions and coding will be provided to assure proper handling. Complete details regarding circumstances and reasons for return are to be included in the request for return.
  • Page 3 MANUAL REVISION HISTORY Platinum Z5 CD™ 888-2408-002 Rev. Date Pages Affected 12-17-01 47926 Title page, added MRH1/MRH2, sections 2 and 4. 06-09-03 Title page, MRH1/MRH2, and page 2-28. 888-2408-002 WARNING: Disconnect primary power prior to servicing.
  • Page 4 888-2408-002 WARNING: Disconnect primary power prior to servicing.
  • Page 5 Guide to Using Harris Parts List Information The Harris Replaceable Parts List Index portrays a tree structure with the major items being leftmost in the index. The example below shows the Transmitter as the highest item in the tree structure. If you were to look at the bill of materials table for the Transmitter you would find the Control Cabinet, the PA Cabinet, and the Output Cabinet.
  • Page 6 888-2408-002 WARNING: Disconnect primary power prior to servicing.
  • Page 7 WARNING The currents and voltages in this equipment are dangerous. Person- nel must at all times observe safety warnings, instructions and regu- lations. This manual is intended as a general guide for trained and qualified personnel who are aware of the dangers inherent in handling potentially hazardous electrical/electronic circuits.
  • Page 8 888-2408-002 WARNING: Disconnect primary power prior to servicing.
  • Page 9 FIRST-AID Personnel engaged in the installation, operation, maintenance or servicing of this equipment are urged to become familiar with first-aid theory and practices. The following information is not intended to be complete first-aid procedures, it is a brief and is only to be used as a reference.
  • Page 10 888-2408-002 WARNING: Disconnect primary power prior to servicing.

  • Page 11: Table Of Contents

    Table of Contents 1 Introduction/Specifications Control Inputs ......2-22 Status Ouputs ......2-22 Introduction .
  • Page 12 Table of Contents Z-Plane Combiner Board ....4-3 MAX HIGH, MAX LOW and UPS Power Levels4-37 5kW Hybrid Combiner ..... . . 4-4 EXC Factor and IPA Factor .
  • Page 13 Table of Contents Typical Coupling Ratios ..... . 5-8 THERMISTOR, Fault ..... . 6-14 EEPROM_DEF, EEPROM U39 Default Load .
  • Page 14 Table of Contents General Power Supply Troubleshooting ..6-28 Critical Power Supply Faults....6-28 PS#_START, Soft Start Circuit Fault ..6-29 PS#_HS_TEMP, Rectifier Heatsink Temperature 6-29 PS#_DSCHG, Discharge circuit fault.

  • Page 15: Introduction/Specifications

    Introduction/ Specifications Introduction This technical manual describes the Harris Platinum Z5 solid-state FM radio transmitter. This manual contains all the information needed to install, operate and service these transmitters. This manual contains the following sections: • Section 1: Introduction/Specifications, identifies the versions of the product available and the possible options, and provides specifications.

  • Page 16: Features/Benefits

    Introduction/Specifications Features/Benefits • Includes the field-proven Harris DIGIT Digital FM Exciter with built in DSP ste- reo generator. As the world’s first all-digital FM exciter the Harris DIGIT accepts AES/EBU digital audio and generates the fully modulated RF carrier totally in the digital domain for the lowest noise and distortion available in any FM trans- mitter (16 bit digital audio quality).

  • Page 17: General Description

    The Harris Platinum Z is a series of highly-functional, cost-effective FM radio transmitters designed using a concept called Z-Axis 3-dimensional electronic design. The Z5CD and Z5FM are 5kW versions of the Platinum Z FM transmitter. The Z5CD (Clearly Digital) utilizes the Harris DigitCD, Digital FM exciter, while the Z5FM would designate an analog exciter such as the Harris SuperCiter is being used.

  • Page 18: Pa/Ipa Modules

    Introduction/Specifications 1.3.4 PA/IPA Modules Each PA Modules consists of two independent RF amplifiers or PAs. Each PA has two MOSFET devices mounted on a compact heat spreading assembly and is capable of providing up to 425 watts (850W per module). Each PA module consists of two RF PAs mounted on opposite sides of the heatsink assembly.

  • Page 19: Directional Rf Sample Port

    1.3.9 Air System The Platinum Z uses a 2 speed fan to pull air in the back of the transmitter and exhausts it out the top. There are air channels up through the PA assembly for cooling. Upon startup, the transmitter will run at high speed for 1 minute, then will drop to a lower speed provided there are no active faults.
  • Page 20 Introduction/Specifications 888-2408-002 WARNING: Disconnect primary power prior to servicing.

  • Page 21: Installation & Initial Turn-On

    Installation & Initial Turn-On Introduction This section contains information for the installation of the Platinum Z5 solid state FM Broadcast Transmitter and for performing the pre-operational checks. NOTE: For Dual transmitter installations refer to the Systems Manual before proceeding with this procedure.

  • Page 22: Air Cooling Requirements

    Installation & Initial Turn-On Air Cooling Requirements Harris transmitters are designed to operate in a free, unobstructed environment with a maximum inlet air temperature of 50°C. This means that the transmitter air system is designed to supply sufficient air at the required static pressure to cool the transmitter only.

  • Page 23: Transmitter Placement

    Installation & Initial Turn-On 2.5.1 Transmitter Placement Set the transmitter in place on a level surface near power and signal cables. Either or both sides of the FM Transmitter may be placed against a wall or other equipment. Complete access is through the front and rear of the transmitter. The floor must be capable of supporting a load of 250 pounds per-square-foot (1221 kg per-square- meter) (refer to Cabinet Outline drawing).

  • Page 24: Exciter Installation

    Installation & Initial Turn-On b. Controller Connections 1. Check the Ribbon cables connected to the back of the controller boards and to the exciter(s). 2. Make sure that all of the boards in the controller are properly seated in the backplane (motherboard) connector. 2.5.3 Exciter Installation The exciter may or may not be removed from the transmitter depending on the...

  • Page 25: 3-Phase Power Supply Installation

    Installation & Initial Turn-On 2.5.4 3-Phase Power Supply Installation The Z5 transmitter can be configured with either a 3-Phase or Single Phase power supply. Operation of the supplies is basically the same with both using the dynamic tap switching for efficiency. However, their physical make-up is different and requires separate installation procedures.

  • Page 26: Power Supply Connections

    Installation & Initial Turn-On 2.5.4.2 Power Supply Connections First, remove the front cover panel from the power supply compartment at the bottom of the transmitter. The power supply connection cables are either tied up in the power supply compartment (in the bottom of the transmitter) or tied up with the power transformers.
  • Page 27 Installation & Initial Turn-On d. Wires 45 and 52 (large orange cables tied up with the transformers) connect to the feed-thru terminals, C3 and C4 at the top of the power supply compart- ment. These are the 52Vdc outputs from the two supplies. See Figure 2-2. The wires connect as follows: •...

  • Page 28: Single Phase Power Supply Installation

    Installation & Initial Turn-On f. To insert the wires into the Wego block, insert a screwdriver into the rectan- gular slot above the wire hole then carefully lift. This will open the contact inside the Wego block and the wire can be inserted. Be very careful not to let the wire ends fray as the connectors are very close together and could cause a short.

  • Page 29: Single Phase Power Supply Connections

    Installation & Initial Turn-On 2.5.5.2 Single Phase Power Supply Connections First, remove the front cover panel from the power supply compartment at the bottom of the transmitter. The power supply connection cables are either tied up in the power supply compartment (in the bottom of the transmitter) or tied up with the power transformers.
  • Page 30 Installation & Initial Turn-On e. Wires #1 and #2 (orange cables tied up on the left side of the power supply compartment) plug into the gray Wego block connector on the front of the power supply tray. See Figure 2-3. Wire #1 goes to the left and #2 in the 3rd hole from the left.

  • Page 31: Transmitter Ac Connections

    Installation & Initial Turn-On 2.5.6 Transmitter AC Connections The ac input for the transmitter should be low impedance, 50/60 Hz, single or three phase depending on transmitter phase supply with sufficient capacity to supply the transmitter. Refer to the “Z2 Outline Drawing” in the drawing package for current ratings, nominal fuse sizes and wire gauge for the 3 phase delta, 4 wire wye, and single phase input voltage combinations.For more information AC power require- ments see “Power Distribution for Optimum Transmitter Performance”...

  • Page 32: Ac Input Connection

    Installation & Initial Turn-On MOV protection may need to be modified. Please consult with an electrician if this applies to your installation. If applicable, the phase-to-earth 275 volt MOVs in the RV7 through RV13 and RV20 positions may be replaced with 510 volt MOVs (Harris part number 560-0042-000, quantity 8).

  • Page 33: Grounding

    Installation & Initial Turn-On 2.5.6.3 Grounding The importance of a good grounding system and lightning protection can hardly be overemphasized for reasons of personnel safety, protection of the equipment, and equipment performance. The following is only a brief overview. Lightning and transient energy via the power line or tower connections can impose serious threats to your personal safety as well as damage the equipment.

  • Page 34: Low Voltage Power Supply And Blower

    An alternate ground connection is a short copper strap on the back of the Platinum Z transmitter, on the bottom right side. Unfold this strap and securely bolt or silver solder it to the building ground. This strap can be removed from the bottom and used at the top.

  • Page 35: External And Failsafe Interlock Connections

    Installation & Initial Turn-On 2.5.9 External and Failsafe Interlock Connections The transmitter is shipped with two jumpers installed on TB1, the Remote Control Interface terminal strip: TB1-7 to TB1-6(GND) is for External Interlock and TB1-8 to TB1-10(GND) is for Failsafe. 2.5.9.1 External Interlock Connection To use the External Interlock connection, remove the jumper between terminals TB1-7 to TB1-6(GND), then connect external interlock wires.

  • Page 36: Initial Turn-On

    Installation & Initial Turn-On 2.5.10 Initial Turn-on Each transmitter is thoroughly checked out during factory final test but adjustment may be required during installation due to shipping, variations in primary power, antenna systems, or transmission line differences. Any remote or extended control connections should be connected only after the transmitter is checked out and fully operational.
  • Page 37 Installation & Initial Turn-On NOTE: If the blower does not run, check the position of wires #1, #2 and #3 for 3-phase or wires #1 and #2 for a single phase, at A17TB1. If these are connected in the wrong position, the fan may not operate (this is also true for the single phase transmitter due to switching on the Low Voltage Supply Board).
  • Page 38 Installation & Initial Turn-On IPA_AB2 IPA_AB1 Figure 2-6 PA Compartment Front View Figure 2-7 PA Compartment Rear View 2-18 888-2408-002 WARNING: Disconnect primary power prior to servicing.
  • Page 39 Installation & Initial Turn-On For the dual IPA configuration, the IPA will be identical to any of the STEP 9 PA modules and may be plugged in with either side up in the IPA slot. To see which IPA is active press [HOME, STATUS D,B]. This should bring up the screen shown in Figure 2-8.
  • Page 40 Installation & Initial Turn-On At this point, if there are no faults, verify that the transmitter display STEP 12 readings closely resemble those on the factory test data sheet for LOW power. If the “FAULT” LED comes on, go to the Fault Log in the Diagnostics Display to find out which fault has been activated and refer to Section VI, Troubleshooting.

  • Page 41: Remote Control Connections

    Installation & Initial Turn-On 2.5.11 Remote Control Connections The Platinum Z5 Transmitter may be operated by remote control by installing a remote control system. If the transmitter is to be remotely controlled, it is important to initiate thorough inspection and maintenance procedures at the transmitter location.

  • Page 42: Control Inputs

    Installation & Initial Turn-On 2.5.11.1 Control Inputs Input control lines are standard ground switching inputs. The inputs can be operated by relay contact or transistor switching. See Figure 2-10. Figure 2-10 Ground Switching for Remote Control Lines 2.5.11.2 Status Ouputs The status output lines on TB1 are transistor type - open collector.
  • Page 43 Installation & Initial Turn-On A series resistor and LED can also be used for extended status indications. Maximum external supply voltage should not exceed +28Vdc. NOTE: Maximum status line current is 25 mA. If the output is used to drive a small printed circuit board type relay, check current requirements for relay coil and be sure to install a circuit protection diode across the coil.

  • Page 44: Ups In/Remote Exciter Select, Configurable Input Tb1-9

    Installation & Initial Turn-On Extended metering can also be connected to TB1 terminals. See Figure 2-13 for an example of extended metering connections. Figure 2-13 Extended Metering UPS IN/Remote Exciter Select, Configurable Input TB1-9 The remote input at TB1-9 is a software configurable input which is set via the Diagnostics Display Menu.

  • Page 45: Using An Uninterruptable Power Supply Or Ups

    Installation & Initial Turn-On 2.6.1 Using an Uninterruptable Power Supply or UPS If the transmitter is backed up with a UPS, to keep it operating during an ac power failure, then the logical thing to do is to lower the transmitter power to conserve the UPS for as long as possible.

  • Page 46: Optimizing Efficiency

    Installation & Initial Turn-On Optimizing Efficiency The transmitter has the ability to Manually or Automatically optimize its own operating efficiency. It is not a requirement, and the transmitter will meet all specifications without activating this function. When activated, the controller will adjust the transmitter operating parameters to get the best possible efficiency.

  • Page 47: Setting The Low Power Alarm

    Installation & Initial Turn-On Setting the Low Power Alarm The transmitter has a low power alarm output for a remote control system. The power level at which this remote alarm output is triggered, at TB1-13 XMTR_PWR_LO_IND, is selectable in the Configuration Menus. To set this power level press [HOME, MORE, CONFIGURATION B,D,B].
  • Page 48 Installation & Initial Turn-On Table 2-1 TB1 Remote Control Interface Connections 2-28 888-2408-002 WARNING: Disconnect primary power prior to servicing.
  • Page 49 Installation & Initial Turn-On Table 2-1 TB1 Remote Control Interface Connections (continued) 888-2408-002 2-29 WARNING: Disconnect primary power prior to servicing.
  • Page 50 Installation & Initial Turn-On Table 2-2 Jumper Setting for installation of a Harris Exciter 2-30 888-2408-002 WARNING: Disconnect primary power prior to servicing.

  • Page 51: Power Distribution For Optimum Transmitter

    Installation & Initial Turn-On 2.10 Power Distribution for Optimum Transmitter Performance This section is applicable to the three phase supplies only, as well as other three phase equipment. For many years HARRIS engineers have recommended that the three phase power distribution system should be either a closed delta or WYE configuration to provide better radio and television transmitter performance by helping prevent line unbalance.

  • Page 52: Three Phase Delta Distribution Transformers

    Installation & Initial Turn-On Another likely source of this problem can come from unbalanced impedances in the power distribution system. Unbalanced impedance will always be seen when an “open” delta three phase distribution system is used. Transformer design textbooks clearly show that the voltage regulation of an unbalanced system is poor. 2.10.4 Three Phase Delta Distribution Transformers Figure 2-19 shows open and closed delta systems.

  • Page 53: Three Phase Wye Distribution Transformers

    Installation & Initial Turn-On Many transmitters are located at the end of a long transmission line which is highly susceptible to transient phenomena. Devices such as Metal Oxide Varistors are inexpensive and very effective in reducing over voltage spikes. These units are limited in the amount of energy that can be dissipated, but will handle, if designed properly, very large currents.
  • Page 54 Installation & Initial Turn-On Today, many transformers are supplied with all of the primary terminals available so that either a delta or WYE connection can be made. Table 2-3 shows the different line-to-line voltages that are available with this configuration. In summary, both symmetrical power distribution systems are satisfactory because of their balanced impedances.

  • Page 55: Operator Guide

    Introduction This section contains normal operational procedures and information pertaining to the function of the Platinum Z5 Transmitter. Most important, is the information regarding use of the Diagnostic System. All of the information in this section assumes the the transmitter and controller are in proper working order.

  • Page 56: Transmitter Controls

    Operator Guide Transmitter Controls The transmitter controls are mostly on the right half of the controller front panel at the top of the transmitter, See Figure 3-1. These controls and their function are listed below. OFF - Used to turn the transmitter off ON - HIGH - Turns the transmitter on to the previous HIGH setting.

  • Page 57: Transmitter Metering

    Operator Guide Transmitter Metering There are five function keys below the Transmitter display on the front of the controller: 1. FWD PWR (Forward Power) 2. RFL PWR (Reflected Power) 3. PA Amps 4. PA Volts 5. APC (Automatic Power Control) These are dedicated metering selections for the 5 most important transmitter parameters.

  • Page 58: Using The Diagnostic Display

    Operator Guide Using the Diagnostic Display The Platinum Z Series transmitters utilizes a very unique and powerful diagnostic system. The diagnostic system is actually your interface to the inner workings of the transmitter. It is used for Status, Metering, Fault Logging, Configuration and even hardware and software Testing of the controller.

  • Page 59: Home

    Operator Guide 3.4.1 HOME HOME takes you to the home layer or root menu. This menu should look like the one in Figure 3-3, which is the first of two screens in this layer. The second screen in the HOME layer is accessed by pressing the “D” function key to the right of the display which is labelled “MORE -”...

  • Page 60: Back

    Operator Guide 3.4.2 BACK BACK takes you to the previous layer in the menu tree, not necessarily to the previous screen. As an example, if you were to press HOME and then choose STATUS you would now be in layer 2 of the STATUS menu. You should see the screen shown in Figure 3-5.
  • Page 61 Operator Guide Example 1 If you wanted to check the temperature of the individual Power Amplifiers on Z Plane A, you would press the following keys; [HOME, METERING C,A,C] After entering this key sequence the screen should look like Figure 3-6. This is equivalent to pressing the following menu items as they appear on each successive screen: METERING, TEMPERATURE, PA, Z PLANE A.

  • Page 62: Asterisk And Pound Signs(*, #)

    Operator Guide 3.4.5 Asterisk and Pound Signs(*, #) The asterisk and the pound sign characters are used in some of the metering menus of the Diagnostics Display. If an asterisk (*) shows up in a metering menu, it means that there is no data being received for that reading. The pound sign will only be used in the Vg (Gate Control Voltage for the individual PAs) menus and signifies that there has been a crossover (this is a condition where one PA Controller crosses over and mutes the PAs associated with another PA Controller).

  • Page 63: Emergency Operating Procedures

    Operator Guide Emergency Operating Procedures 3.5.1 Multiple PA Failures in a Foursome WARNING: THE PA MODULES ARE DESIGNED TO HANDLE VERY HIGH TEMPERATURES AND MAY BE EXTREMELY HOT. DO NOT TOUCH THE MODULES WITH BARE HANDS AFTER THE TRANSMITTER HAS BEEN RUNNING, ESPECIALLY IN HIGH AMBIENT TEMPERATURE ENVIRONMENTS.

  • Page 64: Manual Exciter Switching

    Operator Guide Manual Exciter Switching The active exciter (if dual exciters are installed) can be switched manually from the Status menus in the Diagnostics Display. To manually switch from Exciter 1 to Exciter 2 press [HOME, STATUS D,C]. This will bring up the screen shown in Figure 3-10.

  • Page 65: Optimizing Efficiency

    Operator Guide Optimizing Efficiency The transmitter has the ability to Manually or Automatically optimize its own operating efficiency. It is not a requirement, and the transmitter will meet all specifications without activating this function. When activated, the controller will adjust the transmitter operating parameters to get the best possible efficiency. The user must select whether the function is in Manual or Automatic mode via the Diagnostics Display Menus.

  • Page 66: Fan Speed

    Operator Guide Fan Speed The Platinum Z is equipped with a 2 speed blower. This normally runs at the LOW speed to reduce ambient noise and increase transmitter efficiency. However, if any fault occurs, the fan will automatically switch to high speed until the fault is no longer active.

  • Page 67: Overall System Theory

    Z5FM which is a 5kW FM transmitter supplied with the SuperCiter, analog FM exciter. RF Flow Block Diagram Description Figure 4-1 is a block diagram of RF flow of the Platinum Z5 transmitter. Not shown on this diagram is the control and monitoring associated with the advanced Controller and Diagnostics system.
  • Page 68 Overall System Theory Figure 4-1 RF System Block Diagram 888-2408-002 WARNING: Disconnect primary power prior to servicing.

  • Page 69: Ipas

    Overall System Theory 4.2.2 IPAs The Z5 has 1 IPA Module, which is made up of 2 power amplifiers or PAs. The IPA Module is identical to, and interchangeable with, the PA Modules. The 2 IPAs per IPA Module operate in Main/Alternate mode, meaning that only one of them is active at a time.

  • Page 70: 5Kw Hybrid Combiner

    Overall System Theory This also allows the PA Modules to be HOT-PLUGGABLE, meaning that a PA module may be removed while the transmitter is operating. Interlock pins on the module connectors mute the PA modules before it switches out the unplugged module.

  • Page 71: Ipa

    Overall System Theory Figure 4-2 Exciter Status Screen [HOME, STATUS D,C] 4.3.2 The IPA amplifier and/or module is identical to any one of the PA modules. This allows a PA module to be used in place of a failed IPA. The standard IPA configuration includes dual IPA amplifiers, used in a main/alternate configuration (in other words only one is used at a time).In this configuration the IPA Module is identical to a PA module.

  • Page 72: Main/Alternate Exciter Switching

    Overall System Theory • Splitting of the IPA output into 2 equal amplitude signals 90 degrees out of phase, by way of a 3dB hybrid, to drive the Z Plane dividers. • Air flow sensing • Ambient temperature sensing • IPA 1 and IPA 2 interlocking 4.3.3.1 Main/Alternate Exciter Switching Exciter selection is done via relay K1 and the EXCITER SELECT control signal...

  • Page 73: Main/Alternate Ipa Switching

    Overall System Theory 4.3.3.2 Main/Alternate IPA Switching Selection of IPA_AB1 or IPA_AB2 (both input and output) is done via relays K2, K3 and the IPA DRIVER SELECT control signal from the Life Support Board. NOTE: The term “AB” is used to associate a component with Z-Plane A and Z-Plane B. K2 switches the input RF drive from the exciter to IPA_AB1 or IPA_AB2 while K3 selects the active IPA RF output.

  • Page 74: Air Flow Sensing

    Overall System Theory 4.3.3.4 Air Flow Sensing. Airflow is sensed as the difference in temperature between a heated sensor, RT1, and an ambient sensor, RT2. RT1 is actively biased via R3 which will cause a steady increase in temperature with no air flow. Under normal operation, the voltage difference between the two sensor outputs will stabilize at some value depending on the amount of air flow.

  • Page 75: 8-Way Divider

    Overall System Theory The RF output of the Z-Plane board connects directly to the 3dB hybrid where it is combined with the output of the second Z-Plane Combiner/Divider board. The Z plane boards are identical, but the outputs connect to opposite ends of the 3dB hybrid (one at the top and one at the bottom).

  • Page 76: Pa Modules

    Overall System Theory 4.3.4.3 PA Modules Each of the 8 PA Modules contain two PA Amplifier boards mounted on opposite sides of the PA Module heat sink. The modules are numbered 1 through 8 with the top module in the front being #1 and counting to #4 at the bottom. The top rear module is #5 counting down to #8 at the bottom rear, see Figure 4-5 for the front view and Figure 4-6 for the rear view.
  • Page 77 Overall System Theory When the amplifier is used as the IPA, VG is used to linearly vary the IPA output which then controls the transmitter power output. For an IPA, VG comes from the Life Support Board and is controlled by the APC loop on the Master Controller Board.
  • Page 78 Overall System Theory IPA_AB2 IPA_AB1 Figure 4-5 PA Compartment Front View Figure 4-6 PA Compartment Rear View 4-12 888-2408-002 WARNING: Disconnect primary power prior to servicing.

  • Page 79: Db Hybrid Combiner

    Overall System Theory 4.3.4.4.1 Isolation Boards Each Z Plane has an associated Isolation Board which contains the isolation resistors and disconnect switches for the two 4-way wilkinson combiners and the isolation resistor for the 2-way Wilkinson combiner. The isolation resistors for the four way combiners, R1-R8, are each 50 ohm.

  • Page 80: Harmonic Filter

    Overall System Theory 4.3.5 Harmonic Filter The vertical transmission line at the rear of the cabinet contains the Harmonic Filter. 4.3.6 Directional Coupler Assembly The directional coupler assembly is installed directly before the output from the transmitter. It consists of 3 directional couplers with two of the couplers adjusted to produce a sample of the forward output power, and one coupler arranged to provide a sample of the reflected output power.

  • Page 81: Power Supply Block Diagram Description

    Overall System Theory Power Supply Block Diagram Description There are two different types of power supplies in the transmitter, the PA Power Supply and the Low Voltage Power Supply. 4.4.1 PA Power Supply There are three power supply configurations available for the Z5 transmitter: •...
  • Page 82 Overall System Theory Each transformer has a 3 wire extended DELTA or extended WYE primary (depending on your AC input configuration) and two secondaries labeled A and B which are always WYE wound, with the center tap being the output. The outputs of the 2 secondaries are combined through chokes and filtered by a single 120,000uF capacitor.
  • Page 83 Overall System Theory Figure 4-8 3-Phase Power Supply Simplified Soft-Start and Discharge Circuit 4.4.1.1.1 PA Power Supply Discharge The PA Power Supply Discharge circuit also uses the Soft Start resistor to discharge the 52Vdc PA supply. The discharge circuit is activated when the transmitter is turned off.

  • Page 84: Single Phase Power Supply

    Overall System Theory 4.4.1.2 Single Phase Power Supply Refer to the Overall System Block Diagram in the schematic package and Figure 4- 9 for the following discussion. The power supply consists of two power transformers each with a single center tapped secondary. The center tap is the 52Vdc output and is filtered by a large choke and 3 large filter capacitors.
  • Page 85 Overall System Theory 4.4.1.2.1 Soft Start During transmitter turn on, a fifth set of SCRs is activated (these are located on the Rectifier Boards). See Figure 4-10. These SCRs are connected to the lowest voltage output tap of each transformer secondary (the one with the fewest secondary turns). However, the Soft Start SCRs are connected through a common surge limiting resistor to ground, instead of the direct ground connection provided with the rest of the SCRs.

  • Page 86: Low Voltage Power Supply

    Overall System Theory 4.4.2 Low Voltage Power Supply The Low Voltage Power Supply is a single PC board mounted in the rear of the transmitter near the main contactor. It is designated A19 (assembly 19). The circuit board is the same for the 3-Phase and single phase configurations, only the wiring to and from the board is changed.
  • Page 87 Overall System Theory Figure 4-11 3-Phase Power Supply Simplified Diagram of Transformer and Rectifier Connections 888-2408-002 4-21 WARNING: Disconnect primary power prior to servicing.

  • Page 88: Rectifier Board

    Overall System Theory 4.5.1.1 Rectifier Board The Rectifier Board contains the SCRs which are used for the tap switching as well as rectification of the 3 phase AC. Each secondary winding has four taps, see Figure 4-11. Each of these taps have one SCR to ground. The Power Supply Controller can turn on any one of the four SCRs at a given time.
  • Page 89 Overall System Theory 4.5.1.2.1 Tap Switching Circuit Operation The control signals for the SCRs are active high and come directly from the PS Controller Board. They enter the “B” Rectifier Board at: • J4-1 - DRIVER 1 (activates SCRs for 48V tap) •...
  • Page 90 Overall System Theory labeled SS1-B, SS2-B and SS3-B and are connected to the 48V taps on the transformer “B” secondaries of T1 and T2. This allows the power supply to start charging through R48, a 5 ohm 100W current limiting resistor. After about 2 seconds, the DRIVER 1 signal will activate the normal 48V tap SCRs which will tie the taps directly to ground, bypassing R48.

  • Page 91: Single Phase Pa Power Supply

    Overall System Theory 4.5.2 Single Phase PA Power Supply Refer to the Overall System Block Diagram in the schematic package for the following discussion. The transmitter single phase AC inputs connect directly to K1, the AC mains contactor. The transformer side of the contactor is wired in parallel to power transformers T1 and T2 primaries in the bottom of the transmitter.

  • Page 92: Rectifier Board Circuit Description

    Overall System Theory 4.5.2.2 Rectifier Board Circuit Description Refer to the Rectifier Board schematic for the following. The Rectifier Boards perform three primary functions: • Dynamic secondary tap switching using SCRs, to maintain a relatively constant supply voltage and thus maintain constant transmitter power output despite fluc- tuations in the AC line voltage.
  • Page 93 Overall System Theory 4.5.2.2.2 PA Power Supply Soft-Start Soft-Start is used to limit the surge current during transmitter turn on. The Soft Start and PA Power Supply Discharge circuits are able to use the same resistor, R48 since only one or the other will be active at any one time. A simplified diagram of the Soft Start and PA Power Supply Discharge circuits in shown in Figure 4-10.

  • Page 94: Power Supply Id Jumpers

    Overall System Theory 4.5.2.2.6 16VCT, V+SCR Supply The 16VCT secondary winding is fused by F3 and F4 on the Rectifier Board. These are self-resetting fuses which physically look like disc capacitors. The AC is rectified by CR10 and CR11 and becomes V+SCR which is the gate drive signal for the tap and soft start SCRs.

  • Page 95: Relays

    Overall System Theory Rectifier Boards on the PA power supply transformers. All three voltages pass through the rectifier boards and are sent to the Backplane Board to power all of the controller PC boards. 4.5.4.1 Relays There are three mechanical relays on the Low Voltage Power Supply Board assembly A19.

  • Page 96: Control System Description

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

  • Page 97: Master Controller

    Overall System Theory 4.7.1 Master Controller The Master Controller is responsible for primary transmitter control and is the summary point for all of the information gathering. It controls and/or receives information from the PA Controllers, Power Supply Controllers and Life Support Board and takes action appropriate to the operating conditions of the transmitter.

  • Page 98: Apc, Automatic Power Control

    Overall System Theory The following is a listing of all of the Default Values which are stored in the Firmware: • Forward Factor - 0.007697 • Reflect Factor - 0.000306 • Cal APC Factor - 7.58 • Cal Frequency - 98MHz •...
  • Page 99 Overall System Theory all transmitter power control functions including power level, foldbacks and mute. This makes it a very important number to know and understand for troubleshooting. NOTE: As calibrated from the factory, the digital DAC_APC_REF number should be approximately 660 (this number should be on the factory test data sheet). This number can be checked by pressing [HOME, MORE, CONFIGURATION C,B].

  • Page 100: Calibration Factors And A/D Values

    Overall System Theory 4.7.1.2.1 Manual Power Control It is possible to shut off the APC by opening dip-switch S1-10 (Open = OFF) on the Master Controller Board. This switch opens the APC Loop, disconnecting the APC voltage from the IPAs. When S1-10 is opened, MANUAL PWR REF R25 on the Life Support board controls the transmitter power output.

  • Page 101: Dac_Apc_Ref

    Overall System Theory These cal factors and A/D values will be approximately the same for all Z5 transmitters that are factory calibrated or have been field calibrated at the rated transmitter power of 5kW as detailed in the Maintenance procedures. These numbers are also stored in the Backup memory area of the EEPROM, U39 and can be recalled if necessary.

  • Page 102: Forward Factor And A/D_Fwd_Pwr

    Overall System Theory 4.7.2.2 Forward Factor and A/D_FWD_PWR The Forward Factor is a calibration factor that is calculated during forward power calibration. To check the Forward Factor press [HOME, MORE, CONFIGURATION C,A,A]. All Z5 transmitters are factory calibrated with a forward sample voltage of 8.9vdc at 5kW, as measured at TP9 on the Life Support Board.

  • Page 103: Apc Factor

    Overall System Theory 4.7.2.3 APC Factor APC_Factor is also calculated during the Forward power calibration. APC_Factor allows the micro to calculate the necessary DAC_APC_REF number to obtain any specific power level. For the Z5, APC_Factor is calculated as Forward calibration power divided by the DAC_APC_REF number or: APC_Factor = FWD PWR (kW) / DAC_APC_REF APC_Factor = 5kW / 660 = 7.58...
  • Page 104 Overall System Theory Once the operator has set a power level in kW in these screens, the controller uses the OP_APC_Factor to find the DAC_APC_REF that would represent each of the power levels and sets that number as the power level limit. This maximum DAC_APC_REF setting is called DAC_MAX and is calculated for each mode from the formulas below: For HIGH ON mode:...

  • Page 105: Exc Factor And Ipa Factor

    Overall System Theory 4.7.2.5 EXC Factor and IPA Factor When the transmitter Forward Power is calibrated, the micro samples the exciter and IPA outputs and sends the A/D readings to the screen as: • EXC_Factor [HOME, MORE, CONFIGURATION C,A,D,A] • IPA_Factor [HOME, MORE, CONFIGURATION C,A,C] The calibration merely takes the A/D reading for each of these and makes it equal to 100% in the Diagnostics metering of exciter and IPA power output.

  • Page 106: Vswr Foldback

    Overall System Theory 4.7.3 VSWR Foldback The Master Controller contains another DAC called VSWR_FB_LVL which stands for VSWR Foldback Level. The output of this DAC is directly controlled by the setting in the VSWR Foldback Screen [HOME, MORE, CONFIGURATION B,D,C,D]. The normal setting for this screen is 1.35. Using the formula below, this is equal to 111W for 5kW forward power.

  • Page 107: Master Controller Faults

    Overall System Theory 4.7.3.1 Master Controller Faults For a complete listing of the faults associated with the Master Controller refer to Section VI, Troubleshooting. 4.7.3.1.1 3 Strike Routine There are 4 faults in the transmitter that will initiate what is called a 3 strike routine. They are: •...

  • Page 108: Pa Controller Boards

    Overall System Theory 4.7.4 PA Controller Boards There are two (2) PA Controller Boards in the Z5 transmitter. They utilize micro- controllers which report to the Master Controller, but operate independently of the Master. Each controls half or 8 of the 16 PAs. Table 4-1 on page 4-60 shows which PAs are controlled by each of the PA Controller Boards.

  • Page 109: Metering

    Overall System Theory 4.7.4.2 Metering The PA Controllers are responsible for metering of the following parameters: • PA Current - The current draw of each PA is monitored by measuring the voltage drop across 0.01 ohm resistors, R11-R18, on the Z-Planes. The resistors show up as part of the Divider Schematic.

  • Page 110: Crossover (Xover) Protection

    Overall System Theory 4.7.4.3 Crossover (XOVER) Protection Each PA Controller has what is called a Watchdog Timer. The outputs of the watchdog timers are each monitored by the other PA Controller. If the pulses from the watchdog timer are interrupted, due to either hardware or software problem, the other PA Controller will initiate what is called a Crossover (or XOVER).

  • Page 111: Power Supply Turn On

    Overall System Theory 4.7.5.1 Power Supply Turn On The primary function of the PS Controller is to turn the power supplies on and off. The on/off signal is called PS_DISABLE and comes in on J3-13. The signal originates on the Master Controller but passes through a logic gate on the Life Support Board before reaching the PS Controller.

  • Page 112: Pa Power Supply Discharge

    Overall System Theory 4.7.5.2 PA Power Supply Discharge When the PS_DISABLE signal goes high, all of the SCR taps are disabled and the DISCHARGE signals at J1-7 and J2-7 go low. This activates the PA Power Supply Discharge circuits on the rectifier boards, which allows a quick and safe discharge of the PA supply.

  • Page 113: Watchdog Timer

    Overall System Theory 4.7.5.6 Watchdog Timer The watchdog timer, U4 is basically looking for two things. First, it must receive a pulse from the micro-controller every 1.0mSec. If it does not it will activate the RESET line at TP4, and the supplies will be shut off. It is also monitoring the +20Vdc supply.

  • Page 114: Life Support Board

    Overall System Theory 4.7.6 Life Support Board The Master Controller is backed up by the Life Support Board. The Life Support Board allows safe transmitter operation at reduced power if the Master Controller is not operating. The transmitter does require that the PA and PS Controller Boards be operational to control the power supplies and PAs.
  • Page 115 Overall System Theory 4.7.6.1.1.1 Pulse Stretcher, U4 U4 is a pulse stretcher which will output a 100mSec pulse whenever the transmitter ON button is pressed. Provided there is no power failure signal, POWERFAIL(BAR) from U37-7, The 100mSec pulse from U4-10 will pass through to U6-13, U8-12 and leaves the board to reset the PA and PS Controller Boards at J1-A83.
  • Page 116 Overall System Theory 4.7.6.1.1.4 CONTACTOR_ON(BAR), K4-4 The signal at K4-4 is called CONTACTOR_ON(BAR) and ties to several places, U33-12, U30-12, and U30-10. This signal is low when K4 is in the SET position and the contactor is engaged. a. The CONTACTOR_ON(BAR) signal at U33-12 is only used during Life Support Mode.
  • Page 117 Overall System Theory SUPPLY_DISABLE at U30-11 to shut off the power supplies and a SYSTEM_MUTE via U30-10 which will mute the exciter and IPA. 4.7.6.1.2.1 Remote Transmitter Turn OFF REM_OFF(BAR) is activated via the remote control interface. When the remote control pulls this line low, it will activate optical isolator, U23, bringing U23-6 low.
  • Page 118 Overall System Theory 4.7.6.1.3 External Interlock The External Interlock input can be used for any purpose which requires shutting off the transmitter, such as a protective door being opened or a water (or air) switch on a dummy load. The primary purpose is for the protection of personnel. a.
  • Page 119 Overall System Theory e. FAILSAFE. Discussed earlier. f. PA_15V_FAIL. This fault comes from both of the PA Controller Boards. It is triggered when there is a loss of the -15V on BOTH of the PA Controllers. If the -15V supply is lost, the PA Controllers will not be able to mute the PAs and therefore cannot protect them, so the exciter and IPA will be muted to protect the PAs.
  • Page 120 Overall System Theory 4.7.6.1.6 IPA Select IPA select is software controlled by the Master Controller. It can be switched manually or will switch automatically if the active IPA fails (no RF output). IPA switching is done by latching relay K2. IPA_SELECT_AB1 is a pulsed signal which will go high to select IPA_AB1 (the AB represents Z-Plane A and Z-Plane B).

  • Page 121: Life Support Mode

    Overall System Theory The IPA Voltage sample is taken from the voltage divider made up of R45 and R48. This is sent to the Master Controller for monitoring and protection. 4.7.6.1.8.1 U18 Supply Voltage The supply voltage for U18, VDP1 and VDN1 comes from U22 and diodes CR16, CR17 and CR6.
  • Page 122 Overall System Theory interrupted (which means the Master Controller has failed), U4 will time-out and go to the RESET mode. The Q output will go low and Q_NOT will go high. The low signal from the Q output is inverted at U16-13, and pulls the MASTER_NORMAL(BAR) signal high (this signal is normally low when the Master Controller is working).
  • Page 123 Overall System Theory REM_OFF and FAILSAFE become active due to the signal MASTER_NORMAL(BAR) going high when Life Support is initiated. This is discussed in the paragraphs labeled MASTER_NORMAL(BAR). d. MSTR_NORMAL 1 applies a low to AND gate U25-2. This inhibits the Mas- ter Controller from initiating a SYSTEM_MUTE which would mute the exciters and the IPA.
  • Page 124 Overall System Theory the REM_ON_ENABLE signal at U32-4. If the Controller is in LOCAL mode, U26-5 will be low and the REM_ON_LOW(BAR) command is inhib- ited. When Life Support Mode is initiated, U32-5 and therefore U26-5 is forced high enabling the REM_ON_LOW(BAR) command. c.
  • Page 125 Overall System Theory 4.7.6.2.2 Reflected Power The reflected power sample enters the board at J3. It is detected by CR10 and buffered by U1-1. The voltage at TP7 is directly proportional to the amount of reflected power coming back to the transmitter from the antenna or transmission line.
  • Page 126 Overall System Theory Table 4-1 PA Control Distribution PA Designations on PA Controller Schematics PA Designations on Related Related Combiner and Isolation Isolation Divider Schematics Relay # Resistor # PA Designations PA8 (J8) PA7 (J7) PA6 (J6) PA5 (J5) Z-PLANE A PA1 (J1) PA2 (J2) PA3 (J3)

  • Page 127: Maintenance And Alignment

    PC boards and other major components of the Platinum Z5 FM BROADCAST TRANSMITTER. Routine Maintenance Routine maintenance of the Platinum Z series transmitter basically consists of regular cleaning and monitoring of temperatures, currents, voltages and faults. 5.2.1...

  • Page 128: Transmitter Logbook

    Maintenance and Alignment 5.2.2.2 Transmitter Logbook As a minimum performance characteristic, the transmitter should be monitored (using front panel metering and the Diagnostic Display) and the results recorded in the transmitter logbook at least once a day. 5.2.2.3 Maintenance Logbook The maintenance logbook should contain a complete description of all maintenance activities required to keep the transmitter operational.

  • Page 129: Cleaning

    Maintenance and Alignment 5.2.3 Cleaning Proper airflow is essential in keeping the transmitter in top working condition. If outside air is brought into the building it should be well filtered to keep dirt out of the building and the transmitter. 5.2.3.1 Module cleaning The heatsinks on the modules are high efficiency, and therefore do not have large openings for airflow and will tend to collect dirt over time.

  • Page 130: Routine Annual Tests

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

  • Page 131: System Test

    Maintenance and Alignment 5.4.2 System Test The purpose of the SYSTEM test is to check the combiner configuration, cabling and integrity. The length of time required for the SYSTEM test will be indicated on the display. The test will reduce the transmitter power to 40% of nameplate TPO (2kW) and will be going through a MUTE cycle for each PA.

  • Page 132: Isolation Board Maintenance

    Maintenance and Alignment Isolation Board Maintenance If it is determined that one of the Isolation Boards needs repair or replacement, the recommended procedure is to completely exchange the board. The entire Isolation assembly is relatively inexpensive and easy to remove and replace. The Isolation resistors and RF switches are critical to the proper operation of the combiner system.

  • Page 133: Inspection

    Maintenance and Alignment NOTE: Each Isolation Board is programmed for a specific Z-Plane. Therefore, if more than one Isolation assembly is removed at one time, mark each one as to its proper location. The programming is a simple jumper selection on the PC board.

  • Page 134: Directional Coupler Removal And Replacement

    Maintenance and Alignment Directional Coupler Removal and Replacement First, note that 2 of the couplers are labeled Forward sampling and one is Reflected. They cannot be interchanged as the coupling ratio is different. The difference is how far the coupler is inserted into the base. The Forward couplers are not inserted as far as the reflected and have a small gap between the coupler and the base.

  • Page 135: Setting Maximum Power Limits

    Maintenance and Alignment Setting Maximum Power Limits There is a maximum power limit which can be set for each of the transmitter power settings, LOW and HIGH. The “MAX HIGH SET” sets the maximum power output when the transmitter is on HIGH power. The “MAX LOW SET” sets the maximum power output when the transmitter is on LOW power.

  • Page 136: Setting Fwd Pwr To Display 100

    Maintenance and Alignment Setting FWD PWR to Display 100% This procedure simply makes the transmitter FWD PWR % meter read 100% at the present transmitter power output (this will not change the kW reading on the FWD PWR display). Changing TPO does not require re-calibration and is accomplished with the following 2 steps: Set the power to the desired TPO using the raise and lower buttons.

  • Page 137: Forward Power Calibration

    Maintenance and Alignment 5.11 Forward Power Calibration If at all possible, it is recommended that the transmitter be calibrated at the full 5kW power level, even if your TPO is different. This restores all of the calibration parameters to the same relative values as were set up in the factory. It will also assure that the transmitter will be able to reach its full 6kW power output if so desired (this is a user defined level which is set by the MAX HIGH SET in the configuration menus).
  • Page 138 Maintenance and Alignment Press [HOME,MORE,CONFIGURATION C,A,D,C] to go to the STEP 5 APC Factor screen in Figure 5-4. Set the CAL_APC_FACTOR to 7.58. To access the edit controls press and hold the [D] key and press [C]. Press [BACK] to save the changes. Figure 5-4 APC Calibration Factor Screen [HOME,MORE,CONFIGURATION C,A,D,C] Set R127 on the Life Support Board maximum CW.
  • Page 139 Maintenance and Alignment Set the power level in the FWD POWER CAL screen STEP 10 [HOME,MORE,CONFIGURATION C,C] (see Figure 5-6) to 05.00kW or the TPO at which you are calibrating. Figure 5-6 Forward Power Calibration Screen [HOME,MORE,CONFIGURATION C,C] Set the Transmitter LCD meter (the right-hand display) to read FWD STEP 11 PWR in kW.

  • Page 140: Reflected Power Calibration

    Maintenance and Alignment 5.12 Reflected Power Calibration This procedure can be done using the forward power reading on the transmitter. If the forward power also needs to be calibrated, then an external meter will have to be used. Shut the transmitter off. Turn R128 on the Life Support Board STEP 1 maximum CCW.
  • Page 141 Maintenance and Alignment Press the HIGH ON button and then quickly press and hold the STEP 6 LOWER button for 10 seconds. This will turn the transmitter on at zero power output. Raise the transmitter power very slowly until the Forward Power STEP 7 meter reading is 150 watts (or 00.15 kW).

  • Page 142: Pc Board Replacement Procedures

    Maintenance and Alignment Shut the transmitter off and return the Reflected Power Directional STEP 11 Coupler back to its normal position. Press [HOME, MORE, CONFIGURATION B,D,C,D]. This takes STEP 12 you to the Foldback Set screen. Set the VSWR FOLDBACK to 1.35 and press [BACK] to save the setting.
  • Page 143 Maintenance and Alignment Install the new Life Support Board, and reconnect all wires and STEP 5 cables. Be very careful not to bend the PC board when installing any wires into the Wago block on the rear of the card. The card should be supported from the back side due to the pressure required to open the Terminals.

  • Page 144: Replacing The Power Supply Controller Board

    Maintenance and Alignment 5.13.2 Replacing the Power Supply Controller Board Replacement of a PS Controller Board requires no analog adjustments. Set all dip switches and jumpers to the same position as the board being replaced. If the new board does not have the firmware IC’s already installed, then the firmware will have to be transferred from the old board.

  • Page 145: Replacing The Master Controller Board

    Maintenance and Alignment 5.13.4 Replacing the Master Controller Board In the unlikely event that the Master Controller Board needs to be replaced, there are two possible scenarios: a. Replacement using EEPROM U39 from the old board. This procedure should be tried first. b.

  • Page 146: Replacing Eeprom U39

    Maintenance and Alignment Turn the transmitter on and check the calibration. If the transmitter STEP 7 calibration and configuration seem to be okay, then this procedure is finished. If it is still not working, U39 will have to be replaced using the following procedure “Replacing EEPROM U39”.

  • Page 147: Default Settings

    LOWER button for 10 seconds. This will turn the transmitter on at zero power output. Proceed to "5.14 System Configuration and Calibration" on page 5- STEP 9 Table 5-1 EEPROM U39 Parameter Checklist Platinum Z5 Parameter Default Settings Forward Factor 0.007697 (see Figure 5-3) Reflect Factor 0.000306 (see Figure 5-7)

  • Page 148: System Configuration And Calibration

    Maintenance and Alignment 5.14 System Configuration and Calibration System configuration and calibration is mainly for setting the transmitter up for the first time by factory personnel. The procedures contained here should NOT be done as part of a routine maintenance or adjustment schedule. The following procedure should only be done if EEPROM U39 on the Master Controller Board is bad or suspect (EEPROM U39 is the memory chip which contains all of the Backup and Customer configuration and calibration settings).
  • Page 149 Maintenance and Alignment b. UPS/EXCITER - This is the configurable remote input at TB1-9. Set for UPS if the low power UPS mode is to be used, or to EXC if it is going to be used for remote exciter select. c.

  • Page 150: Calibration

    Maintenance and Alignment 5.14.2 Calibration To finish replacing the Master Controller EEPROM U39 a complete calibration is required. To calibrate the transmitter refer to the following procedures in this order: • "5.12 Reflected Power Calibration" on page 5-14, then • "5.11 Forward Power Calibration"...
  • Page 151 Maintenance and Alignment Firmware IC removal: • Shut off the Low Voltage breaker in the back of the transmitter. • Pull out the controller and remove the pc board hold-down bracket. • It will be necessary to remove the appropriate PC board and place it on an anti- static work surface (a large anti-static bag works well if an anti-static mat is not available).
  • Page 152 Maintenance and Alignment Table 5-2 Z5 Minimum Recommended Transmitter Log Readings 5-26 888-2408-002 WARNING: Disconnect primary power prior to servicing.

  • Page 153: Troubleshooting

    Troubleshooting Introduction In order to assist in the troubleshooting of the Platinum Z5 transmitter this section will concentrate in the following areas: • Using the Diagnostics Display System, concentrating on the Fault Log. • Defining all of the transmitter fault indications, their origin, and their effect on the transmitter.

  • Page 154: Power Amplifier Repair

    Troubleshooting Power Amplifier Repair Field replacement of the MOSFETs on the PAs should NOT be attempted. To repair a PA requires an extensive amount of test equipment and expertise due to the tight tolerances allowed for calibration of the test equipment setup and especially for phase and gain of the PA.

  • Page 155: Multiple Pa Failures In A Foursome

    Troubleshooting Table 6-1 Transmitter Power vs. Failure Modes Platinum Z5 Best Case Power Out Worst Case Power Out 1 PA Failed 100% 100% 2 PA Failed 100% 1 Module Removed 2 Modules Removed *1 Power Supply Failed *1 PA Controller Failed *Loss of a PA Controller or Power Supply represents an equivalent loss of 8 of the 16 PAs.

  • Page 156: Software Revision

    Troubleshooting Software Revision Each of the controller boards contains its own software (actually firmware) and therefore each controller has its own software revision number or letter. It is possible to get the revision numbers from the Diagnostics Display Menu labeled, “SOFTWARE REV.”...
  • Page 157 Troubleshooting • ISO_AZ_OT - The predicted temperature of R9 on the “A” Z-Plane Isolation board is greater than 130 • ISO_BZ_OT - The predicted temperature of R9 on the “B” Z-Plane Isolation board is greater than 130 • Strike 1 - When any of the above fault conditions is met, the transmitter output is muted (DAC_APC_REF is brought to zero) for 3 seconds (6 seconds for trans- mitters with a Single Phase power supply).

  • Page 158: Diagnostics Display Menu Tree

    Troubleshooting Diagnostics Display Menu Tree The most important documentation concerning the Diagnostics Display is the “Diagnostics Display Menu Tree” located in the schematic drawing package. This shows the complete Diagnostics Display menu structure. The menus flow from the Main Menu at the left (on each sheet) up to 6 layers deep to the right. Due to the number of menu screens, the drawing is divided by main menu items into 3 drawings.

  • Page 159: Front Panel Fault Led

    Troubleshooting 6.6.1 Front Panel Fault LED When a fault is detected the Fault LED on the front panel of the controller will illuminate a steady red as long as there is an active fault. If there are faults in the log, but none are active, the Fault LED will flash to alert the technician to check the Fault Log.

  • Page 160: Fault Listing

    Troubleshooting • PAC - Power Amplifier Controller • COMM - Communications • XOVER - Crossover Protection: One PA Controller crosses over to protect the PAs controlled by the other PA Controller, should it become inoperative. • PSC - Power Supply Controller •...

  • Page 161: Self Diagnostics

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

  • Page 162: Pa Muting Test

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

  • Page 163: Pa Rf Switch Test

    Troubleshooting a. The most likely problem is a defective PA RF Switch on an Isolation Board (K1-K8). The PA RF switch could simply have bad or open contacts which would disconnect the resistor from the PA. The PA would operate normally as long as the system is balanced, but the resistor would not heat up when the PA is muted.

  • Page 164: Hardware Test

    Troubleshooting 6.7.2 Hardware Test The other option in Figure 6-4 is to test the hardware. Pressing [D] should bring up the screen in Figure 6-6. This screen gives 3 more choices: a. LCD/LED Test - This is a test of all of the LCD segments and LEDs on the front panel to make sure the overlay indicators are operational.

  • Page 165: General Troubleshooting Tips

    Troubleshooting General Troubleshooting Tips 6.8.1 Foldback Conditions The Master Controller is responsible for transmitter power foldback conditions, however a foldback condition by itself will not cause a fault to be registered in the Fault Log. Foldback limits in the transmitter are always set lower than the actual fault limit.

  • Page 166: Master Controller Related Faults

    Troubleshooting Master Controller Related Faults The following is a listing of the faults which are handled by or merey related to the Master Controller. A quick reference for each of these faults is given in Table 6-3 on page 6-35. 6.9.1 THERMISTOR, Fault The Thermistor fault is detected if a thermistor temperature reading is 5°...

  • Page 167: Eeprom_Def, Eeprom U39 Default Load

    Troubleshooting 4. System ISO Temp - ISO_AB. Located on the 3dB hybrid which com- bines the Z-Planes. Is above the PA Modules under the rectangular cover. The sense line (BNC coax) comes out the top of the box. 5. Power Supply Temps - PS1 and PS2. These sensors are part of a screw connector bolted to the top of the power supply heatsink (it is covered with heat-shrink tubing).

  • Page 168: Rfl_Pwr, Reflected Power Fault

    Troubleshooting If a PAC_REF fault appears along with the MSTR_REF fault, then the +5V reference is most likely the problem. If only the MSTR_REF fault is present then the Master Controller or a connection between the Life Support Board and the Master Controller should be suspected.

  • Page 169: Failsafe, Interlock Fault

    Troubleshooting 6.9.7 FAILSAFE, Interlock Fault This fault will mute the transmitter output anytime the Failsafe interlock contacts are opened. There must be a closed contact between the failsafe interlock contacts in order for the transmitter to operate. This fault also flashes the Interlock Fault LED on the controller front panel.

  • Page 170: Ups, Uninterruptable Power Supply Fault

    Troubleshooting 6.9.10 UPS, Uninterruptable Power Supply Fault This fault indicates that the transmitter has switched over to the UPS (or generator possibly). The transmitter power output is now controlled by the UPS Power Level setting in the Configuration menus of the Diagnostics Display. To check or set the UPS Power Level press [CONFIGURATION B,D,A].

  • Page 171: Ipa_Ab#_Out, Fault

    Troubleshooting 6.9.17 IPA_AB#_OUT, Fault This fault indicates that the IPA_AB1 or IPA_AB2 is not physically plugged into the connector. Each amplifier has 2 edge connections which are slightly shorter than the others. These are used for interlocking. If the amplifier is not inserted far enough into the connector, these 2 pins will not make contact and the amplifier will not be activated.

  • Page 172: Iso_##_Ot, Over-Temperature

    Troubleshooting 6.9.23 ISO_##_OT, Over-Temperature There are 3 System Level ISO loads in the Z5 transmitter. These are designated : • ISO_Az and ISO_Bz - These 2 are the 2.5kW ISO loads located in the middle of the Isolation Boards. Their component designation is R9 on the Isolation Board schematic.

  • Page 173: Exc#_Fault, Fault

    Troubleshooting • ISO_Az or ISO_Bz - These faults will most likely be preceded by PA and PA_ISO faults which have imbalanced the Z-Plane outputs. PA currents, voltages and temperatures and PA_ISO load temperatures should be checked as a likely cause of this problem. •...

  • Page 174: Pa Controller Faults

    Troubleshooting Table 4-1 on page 4-60 is intended to ease this confusion. For instance, in the process of troubleshooting a PA problem it is found that amplifier B2 has no gate control voltage. Tracking this back to its source can be tricky. Table 4-1 gives you the necessary information to skip steps or at least verify your path.

  • Page 175: Pa Current Foldback

    Troubleshooting 2 PAs failed, the transmitter could be as high as 97% power or worst case around 84% (possibly less based on individual operating conditions), depending on the location of the failed PAs. See “Multiple PA Failures in a Foursome ” earlier in this chapter.

  • Page 176: A Or B#_Ot, Pa Over-Temperature

    Troubleshooting 6.11.6 A or B#_OT, PA Over-Temperature The temperature of each PA is sensed by thermistor, RT1 (located on each individual amplifier board). If the temperature reaches 100°C, the transmitter will mute and disconnect the problem PA via the isolation switch. If one of the thermistors or its wiring is shorted the temperature indication will be 155°C.

  • Page 177: Pa_Iso_Ot

    Troubleshooting 6.11.9 PA_ISO_OT This is a general over-temperature fault which will shut the transmitter off if one of the PA Isolation resistors in the combiner physically reaches 170°C (no prediction). This protects against a failure in the combiner system where the Isolation resistor does not get switched out of circuit.

  • Page 178: Combiner Iso Faults

    Troubleshooting 6.11.12 Combiner ISO Faults There are two more ISO faults: • PAC_ISOAz and PAC_ISOBz (2.5kW combiner ISO Resistors Az and Bz located on the Isolation Boards). This is a temperature fault which is caused by an imbalance between the outputs of the two foursomes on the respective Z Plane. If one of these loads reaches 145°C the PA Controllers will mute all of the PAs.

  • Page 179: Pac#_-15V, Pa Controller Ps Fault

    Troubleshooting 6.11.15 PAC#_-15V, PA Controller PS Fault This is a critical fault since the affected PA Controller has basically lost its muting ability if the -15V is lost. When this fault is detected the affected PA Controller will request that the other PA Controller mute its PAs (XOVER) and switch them out. This will cause a major system imbalance and the transmitter power will in most cases go to approximately 33% of nominal power output.

  • Page 180: Power Supply Controller Faults

    Troubleshooting 6.12 Power Supply Controller Faults The following paragraphs give a detailed description of all faults associated with the PS Controller Boards. A quick reference of these faults is given in Table 6-5 on page 6-39. There are two types of power supply faults: a.

  • Page 181: Ps#_Start, Soft Start Circuit Fault

    Troubleshooting NOTE: Since one power supply controller is able to control up to two power supplies, one of the power supplies can be turned off, due to a fault, while the other one continues to operate normally. Due to the distribution of voltage to the PAs, this will affect all of the PAs associated with one of the PA Controllers.

  • Page 182: Ps#_Phs_Ls, Phase Loss (100-120 Hz Ripple)

    Troubleshooting 6.12.2.4 PS#_PHS_LS, Phase Loss (100-120 Hz ripple) When Phase Loss is detected the transmitter will mute for 20 seconds and then try to restart. It will continue to do this until it is successful. For all 3 phase transmitters, detection is based on the level of 100 to 120 Hz ripple at the output of a DSP band pass filter (on the PS Controller) operating on the DC input voltage data.

  • Page 183: Ps#_Jump

    Troubleshooting 6.12.2.7 PS#_JUMP If a power supply tap fails and the next one available is two or more taps away, a JUMP fault is triggered and the supply will be shut off and discharged. The only situations where this could happen are: •...
  • Page 184 Troubleshooting Table 6-2 Power Supply Tap Troubleshooting Chart 3 Phase Power Supply Single Phase Supply Rectifier Board "A" Rectifier Board "B" SCRs Fuses SCRs Fuses SCRs Fuses TAP 1 TAP 2 TAP 3 TAP 4 Soft Start There are no Soft Start SCRs on Rectifier Board "A"...
  • Page 185 Troubleshooting Figure 6-7 3-Phase Power Supply Component Locator, Top View 888-2408-002 6-33 WARNING: Disconnect primary power prior to servicing.
  • Page 186 Troubleshooting Figure 6-8 Single Phase Power Supply Rectifier Assembly Component Locator, Top View 6-34 888-2408-002 WARNING: Disconnect primary power prior to servicing.
  • Page 187 Troubleshooting Table 6-3 Platinum Z5 Master Controller Related Faults ABBREVIATION COMMENT ACTION MSTR_REF +5V reference fault. Indicates +5V Mute XMTR (IPA & Exciter, Power supplies) reference is < 4.6V REF_WARNING Indicates +5V Reference is out of Reports fault in Log without shutting down the tolerance at the Master Controller Board PAs.
  • Page 188 Troubleshooting Table 6-3 Platinum Z5 Master Controller Related Faults IPA_AB1_OUT IPA_AB1 is not inserted completely into Switch to IPA_AB2 if it is not faulted the connector IPA_AB2_MUTE IPA_AB2 current still present with Vg < - Mute XMTR (exciter and PAs) IPA_AB2_LOW IPA_AB2 power is <...
  • Page 189 Troubleshooting Table 6-4 Platinum Z5 PA Controller Related Faults ABBREVIATION COMMENT ACTION PAC#_REF +5V voltage reference fault (< 4.6V) Mute all PAs for the designated PA Controller Transmitter will go to about 20% power and energize all its relays (n = 1 or 2) as long as only one PA Controller was affected.
  • Page 190 Troubleshooting Table 6-4 Platinum Z5 PA Controller Related Faults PAC#_ISOAZ Will follow 3 Strike Routine (described in Designated ISO load Temp > 145 Section 6) PAC#_ISOBZ Means ISO_APC foldback has failed to reduce temperature of the load. Fold- back level is 135...
  • Page 191 Troubleshooting Table 6-5 Platinum Z5 PS Controller Related Faults ABBREVIATION COMMENT ACTION PSC# +20V +20V DC supply to PSC failed Shut PS OFF and discharge PS#_DSCHG Discharge circuit failed which means the Transmitter is shut OFF PS will not discharge. If discharge...
  • Page 192 Troubleshooting 6-40 888-2408-002 WARNING: Disconnect primary power prior to servicing.

  • Page 193: Parts List

    Parts List Part List Index 888-2408-002 WARNING: Disconnect primary power prior to servicing.
  • Page 194 Parts List 888-2408-002 WARNING: Disconnect primary power prior to servicing.

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