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Harris ZX2500 Technical Manual

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TECHNICAL MANUAL
888-2595-001
ZX Series FM
Transmitter
ZX Series
FM Transmitters
ZX2500, ZX3750, ZX5000, ZX7.5, & ZX10
Dec 20, 2011
T.M. No. 888-2595-001
Rev: J
© Copyright Harris Corporation 2009, 2010, 2011
All rights reserved

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  • Page 1 TECHNICAL MANUAL 888-2595-001 ZX Series FM Transmitter ZX Series FM Transmitters ZX2500, ZX3750, ZX5000, ZX7.5, & ZX10 Dec 20, 2011 T.M. No. 888-2595-001  Rev: J © Copyright Harris Corporation 2009, 2010, 2011 All rights reserved...
  • Page 2 888-2595-001 12/20/11 WARNING: Disconnect primary power prior to servicing.
  • Page 3 Replaceable Parts Service Replacement parts are available from HARRIS Service Parts Department from 7:00 AM to 11:00 PM US Central Time (UTC-6), seven days a week. Telephone +1-217-222-8200 or email servicepartsreq@harris.com to contact the Service Parts Department.
  • Page 4 888-2595-001 12/20/11 WARNING: Disconnect primary power prior to servicing.
  • Page 5 Manual Revision History ZX Series FM Transmitter Manual REV. DATE Pages Affected 2009 June 2009 July P44299 Added service revisions. 2009 Dec 58482 Revised Title Page, MRH1, TOC, added Appendix-A 2010 Jan 58572 Revised Title Page, MRH1, Sheets 2-15 and 2-16 2010 May 58978 Revised to include 7.5 and 10 kW models...
  • Page 6 MRH-2 888-2595-001 12/20/11 WARNING: Disconnect primary power prior to servicing.
  • Page 7 • In the ten digit part numbers, if the last three numbers are 000, the item is a part that Harris has pur- chased and has not manufactured or modified. If the last three numbers are other than 000, the item is either manufactured by Harris or is purchased from a vendor and modified for use in the Harris product.
  • Page 8 viii 888-2595-001 12/20/11 WARNING: Disconnect primary power prior to servicing.
  • Page 9 12/20/11 888-2595-001 ix WARNING: Disconnect primary power prior to servicing.
  • Page 10 888-2595-001 12/20/11 WARNING: Disconnect primary power prior to servicing.
  • Page 11 The installation, operation, maintenance, and service of this equipment involves risks both to personnel and equipment, and must be performed only by qualified personnel exercising due care. HARRIS CORPORATION shall not be responsible for injury or damage resulting from improper procedures or from the use of improperly trained or inexperienced personnel performing such tasks.
  • Page 12 WHILE IT IS HOT DUE TO THE POSSIBILITY OF A CASE RUPTURE AND SUBSE- QUENT INJURY. 888-2595-001 12/20/11 WARNING: Disconnect primary power prior to servicing.
  • Page 13 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 brief and is only to be used as a reference.
  • Page 14 888-2595-001 12/20/11 WARNING: Disconnect primary power prior to servicing.

  • Page 15: Table Of Contents

    Table of Contents Section 1 Section 3 Introduction Operation Manual Contents ......1-1 Introduction.......3-1 Features / Benefits.
  • Page 16 Reverse Power Meter Calibration ... 5-18 Contacting Harris Service ....6-1 Set Transmitter Power Level (Case 1: Troubleshooting Table .
  • Page 17 Table of Contents Installation Procedure ..... A-4 Operation....... . A-5 Access main page .
  • Page 18 Table of Contents (Continued)

  • Page 19: Manual Contents

    ZX Series  Section 1 Introduction Manual Contents This technical manual addresses the following Harris ZX series of solid-state radio transmitters: • ZX2500 – 2.5 kW FM transmitter • ZX3750 – 3.75 kW FM transmitter • ZX5000 – 5 kW FM transmitter •...

  • Page 20: Features / Benefits

    Appendix A: FM WEB remote option, proivdes information about the optional WEB remote interface card. Features / Benefits The Harris ZX Series of transmitters offers the following useful features and benefits: • HD Radio capable with on-the-fly switching between FM, FM+HD, or HD mode when used with FlexStar exciter.

  • Page 21: General Product Description

    The exciter accepts an audio signal in either analog or digital format and modulates it onto an RF carrier. Depending on the format of modulation, digital HD Radio or traditional FM, the exciter may be any one of these Harris exciters: 12/20/11 888-2595-001 1-3...

  • Page 22: Amplifier

    ZX Series Section 1 Introduction • Micromax FM – FM exciter with analog modulator. • Digit CD – Digitally synthesized FM exciter. • FlexStar HDX - Tri-mode exciter capable of either traditional FM or digital HD Radio transmissions. 1.3.2 Amplifier The amplifier chassis accepts a low level on-channel RF signal from the exciter and amplifies it to the desired output level for transmission.

  • Page 23: Tri-Mode Operation

    Section 1 Introduction ZX Series FLX-11 = single FM output FLX-12 = dual FM outputs HDPL-21 = single tri-mode output (FM, FM+HD, HD) HDPL-22 = dual tri-mode outputs Tri-mode Operation All ZX transmitters are designed to operate in any one of three different modes: 1.
  • Page 24 PA Modules* PS Modules Cooling Fans ZX5000 8 + 1 ZX3750 6 + 1 ZX2500 4 + 1 NOTE: “+1” designation indicates an IPA module: a PA module installed in the IPA posi- tion. 888-2595-001 12/20/11 WARNING: Disconnect primary power prior to servicing.
  • Page 25 Section 1 Introduction ZX Series Figure 1-3 Positions of PA and PS modules in various ZX series transmitter models The transmitter models at 7.5kW and above are made by combining the outputs of multiple ZX3750 or ZX5000 amplifier chassis in an integrated system. The number of amplifier chassis per model is as follows: ZX7.5 = 2 x ZX3750 ZX10 = 2 x ZX5000...

  • Page 26: Simplified Block Diagrams

    ZX Series Section 1 Introduction Simplified Block Diagrams Figures 1-4 through 1-6 provide simplified block diagrams of the amplifier models discussed in this manual. Figures 1-7 and 1-8 provide a simplified block diagram of the ZX7.5 and ZX10 model transmitters. Consult the exciter manual for a block diagram of the exciter.
  • Page 27 Section 1 Introduction ZX Series Figure 1-4 ZX2500 amplifier simplified block diagram 12/20/11 888-2595-001 1-9 WARNING: Disconnect primary power prior to servicing.
  • Page 28 ZX Series Section 1 Introduction Figure 1-5 ZX3750 amplifier simplified block diagram 1-10 888-2595-001 12/20/11 WARNING: Disconnect primary power prior to servicing.
  • Page 29 Section 1 Introduction ZX Series Figure 1-6 ZX5000 amplifier simplified block diagram 12/20/11 888-2595-001 1-11 WARNING: Disconnect primary power prior to servicing.
  • Page 30 ZX Series Section 1 Introduction Figure 1-7 ZX7.5 similified block diagram Figure 1-8 ZX10 simplified block diagram 1-12 888-2595-001 12/20/11 WARNING: Disconnect primary power prior to servicing.

  • Page 31: Major Subassemblies

    Section 1 Introduction ZX Series Major Subassemblies Figures 1-7 through 1-9 identify some of the major subassemblies contained the ZX series amplifier. Figures 1-10 through 1-14 indentify the major subassemblies found in full-cabinet transmitters with output powers of 7.5kW and above.   ...
  • Page 32 Exciter interface port (D-sub 15) System interface port (D-sub 15HD) Remote control port (D-sub 25) [203] AC mains inputs: PowerCon NAC3MPA (ZX5000) IEC C20 (ZX2500, ZX3750) [206] [204] [204] Individual fan alarm LEDs [205] Chassis cooling fan [206] Hex key latch to open rear door...
  • Page 33 Section 1 Introduction ZX Series [301] AC mains filters (ZX5000) [302] 8X PS interface board [303] 2X IPA splitter board [304] 3dB attenuator assembly [305] 8X splitter board [306] PA backplane board [307] Output assembly (combiner, harmonic filter, and directional couplers) [301] [302]...
  • Page 34 ZX Series Section 1 Introduction [101] Air exhaust ports [102] RF output flange [103] ZX5000 amplifier chassis [104] ZX5000 amplifier chassis [105] AC distribution chassis [106] System metering assembly [107] Exciter Exciter switcher: 1RU drawer between upper and lower exciter [108] Exciter Figure 1-12 ZX10 transmitter front view [201] RF output flange...
  • Page 35 Section 1 Introduction ZX Series [301] 2.5kW RF load [302] Component panel (side wall) [303] Cabinet rear door Figure 1-14 ZX10 transmitter with rear door removed [401] Coaxial transfer relay [402] Reserve exciter RF test load [403] 2X splitter RF load [404] 2X splitter (700W hybrid) [405] Remote terminal board [406] 5X HD15 divider board...

  • Page 36: Transmitter Accessories

    Customized Rack Integration ZX transmitters up to the 5000W power level are often purchased as stand-alone units and mounted in an equipment rack provided by the customer. Alternatively, Harris sometimes provides a complete rack integration package, especially for customers requiring ducted output and/or input air. Transmitters at the 7.5kW level and above are furnished with racks as part of an integrated system.

  • Page 37: Dual-Drive / Main-Alternate Switcher

    Section 1 Introduction ZX Series 1.9.4 Dual-Drive / Main-alternate Switcher A second exciter and exciter switchover controller are sometimes provided. The operation of the main alternate switcher is addressed in a separate manual. 12/20/11 888-2595-001 1-19 WARNING: Disconnect primary power prior to servicing.

  • Page 38: Section 1 Introduction

    Overview: The present document provides a controlled source for specifications for the ZX10, ZX7.5, ZX5000, ZX3750, and ZX2500 models of FM transmitter. This information mirrors some of the information contained in outline drawing 839-8464-033. Many of the exciter-dependent parameters are derived from the data sheets of the respective exciters and are subject to change according to any changes in the exciter design.
  • Page 39 Phase response variation: +/- 0.5 from linear phase, 30 Hz to ZX2500: 16 RU amp + 1 RU exciter, 62 cm (25”) depth 53 kHz, limited by measurement equipment (see stereo ZX3750: 16 RU amp + 1 RU exciter, 62 cm (25”) depth separation below).
  • Page 40 9850-001). Sync input requirement: 2.82 V p-p or TTL (1.75”) level. Sync input connector: BNC female. ZX2500: 16 RU amp + 1 RU exciter, 62 cm (25”) depth ZX3750: 16 RU amp + 1 RU exciter, 62 cm (25”) depth Harmonic / spurious output: Meets or exceeds FCC, ZX5000: 16 RU amp + 1 RU exciter, 62 cm (25”) depth...
  • Page 41 Section 1 Introduction ZX Series ZX2500: < 73 dBA (65 dBA) Non-linear crosstalk: L+R to L-R and L-R to L+R due to ZX3750: < 73 dBA (65 dBA) distortion products: 75 dB below 100% modulation ZX5000: < 73 dBA (65 dBA) reference, DC - 15 kHz.
  • Page 42 (1.75”) meets or exceeds all FCC, IC, CE, Chinese requirements. ZX2500: 16 RU amp + 1 RU exciter, 62 cm (25”) depth Meets or exceeds standard NRSC-5A emission limits in all ZX3750: 16 RU amp + 1 RU exciter, 62 cm (25”) depth modes.
  • Page 43 User remote interface: D-sub 25-pin female. input available as option. N+1 interface: D-sub 25-pin female. ZX2500: 17 m3/min (600 cfm) approx. RF sample out: BNC jack, -66 dBc, post harmonic filter. ZX3750: 17 m3/min (600 cfm) approx. 19 kHz pilot sync output: BNC female, unbalanced, 50 ohms ZX5000: 17 m3/min (600 cfm) approx.
  • Page 44 ZX Series Section 1 Introduction Mono total harmonic distortion: 0.002%*/0.01% THD, 10 Hz Crosstalk, SCA to SCA: 80 dB below 100% modulation to 22 kHz bandwidth. (referenced to +/- 6 kHz deviation and 150 s de-emphasis Mono intermodulation distortion: CCIF: 0.005% (14/15 kHz per channel).

  • Page 45: Field Services

    Field Services Some Harris customers choose to install their transmitter themselves, while others prefer to have their transmitter installed and/or commissioned by Harris or a Harris- provided contractor in their region. Contact your Harris sales representative for more information on obtaining Harris field service assistance.

  • Page 46: Commissioning

    If the transmitter is installed by station staff or representatives, you may still have a Harris service engineer perform an operational check-out and/or proof of performance of the transmitter. If you require a special test protocol beyond the tests recorded in the factory test data report, please notify Harris at your earliest convenience.

  • Page 47: Installation And Outline Drawings

    2.4.1 Installation and Outline Drawings To aid in the installation process, Harris typically provides three key drawings with each transmitter shipment: the Outline Drawing, the System Interconnect drawing, and the Mains Interconnect drawing. Please locate these drawings before proceeding, as they will be referenced several times in the following pages.

  • Page 48: Ac Mains Requirements

    ZX Series Section 2 Installation AC Mains Requirements 2.6.1 Transmitters with AC Distribution Chassis Larger transmitters featuring the in-rack AC distribution chassis require only AC mains connection to this chassis. All AC mains distribution within the transmitter is provided by the chassis and its supporting mains cables. The AC distribution chassis has separate versions for each of these three input voltage options: •...

  • Page 49: Transmitters Without Ac Distribution Chassis

    Section 2 Installation ZX Series Figure 2-1 AC mains connection to transmitter (transmitter rack side panel removed for clarity NOTE: The illustration in Figure 2-1 has been exaggerated for the purpose of clarity. It is not typically necessary to fully disconnect the AC distribution chassis and com- pletely remove it from the cabinet.
  • Page 50 ZX Series Section 2 Installation The ZX2500 and ZX3750 amplifier chassis have three 208-240 VAC 50/60Hz single- phase feeds via IEC C20 inlets. The three inputs are completely independent and may be wired to separate AC phases for increased redundancy.

  • Page 51: Surge Suppression Devices

    Surge Suppression Devices Harris strongly recommends the use of surge protection devices on the incoming AC mains lines. These devices protect against damages due to transients arising from both natural and man-made sources. (e.g. lightning and inductive load switching). Clear preference is to be given to “series”...

  • Page 52: Overview Of Rf Grounding Practices

    AC input cord(s) must terminate at the PE terminal at the AC mains source. In the case of a Harris-supplied AC distribution chassis, the green/yellow earth wire from the incoming AC mains service terminates at the PE terminal of the AC distribution chassis (ground symbol inside circle).

  • Page 53: Cooling System Requirements

    Section 2 Installation ZX Series Lightning and transient energy via the power line or tower connections can impose serious threats to personnel safety, as well as damage the equipment. For these reasons, a good protective grounding system to divert these forms of energy to earth ground is imperative.
  • Page 54 ZX Series Section 2 Installation To avoid operational problems due to excessive temperature, the blower openings must not be blocked. The transmitter Outline Drawing provides an indication of the relative location of the transmitter blowers and the necessary clearances to respect. Air input is from the transmitter front with hot air exhaust at the rear of the amplifier.

  • Page 55: Personnel And Equipment Protection

    Section 2 Installation ZX Series 2.10 Personnel and Equipment Protection All electrical equipment can pose a safety hazard if not operated properly or if proper safety precautions are not taken. Every care should be taken during the site planning process to maximize personnel protection on site, both during the installation and once the transmitter has been placed into operation.

  • Page 56: Remote Control Installation

    ZX Series Section 2 Installation > External interlock: The external INTERLOCK A and B signal lines are available on pins 2 and 3 the 25-pin REMOTE CONTROL connector at the rear of the amplifier chassis or on the remote terminal board in larger models. The two interlock pins must be bridged to turn on the ZX transmitter.
  • Page 57 Section 2 Installation ZX Series Table 2-1 10/100 BASE T (RJ45, amplfier rear) Designation Remarks RD + Receive Data (positive) RD - Receive Data (negative) TD + Transmit Data (positive) TD - Transmit Data (negative) Ground 4,5,7,8 Table 2-2 REMOTE CONTROL (D-sub 25, amplifier rear) Designation Remarks Signal ground...
  • Page 58 ZX Series Section 2 Installation Table 2-2 REMOTE CONTROL (D-sub 25, amplifier rear) Designation Remarks TX OFF Ground pin to turn transmitter Input COMMAND off. (momentary) POWER RAISE Ground pin to raise output Input COMMAND power. (momentary) POWER LOWER Ground pin to lower output Input COMMAND power.
  • Page 59 Section 2 Installation ZX Series Table 2-2 REMOTE CONTROL (D-sub 25, amplifier rear) Designation Remarks EXCITER OK Open collector Output STATUS 24V @ 100mA max. Open = exciter reporting internal fault or exciter switcher reporting emergency exciter switchover. Ground = exciter OK LOW GAIN FAULT Open collector Output...
  • Page 60 ZX Series Section 2 Installation Table 2-2 REMOTE CONTROL (D-sub 25, amplifier rear) Designation Remarks AC MAINS LOW Open collector Output FAULT 24V @ 100mA max. Ground = one or more mains inputs < 190V MUTE ACTIVE Open collector Output FAULT 24V @ 100mA max.

  • Page 61: Exciter Connections

    Section 2 Installation ZX Series Table 2-3 Remote Terminal Board (D-sub 9 and screw terminals, cabinet rear area, component panel ZX7.5 & ZX10 only). Designation Remarks INTERLOCK B Connect pins A and B to allow Input transmitter to turn on. SYS FWD MTR Output Forward power sample, power...
  • Page 62 ZX Series Section 2 Installation When special cables (non-straight-through) are provided, a separate schematic is provided in the accompanying drawing package to aid in signal tracing during troubleshooting. When no schematic is provided, it is generally safe to assume that the cable in question is straight-through.
  • Page 63 Section 2 Installation ZX Series Table 2-4 EXCITER INTERFACE (D-sub 15, amplfier rear) Designation Remarks EXC_SUM_FAULT Exciter grounds pin to signal Input it has internal alarm exciter switcher grounds pin to signal an emergency exciter switchover has occurred. No connection PA_APC Analog voltage from Output...

  • Page 64: System Bus Connections

    ZX Series Section 2 Installation NOTE: The RF splitter has a bracket designed for mounting to a cabinet rear rack rail behind the amplifier chassis. The splitter can be removed from the angle bracket and rotated as necessary to facilitate mounting. 2.12 System Bus Connections The system bus port provides a means to connect multiple PA chassis to together for parallel operation in transmitters at the 7.5kW level and above.
  • Page 65 Section 2 Installation ZX Series Install all PA and PS modules in transmitter. If transmitter was shipped STEP 5 with all PA and PS modules in place, loosen thumsbscrews on PA modules, insert PA modules fully into sockets, and re-tighten thumbscrews.
  • Page 66 ZX Series Section 2 Installation If tri-mode operation is anticipated, verify FlexStar exciter currently has STEP 9 correct operating mode selected (FM, FM+HD, HD) and transmitter has assumed same mode. Open front door of amplifier chassis and verify following alarms on STEP 10 controller card: a.
  • Page 67 STEP 22 materials for major subassemblies in safe, dry location (modules, exciter, amp chassis). These could be useful should it become necessary to return equipment to Harris or ship equipment to another site at a future date. Procedure complete. STEP 23...
  • Page 68 ZX Series Section 2 Installation 2-24 888-2595-001 12/20/11 WARNING: Disconnect primary power prior to servicing.

  • Page 69: Operation

    ZX Series  Section 3 Operation Introduction This section contains information concerning operation of the transmitter and its controls, indicators, and adjustments. Basic procedures for the transmitter operator are included in the second half of this section. Controls and Indicators 3.2.1 Front Panel The front panel of the amplifier chassis contains the basic controls for daily operation of...
  • Page 70 ZX Series Section 3 Operation Figure 3-1 Front panel of ZX amplifier chassis. Table 3-1 Front panel of ZX amplfier chassis Item Description [001] Multimeter Provides digital readout of important operational parameters. [002] STATUS LEDs Indicates the current transmitter mode (FM, FM+HD, HD, or SL) and the current transmitter status.

  • Page 71: Controller Board

    Section 3 Operation ZX Series Table 3-1 Front panel of ZX amplfier chassis Item Description [004] Meter select button Changes the parameter currently being displayed by the meter. [005] OFF button Switches the transmitter off. [006] ON button Switches the transmitter on. 3.2.2 Controller board The controller board on the reverse side of the amplifier chassis front door contains...
  • Page 72 ZX Series Section 3 Operation Table 3-2 Controller board inside amplifier chassis Item Description [101] APC IDLE potentiometer Adjustment to set the maximum drive level when one or more PA modules are switched off. Consult the APC alignment procedures of Section 5 - Maintenance of this manual for more information.
  • Page 73 Section 3 Operation ZX Series Table 3-2 Controller board inside amplifier chassis Item Description [108] JP3 and S16 - Module programming Two factory-preset settings that vary according to PA module type and mode of operation. Consult the controller board portion of Section 4 – Theory of Operation for more information on these settings.

  • Page 74: Internal Leds

    ZX Series Section 3 Operation 3.2.3 Internal LEDs In addition to the alarm LEDs on the controller board, there are other LEDs inside the amplifier chassis that are useful in determining the operational status of the transmitter. Figure 3-3 LEDs inside amplifier chassis Table 3-3 LEDs inside amplifier chassis Item...

  • Page 75: System Metering Assembly

    Section 3 Operation ZX Series Table 3-3 LEDs inside amplifier chassis Item Description AC 1 FAULT AC mains low fault LEDs AC 2 FAULT Indicates one or more AC mains inputs are below the 190V threshold AC 3 FAULT needed for the RF amplifying section to operate. IPA 1 ON IPA on/off status LEDs IPA 2 ON...

  • Page 76: Basic Operational Procedures

    ZX Series Section 3 Operation Table 3-4 ZX system metering assembly Item Description [001] Calibration potentiometers Provides fine calibration of the forward and reverse power readings. FM = FM mode forward power calibration. FM+HD = FM+HD mode forward power calibration HD = HD or SL mode forward power calibration REV = reverse power calibration, all modes [002]...

  • Page 77: Power Raise/Lower Procedure

    Section 3 Operation ZX Series Perform Basic Functional Check procedure (see 3.4.4) as desired to STEP 7 assess transmitter status. Procedure complete. STEP 8 3.4.2 Power Raise/Lower Procedure The electronic RAISE/LOWER power control is typically left at or near its maximum setting to achieve the full power level determined by the POWER LIMIT potentiometer(s) on the controller board.

  • Page 78: Basic Functional Check Procedure

    ZX Series Section 3 Operation RF MUTE ACTIVE alarm clears and power ramps up from zero to new STEP 5 power level. Consult Section 5 – Maintenance for power adjustment procedure if STEP 6 power level in new mode is not correct. Procedure complete.
  • Page 79 Section 3 Operation ZX Series c. Check status of IPA ON lights inside IPA heatsink. d. Check status of red LEDs behind each PA module. NOTE: Consult Section 3.2 - Controls and Indicators for the location of these indicators. If alarms are being reported inside transmitter (STEP 5), notify station STEP 6 engineering staff and/or proceed to perform Advanced Functional Check Procedure is Section 5 - Maintenance.
  • Page 80 ZX Series Section 3 Operation 3-12 888-2595-001 12/20/11 WARNING: Disconnect primary power prior to servicing.

  • Page 81: Theory Of Operation

    ZX7.5 (ZX3750 amplfier) = 839-8464-084 ZX5000 = 839-8464-082 ZX3750 = 839-8464-084 ZX2500 = 839-8464-086 RF power from the exciter passes through a 3dB attenuator and a two-way Wilkinson splitter. The resulting two outputs drive the inputs of a PA module serving as an intermediate power amplifier (IPA).

  • Page 82: Output Assembly

    Consult output assembly schematic based on amplifier chassis type. ZX5000: 839-8464-080 ZX3750: 839-8464-087 ZX2500: 839-8464-088 The output from the PA modules is passed through RG-142 BNC cables from the PA backplanes to the output assembly. The output assembly is a combination Wilkinson power combiner and harmonic filter.
  • Page 83 The loss of a single IPA results in the following power outputs for the various transmitter models: ZX2500 / ZX3750 / ZX5000 = -6dB (25%) ZX7.5 / ZX10 = -2.5 dB (56.3%) The loss figures given here should be considered a worst-case scenario. The regulating action of the transmitter automatic power control (APC) will attempt to raise the power output to compensate for the drop.

  • Page 84: Ac-Dc Interconnect Wiring Diagram

    Each amplifier chassis has three separate AC input connections. Each connection may assigned to a different phase for three phase operation or bridged together for single phase operation. Each AC input features either a IEC C20 inlet (ZX2500, ZX3750) or PowerCon NAC3MPA (ZX5000) connection depending on transmitter model. The use of NAC3MPA connectors for the ZX5000 module is required to meet the higher current demands of this chassis in accordance with CE area regulations.

  • Page 85: Pa Backplane

    Section 4 Theory of Operation ZX Series The output of the line filters is supplied to the inputs or a series of power supply (PS) modules plugged into the 8x PS interface board (see also 801-0203-531). The PS modules convert AC mains power in the 190V - 264V range into DC power in the 43V - 53V range up to 1250W (nominally 25A at 50V).

  • Page 86: Pa Temperature Alarm

    ZX Series Section 4 Theory of Operation comparator U2C. In a non-faulted state, U2C will have a low output, based on a near zero input at the (+) input at pin 10 and a 2.25V input at the (-) input at pin 11 due to voltage divider R43-R51.

  • Page 87: Socket Interlock Module Fault Sensor

    Section 4 Theory of Operation ZX Series 4.5.4 Socket Interlock Module Fault Sensor In addition to the three fault conditions described above, a >3V PA current sample to command a PS module shutdown can also be generated via R1-Q1 whenever the PA module is unplugged and the connection to the ground of the base of Q1 via J5-V, J5-A, J6-V, J6-A is broken The PA backplane reports a module shutdown status to the controller board (via a...

  • Page 88: I/O Filter Pcb

    ZX Series Section 4 Theory of Operation The individual PA current samples from each half of the IPA module are summed in amplifier U2A and passed to the IPA_CURRENT sample line via RFI network R40- C13-R41 and J7-12. Another noticeable difference with the IPA backplane, when compared with the PA backplane is the alarm comparator threshold from voltage divider R45-R66 (R7-R70) is +1.25V instead of +2.5V.

  • Page 89: Ps Interface Pcb

    Section 4 Theory of Operation ZX Series Q17 provides a ground to this amplifier chassis and all chassis connected to the SYSTEM INTERFACE bus when a “Exciter Ready” mute is being called for by the FlexStar exciter while switching modes. J3 and J4 provide an interface point for an optional Web Remote daughter board.

  • Page 90: Fan Monitor Pcb

    ZX Series Section 4 Theory of Operation Comparators U1C and U1D perform a similar function as U1B for PA modules 7 and 6, respectively. Similar circuits for PA modules P5 through PA 1 on pages 2 and 3 of the schematic.

  • Page 91: Load Pcb

    Section 4 Theory of Operation ZX Series Jumpers JP1, JP2, and JP3 disable the alarms for fans 2, 4, and 5, respectively, allowing these fans to be permanently removed from lower power models without causing a persistent low fan speed alarm. 4.10 16X Load PCB Consult drawing 801-0203-321 The 16X load board monitors the flange temperature of the output assembly ballast...

  • Page 92: Transmitter Controller Pcb

    ZX Series Section 4 Theory of Operation A socket interlock is provide by a jumper connection between pins J1-A and J1-V. Circuits on the PA backplane will not supply 50V power to module until the J1-A to J1- V connection is satisfied. 4.12 Transmitter Controller PCB Consult drawing 801-0203-541 The transmitter controller board serves as both the main interface to the user and the...

  • Page 93: Auto Restart

    Section 4 Theory of Operation ZX Series The logic output of U13 is shifted via voltage divider network R78-R79 to approximately +2V when logic high and 0V when logic low. This line is diode-or combined with +5V pulses coming from either the auto restart timer U14 or optoisolator U30A controlled by the ON pushbutton and passed through buffer transistor Q13 to increase its ability to drive low impedance loads.

  • Page 94: Apc Circuit And Power Level Adjust

    ZX Series Section 4 Theory of Operation Each of these necessary conditions control the logic state at the gate of transistor Q4 via diode-or network CR4A through CR4E. When the gate of Q4 is logic high for any reason, no restart pulses will be generated by U14. The logic high condition at the gate of Q4 also causes transistor Q5 to conduct, grounding the base of transistor Q1, thereby preventing it from charging capacitor C46.
  • Page 95 Section 4 Theory of Operation ZX Series compared by U25A against a fixed +2V reference from network R109-CR17-C16-R64 unless it is overridden by stronger signal through the diode-or network. • Reverse power sample from JP1-U24A-CR9 forces the APC to follow the reverse power level (reverse foldback) •...

  • Page 96: Operating Mode And Bias Level Control

    FM_ON_STATUS and HD_ON_STATUS lines available at the transmitter interface connector of the Harris FlexStar HDX exciter. These lines are pulled low by the exciter when the FM carrier or HD carriers are present at the exciter output. These lines are passed via the I/O flter board to the controller via the FM_ON_BUS and HD_ON_BUS signal lines.

  • Page 97: Metering

    Section 4 Theory of Operation ZX Series with non-standard ratio) is most likely to require the standard FM+HD mode as a backup should the main transmitter fail. It is unlikely that it would require an HD-only mode as a backup in a failure scenario. This made making the third mode HD-or-Split Level a logical choice.
  • Page 98 ZX Series Section 4 Theory of Operation DS13, DS14, DS15, and DS16 via driver transistors Q9, Q12, Q11, and Q10, respectively. When appropriate, decimal point scaling is provided by SPDT switches U18 and U19. Switch U19 activates the third digit decimal point for 1/10 unit reading precision whenever the reverse power, PA volts, or PA current metering options are selected (e.g.

  • Page 99: Fault And Status Signaling

    Section 4 Theory of Operation ZX Series Similar functionality is provided for PA modules 2 through 8 by the remaining positions in U22, U23, U1, U2. In addition to the total PA stage current, the current of each individual PA module may be read by means of a series of selector pushbuttons whenever the meter is already in the PA AMPS position.

  • Page 100: Load Temperature Fault Sensor

    ZX Series Section 4 Theory of Operation Since a LOW_GAIN_FAULT will always be present when the transmitter is off (because the power is indeed low i.e zero ), the red segments will always glow when the transmitter is switched off. LEDs DS4 through DS12 provide signalization of a variety of fault conditions.

  • Page 101: System Interconnect

    Section 4 Theory of Operation ZX Series The system metering assembly provides a measurement of the final system RF forward and reverse power level in larger model transmitters. Forward and reverse power samples from directional couplers at the final system output enter through SMA connectors J5 and J6.
  • Page 102 ZX Series Section 4 Theory of Operation open collector of a FET on the option web remote board (Q1 on page 2 of 8010203391), or a remote ground closure coming in from outside if the REMOTE ENABLED mode has been selected (ON_CMD line passing U5 on page 4 of 8010203541). When multiple PA chassis are connected together via the system bus, all ON_CMD_BUS lines are bridged.

  • Page 103: Power Control Sharing

    Section 4 Theory of Operation ZX Series along their length, the exciter main/alt switcher will respond by changing its exciter selection. This ground connection could come from the optional web remote card in any chassis, or directly to the J10 USER REMOTE connector from an external remote control system installed by the end-user.
  • Page 104 ZX Series Section 4 Theory of Operation Figure 4-2 Simplified schematic of power control sharing (general case of up to four PA chassis) As mentioned previously, the POWER RAISE and POWER LOWER pushbuttons are ganged together when all PA chassis are in remote enabled mode. This allows all APC circuits to rise and fall together when the power level is temporarily adjusted via these buttons, thereby preserving at all times the “dominant-vs-reserve”...

  • Page 105: Maintenance And Alignments

    ZX Series  Section 5 Maintenance and Alignments Introduction This section provides maintenance and alignment information for qualified technical personnel and is divided into four principal parts. The first part of this section provides a general overview of good maintenance practices. The second part of this section provides basic maintenance procedures for the operator or first-level technician: Basic Procedures...

  • Page 106: General Maintenance Guidelines

    Personnel Training A transmitter’s performance and longevity will be maximized if it is properly maintained by a well-trained, technically skilled individual. To this end, Harris offers a variety of training classes, both specific to ZX series transmitters and general courses on the fundamentals of RF technology.

  • Page 107: Recommended Tools And Equipment

    Section 5 Maintenance and Alignments ZX Series WABE - Western Association of Broadcast Engineers Hong Kong: SBE - Society of Broadcast Engineers - Hong Kong Chapter India: BES - Broadcast Engineering Society Korea: KOBETA - Korean Broadcast Engineers & Technicians Association Mexico: AMITRA - Asociación Mexicana de Ingenieros y Técnicos en Radiodifusión Phillipines:...
  • Page 108 ZX Series Section 5 Maintenance and Alignments h. Ratchet wrench with assorted sockets i. Diagonal cutters j. Wire strippers k. Needle-nose pliers l. General purpose pliers m. Inspection mirror n. Fine adjustment screwdriver (“tweaker”) 2. Multimeter with probe leads (ohmmeter, ammeter, voltmeter) 3.

  • Page 109: Spares Holding

    Spares Holding The ability to quickly resolve any equipment problems is greatly helped by maintaining a complement of spare parts on site. Harris offers a variety of ready-made spares kits for the ZX series transmitters addressed by this manual: (990-1202-002) KIT, MODULE SPARES, ZXB (all models)

  • Page 110: Transmitter Logbook

    ZX Series Section 5 Maintenance and Alignments WARNING: NEVER PERFORM TRANSMITTER MAINTENANCE WHILE ALONE AND/OR NOT FULLY ALERT. SERIOUS BODILY INJURY OR DEATH COULD RESULT FROM FAIL- URE TO OBSERVE PROPER SAFETY PRECAUTIONS. 5.2.5 Transmitter Logbook To aid in any future troubleshooting, the transmitter should be monitored (using front panel and/or remote control metering) and the results recorded in a transmitter log at least once a day.

  • Page 111: Routine Maintenance

    Section 5 Maintenance and Alignments ZX Series 5.2.7 Routine Maintenance Routine maintenance of the ZX series transmitter consists of regular cleaning and the monitoring of power, voltages, and current readings to detect of any deviations that might indicate a developing problem. To maximize equipment reliability and longevity, it is important to develop and stick to a well designed maintenance routine.

  • Page 112: Basic Maintenance Procedures

    ZX Series Section 5 Maintenance and Alignments Basic Maintenance Procedures The maintenance procedures provided in this section may be routinely performed by operators with basic technical skills. No special equipment or training is required. 5.3.1 Power Amplifier (PA) Module Swap Procedure The PA modules are hot-pluggable and may be swapped at any time while the transmitter is operating.

  • Page 113: Procedure

    Section 5 Maintenance and Alignments ZX Series TRANSMITTER HAS BEEN RUNNING, ESPECIALLY IN HIGH AMBIENT TEMPERA- TURE ENVIRONMENTS. Insert replacement PA module. Corresponding power supply should STEP 5 restart immediately upon PA module re-insertion. Hand-tighten PA module thumbscrews to secure module in place. Do STEP 6 not use a screwdriver.

  • Page 114: Power Supply (Ps) Module Swap Procedure

    ZX Series Section 5 Maintenance and Alignments 5.3.2 Power Supply (PS) Module Swap Procedure The PS modules are hot-pluggable and may be swapped at any time while the transmitter is operating. Any PS module may be swapped with a PS module in another position.

  • Page 115: Air Filter Replacement Procedure

    Do NOT under any circumstance install a wet or moist filter in the transmitter. Contact Harris Broadcast Service to purchase additional filter media, as necessary.

  • Page 116: Pa Module Cleaning Procedure

    ZX Series Section 5 Maintenance and Alignments Open amplifier front door. STEP 1 Open filter retainer door by loosening thumbscrews on reverse side of STEP 2 front door. Remove filter media from filter retainer frame. STEP 3 Install replacement media in retainer frame. STEP 4 Close filter retainer door and tighten thumbscrews.

  • Page 117: Advanced Maintenance Procedures

    Section 5 Maintenance and Alignments ZX Series Blow compressed air into heatsink fins to remove dust buildup. If STEP 2 compressed air is not available, use a vacuum cleaner to suction dust from heatsink. Use dry paintbrush to dislodge stubborn dust. STEP 3 Replace PA module in transmitter.
  • Page 118 ZX Series Section 5 Maintenance and Alignments Check readings at test points on controller board with voltmeter and STEP 4 compare to factory test data report. Log results for future reference. a. IPA CURRENT: in general should be < 12A b.
  • Page 119 Section 5 Maintenance and Alignments ZX Series Table 5-2 PA TEMP test point scale Max PA PA TEMP test temperature point (volts) (degrees C) 0.14 0.17 0.20 0.23 formula: T( C) = 35.294Ln(V) + 75.388 0.26 0.30 0.35 0.40 0.47 0.54 0.63 0.74...

  • Page 120: Forward Power Meter Calibration

    ZX Series Section 5 Maintenance and Alignments Table 5-3 LOAD TEMP test point scale Max load LOAD TEMP test temperature point (volts) (degrees C) 0.12 0.13 0.15 0.16 0.18 0.20 0.22 formula: T( C) = 40.858Ln(V) + 98.751 0.25 0.28 0.32 0.36 0.41...

  • Page 121: Precision Directional Coupler

    Section 5 Maintenance and Alignments ZX Series Obtain calibrated reading of transmitter forward power from external STEP 1 precision measurement source. Determine operating mode via front panel STATUS LEDs (FM, STEP 2 FM+HD, or HD). If amplifier chassis reading is to be calibrated, perform these steps STEP 3 a.Select forward power reading on amplifier front panel meter via meter select pushbutton.

  • Page 122: Reverse Power Meter Calibration

    If reading is less than 1% of transmitter rated power, perform these steps to generate a sufficient reading. a. ZX2500 / ZX3750 / ZX5000: lower transmitter power to 2% of name- plate rating, switch off transmitter, break output transmission line, switch on transmitter.

  • Page 123: Set Transmitter Power Level (Case 1: Internal Transmitter Apc Control)

    Section 5 Maintenance and Alignments ZX Series If system meter reading is to be calibrated, calibrate reverse reading via STEP 3 front panel REV trimmer potentiometer on system metering assembly face to immediate left of meters. Reverse any steps taken to create temporary high reverse power reading. STEP 4 Procedure complete.
  • Page 124 ZX Series Section 5 Maintenance and Alignments Tools required: Small adjustment screwdriver Verify current operating mode is FM based on amplifier front panel STEP 1 STATUS LED display. Open amplifier front door and locate POWER RAISE pushbutton on STEP 2 controller board upper edge.

  • Page 125: Set Transmitter Power Level (Case 2: Exciter Apc Control With Flexstar Hdx)

    Section 5 Maintenance and Alignments ZX Series 5.4.5 Set Transmitter Power Level (Case 2: exciter APC control with FlexStar HDX) Use this procedure when the transmitter power level is being controlled via an analog voltage fed back to the exciter. This is always the case when operating with the FlexStar HDX exciter, except possibly if the FlexStar exciter is being used for FM-only service.
  • Page 126 ZX Series Section 5 Maintenance and Alignments Locate POWER LIMIT potentiometer for current operating mode on STEP 5 transmitter controller board. Each mode has its own power set potentiometer (POWER LIMIT - FM, FMHD, HD). Dial POWER LIMIT potentiometer for current mode fully clockwise. STEP 6 Transmitter APC power controls rises to its maximum boost setting and a FORWARD POWER LOW alarm is reported, indicating transmitter...

  • Page 127: Apc Setup For Multiple Pa Chassis

    Section 5 Maintenance and Alignments ZX Series Re-insert PA module and verify individual PA module currents remain STEP 15 roughly equal under both pre-fault and post-fault conditions. Procedure complete. STEP 16 5.4.6 APC Setup for Multiple PA Chassis This procedure clarifies the setup and alignment of the APC power control for ZX7.5 and higher power models.

  • Page 128: Set User Reverse Power Foldback Threshold (Zx2500 / Zx3750 / Zx5000)

    STEP 13 5.4.7 Set User Reverse Power Foldback Threshold (ZX2500 / ZX3750 / ZX5000) Use this procedure to set the user-defined reverse power foldback threshold for all single PA-chassis transmitter models. The user reverse power foldback is designed to reduce power when the average reflected power at the transmitter output exceeds a given level set by the user.

  • Page 129: Set User Reverse Power Foldback Threshold (Zx7.5, Zx10)

    Section 5 Maintenance and Alignments ZX Series Press OFF button to switch transmitter off. STEP 2 Open amplifier front door. STEP 3 Locate POWER LIMIT - REV potentiometer on upper edge of STEP 4 transmitter controller board. Disconnect transmission line from transmitter output. STEP 5 Press ON pushbutton to turn transmitter on.

  • Page 130: Periodic Cleaning And Inspection

    In the case of a single amplifier chassis transmitter (ZX2500 / ZX3750 / ZX5000), the transmitter must be switched off and mains power removed to perform safely many of the steps given below. In the case or larger model transmitters (ZX7.5 / ZX10), one PA chassis may be shut down and...
  • Page 131 Section 5 Maintenance and Alignments ZX Series Verify no loose hardware has fallen to bottom of amplifier chassis over STEP 8 time. Vacuum any dust accumulations from rear chamber of amplifier chassis. STEP 9 Vacuum any dust accumulations from fins of output assembly. Use long STEP 10 vacuum cleaner attachment as necessary to gain access to heatsink fins via air input plenum on far right side behind front door.

  • Page 132: Service One Pa Chassis While Transmitter Is On Air (Zx7.5/Zx10)

    ZX Series Section 5 Maintenance and Alignments As desired, use off-air opportunity to verify reserve exciter and exciter STEP 26 switchover functionality (where applicable). Note any findings and resolutions in station maintenance log. STEP 27 Procedure complete. STEP 28 5.4.10 Service one PA chassis while transmitter is on air (ZX7.5/ZX10) Higher power ZX transmitter models are designed to be serviced without the need to switch the transmitter off completely.
  • Page 133 Section 5 Maintenance and Alignments ZX Series load instead of the antenna output. The phase and gain balance of the ZX transmitter does not normally require adjustment in the field. This procedure provides a quick confirmation that phase and gain balance is correct. Under normal operating circumstances, virtually no power is directed to the combiner load.

  • Page 134: Special Part Replacement Notes

    ZX Series Section 5 Maintenance and Alignments chassis reading may increase, while others decrease, but total level remains roughly constant. If both reverse power levels increase dramatically, PA imbalance should be suspected. Perform these checks: a.Verify both PA chassis have similar PA AMPS readings to within +/- 10 b.Verify drive cables to PA chassis have not been replaced with an incorrect length cable.
  • Page 135 Section 5 Maintenance and Alignments ZX Series [001] [002] [001] Thumbscrew [003] [002] Amplifier cover [003] Power amplifier assembly [004] Mating surface (apply thermal pad or thermal compound) [004] [005] Aluminum heatsink [005] Figure 5-3 Removal of PA amplifier assembly from heatsink If a module has failed with a persistent PA overcurrent fault, there may be uncertainty as to which half of the module has actually failed.

  • Page 136: Ps Module (736-0445-000)

    Modules are hot-pluggable; they can be removed and replaced while transmitter is running. • Internal fans will run for approximately five seconds after module is unplugged. • Contact Harris or supply manufacturer for factory repair options. 5-32 888-2595-001 12/20/11 WARNING: Disconnect primary power prior to servicing.

  • Page 137: Transmitter Controller Pcb (901-0203-541)

    ZX Series 5.5.4 Transmitter Controller PCB (901-0203-541) • Replacement boards can come from Harris already tuned and tested at nominal power level for your transmitter model. Be sure to request this when ordering a replacement board. • Match all jumper settings on old board before installing replacement.

  • Page 138: Rf Output Assembly (971-0023-026/027/028)

    ZX Series Section 5 Maintenance and Alignments • Verify push-on (faston) DC connectors make snug contact upon connection. Remove connector and gently press closed with pliers if connection is loose. • Note three fuses for AC MAINS LOW alarm(s). It may not be necessary to remove entire board if only fuse is blown (false AC MAINS LOW alarm).
  • Page 139 Section 5 Maintenance and Alignments ZX Series Consult Figure 5-4 and Figure 5-5 to become familiar with the major parts of the output assembly. [002] [001] [006] [001] Directional couplers for forward, reverse metering, customer RF monitor sample. [002] 20-pin ribbon cable connection to 16X [003] load board.
  • Page 140 ZX Series Section 5 Maintenance and Alignments [101] [101] Combiner with combiner support frame. [102] Heat sink base with 16X load board. [103] Ballast load. [102] [103] Figure 5-5 Output assembly opened for servicing. Tools required: 8mm nut driver (7/16) SMA nut driver Switch transmitter off.
  • Page 141 Section 5 Maintenance and Alignments ZX Series NOTE: Some users prefer to leave these four cables attached until the output assembly is already outside the chassis. Excess cable length has been provided for these cables for this purpose. Loosen four black thumbscrews on base of output assembly to free STEP 8 assembly from chassis wall.

  • Page 142: Output Assembly Ballast Load (700-1225-000)

    ZX Series Section 5 Maintenance and Alignments Close transmitter rear door and secure with hex key. STEP 20 Apply AC mains power. STEP 21 Press front panel ON button to turn transmitter on. STEP 22 Check forward and reverse power calibrations per procedures contained STEP 23 earlier in this section.

  • Page 143: Rf Splitter (901-0203-511/561/571)

    Section 5 Maintenance and Alignments ZX Series necessary. Coverage should be complete, but so thin as to be translucent. Press load to base and wiggle load slightly, as desired, to ensure STEP 6 compound fills all gaps. Attach replacement load to output assembly heatsink with mounting STEP 7 screws.

  • Page 144: I/O Filter Pcb (901-0203-551)

    If a quick swap is desired, entire fan door may be lifted off its hinges, removed from transmitter, and replaced with spare door assembly. A spare fan door assembly is available from Harris as an option. 5.5.15 Front Panel Multimeter (632-1201-000) •...

  • Page 145: Ac Mains Filter (476-0528-000 Or 609-0125-000)

    Section 5 Maintenance and Alignments ZX Series 5.5.16 AC Mains Filter (476-0528-000 or 609-0125-000) • No user adjustments. • Cannot be repaired in field due to high voltage potting compound inside case. 5.5.17 Front Panel Filter (943-5567-408) • All ZX transmitters ship with spare filter media. •...

  • Page 146: Kw Rf Load

    ZX Series Section 5 Maintenance and Alignments 5.5.22 2.5 kW RF Load • No user adjustments. • Visually inspect new unit for physical integrity. • Check input resistance with multimeter. Resistance should be between 45 ohms and 55 ohms. • Thoroughly allow old load to cool down before attempting to replace it.

  • Page 147: Troubleshooting

    Contacting Harris Service To provide our customers with world-class, round-the-clock technical support, Harris offers a unified Customer Support Portal for all Harris products at https:// support.broadcast.harris.com/ From the site’s user-friendly interface and self-service menu, registered users can: •...

  • Page 148: Troubleshooting Table

    Telephone: +86 (0) 21 5292 5660 facsimile: +86 (0) 21 5292 5955 e-mail: Jmei@harris.com. To ensure you get the best assistance as quickly as possible, you should have the following items on hand before contacting Harris: • Transmitter factory test data report •...
  • Page 149 Section 6 Troubleshooting ZX Series Table 6-1 Transmitter Front Panel Symptom Cause and Solution MODE LED is green Transmitter is switched on and operating normally with no alarms being reported. MODE LED is yellow Transmitter is switched on but alarms are being reported. Open amplifier front door and inspect alarm LEDs on controller board (reverse side of front door).
  • Page 150 ZX Series Section 6 Troubleshooting Table 6-2 Controller Board Alarm LEDs Symptom Cause and Solution FORWARD POWER System gain or exciter drive not sufficient to achieve power level set by LOW alarm POWER LIMIT potentiometer. Check for other alarms that might explain inability to make full power (e.g.
  • Page 151 Section 6 Troubleshooting ZX Series Table 6-2 Controller Board Alarm LEDs Symptom Cause and Solution LOW FAN SPEED One or more chassis fans have not achieved full speed. Consult individual alarm fault LEDs on transmitter rear door to determine which fan is affected. Physical arrangement of fault LEDs on rear door mimics physical layout of fans on rear door.
  • Page 152 ZX Series Section 6 Troubleshooting Table 6-2 Controller Board Alarm LEDs Symptom Cause and Solution LOAD Amplifier chassis has shut down because one or more output assembly ballast OVERHEATED loads had a temperature above 125C. Suspect incorrectly connected PA alarm output coax cables if maintenance was just performed on transmitter.
  • Page 153 Section 6 Troubleshooting ZX Series Table 6-2 Controller Board Alarm LEDs Symptom Cause and Solution PA MODULE One or more PA modules have shut down. This could be due to several SHUTDOWN alarm conditions: > PA module has been removed from socket. Check module insertion. >...
  • Page 154 ZX Series Section 6 Troubleshooting Table 6-3 Module Alarm LEDs Symptom Cause and Solution PA REVERSE PA module has experienced a reverse power level of >25W (peak). POWER alarm (left LED behind PA If only one PA has alarm, suspect failure of detection circuit on PA module) backplane or BNC coax cable from PA backplane to output assembly.
  • Page 155 Section 6 Troubleshooting ZX Series Table 6-3 Module Alarm LEDs Symptom Cause and Solution PA TEMPERATURE PA module has experienced a transistor flange temperature >99C. alarm (center LED behind Allow module to cool, as necessary, and remove from transmitter. Inspect PA module) heat sink for significant obstruction and remove debris, as necessary.
  • Page 156 ZX Series Section 6 Troubleshooting Table 6-4 Power Control and Metering Symptom Cause and Solution Forward output power Verify automatic power control (APC) circuit has not been aligned too high incorrectly. Consult Section 5 – Maintenance for procedure to follow to realign APC circuit.
  • Page 157 Section 6 Troubleshooting ZX Series Table 6-4 Power Control and Metering Symptom Cause and Solution Power has dropped to Possible shut down of both halves of IPA. Inspect IPA status LEDs though 0% but all PS modules IPA heatsink fins to determine status. Consult component locator sticker to appear to be on (PA/ right of controller board (reverse side of front door) for aid in locating IPA (PS) ON lit)
  • Page 158 ZX Series Section 6 Troubleshooting Table 6-4 Power Control and Metering Symptom Cause and Solution PA AMPS reading This is normal. This is a false reading and may be safely ignored. briefly surges several seconds after transmitter is switched off, then falls to zero Poor metering Possible incorrect meter scale selected in remote control.
  • Page 159 Section 6 Troubleshooting ZX Series Table 6-5 Transmitter Control Symptom Cause and Solution No RJ-45 connectivity Possible no web remote installed. Consult factory test data or original on transmitter rear transmitter paperwork to determine if web remote option has been fitted. interface panel Possible incorrect IP address.
  • Page 160 ZX Series Section 6 Troubleshooting Table 6-6 Signal Performance Symptom Cause and Solution Poor FM audio Possible fault in exciter. Consult exciter manual for more information on performance (FM troubleshooting problem. Amplifier has virtually no impact on transmitted noise, THD, stereo signal metrics in an FM system.
  • Page 161 Section 6 Troubleshooting ZX Series Table 6-7 Output combining (ZX7.5 and higher power models only) Symptom Cause and Solution Load is intercepting RF power. This is normal if one PA chassis is 2.5kW RF load hot switched off or PA chassis output power levels are otherwise unbalanced. If all PA chassis are switched on and indicate equal PA FWD kW power outputs on front panel meters, check for balanced PA AMPS readings as confirmation that forward power calibrations are trustworthy.
  • Page 162 ZX Series Section 6 Troubleshooting 6-16 888-2595-001 12/20/11 WARNING: Disconnect primary power prior to servicing.

  • Page 163: Parts List

    ZX Series  Section 7 Parts List Replaceable Parts ZX5000 List Index Table 7-1 XMTR, ZX5000 CONFIG- - - - - - - - - - - - - - - - - 995 0035 009 (A) Table 7-2 KIT, ZXB STANDALONE - - - - - - - - - - - - - - - 952 9232 034 (A) Table 7-3 EXC INTERFACE CABLE KIT, ZXB TO FLEXSTAR HD952 9232 035 (A) EXC INTR CABLE KIT, ZXB TO ...

  • Page 164: Zx5000 Replaceable Parts List

    ZX Series Section 7 Parts List ZX5000 Replaceable Parts List Table 7-1 XMTR, ZX5000 CONFIG - 995 0035 009 (A) Harris PN Description Qty UM Ref Des 817 2311 030 DWG, FAMILY TREE, ZX5000 0 DWG 952 9232 034 KIT, ZXB STANDALONE...
  • Page 165 CHASSIS, BOOST AMP 1 EA 952 9239 012 ASSY, CABLE FLEXSTAR BOOST AMP 1 EA Table 7-6 ASSY, AMPLIFIER, ZX 5000 - 981 0090 006 (E) Harris PN Description Qty UM Ref Des 256 0031 000 CABLE ASSY, FFC, 15C 3 LG...
  • Page 166 MODULE, DUAL PA, IBOC 9 EA A20 A21 A22 A23 A24 A25 A26 A27 A28 Table 7-7 ASSY, BASIC, ZX 16RU - 971 0023 006 (B) Harris PN Description Qty UM Ref Des 358 2589 000 MOUNT, RIBBON CABLE, 2’’ 5 EA...
  • Page 167 SPRING, PS FRAME 1 EA 943 5567 542 LABEL, HOT MODULE 1 EA Table 7-8 ASSY, FM 16X OUTPUT ASSEMBLY - 971 0023 028 (C) Harris PN Description Qty UM Ref Des 275-252-000 TERM, 50 OHM, SMA PLUG 1 WATT 3 EA...
  • Page 168 ASSY, MODULE HEATSINK 1 EA 9929992021G PWA, PA, IBOC 2 EA A1,A2 Table 7-11 KIT, MODULE SPARES, ZXB - 990 1202 002 (A) Harris PN Description Qty UM Ref Des 736 0445 000 PSU, 48VDC 1200W 90-264VAC 1 EA 9929992041G...

  • Page 169: Zx10 Replaceable Parts List

    Section 7 Parts List ZX Series ZX10 Replaceable Parts List Table 7-14 *!XMTR, ZX10 CONFIG - 995 0035 013 (A P) Harris PN Description Qty UM Ref Des 939 8221 031 PNL, 19.0X1.718X0.125 HF142 0 EA 939 8221 032 PNL, 19.0X3.468X0.125 HF142...
  • Page 170 CHASSIS, BOOST AMP 1 EA 952 9239 012 ASSY, CABLE FLEXSTAR BOOST AMP 1 EA Table 7-16 ASSY, AMPLIFIER, ZX 5000 - 981 0090 006 (J P) Harris PN Description Qty UM Ref Des 414 0344 000 CORE, EMI SUPRESSION, 0.275 ID...
  • Page 171 Section 7 Parts List ZX Series 448 1033 000 HINGE, CONCEALED 2 EA 448 1128 000 LATCH, COMPRESSION 1 EA 448 1149 000 LATCH, FLUSH MOUNT, BLACK 1 EA 464 0357 000 HEX KEY, 5/16 , 'T' HANDLE 1 EA 610 1068 000 KEYING PLUG 2 EA...
  • Page 172 ZX Series Section 7 Parts List Table 7-18 ASSY, FM 16X OUTPUT ASSEMBLY - 971 0023 028 (C P) Harris PN Description Qty UM Ref Des B/M NOTE: 0 DWG 275-252-000 TERM, 50 OHM, SMA PLUG 1 WATT 3 EA...
  • Page 173 Section 7 Parts List ZX Series Table 7-20 XMTR, BASIC, ZX10 (ZX7.5) - 981 0090 097 (D P) Harris PN Description Qty UM Ref Des 358 1866 000 BUMPER, MOLDED 2 EA 358 3976 000 BOLT, EYE, 1/2-13 X1, ZINC PLATE...
  • Page 174 ZX Series Section 7 Parts List 7-12 888-2595-001 12/20/11 WARNING: Disconnect primary power prior to servicing.

  • Page 175: Appendix A - Fm Web Remote Option

    Remote Option Introduction This appendix provides information on the Harris FM Web Remote, a purchase option for the ZX series of FM transmitters. The information is organized in a structure that mirrors the larger transmitter manual: there are subsections addressing the following...
  • Page 176 A-1 for a photo of the web remote installed on the I/O board. The web remote provides monitoring and control not only for the amplifier chassis but also the Harris Flexstar Main/Alt Controller (981-0193-001) and ZX System Metering Panel (981-0090-070) via the normal D-sub connections to these units, when present.

  • Page 177: Installation

    Appendix A - FM Web Remote Option ZX Series Installation A.2.1 Internet Security The FM Web Remote is designed for use in a LAN environment. It has a moderate level of password protection but does not employ packet encryption. Accordingly, it should not be hooked directly to the Internet without additional precautions being taken.

  • Page 178: Installation Procedure

    W35. For this reason, an additional 50C is provided in the 981-0090-089 upgrade kit. If you have not received this cable and require it complete installation, please contact your Harris representative. Physically re-install I/O panel in amplifier chassis.

  • Page 179: Operation

    Appendix A - FM Web Remote Option ZX Series Attempt to access configuration page via procedure in section A.5.1. STEP 11 Default password is "expert". Default IP address is 192.168.1.99 unless otherwise indicated. NOTE: To access the web remote for the first time, there are two different options: •...
  • Page 180 Appendix A - FM Web Remote Option ZX Series Figure A-2 Main page awaiting entry of password key. Enter "guest" or "operator" password key in box at upper right. Status STEP 4 bar should change color and readings should instantly display upon successful input of full password.
  • Page 181 It also provides an easy means to communicate transmitter readings to Harris Cus- tomer Service personnel.
  • Page 182 Appendix A - FM Web Remote Option ZX Series Table A-1 Elements on main page. STATUS Operational status of amplifier chassis. [ON/OFF/FAULT/???] [ON] = Transmitter is switched on. [OFF] = Transmitter is switched off. [FAULT] = Transmitter is switched on but has active faults. [???] = Web remote is awaiting input of a valid password or has lost serial data link.
  • Page 183 NOTE: requires a valid e-mail application installed on PC viewing webpage. EVENT LOG SERIAL NUMBER Transmitter serial number, as entered on configuration page. Harris Customer Ser- (lower compartment, vice may ask you for this number if you call for assistance. This helps us locate upper right) your records.
  • Page 184 Appendix A - FM Web Remote Option ZX Series Table A-2 List of transmitter log messages. LOG MESSAGES RF > OK Transmitter RF output power has risen above RF WARN and RF ALARM thresh- THRESHOLD olds as set on configuration page. RF <...

  • Page 185: Theory Of Operation

    I/O board and plug in a replacement board sent in advance from the Harris factory. A small green LED at the lower edge of the card blinks once a second when the web remote is operating correctly. This LED is not visible from...

  • Page 186: Maintenance

    Appendix A - FM Web Remote Option ZX Series remote during bench testing or other troubleshooting operations when the card is visible. The web remote serves out a main HTML status page that receives updated readings via an AJAX data stream on port 80. This data stream may be also used by customized external pages created by the user or by third-party remote control systems, if suitably programmed.
  • Page 187 Appendix A - FM Web Remote Option ZX Series Configuration page with password pop-up prompt should display. STEP 3 Figure A-4 Configuration page with password prompt. Enter "expert" level password key in box at center and press SUBMIT STEP 4 button.
  • Page 188 Appendix A - FM Web Remote Option ZX Series Figure A-5 Configuration page Change settings, as desired, and press labeled button to right of modified STEP 6 field to submit change for permanent storage in memory. NOTE: The corresponding button should be pressed after each field is changed. Other- wise, the changes will not be saved.

  • Page 189: Configuration Settings

    Appendix A - FM Web Remote Option ZX Series CAUTION: INCORRECT SETTINGS COULD CAUSE A LOSS OF BOARD CONNECTIVITY. CAREFULLY READ TABLE A.5.1 TO UNDERSTAND THE IMPLICATIONS OF CHANGING EACH PARAMETER. Toggle "E-MAIL Enabled" button off-on to send a test e-mail message, STEP 7 as desired.
  • Page 190 The transmitter serial number. This is typically entered in the factory and does not require updating in the field. Harris Customer Service may ask you for this number if you call for assistance. This helps us locate your records. If the web remote is moved to a new transmitter, be sure to update this field.

  • Page 191: Perform Simple Reset

    Appendix A - FM Web Remote Option ZX Series Table A-3 List of settings on configuration page. WRITE The SNMP WRITE community for SET commands. COMMUNITY VALID SET VALUE As an added security measure, the value “written” by the SNMP SET must match this value.

  • Page 192: Perform Expert Reset

    Appendix A - FM Web Remote Option ZX Series Figure A-6 Reset of web remote via WEB RESET hole on I/O panel. A.5.3 Perform Expert Reset Purpose: To be used if the IP address and/or expert password has been forgotten or connectivity has otherwise been lost.

  • Page 193: Change Clock Battery

    Appendix A - FM Web Remote Option ZX Series Web remote memory resets IP address, subnet mask, default gateway, STEP 3 and expert password to values listed above. Connect to web remote configuration page with PC to 192.168.1.99/ STEP 4 config.htm and change IP address and/or expert password to desired values.

  • Page 194: Use Microchip Discoverer Utility

    Appendix A - FM Web Remote Option ZX Series Note log entry time stamp as compared to quality external clock. STEP 2 Access configuration page and recalibrate on-board time to correct STEP 3 value, as desired. Repeat steps 1 and 2 several hours or several days later. STEP 4 Note if on-board clock has lost or gained seconds relative to quality STEP 5...

  • Page 195: Troubleshooting

    Appendix A - FM Web Remote Option ZX Series Launch discoverer application on PC installed on same LAN as web STEP 1 remote. Press Discover Devices button. STEP 2 Consult results window to determine current IP address of web remote. STEP 3 Attempt to contact web remote on current IP address or perform an STEP 4...

  • Page 196: Usb Flash Drive

    1. Microchip Ethernet Discoverer.exe - a utility that may be useful to determine the IP address of a lost web remote. 2. HARRIS-TX-ZXB-MIB.mib - a text copy of the SNMP MIB for the web remote in ASN.1 format. 3. Enhanced.htm - a special version of the web remote with dual language support.
  • Page 197 It is anticipated that the contents of the USB flash drive will evolve over time and may include additional files not listed here. The user is encouraged to fully explore the contents of the flash drive to learn about the latest ways to extend the functionality of their Harris FM Web Remote. 12/20/11 888-2595-001 A-23...
  • Page 198 Appendix A - FM Web Remote Option ZX Series A-24 888-2595-001 12/20/11 WARNING: Disconnect primary power prior to servicing.

This manual is also suitable for:

Zx7.5Zx10Zx3750Zx5000

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