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Harris DX-10 Technical Manual

Harris DX-10 Technical Manual (332 pages)

AM BROADCAST TRANSMITTER

Brand: Harris | Category: Transmitter | Size: 3 MB

Table of Contents

Table of Contents
12
Section I
25
Introduction/Specifications
25
Scope and Purpose
25
Specifications
25
Installation
27
Introduction
27
Unpacking
27
Returns and Exchanges
27
Factory Test Data
27
General Installation Information
27
Transmitter Space Requirements
27
Access for External Connections
27
AC Power
28
Transmitter Cooling
28
Transmitter Grounding & RF Output Connections
29
Setup Procedures
29
General Requirements
29
Equipment Placement
30
Pre-Installation Inspection
30
Mechanical Installation
30
Equipment Positioning
30
Transmitter Leveling
30
Ground Strap Installation
30
Electrical Installation
30
Power Requirements
31
Delta and Wye Connections
31
High Voltage Transformer, Primary Winding Termi
31
Wire Delta AC Power Wiring
31
AC Power Wiring, Three Wire Delta Configuration
31
Transformer Connections, 3-WIRE DELTA CONNECTION
31
Blower Motor Junction Box Strapping
31
AC Input Power Connection
31
Wire WYE AC Power Wiring
33
AC Power Wiring, Four Wire WYE Configu
33
Connection
33
Blower Motor Junction Box Strapping
33
Other "FOUR WIRE WYE" Connections
33
AC Input Power Connection
33
Power Wiring Check
33
Meter Shunt Removal
33
Controller Battery Backup
35
Customer Interface Connections
35
Audio Input Connections
35
Audio Phasing
35
Audio Source Impedance
35
Selecting Source Impedance
35
RF Output Terminal Installation
35
Dummy Antenna Information
36
External Interlock (Fail-Safe)
36
Using the External Interlock
36
PA Turn off
36
Modulation Monitor Connection
36
Frequency Monitor Connection
37
Remote Control Connections
37
Functions Which Can be Controlled or Monitored
37
Interface Information
37
Remote "CONTROL
37
Remote "STATUS" Indications
38
Remote Meter Readings
38
Puts)
38
Explanation of Selected Functions
38
External Interlock (FAIL-SAFE)
38
OFF" Function (Remote "OFF" Control)
38
PA Turn off
38
OFF" Function, "PA Turn OFF," and External Inter- Lock
38
Use of OFF, PA Turn OFF, and External Interlock Functions
39
Transmitter Turn on
39
Raise/Lower
39
Forward" and "Reflected" Power, Remote Meter Readings
39
Bandpass Filter VSWR and Antenna VSWR, Remote Meter Readings
39
RF Drive Estimate, Remote Meter Reading (at TB1-9)
39
Monitor Signal
39
Remote Status Indications
39
RF Combiner Crowbar Not Operational
39
Pre-Turn on Checks; Mechanical
39
Pre-Turn on Checks; Electrical
40
Initial Turn on Procedures
40
Low Voltage Power Supplies Check
41
Fan Rotation Check
41
RF Driver Operation Check
42
PA Checkout
42
Tuning, at about 1 Kilowatt Output
42
Tuning and Verifying Correct Operation at High Power
43
Modulation Monitor;Setting Sample Levels
43
Setting Modulation Monitor Sample Level
43
Controller;Battery Backup
44
Installing Batteries
44
Modulation Check
44
Audio Gain Adjustment
44
Recording Normal Meter Readings
44
Final Matching into Antenna
45
Removing the Shorting Straps on L103 and L104 if Required
45
Finishing up
45
Optional Audio Phasing
45
Operation
53
Introduction
53
Operating Procedures
53
Daily Preoperational Checkout (Local Control)
53
Daily Preoperational Checkout (Remote Control)
53
Transmitter Turn-On Procedure
53
Transmitter Turn-OFF Procedure
54
Emergency Operating Procedures
54
AC Power Failure (When Not Using Controller Backup Battery)
54
AC Power Failure
54
Is Used)
54
Transmitter will Not Come on
54
Transmitter Shuts off
55
Fault Status Indications will Not Clear When Reset, or Fault Indications Continue to Occur
55
Remote Status LED Is Red
55
Oscillator, Buffer Amp or Driver Fault
55
RF Amp "Envelope OK" Fault (Remote "Envelope Error" Fault)
55
Audio Input +15V or -15V Fault. A/D Converter +15V, -15V, +5V Fault
55
A/D Converter Conversion Error Fault
55
Modulation Encoder Cable Interlock Fault
55
DC Regulator +5V or B- Fault
55
Output Monitor +5V or -5V Fault
55
Overloads
56
Supply over Current
56
VSWR Sensor "Status" Indicator Is Red (Remote VSWR Self Test Pass/Fail Fault)
56
Type 3 Fault Indication (Remote Indication Only)
56
Bandpass Filter VSWR Fault (Remote: "Internal VSWR Fault")
56
Antenna VSWR Fault
56
VSWR Faults
56
VSWR Fault Indication Stays on
57
Tuning and Loading Control Adjustment
57
System Operation
73
Introduction
73
Protection of Personnel
73
Discharging the High Voltage Supply
73
Location of Door Interlocks and Grounding Switches
73
Door Interlock Switches
74
Grounding Switches
74
Non-Interlocked Compartment
74
Block Diagram Description
74
RF Section
74
Oscillator
80
RF Amplifier Stages
80
Driver Supply Regulator
80
RF Status Indications: RF Sense Data Lines
80
Status Indications as Troubleshooting Aids
80
Combiner and Splitter
80
Power Amplifier
80
Combiners, Output Network and Output Cir
80
Audio Input and Modulation Section
80
Controller Section ("Controller" and "LED" Boards)
81
Transmitter Power Supplies
81
High Voltage Supply
81
Low Voltage Supply
81
Driver Supply Regulator, A22
81
DC Regulator Board, A30
81
External Interface
81
Digital Terms and Concepts
81
Quantized Amplitude Modulation
82
Amplitude Modulation - a Review
83
Amplitude Modulation in the DX-10 Transmitter
83
Analog to Digital Conversion
84
Sample Time Interval
84
Digital to Analog Conversion
85
Power Amplifier Section Principles
85
BIG STEPS" and BINARY STEPS
86
Modulation Encoder
86
RF Output Bandpass Filter
86
Switching RF Amplifiers on or off
86
RF Combiner
87
Summary: DX-10 Digital Modulation
87
Engineering Description
87
Digital Modulation Characteristics
87
Transient Protection
87
Overvoltage and Undervoltage Protection
88
Brown-Out" Protection
88
Phase Loss Protection
88
Transmitter Power Supplies
88
Turning Supplies on and off
88
Low Voltage Supply
88
High Voltage Supply
88
Low Voltage Power Supply, Circuit Description
88
Low Voltage Supply, Primary Power Circuit
88
Power Distribution Board, A39
89
High Voltage Power Supply, Circuit Description
89
High Voltage Supply Transformer T1
89
High Voltage Supply Primary Power Contactors
89
High Voltage Step-Start (K1, K2, R31-R33)
89
Phase Supply and Rectifier Assembly
89
Supply Filtering
90
Fuses in DC Lines
90
Power Supply Discharge Circuit
90
Mechanical Shorting Switches, S9 and S10
90
115VDC and +230VDC Supply Filter Capacitor Discharge Paths
90
Supply Current Meter, M2
90
Fuse Board, A24
91
Voltage Sample Circuits on the Fuse Board
91
Power Supply Protection" Sample
91
Voltmeter" Sample
91
High Voltage "Overvoltage" Sample
91
Analog Input" Sample
91
Power Supply Sample
91
Blower B1, Air Flow Sensing Unit S7 and Temperature Actuated Switch
91
Blower
91
Air Flow Sensing Unit S7 and Temperature Actuated Switch
91
Interlocks and Interlock Relays
92
Voltage Regulators
92
Voltage Regulator Assemblies
92
Other Voltage Regulators
92
RF Circuit Descriptions, for RF Circuits Not on Printed Circuit Boards
92
RF Driver Combiner Description
92
Grounding Block for the Driver and Output Com
92
RF Drive Splitter, A15
93
RF Drive Cables
93
RF Power Amplifier Description
93
RF Output Combiner Description
94
RF Samples for the Output Combiner
94
Bandpass Filter (Output Network) Description
94
There Are no Operator Tuning Adjustments for the Bandpass Filter/Output Network
94
Bandpass Filter/Output Network Circuit Description
94
Output Sample/Output Monitor
95
TEE Matcher: "Tune" and "Load" Controls
95
Adjusting "Tuning" and "Loading" Controls
95
To Adjust Tuning and Loading
95
Circuit Description
95
Modulation Monitor Sample Coil (L107)
95
Spark Gap, E101
95
Maintenance/Alignments
97
Introduction
97
Maintenance
97
Maintenance Logbook
97
Discrepancy
97
Time/Date
97
Corrective Action
97
Defective Parts(S)
97
System Elapse Time
97
Name of Repairman
97
Fixed Resistors
98
Variable Resistors
98
Fuses
98
Switches
98
Indicators and Front Panel Switches
98
Printed Circuit Boards
98
Air System
98
Corrective Maintenance
98
Replacing Boards and Components on Boards
98
Boards Which Can be Replaced with no Adjustments
98
Boards Which Require Preset Switch Settings or
99
Modulation Encoder A36
99
Controller A38
99
Buffer Amplifier A16
99
Predriver A10
99
RF Amplifiers
99
Driver Combiner/Motherboard A14
100
Binary Combiner/Motherboard A18
100
Printed Circuit Boards Which Require Adjustments
100
A to D Converter A34
100
Delay Adjustment R78
100
Offset Adjustment R7
100
Analog Input Board A35
101
Maximum Power Adjust A35R27
101
Modulated B- Adjustments A35R85 (Gain) and A35R84 (Offset)
101
Audio Gain Adjust A35R15
101
Dither Level Adjust A35R43
101
Oscillator A17
101
Carrier Frequency Adjust A17C1 and A17C3
102
Oscillator Sync Adjustment A17S1 and
102
Driver Supply Regulator A22
102
Open Loop Adjust A22R2, Closed Loop Adjust A22R12, Loop Select A22S1
102
DC Regulator A30
102
Modulated B- Level A30R38, and Clip Ad
103
Output Monitor A27
103
DETECTOR NULL (Antenna) Adjustment
103
DETECTOR NULL (Bandpass Filter) Adjust
103
Ment
104
Fine Tuning
104
Trip Threshold Adjustment
104
Forward/Reflected Power Adjustments C6
105
Modulation Monitor Sample Adjustments
105
LED Board Replacements A32
105
Overload Adjustment Procedures
105
Under Drive Overload A32R92 and Over- Drive Overload A32R88
105
Average PA Current Overload Set A32R102
106
Peak PA Current Overload Set A32R98
106
Power Supply Protection Overload A32R23
106
Envelope Error Fault Indicator A32R65 (Level) and A32R68 (Offset)
106
Board Replacement Instructions
107
Main Combiner/Motherboard Replacement A19 and
107
Replacement of the Main Combiner/Motherboards
107
Lower Main Combiner/Motherboard Replacement
107
Binary Combiner/Motherboard Removal and Re
108
Driver Combiner/Motherboard A14 Removal and Re
108
Replacement of the Driver Combiner/Motherboard
108
RF Driver Splitter A15, Removal and Replacement
108
Blower Motor B1 Replacement
109
Other Transmitter Circuit Checks
109
Airflow Switch S7 Adjustment
109
Tuning/Frequency Change Procedure
109
Test Equipment Required for Frequency Change
109
Installation of Frequency Determined Components
110
Setting of Frequency Determined Jumpers and Switches
110
DX10/15 Output Network Tuning
110
RF Circuits Checkout
112
Oscillator A17
112
Buffer A16
112
Predriver Adjustment A10
112
RF Driver Adjustments
113
Initial Tuning at Low Power (1 Kw)
114
Output Monitor A27 Adjustments
114
DETECTOR NULL (Antenna) Adjustment
114
DETECTOR NULL (Bandpass Filter) Adjust
115
Fine Tuning
115
Trip Threshold Adjustment
115
Forward/Reflected Power Adjustments C6
116
Modulation Monitor Sample Adjustments
116
Final Initial Tuning at Low Power
116
Modulated B-Check
116
A to D Phasing Check
117
Initial Tuning at High Power (10 Kw)
117
Modulated B-Check
117
Final Output Network Tap Settings
117
Bandpass Filter Response
118
Output Monitor A27 Final Adjustments
118
Antenna and Bandpass Filter Final Adjust
118
Forward and Reflected Power Null Adjustments A27C3 and A27C4
118
Modulation Monitor Sample Adjustments
118
Oscillator Sync Adjustment A17S1 and
118
Completion of Basic Frequency Change of DX-10
119
Binary Amplifier Phase Alignment
119
Binary Amplitude Alignment
119
Neutralization Adjustment
120
Overall Modulated B- Adjustment
120
Gain Adjust A35R85
120
Offset Adjustment A35R84
120
Modulated B- Level A30R38 DC Regulator
120
Clip Adjustment A30R39 DC Regulator
120
Other Adjustments
121
Audio Gain Adjust A35R15
121
Offset Adjust A34R75
121
Dither Adjust A35R43
121
Envelope Error Fault Adjusts A32R65 and
121
AM Stereo Installation and Tuning Hints
121
Interfacing for Stereo
121
Adjustments that Affect IPM
121
RF Driver Tune L2
121
Bandpass Tuning C101
121
Troubleshooting
129
Introduction
129
Initial Troubleshooting, Critical OFF-AIR Situations
129
Symptom: Transmitter will Not Turn On-No Front Panel Indicators Are Illuminated
129
Loss of AC Power
129
Loss of +5V Supply on LED Board
129
Loose Ribbon or Amp Connectors
129
Symptom: Transmitter will Not Turn ON-All Front Panel Indicators Are Illuminated Green
129
B" Circuit Not up to Operating Volt
129
Contactor Turn on Logic
129
Symptom: Transmitter will Not Turn ON-One or
130
Symptom: Transmitter will Turn on but Immedi
130
Transmitter Faults
130
Symptom: Transmitter Turns on but There Is no Power Output
130
PA Turn-Off Command Given to Transmitter
130
PA Turn-Off Switch Set to the PA off Posi
130
External PA Turn-Off Circuit Activated
130
Transmitter Type 4 and Type 5 Faults
130
Power Output of Transmitter Is Lowered to
130
Symptom: Transmitter Turns on but Transmitter Output Is Lower than Normal
130
Antenna VSWR Caused by an Impedance Change in the Transmitter Load
131
Bandpass Filter VSWR Caused by Problems in the Output Network
131
Symptom: Transmitter Turns on but Transmitter will Not Modulate
131
Modulation Not Reaching Transmitter
131
Analog Input Board
131
Troubleshooting Front Panel Indicator Faults
131
Overloads- Intermittent or Continuous
131
RED or AMBER)
131
Main Power Supply Overcurrent Fault
131
Random Faults with Audio
131
Faults with Tone Modulation
132
Supply Current Overloads on Turn on
133
Main Power Supply-Overvoltage Fault
133
Supply Voltage too High
133
Main Power Supply-Supply Fault
133
Input AC 3 Phase Line Imbalance
133
Open High Voltage Rectifier(S)
133
Failed High Voltage Transformer
133
Low Frequency, High Level Modulation
134
RF Driver-Underdrive Fault
134
High Voltage Supply Short
134
Failed Driver Supply
134
No Drive to the Driver Stage
134
RF Driver Module Failure
134
Excessive RF Amplifier Failure
134
Driver Supply Regulator Failure
134
Driver Supply Regulator Loop Select
134
Severe Driver Mistuning
135
Drive Sensing Circuit Failure
135
RF Driver-Overdrive Fault
135
Driver Supply Regulator Failure
135
Driver Supply Regulator Loop Select
135
Interlocks
135
Door Interlock
135
External Interlock
135
External Interlock Terminals Open
135
External Interlock Fuse F6
135
External Interlock Relay K4
136
Air Interlock
136
Blower Not Operating Properly, Failed/Run
136
Top Air Exhaust Restricted
136
Center Rear Panel Open
136
Air Interlock Sensing Circuitry
136
Air Interlock Switch S7
136
All Other Front Panel Faults
136
Oscillator Fault
136
Buffer Fault
136
RF Amp Envelope Error Fault
137
Analog Input +15V and -15V Supply Faults
137
A to D Converter +15V, -15V, and +5V Supply
137
Faults
137
A to D Converter Conversion Error Fault
138
Modulation Encoder Cable Interlock
138
All RF Amplifier Modules Are in Place
138
All Modulation Encoder Ribbon Cables Are
138
In Place
138
Isolating a Cable Interlock Problem
138
DC Regulator +5V and B- Supply Faults
138
Output Monitor +5V and -5V Supply Faults
138
Output Monitor VSWR Faults
138
Two Stage VSWR Action
139
First Stage VSWR Protection
139
Symptom: VSWR LED Flashes Red
139
Second Stage VSWR Protection
139
Symptom: the VSWR Goes to Red and Remains on
139
Combination of both Stages of the VSWR Circuit
139
Action
139
Symptom: the VSWR LED Flashes then Remains Lit RED
139
Antenna VSWR Fault
140
Antenna VSWR Caused by an Impedance Change in the Transmitter Load
140
Bandpass Filter VSWR Fault
140
Bandpass Filter VSWR Caused by Problems
140
Initial Troubleshooting-Less Serious, Not off AIR
140
Symptom: RF Output and PA Current Lower than
140
Failed RF Amplifier Module
140
Intermittent VSWR Condition Causing Power Foldback
140
Symptom: Loss of Positive Peak Capability
140
Power Supply Voltage Low
140
Audio Processor Equipment Defective or in
141
Incorrect Transmitter Tuning
141
Transmitter Operated in Flexpatch™ Mode
141
Failed RF Amplifier
141
Loss of a Big Step
141
Symptom: Higher than Normal Audio Distortion
141
Failed RF Amplifier(S)
141
Finding a Missing Step
141
Transmitter Mistuning
143
Operating into a Bandwidth Restricted Antenna
143
Mistuning of the Bandpass Tuning Control C101
143
Low RF Drive Level to the RF Amps
143
Additional Tips for Troubleshooting Audio THD
143
Consistent Loss of RF Amplifier Modules
143
Symptom: Consistent Loss of an RF Amp in One Par
143
Improper RF Drive
143
Improper Drain Phasing
143
Defective Output Toroid
144
Symptom: Consistent Loss of Modules in Random
144
A to D Phasing Improperly Set
144
Modulated B- Improperly Set
144
Improper VSWR Circuit Operation
144
Improper Setting of the Oscillator Sync Cir
144
Improper Overload Settings
144
Improper Air Flow
144
Transmitter Mistuning
144
Symptom: Excessive Carrier Shift
144
Transmitter Mistuning
145
Mistuning of the Bandpass Tuning Control
145
Low RF Drive Level to the RF Amps
145
Other Troubleshooting Techniques
145
Handling Mosfet's
145
Testing Mosfet's
145
Using Flexpatch™ for Bypassing a Failed RF Amp
145
Using Flexpatch™ for Isolating Modulation en
146
Measuring RF Drive Level
146
Measuring Steps 18-42
148
Measuring Binary RF Amp Drive Amplitude
148
Measuring Drive Phasing
148
Scope Setup
148
Excessive Drive Phase Difference
149
Measuring Steps 18-42
149
Measuring Binary RF Amp Drive Phasing
149
RF Amplifier Drain Phasing
149
Excessive Drive Phase Difference
150
Measuring Steps 18-42
150
Section VIA
153
Emergency Operating Procedures
153
Introduction
153
What to Do if an Overload Occurs
153
Power Supply Failure
153
Crystal Failure
153
Predriver Amplifier Failure
154
High Voltage Power Supply Overcurrent
154
RF Overdrive or Underdrive
154

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