Damaged or undamaged equipment should not be returned unless written approval
and a Return Authorization is received from HARRIS Broadcast Communications
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. Custom equipment or special order equipment is
not returnable. In those instances where return or exchange of equipment is at the
request of the customer, or convenience of the customer, a restocking fee will be
charged. All returns will be sent freight prepaid and properly insured by the
customer. When communicating with HARRIS Broadcast Communications
Division, specify the HARRIS Order Number or Invoice Number.
Unpacking
Carefully unpack the equipment and preform a visual inspection to determine that
no apparent damage was incurred during shipment. Retain the shipping materials
until it has been determined tha t all re ceived equipment i s not d amaged. Locate and
retain all PACKING CHECK LISTs. Use the PACKING CHECK LIST to help
locate and identify any components or assemblies which are removed for shipping
and must be reinstalled. Also remove any shipping supports, straps, and packing
materials prior to initial turn on.
Technical Assistance
HARRIS Technical and Troubleshooting assistance is available from HARRIS
Field Service during normal business hours (8:00 AM - 5:00 PM Central Time).
Emergency service is available 24 hours a day. Telephone 217/222-8200 to contact
the Field Service Department or address correspondence to Field Service
Department, HARRIS Broadcast Communications Division, P.O. Box 4290,
Quincy, Illinois 62305-4290, USA. Technical Support by e-mail:
[email protected]m. The HARRIS factory may also be contacted through a FAX
facility (217/221-7096).
Replaceable Parts Service
Replacement parts are available 24 hours a day, seven days a week from the
HARRIS Service Parts Department. Telephone 217/222-8200 to contact the service
parts department or address correspondence to Service Parts Department, HARRIS
CORPORATION, Broadcast Systems Division, P.O. Box 4290, Quincy, Illinois
62305-4290, USA. The HARRIS factory may also be contacted through a FAX
facility (217/221-7096).
NOTE:
The # symbol used in the parts list means used with (e.g. #C001 = used with C001).
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Page 3
Manual Revision History
Z3-48HD+ Technical Manual
REV.DATEECNPages Affected
ANov., 2007Entire Manual
A1Dec., 2007Minor changes in Manual
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Page 5
Guide to Using Har ris Parts List Information
t
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. In the Replaceable
Parts List Index the Control C abinet, PA Cabinet, and Output Cabinet show up one i ndentation level b elow the T r ansmitter
and implies that they are used in the Transmitter. The Controller Board is indented one level below the Control Cabinet so
it will show up in the bill of material for the Control Cabinet. The tree structure of this same index is shown to the right of
the table and shows indentation level versus tree structure level.
Example of Replaceable Parts List Index and equivalent tree structure:
The part number of the item is shown to the right of the description as is the page in the manual where the bill for that part
number starts. Inside the actual tables, four main headings are used:
Control Cabinet
992 9244 002
Controller Board
992 8344 002
Transmitter
994 9283 001
PA Cabinet
992 9400 002
PA Amplifier
992 7894 002
PA Amplifier Board
992 7904 002
Output Cabine
992 9450 001
• Table #-#. ITEM NAME - HARRIS PART NUMBER - this line gives the information that corresponds to the
• Replaceable Parts List Index entry;
• HARRIS P/N column gives the ten DIGIT Harris part number (usually in ascending order);
• DESCRIPTION column gives a 25 character or less description of the part number;
• REF. SYMBOLS/EXPLANATIONS column 1) gives the reference designators for the item (i.e., C001, R102,
etc.) that corresponds to the number found in the schematics (C001 in a bill of material is equivalent to C1 on the
schematic) or 2) gives added information or further explanation (i.e., “Used for 208V operation only,” or “Used
for HT 10LS only,” etc.).
Inside the individual tables some standard conventions are used:
• A # symbol in front of a component such as #C001 under the REF. SYMBOLS/EXPLANATIONS column
means that this item is used on or with C001 and is not the actual part number for C001.
• In the ten digit part numbers , if the last th ree numbers are 000, t he item is a part that Harris has pu rchased 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.
• The first three digits of the ten DIGIT part number tell which family the part number belongs to - for example, all
electrolytic (can) capacitors will be in the same family (524 xxxx 000). If an electrolytic (can) capacitor is found
to have a 9xx xxxx xxx part number (a number outside of the normal family of numbers), it has probably been
modified in some manner at the Harris factory and will therefore show up farther down into the individual parts
list (because each table is normally sorted in ascending order). Most Harris made or modified assemblies will
have 9xx xxxx xxx numbers associated with them.
The term “SEE HIGHER LEVEL BILL” in th e d escript ion column imp lies that the reference designated part number will
show up in a bill that is higher in the tree structure. This is often the case for components that may be
frequency determinant or voltage determinant and are called out in a higher level bill structure that is more
customer dependent than the bill at a lower level.
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!
WARNING:
THE CURRENTS AND VOLTAGES IN THIS EQUIPMENT ARE DANGEROUS. PERSONNEL MUST AT ALL TIMES OBSERVE SAFETY WARNINGS, INSTRUCTIONS AND REGULATIONS.
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. It is not intended to
contain a complete statement of all safety precautions which should be observed by personnel in
using this or other electronic equipment.
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.
During installation and operation of this equipment, local building codes and fire protection
standards must be observed.
The following National Fire Protection Association (NFPA) standards are recommended as reference:
- Automatic Fire Detectors, No. 72E
- Installation, Maintenance, and Use of Portable Fire Extinguishers, No. 10
- Halogenated Fire Extinguishing Agent Systems, No. 12A
!
WARNING:
ALWAYS DISCONNECT POWER BEFORE OPENING COVERS, DOORS, ENCLOSURES, GATES, PANELS OR SHIELDS. ALWAYS USE GROUNDING STICKS AND
SHORT OUT HIGH VOLTAGE POINTS BEFORE SERVICING. NEVER MAKE INTERNAL
ADJUSTMENTS, PERFORM MAINTENANCE OR SERVICE WHEN ALONE OR WHEN
FATIGUED.
Do not remove, short-circuit or tamper with interlock switches on access covers, doors, enclosures,
gates, panels or shields . K e ep away from li ve circui ts , k now your equ ip ment and do n’t take chances.
!
WARNING:
IN CASE OF EMERGENCY ENSURE THAT POWER HAS BEEN DISCONNECTED.
!
WARNING:
IF OIL FILLED OR ELECTROLYTIC CAPACITORS ARE UTILIZED IN YOUR EQUIPMENT, AND IF A LEAK OR BULGE IS APPARENT ON THE CAPACITOR CASE WHEN
THE UNIT IS OPENED FOR SERVICE OR MAINTENANCE, ALLOW THE UNIT TO COOL
DOWN BEFORE ATTEMPTING TO REMOVE THE DEFECTIVE CAPACITOR. DO NOT
ATTEMPT TO SERVICE A DEFECTIVE CAPACITOR WHILE IT IS HOT DUE TO THE
POSSIBILITY OF A CASE RUPTURE AND SUBSEQUENT INJURY.
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FIRST-AID
Personnel engaged in the installation, operation, maintenance or servicing of this equipment
are urged to become famil iar with fi rst -aid the ory 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. It is the duty of all personnel using the equipment to be prepared to give adequate
Emergency First Aid and there by prevent avoidable loss of life.
Treatment of Electrical Burns
1. Extensive burned and broken skin
a. Cover area with clean sheet or cloth. (Cleanest available cloth
article.)
b. Do not break blisters, remove tissue, remove adhered particles of
clothing, or apply any salve or ointment.
c. Treat victim for shock as required.
d. Arrange transportation to a hospital as quickly as possible.
e. If arms or legs are affected keep them elevated.
NOTE:
If medical help will not be available within an hour and the victim is conscious and
not vomiting, give him a weak solution of salt and soda: 1 level teaspoonful of salt
and 1/2 level teaspoonful of baking soda to each quart of water (neither hot or
cold). Allow victim to sip slowly about 4 ounces (a half of glass) over a period of
15 minutes. Discontinue fluid if vomiting occurs. (Do not give alcohol.)
2. Less severe burns - (1st & 2nd degree)
a. Apply cool (not ice cold) compresses using the cleanest available
cloth article.
b. Do not break blisters, remove tissue, remove adhered particles of
clothing, or apply salve or ointment.
c. Apply clean dry dressing if necessary.
d. Treat victim for shock as required.
e. Arrange transportation to a hospital as quickly as possible.
f. If arms or legs are affected keep them elevated.
REFERENCE:
ILLINOIS HEART ASSOCIATION
AMERICAN RED CROSS ST ANDARD FIRST AID AND PERSONAL SAFETY
MANUAL (SECOND EDITION)
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Page 12
Table of Contents
2888-2508-001
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Section I
Operator Guide
1.1Introduction
This manual is to provide information regarding the Z3-48HD+ Transmitter System’s
operation. In addition to the System Controllers, other System-specific functions are
discussed. Any further site-specific functionallity will be discussed in the site-specific
data packages provided with the Z3-48HD+ Transmitter System, including the
individual Z16HD+ transmitter manuals.
The Z3-48HD+ System is made of a ZD32HD+ dual transmitter and one additional
Z16HD+ transmitter cabinet. The ZD32HD+ is made of two Z16HD+ transmitter
cabinets. Most everything in the ZD32HD+ remains as the instruction book and
drawings describe except for the Drive. There are two System Controllers in the Z3-48
system. One System Controller controls and monitors only the ZD32 (transmitters A
and B). The second System Controller controls and monitors the Z3-48 which includes
the Z16 and the ZD32.
1
NOTE:
It is important to have and study all documentation of all units involved in a Z348HD+ system prior to begining installation of this complex system.
The ZD32 consists of the two cabinets on the right hand side of the system. These are
known as transmitters A and B to keep the ZD32 documentation consistent with that of
the Z3-48 system. The extra cabinet required to make up the Z3-48 system will be on
the left and be known as transmitter C. This arrangement also keeps the RF line and
combiner arrangement to a minimum for those sites that may require equipment to go in
a small space. Both of the System Controllers will be located in a separate rack next to
the system if dual exciters and Boost amps are required. Space for the System
Controllers is not available in the transmitter for this configuration.
Operation of the Z3-48HD+ in any of several modulation format modes can be
accomplished from the FlexStar HDx-FM exciter GUI panel. See exciter manual for
further details. HD modes are only available with the FMHD22 version of the
FlexStarTM Exciter.
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Section I Operator Guide
There are several methods of combining the analog (FM) and digital (HD) RF to create
an IBOC signal - also known as Modulation Format - that may be used in a typical
IBOC system including a backup mode. The four modes of operation are:
FM - Analog RF only; this could be the analog backup mode in the event of a
digital failure.
FM+HD - Analog & digital (at -20dB) RF, also known as Common Combining.
HD - Digital RF only, used for Separate Combining, such as 10dB combined,
dual-feed and interleaved antenna, and dual antennas.
SLC - Analog & digital (at various ratios) RF, also known as Split-level or
Mid-level Combining.
Transmitter operation can be initiated or terminated as desired by depressing the ON
HI, ON LOW, or OFF push-buttons. All three transmitters will be commanded into the
selected mode when the Z3-48 System Controller switch is depressed.
The System Controllers also provide the necessary RF metering, common external
transmitter interlock and transmitter interfac e, and combine d transmitter re mote control
functions. APC function is retained by the individual transmitters and its RF source.
Z3-48HD+
• System Controller P/N 992-8850-005
•System Control Board
•Assembly #992-8853-001
•PWB #843-5293-076
•Schematic #839-8118-181
•Display Board
•Assembly #992-8388-005
•PWB #843-5215-004
•Schematic #839-8025-004
NOTE:
Parts list is in Section II.
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Z3-48HD+
1.2Installation Instruction
1.2.1Returns And Exchanges
Damaged or undamaged equipment should not be returned unless a Return
Authorization is issued. When communicating with Harris Corporation, Broadcast
Division, specify the order number or invoice number. Include complete details
regarding circumstances and reasons for return in the request. Custom or special order
equipment is not returnable. In instances where return or exchange of equipment is at
the request or convenience of the customer, a restocking fee will be charged. Special
shipping instructions and coding will be provided to i nsure proper handli ng. All returns
will be sent freight prepaid and properly insured by the customer.
1.2.2Unpacking
Carefully unpack the transmitter and save all packing material. Inspect thoroughly for
any damage incurred in shipment. Retain all PACKING CHECK LISTS to help locate
and identify any components or assemblies removed for shipping. Remove any
shipping supports, and straps prior to initial turn on.
Section I Operator Guide
Before cabinet placement takes place, it is important to determine which cabinet is
transmitter C (left side as viewed from the front), transmitter A (middle), and
transmitter B (right side). This can be determined by looking at the tags on the front of
the transmitter or matching serial numbers of the cabinet to the provided test data. The
serial numbers of the cabinets can be found on the left side wall inside the module
compartment. A typical system will have the FlexStar HDx-FM Exciter(s) in the left
cabinet.
1.2.3Installation
NOTE:
It is important to have and study all documentation of all units involved in a Z348HD+ system prior to begining installation of this comlex system.
The cabinets may be mounted together using four Cabinet Brackets and hardware
provided with the system. The Cabinet Brackets mount between the transmitters on top
using the 3/8" hardware into threads found near the front and back of any two cabinets.
1/2" hardware is provided to bolt two cabinets together near the bottom. These holes
may be accessed inside the power supply compartments of all three cabinets. The
supply may need to be pushed forward a few inches in order to gain access to the back
hole.
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Section I Operator Guide
Several cables will be secured inside the cabinets that need routed to the other cabinets
A hole located in each cabinet is provided for cable routing between cabinets. If a hole
cap is still in place, remove cap from both cabinets for interconnecting cables. Refer to
the wiring diagrams in the System Drawing Package for wire destinations. Each wire
will be marked with a wire or cable number located near the end of each wire. After
routing, cables may be permanently attached to other existing cabling. Keep in mind
some units are mounted on slides and cables are long enough to slide out with the unit
for continuous operation.
The exciter interconnect consists of various cables. Not all of these cables are necessary
in some applications. Depending on how many exciters and what type of IBOC system,
some cables may not be needed. See drawings in the Z16 manual drawing package for
further information.
The combiners and loads are usually placed where specified by the layout diagram in
the System Drawing Package. Placement of Directional Coupler assemblies are also
specified by the layout diagram. A provided coax cable should be connected between
the System Controllers and three coupler ports each; the forward power, reflected
power, and the reject load forward power.
Z3-48HD+
The reject load’s (if provided) interlock cables should be connected. Connections for
addition station interlocks may be provided depending on the configuration of the
system. Refer to the System Drawing Package for further information.
AC connections for the transmitters are located near the top in the back left side of each
cabinet. See the Z16 manual for further information. One AC connection must be made
for the Z3-48HD+ exciter(s). This TB7 terminal block is located inside the AC input
compartment of transmitter cabinet C. This input should be on a separate AC feed in
case this transmitter’s breaker is off, the exciters can operate the remaining operating
transmitters at a reduced power level. Another AC feed must be connected to the
controller rack (if provided) or each piece of equipment if a rack is not provided. This
AC feed should again be on a separate AC feed from the transmitter in case one
transmitter breaker is off. Each Harris-made piece of equipment to be placed in an
existing rack can be operated at 120 or 240 VAC depending on the AC input card
position.
Connect transmission line between the transmitters and the combiners per the layout
supplied in the System Drawing Package. Any unequal change to the transmission line
length from transmitter to combiner will have to be adjusted for in the drive circuit.
Combiner input phasing is important for proper operation. Confirm the ports of the
4.77dB hybrid are aligned according to the markings on the combiner. This combiner is
not symmetrical so it must be connected properly. Also connect transmission line to the
reject loads. Placement of the loads and length of line to the loads is not critical. Only
transmission line for the typical layout is supplied with the system unless otherwise
specified with the order.
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Z3-48HD+
1.3Transmitter Operation
a. Ensure all RF connections are tight, and that all control and AC service (mains)
connections are correct and secure using the correct voltage and frequency settings.
b. Set the REMOTE/DISABLE switches on all transmitters to the REMOTE posi-
tion.
c. Start transmitter A (middle cabinet) by depressing the ON HI pushbutton on the
transmitter cabinet A. Operate transmitter at or near 100%. The ZD32 System
Controller FWD PWR should read near 25%. Press LOWER button until transmitter cabinet A FWD PWR is near 20%. Turn off transmitter cabinet A by
depressing the OFF pushbutton.
d. Start transmitter B (right side) by depressing the ON HI pushbutton on the trans-
mitter cabinet B. Operate transmitter at or near 100%. The ZD32 System Controller FWD PWR should again read near 25%. Press LOWER button until
transmitter cabinet B FWD PWR is 20%. Turn off transmitter cabinet B by
depressing the OFF pushbutton.
Section I Operator Guide
e. Start transmitter C (left side) by depressing the ON HI pushbutton on the trans-
mitter cabinet C. Operate transmitter at or near 100%. The Z3-48 System Controller FWD PWR should read near 22%. Press LOWER button until transmitter
cabinet C FWD PWR is 20%. Turn off transmitter cabinet C by depressing the
OFF pushbutton.
f. Start combined transmitter operation by depressing the ON HI pushbutton switch
on the ZD32 System Controller. Both A & B transmitters should begin operation
and be producing RF power.
g. The ZD32 System Controller FWD PWR meter should be reading near 20%.
Select the REJ PWR meter position on the ZD32 Sys tem Controller and verify its
reading is near 0%. If this reading is more than 2-3%, this may be the result of
either amplitude or phase mismatch between the two combiner inputs. Adjust the
power level 2-3% out of just one transmitter, A or B. If this minimizes the reject
power to near zero, continue on to the next step. If power fro m each transm itter is
back to the same and more than 10% reject power exists, a phase mismatch may
be adjusted by changing the physical length of W901A or W901B in the drive
circuit. Some experimentation will be required. Add or remove BNC elbow adaptors or a very short length of cable (2-6 inches) to one or the other existi ng cables
at the drive splitter SP2 outputs located in cabinet A (middle). Any reject power
may be the result of a different connection from what was originally used at the
Harris test facility. Additionally, some phase adjustment can be accomplished on
the BoostPro GUI screen. See the BoostPro documentation for more details. Usually, no adjustment of amplitude or phase will be necessary.
h. Start the third cabinet C by depressing the ON HI pushbutton on the Z3-48 Sys-
tem Controller. All three transmitters should be operating and producing power.
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Section I Operator Guide
i. The Z3-48 System Controller FWD PWR meter should be reading near 20%.
Select the REJ PWR meter position on the Z3-48 system Controller and verify its
reading is near 0%. If this reading is more than 2-3%, this again may be the result
of either amplitude or phase mismatch between the two combiner inputs to the
4.77dB combiner. Adjust the power level 2-3% out of just transmitter C. If this
minimizes the reject power to near zero, continue on to the next step. If power
from each transmitter is back to the same or more than 10% reject power exists, a
phase mismatch may be adjusted by changing the physical length of W900 in the
drive circuit. Some experimentati on will be required. Add or re move BNC elbow
adaptors or a very short length of cable (2-6 inches) to W900 at the transmitter C
Exciter Switch board output. Reject power may be the result of a different connection from what was originally used at the Harris test facility. Usually, no
adjustment of amplitude of phase will be necessary.
j. Once reject power is down below 5% on both System Controllers, raise power in
all three transmitters to 100% watching that reject power does not exceed 10%. If
any reject power exists, repeat the above steps for adjustment of amplitude or
phase of all combiner inputs. Some fluctuation of power will be noticed due to
the type of detection used for an IBOC signal and its peaks.
Z3-48HD+
k. Select the RFL PWR position on the transmitters and the Sys tem Controlle rs and
verify that they all read at or near 1.01VSWR.
l. Depress the LOW ON push-button switch on both System Controllers and verify
that all transmitter output levels drop to approximately 50% and that the System
Controllers also indicate near 50% in the FWD PWR positions.
1.3.1RF Metering
Three metering functions are provided by each System Controller. They are: Forward
output power in percent of allowed forward power (FWD PWR); reflected power
displayed as load VSWR (RFL PWR); and combiner reject load power in percent of
normal (REJ PWR). Below are the approximate values of the normal average RF levels
for a Z3-48HD+ combined transmitter system calibrated at full output in the combined
mode. See Table 1-1.
Table 1-1 System Controller Average Power Metering
Indication
FWD PWR 100%RFL PWR 1.00REJ PWR 100%
Z3-48 System Controller
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FM+HD21kWAs Indicated4.67kW
HD only10.5kWAs Indicated2.33kW
FM only30 kWAs Indicated6.67kW
Page 19
Z3-48HD+
P
2
Table 1-1 System Controller Average Power Metering
ZD32 System Controller
A REJ PWR reading of 100% will be one-fourth the total output power when the 3 dB
hybrid combiner is used, such as with the ZD32 System Controller. The REJ PWR
reading of 100% will be set for 2/3 the total output power from one transmitter when the
4.77dB hybrid combiner is used such as with the Z3-48 System Controller. Up to 2/3 of
the power from transmitter C or 1/3 of the power from the ZD32 could be present at the
4.77dB reject load. See Table 1-2 on page 1-8 for power results when one or two
transmitters are OFF. When a backup mode is used, consideration must be given to the
maximum power in the reje ct load a llowed by the overload and the maximum power the
load is capable of. As a result of this consideration, some variations from the chart exist
and are noted in the Factory Test Data Sheet.
Section I Operator Guide
FM+HD14 kWAs Indicated3.5kW
HD only7kWA s Indicated1.75kW
FM only20kWAs Indicated5kW
The following formula can be used for calculating expected power results at the antenna
port given different power level inputs as in the last two columns of Table 1-2:
The System Controllers each display values of the selected functions on a 3-1/2” digit
panel meter. Three momentary pushbutton switches allow selection of the metering
mode for the System Controller. A momentary depression of one of the three meter
select switches will put the digital metering system into the desired mode. The meter
will remain in that selected mode until another metering selection pushbutton switch is
depressed. Following an AC power interrupti on the metering system will automatically
power on in the FWD PWR mode, displaying the forward output power level, in
percent of normal.
Full OperationOne TX OFFOne TX OFFTwo TX OFFTwo TX OFFOne TX ½ Power One TX ½ Powe
Power%Power%Power%Power%Power%Power%Power%
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Z3-48HD+
Section I Operator Guide
1.3.2Control Functions
Three momentary push-button switches allow system ON and OFF control functions to
be exercised from the front of the System Controllers. These pushbuttons are: OFF, ON
HI, and ON LOW. Depressing one of these three pushbutton switches will
simultaneously command both transmitters controlled by that System Controller into
the selected ON mode, or will return both transmitters controlled by that System
Controller to the OFF mode simultaneously.
Three LEDs indicate actual transmitter status, LOW, HI and OFF. The indicators are
controlled by the transmitter status outputs of both transmitters controlled by that
System Controller.
NOTE:
In order for these System Controller commands to be accepted by the individual
transmitter control units, the REMOTE/DISABLE switches on each individual
transmitter MUST be in the REMOTE position; or red LED off.
1.3.3Status Indicators
The System Controllers each incorporate four LED status indicators to provide
important information about the operation conditions of the combined transmitter
system controlled by that System Controller. These indicators are RF POWER, SWR,
EXT INTERLOCK, and REJ LOAD.
The RF POWER indicator illuminates red if the system is in operation and the forward
output power level at the combiner output drops below a preset level, usually 90%. The
indicator will extinguish if the level rises above the preset level or the system is turned
off.
The SWR FAULT LED indicator will illuminate if the reflected RF power level at the
combiner output rises above a preset level, 1.3:1. If this level has been exceeded, the
LED will illuminate. The System Controller takes no action but the transmitters
themselves will either foldback or turn off depending on the level of VSWR. The
indicator will extinguish with the next System Controller ON command.
The EXT INTLK LED indicator will illuminate if the connection between J1-6 and J125 is broken. System operation, controlled by that System Controller , will automatically
be terminated and returned to the OFF state. Once the connection between J1-6 and J125 is restored, an ON command is required to restore operation. These connections are
routed through the Reject Load interlock terminals. The 5kW load interlock is
connected to the ZD32 System Controller. The 10kW load interlock is connected to the
Z3-48 System Controller.
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Section I Operator Guide
The REJ LOAD LED indicator is actually two indicators in one. One half of the
indicator is an amber LED, the other is a red LED. If the RF power delivered to the
combiner reject load associated with that System Controller exceeds a preset warning
level, usually 90%, the amber portion of the LED will illuminate. It will remain
illuminated until the RF leve l drops below the pr eset level. If the RF power deli vered to
the reject load associated with that System Controller exceeds the safe operation level
for the load, the System Controller will te rminate ope ration of the transmitt ers that feed
that particular load and the red portion of the REJ LOAD will be illuminated. It will
remain illuminated until the next ON command of that particular System Controller is
exercised.
1.3.4Remote Control
The REMOTE/LOCAL push-button switch on the front panel of the System Controllers
allow the operator to determine if the unit will accept remote system level ON or OFF
commands. In the LOCAL mode (red LED illuminated) only the front panel switches
on the System Controller may be used to turn the system on or off. For normal
operation, the ZD32 System Controller should always remain in the REMOTE mode as
the Z3-48 System Controller uses the ZD32 remote inputs to control that portion of the
system.
Z3-48HD+
Remote system level commands, status and metering functions are available at J1 and
J11 on the System Controller. System commands are active when the REMOTE/
LOCAL switch on the front of the System Controller is in the REMOTE position.
Status and metering information is always available at J1 and J11 regardless of the
position of the REMOTE/LOCAL switch.
Table 1-10 on page 1-17, System Controller Remote Connections, gives details of the
commands, status and metering functions available at J1 and J11 on the rear of both
System Controllers. It is recommended that J1 be used only for fail-safe/interlock and
J11 be connected to a remote control (if used) for remote metering, status, and
commands.
1.3.5Interlock Considerations
In a hybrid combiner system, if the reject presents an open interlock, both transmitters
associated with that System Controller will be interlocked off. Once the interlock is
closed, an ON command is required to restore normal operation. The interlocks are
routed through the Reject Load interlock terminals. The 5kW load interlock is
connected to the ZD32 System Controller. The 10kW load interlock is connected to the
Z3-48 System Controller. Additional devises can be wired in series with the load
interlocks if required.
1-10888-2621-00112/5/07
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Page 23
Z3-48HD+
Section I Operator Guide
1.3.6Drive Functions
Exciter muting and main/alternate functions are controlled by transmitter C of the Z348HD+. This is the cabinet on the left in a typical layout.
Exciter Main/Alternate control can be accessed through the transmitter C controller
LCD display screen. From HOME, press STATUS/MORE/EXCITER/SWITCH.
Observe status ON indicators for exciter 1 or exciter 2.
For exciter main/alternate operation, all exciters’ AC should be on at all times
regardless if a TX is shut down. This is accomplished by a separate AC feed for
transmitters and exciter(s). Transmitter C contains a separate AC input for the exciters.
The System Controller should also operate from a separate AC feed from the
transmitters. The System Controllers are usually located in a separate rack with a
separate AC feed.
When transmitter C is turned on, the power supply starts to ramp up and as soon as it is
at full voltage, the mute line is pulled low by an open collector output and un-mutes the
on air exciter as determined by transmi tter C. The Auxiliary output of the Flexstar HDxFM exciter is always ON (un-muted) and operating in the mode established within the
exciter . This signal is routed through t he transmitter C Exciter Switc h Board to a splitter
SP2 located in transmitter A (center cabinet). The outputs of this splitter go to the inputs
of the Exciter Switch Boards in transmitter A and transmitter B. If two Boost Pro
amplifiers are used in each transmitter A and transmitter B, the signal is switched
between the two Boost Pro inputs by the Exciter Switch Boards. The Exciter Switch
Board also controls the output of each Boost Pro by selecting the on air Boost Pro’s
output and routing it to the transmitter IPA stages. If only one Boost Pro is in each
transmitter, the controller of that transmitter will be set for only one RF source through
the LCD display screen and the Exciter Switch Board will not switch.
If during operation, the on air exciter fails, a ten second window exists to allow the
exciter to retry and come back on line by itself. If after 10 seconds power still does not
exist, a command from transmitter C Life Support Board swit ches the exciter outputs t o
the backup exciter, restoring RF drive to all transmitters.
If transmitter C is turned OFF and should a failure occur in the on air exciter, automatic
switching of the exciter’s auxiliary output will not occur but will continue to try to use
the Auxiliary output from the exciter that was on air. When transmitter C is turned back
ON, automatic switching will make the switch. If a long term OFF state is expected on
transmitter C, the auxiliary outputs can be manually changed for RF drive to
transmitters A and B. If power is re moved from transm itter C, the Exci ter Switch Board
will switch back to exciter 1 outputs but still using the always on auxiliary output.
Should the backup exciter’s auxiliary output be needed to keep transmitter A and B
operating, a manual change will be required as described earlier.
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Page 24
Section I Operator Guide
In this system, the HDx-FM Exciter's AUX output is used to drive the BoostPro boost
amplifier(s) in the other TX cabinet. Phase of this drive will be shifted within the
BoostPro and there are Phase adjustments in the BoostPro. If there is a phase delay
beyond what these two adjustments can compensate for, some line length adjustment
may be necessary for proper transmitter output phasing. See Z16 manual for more
information. As discussed earlier, W901A and W901B length can be changed or BNC
elbow adapters can be removed or added inline.
!
CAUTION:
CARE SHOULD BE TAKEN NEVER TO REPLACE THESE CABLES WITH AN
UNKNOWN CABLE, POSSIBLY CAUSING FULL COMBINED TRANSMITTER
POWER OUTPUT TO GO TO A COMBINER REJECT LOAD ONLY DESIGNED
TO CARRY QUARTER TOTAL POWER.
1.3.7HDx-FM Exciter/BoostPro Control
Z3-48HD+
The Forward Power sample of each RF source is routed directly to the transmitter
controlling each RF source(s). The transmitter will use these samples to determine if
there is an RF source failure. The sample(s) are also used to display power on the LCD
display screen.
Mute and Active signals for the Flexstar exciter(s) are exclusively controlled by
transmitter C and come from the Life Support Board. The active signal is used for the
exciters to know which one should be the on air exciter and is determined from the
display inputs, input signals, and internal logic. A high on the active line indicates
exciter 1 should be the on air exciter. If the active line is pulled low, exciter 2 will now
be the on air exciter. The mute signal routed to the exciter(s) turns off the main RF
output only as dictated by the exciter setup for this Z3-48 system. The auxiliary output
remains on at all times to provide drive to the other parts of the system, specifically
transmitter A and B.
1-12888-2621-00112/5/07
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Page 25
Z3-48HD+
1.4Alignments
NOTE:
All adjustments required have been made at the factory using calibrated test loads
and power meters to verify operating power levels. The following alignments are
to be performed only in the event of a field replacement involving any of these
components.
Three RF to DC sample transducers, in conjunction with RF directional couplers, are
used in each system, ZD32 and Z3-48, to monitor the RF power levels in that system.
The DC samples are routed through coaxial cables to the input jacks on the back of the
System Controllers.
The linearizer test point voltages are initially set using the tables below as determined
by the type of system with adjustments made using the corresponding sample
calibration pot (R37, R45 or R78). Variation of these voltages will exist depending on
desired high power output and linearity of circuit.
Section I Operator Guide
Table 1-3 ZD32 System Controller: FM+HD Mode
TEST
POINT
TP20.275 Volts14kW of system forward powerR37
TP30.075 Volts560 Watts of simulated reflected powerR45
TP40.275 Volts100% of reject power; 3.5kWR78
TARGET
VOLTAGE
SET UP CONDITIONSAMPLE
Table 1-4 ZD32 System Controller: HD Only Mode
TEST
POINT
TP20.275 Vo lts7kW of system forward powerR37
TP30.075 Volts280 Watts of simulated reflected powerR45
TP40.275 Volts100% of reject power; 1.75kWR78
TARGET
VOL TAGE
SET UP CONDITIONSAMPLE
CAL
CAL
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Page 26
Section I Operator Guide
Table 1-5 ZD32 System Controller: FM Only Mode
Z3-48HD+
TEST
POINT
TP20.275 Volts20kW of system forward powerR37
TP30.075 Volts800 Watts of simulated reflected powerR45
TP40.275 Volts100% of reject power; 5kWR78
TARGET
VOLTAGE
SET UP CONDITIONSAMPLE
Table 1-6 Z3-48HD+ System Controller: FM+HD Mode
TEST
POINT
TP20.275 Volts21kW of system forward powerR37
TP30.075 Volts840 Watts of simulated reflected powerR45
TP40.275 Volts100% of reject power; 4.67kWR78
TARGET
VOL TAGE
SET UP CONDITIONSAMPLE
CAL
CAL
Table 1-7 Z3-48HD+ System Controller: HD Only Mode
TEST
POINT
TP20.275 Volts10.5kW of system forward powerR37
TP30.075 Volts420 Watts of simulated reflected powerR45
TP40.275 Volts100% of reject power; 2.33kWR78
TARGET
VOL TAGE
SET UP CONDITIONSAMPLE
Table 1-8 Z3-48HD+ System Controller: FM Only Mode
TEST
POINT
TP20.275 Volts30kW of system forward powerR37
TP30.075 Volts1200 Watts of simulated reflected powerR45
TP40.275 Volts100% of reject power; 6.67kWR78
TARGET
VOL TAGE
SET UP CONDITIONSAMPLE
CAL
CAL
1-14888-2621-00112/5/07
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Page 27
Z3-48HD+
T o set t he forward power metering calibration, set the transmitters as follows (see Table
1-9 on page 1-15):
Section I Operator Guide
• Set transmitter system (only those controlled by that particular System
Controller) to operate at 100% of normal operating power (not necessarily
full power capability).
• Adjust R88, FWD PWR CAL, for 100% forward power reading on the front
panel. Some fluctuation of power will be noticed due to this type of detection
used for an IBOC signal and its peaks.
• Set transmitter power to zero and adjust R90, FWD PWR METER ZERO,
for a reading of 0%.
• Repeat previous steps as needed.
Table 1-9 System Controller RF Metering Inputs
JACKPURPOSELINEARIZER
TEST POINT
J6System Forward PowerTP2R37R88R90
J7System Reflected PowerTP3R45N/AR132
J8System Reject Load PowerTP4R78R80R70
To set the reject power metering calibration, set the transmitters as follows:
SAMPLE
CAL
METER
CAL
METER
ZERO
• For a particular System Controller, turn ON only the transmitters needed to
run maximum power into the Reject Load. See table 1-2 for configuration of
maximum Reject Load power.
• Adjust R80, REJ PWR CAL, for a 100% reject power reading.
• Turn the transmitter power output to zero and adjust R70, REJ PWR
METER ZERO, for a reading of 0%. Repeat as needed until both conditions
are met.
To set the reflected power meter calibration and overload:
• Adjust each transmitter (only those controlled by that particular System
Controller) to operate at a forward power of half the stated reflected power
in tables above so that the system combined power is the stated reflected
power from the appropriate table. If total power output (100% forward
power) is different than stated in table, set transmitter for 0.04 times total
power out. Adjust target voltage proportionally.
12/5/07888-2621-0011-15
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Page 28
Section I Operator Guide
• Reverse the reflected power coupler on the appropriate combiner output by
loosening the hose clamps holding it to the transmission line and reattaching
it to the line in its reverse position. This must be done without disassembling
the coupler itself.
• Use R45, R FL PWR SAMPL CAL, to set test point TP3 voltage to the target
voltage in tables above. Return the coupler to its original position.
• Adjust R132, VSWR ZERO, to read 1.01 reflected power on the front panel
while the system is operating at full power and operating with no reflected
power. Removi ng the sample cable from the System C ontroller input J7 wi ll
assure no reflected power reading.
• Verify the VSWR metering circuit by operating system at full power and
forcing TP3 to read the target voltage from the tables with an external DC
voltage source connected to J7.
• Verify that the VSWR reading is 1.50:1.
• Set the system controller VSWR trip threshold with R158, SWR TRIP SET,
to trip at a VSWR of 1.30:1.
• Remove external DC voltage source and reconnect sample input cable to J7
of System Controller.
Z3-48HD+
To set other overloads and set points:
• Turn the system output power (only that controlled by the particular System
Controller) to 90% and adjust R197, LO RF TRIP SET, until the low power
LED just turns on. Raise and lower the power above and below 90% and
verify the LED comes on at the 90% point, adjust as needed.
• Using an external voltage source connected to J8 of the System Controller;
force the reject power meter to read 90% and set R161, REJ PWR
WARNING SET, until the reject warning LED comes on.
• Set the reject power meter to read 104% with an external voltage source and
adjust R169, REJ PWR TRIP SET, until transmitters receive an OFF
command. If back-up modes of operation are used, the REJ PWR TRIP SET
can be set for up to the rating of the load. A ZD32 reject load typically has a
rating 5KW but for example, the FM+HD mode, 3.5KW is the most power
this load will absorb. If FM only was the backup mode, the trip set could be
at 5KW divided by 3.5KW or 143%. See test data sheets for the set point as
done in the factory.
• Remove external DC voltage source and reconnect sample input cable to J8
of System Controller.
1-16888-2621-00112/5/07
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Page 29
Z3-48HD+
Table 1-10 System Controller Remote Connections
Section I Operator Guide
Terminal
Remote
J1-1J11-1TX ON LOW
Terminal
Serial
FunctionRemarks
Momentary connection to ground sets the system
COMMAND
to LOW POWER ON mode. Maximum open
circuit voltage is approximately 15VDC
J1-2J11-14TX ON HIGH
COMMAND
Momentary connection to ground sets the system
to HIGH POWER ON mode. Maximum open
circuit voltage is approximately 15 VDC.
J1-3J11-2TX OFF COMMANDMomentary connection to ground sets the system
to OFF mode. Maximum open circuit voltage is
approximately 15 VDC.
J1-4J11-15SPARE COMMANDNot used.
J1-5N/AMASTER FAIL-
SAFE
Connection to +15 VDC source at J1-25 through a
normally closed contact set, in customer
equipment, allows transmitter operation. If not
used, a jumper must be installed between this
terminal and J1-25.
J1-6N/AMASTER
INTERLOCK
Not available for use. This input is used for the
combiner reject load in this configuration.
J1-7J11-4R/C STATUSProvides a connection to ground through 200
Ohms when the REMOTE mode has been selected.
J1-8J11-17FWD PWR SAMPLEProvides 0-4 VDC sample through 2k Ohms of the
RF forward output power.
J1-9J11-5RFL PWR SAMPLEProvides 0-4 VDC sample through 2k Ohms of the
RF reflected output power.
J1-10J11-18REJ PWR SAMPLEProvides 0-4 VDC sample through 2k Ohms of the
RF reject load power.
J1-11J11-6IPA A PWR
Not used.
SAMPLE
J1-12J11-19IPA B PWR
Not used.
SAMPLE
J1-13J11-7SWR FAULT
STATUS
Provides ground connection through 200 Ohms
when the reflected output RF power level has
exceeded the safe operating level , and the system
controller has terminated transmitter operation.
Can sink 25mA to ground and is suitable for use
with circuits up to 15 VDC.
12/5/07888-2621-0011-17
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Page 30
Section I Operator Guide
Z3-48HD+
Table 1-10 System Controller Remote Connections
J1-14J11-20LOW RF STATUSProvides ground connection through 200 Ohms
when the forward RF output power level drops
below a preset level.
J1-15J11-8REJ PWR
WARNING
J1-16J11-21REJ PWR FAULTProvides ground connection through 200 Ohms
J1-17J11-9TX ON STATUSProvides ground connection through 200 Ohms
mode. Can sink 25mA to ground and is s uitable fo r
use with circuits up to 15 VDC.
J1-23J11-12GROUNDProvides connection to circuit ground.
J1-24J11-25GROUNDProvides connection to circuit ground.
J1-25+15 VDCProvides connection to a current limited +15 VDC
used for external interlock and fail-safe signaling.
1-18888-2621-00112/5/07
WARNING: Disconnect prim ary power prior to servic ing.
Harris PNDescriptionQty UM Reference Designators
922 1203 425CABLE, COAX, W301 EA
922 1203 426CABLE, COAX, W311 EA
922 1203 427CABLE, COAX, W321 EA
922 1203 432CABLE, CONTROL W281 EA
922 1203 908CABLE, CONTROL, W41 EA
952 9238 087CABLE, CONTROL, W35/W331 EA
2-2888-2621-001
WARNING: Disconnect prim ary power prior to servic ing.
Page 33
Z3-48HD+
Section II Parts List
Table 2-4 ASSY, DIR COUPLER - 927 8096 010 (E)
Harris PNDescriptionQty UM Reference Designators
358 0498 000CLAMP, HOSE DIA 2.563 MIN 3.50 MAX 2 EA
620 0581 000COUPLING, SLEEVE, 3-1/81 EA
827 8096 010ASSY INSTR, DIR COUPLER0 DWG
839 7900 147INNER COND. 3-1/81 EA
939 8118 901OUTER CONDUCTOR 2 HOLES,1 EA
992 9701 002ASSY, DIRECTIONAL COUPLER,42DB 1 EA
992 9701 005ASSY, DIRECTIONAL COUPLER,49DB 2 EA
Table 2-5 ASSY, DIR COUPLER - 927 8096 012 (A)
Harris PNDescriptionQty UM Reference Designators
358 0498 000CLAMP, HOSE DIA 2.563 MIN 3.50 MAX 2 EA
620 0581 000COUPLING, SLEEVE, 3-1/81 EA
827 8096 011ASSY INSTR, DIR COUPLER0 DWG
839 7900 147INNER COND. 3-1/81 EA
939 8118 902OUTER CONDUCTOR, 1 HOLE,1 EA
992 9701 002ASSY, DIRECTIONAL COUPLER,42DB 1 EA
Harris PNDescriptionQty UM Reference Designators
250 0274 000CORD, AC, 3C, NEMA/IEC PLUG1 EA
358 3223 000FEMALE SCREWLOCK .56"4-401 EA
398 0081 000FUSE,SLO CART 2A 250V1 EA
472 1693 000XFMR, PWR, DP241-6-281 EA
484 0296 000* FILTER RFI POWER LINE1 EA
813 4999 023STDOFF 6-32X5/16 1/4 HEX14 EA
839 8118 218SCHEM, OVERALL PTD SYS0 DWG
917 2435 050HANDLE, CTLR/DIGIT2 EA
922 1085 071CABLE, PT CONTROLLER1 EA
922 1200 002CABLE ASSY, RIBBON, 25C1 EA
922 1203 113WINDOW, SYSTEM CONTROLLER1 EA
939 8118 180COVER, SYSTEM CONTROLLER1 EA
943 5293 071FRAME, FRONT PANEL MTG.1 EA
943 5293 072REAR PNL, SYSTEM CONTROL1 EA
943 5293 075CHASSIS, SYSTEM CONTROL1 EA
943 5293 646FRONT PANEL, SYSTEM CONTROL,1 EA
992 8388 005DISPLAY BD, DUAL TX CNTRL1 EA
992 8853 001PWA, SYSTEM CONTROLLER1 EA
888-2621-0012-3
WARNING: Discon nect primar y power prior t o servicing .
384 0826 000LED LIGHT BAR, RED ESD4 EADS004,DS005,DS006,DS011
384 0827 000LED LIGHT BAR, GREEN ESD2 EADS009,DS010
384 0849 000LED LIGHT BAR, GREEN ESD1 EADS007
384 0850 000LED LIGHT BAR, RED ESD2 EADS003,DS008
384 0858 000LED LIGHT BAR, YELLOW ESD1 EADS013
386 0135 000*ZENER 1N4733A 5.1V 5% 1W1 EACR032
404 0824 000SOCKET, DIP14, LO PROFILE6 EA