Harris Z3-48HD+ Technical Manual

Page 1
Z3-48HD+
TECHNICAL MANUAL
888-2621-001
Z3-48HD+
T.M. No. 888-2621-001
© Copyright Harris Corporation 2007 All rights reserved
Rev. A1: Dec., 2007
Page 2
Returns And Exchanges
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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Manual Revision History
Z3-48HD+ Technical Manual
REV. DATE ECN Pages Affected
A Nov., 2007 Entire Manual
A1 Dec., 2007 Minor changes in Manual
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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:
Replaceable Parts List Index Part Number Page
Table 7-1. Transmitter 994 9283 001 7-2 Table 7-2. Control Cabinet 992 9244 002 7-3 Table 7-3. Controller Board 992 8344 002 7-6 Table 7-4. PA Cabinet 992 9400 002 7-7 Table 7-5. PA Amplifier 994 7894 002 7-9 Table 7-6. PA Amplifier Board 992 7904 002 7-10 Table 7-7. Output Cabinet 992 9450 001 7-12
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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Table of Contents
Section I
Operator Guide
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Installation Instruction. . . . . . . . . . . . . . . . . . . . . . . . .1-3
Returns And Exchanges . . . . . . . . . . . . . . . . . . . . . .1-3
Unpacking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Transmitter Operation . . . . . . . . . . . . . . . . . . . . . . . . .1 -5
RF Metering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
Control Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
Remote Control. . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
Interlock Considerations . . . . . . . . . . . . . . . . . . . . .1-10
Drive Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
HDx-FM Exciter/BoostPro Control . . . . . . . . . . . . 1-12
Alignments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13
Section II Parts List
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
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Table of Contents
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Section I Operator Guide
1.1 Introduction
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+
1.2 Installation Instruction
1.2.1 Returns 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.
1.2.2 Unpacking
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.
1.2.3 Installation
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+
1.3 Transmitter 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.
1.3.1 RF 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 1.00 REJ PWR 100%
Z3-48 System Controller
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FM+HD 21kW As Indicated 4.67kW HD only 10.5kW As Indicated 2.33kW FM only 30 kW As Indicated 6.67kW
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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+HD 14 kW As Indicated 3.5kW HD only 7kW A s Indicated 1.75kW FM only 20kW As Indicated 5kW
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:
P1 P2 P3++()
-----------------------------------------------------
out
=
3
where P1, P2, and P3 are the power levels from each transmitter.
Below is an Expected Power Results for Failure Conditions table.
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Section I Operator Guide
r
r
r
Table 1-2 Expected Power Results for Failure Conditions
Z3-48HD+
FM + HD
TX C 7kW 100 7kW 100 0 0 7kW 100 0 0 7kW 100 3.5kW 50
TX A 7kW 100 0 0 7kW 100 0 0 0 0 3.5kW 50 7kW 100
TX B 7kW 100 7kW 100 7kW 100 0 0 7kW 100 7kW 100 7kW 100
Z3-48 System
FWD 21kW 100 9.33kW 44 9.33kW 44 2.33kW 11 2.33kW 11 17.1kW 81 17.1kW 81
REJ 0 0 1.17kW 25 4.67kW 100 4.67kW 100 1.17kW 25 0.1kW 2 0.4kW 8
ZD32(A/B) System
FWD 14kW 100 3.5kW 25 14kW 100 0 0 3.5kW 25 10.2kW 72 14kW 100
REJ 0 0 3.5kW 100 00003.5kW 100 0.3kW 8 0 0
HD Only
TX C 3.5kW 100 3.5kW 100 0 0 3.5kW 100 0 0 3.5kW 100 1.75kW 50
TX A 3.5kW 100 0 0 3.5kW 100 0 0 0 0 1.75kW 50 3.5kW 100
TX B 3.5kW 100 3.5kW 100 3.5kW 100 0 0 3.5kW 100 3.5kW 100 3.5kW 100
Z3-48 System
FWD 10.5kW 100 4.67kW 44 4.67kW 44 1.17kW 11 1.67kW 11 8.55kW 81 8.54kW 81
REJ 0 0 0.58kW 25 2.33kW 100 2.33kW 100 0.58kW 25 0.05kW 2 0.2kW 8
ZD32(A/B) System
FWD 7kW 100 1.75kW 25 7kW 100 0 0 1.75kW 25 5.1kW 72 7kW 100
REJ 0 0 1.75kW 100 00001.75kW 100 0.15kW 8 0 0
Full Operation One TX OFF One TX OFF Two TX OFF
Power % Power % Power % Power % Power % Power % Power %
Full Operation One TX OFF One TX OFF Two TX OFF Two TX OFF One TX ½ Power One TX ½ Powe
Power % Power % Power % Power % Power % Power % Power %
Two TX OFF One TX ½ Power One TX ½ Powe
FM Only
TX C 10kW 100 10kW 100 0 0 10kW 100 0 0 10kW 100 5kW 50
TX A 10kW 100 0 0 10kW 100 0 0 0 0 5kW 50 10kW 100
TX B 10kW 100 10kW 100 10kW 100 0 0 10kW 100 10kW 100 10kW 100
Z3-48 System
FWD 30kW 100 13.33kW 44 13.33kW 44 3.33kW 11 3.33kW 11 24.4kW 81 24.4kW 81
REJ 0 0 1.67kW 25 6.67kW 100 6.67kW 100 1.67kW 25 0.14kW 2 0.57kW 8
ZD32(A/B) System
FWD 20kW 100 5kW 25 20kW 100 0 0 5 25 14.57kW 72 20kW 100
REJ005kW100000051000.43kW 8 0 0
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 Operation One TX OFF One TX OFF Two TX OFF Two TX OFF One TX ½ Power One TX ½ Powe
Power % Power % Power % Power % Power % Power % Power %
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Z3-48HD+
Section I Operator Guide
1.3.2 Control 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.
1.3.3 Status 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.
1.3.4 Remote 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.
1.3.5 Interlock 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.
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Z3-48HD+
Section I Operator Guide
1.3.6 Drive 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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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.
1.3.7 HDx-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.
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Z3-48HD+
1.4 Alignments
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
TP2 0.275 Volts 14kW of system forward power R37 TP3 0.075 Volts 560 Watts of simulated reflected power R45 TP4 0.275 Volts 100% of reject power; 3.5kW R78
TARGET
VOLTAGE
SET UP CONDITION SAMPLE
Table 1-4 ZD32 System Controller: HD Only Mode
TEST
POINT
TP2 0.275 Vo lts 7kW of system forward power R37 TP3 0.075 Volts 280 Watts of simulated reflected power R45 TP4 0.275 Volts 100% of reject power; 1.75kW R78
TARGET
VOL TAGE
SET UP CONDITION SAMPLE
CAL
CAL
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Section I Operator Guide
Table 1-5 ZD32 System Controller: FM Only Mode
Z3-48HD+
TEST
POINT
TP2 0.275 Volts 20kW of system forward power R37 TP3 0.075 Volts 800 Watts of simulated reflected power R45 TP4 0.275 Volts 100% of reject power; 5kW R78
TARGET
VOLTAGE
SET UP CONDITION SAMPLE
Table 1-6 Z3-48HD+ System Controller: FM+HD Mode
TEST
POINT
TP2 0.275 Volts 21kW of system forward power R37 TP3 0.075 Volts 840 Watts of simulated reflected power R45 TP4 0.275 Volts 100% of reject power; 4.67kW R78
TARGET
VOL TAGE
SET UP CONDITION SAMPLE
CAL
CAL
Table 1-7 Z3-48HD+ System Controller: HD Only Mode
TEST
POINT
TP2 0.275 Volts 10.5kW of system forward power R37 TP3 0.075 Volts 420 Watts of simulated reflected power R45 TP4 0.275 Volts 100% of reject power; 2.33kW R78
TARGET
VOL TAGE
SET UP CONDITION SAMPLE
Table 1-8 Z3-48HD+ System Controller: FM Only Mode
TEST
POINT
TP2 0.275 Volts 30kW of system forward power R37 TP3 0.075 Volts 1200 Watts of simulated reflected power R45 TP4 0.275 Volts 100% of reject power; 6.67kW R78
TARGET
VOL TAGE
SET UP CONDITION SAMPLE
CAL
CAL
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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
JACK PURPOSE LINEARIZER
TEST POINT J6 System Forward Power TP2 R37 R88 R90 J7 System Reflected Power TP3 R45 N/A R132 J8 System Reject Load Power TP4 R78 R80 R70
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.
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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.
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Z3-48HD+
Table 1-10 System Controller Remote Connections
Section I Operator Guide
Terminal
Remote
J1-1 J11-1 TX ON LOW
Terminal
Serial
Function Remarks
Momentary connection to ground sets the system
COMMAND
to LOW POWER ON mode. Maximum open circuit voltage is approximately 15VDC
J1-2 J11-14 TX ON HIGH
COMMAND
Momentary connection to ground sets the system to HIGH POWER ON mode. Maximum open circuit voltage is approximately 15 VDC.
J1-3 J11-2 TX OFF COMMAND Momentary connection to ground sets the system
to OFF mode. Maximum open circuit voltage is
approximately 15 VDC. J1-4 J11-15 SPARE COMMAND Not used. J1-5 N/A MASTER 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. J1-6 N/A MASTER
INTERLOCK
Not available for use. This input is used for the
combiner reject load in this configuration. J1-7 J11-4 R/C STATUS Provides a connection to ground through 200
Ohms when the REMOTE mode has been selected. J1-8 J11-17 FWD PWR SAMPLE Provides 0-4 VDC sample through 2k Ohms of the
RF forward output power. J1-9 J11-5 RFL PWR SAMPLE Provides 0-4 VDC sample through 2k Ohms of the
RF reflected output power.
J1-10 J11-18 REJ PWR SAMPLE Provides 0-4 VDC sample through 2k Ohms of the
RF reject load power.
J1-11 J11-6 IPA A PWR
Not used.
SAMPLE
J1-12 J11-19 IPA B PWR
Not used.
SAMPLE
J1-13 J11-7 SWR 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.
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Section I Operator Guide
Z3-48HD+
Table 1-10 System Controller Remote Connections
J1-14 J11-20 LOW RF STATUS Provides ground connection through 200 Ohms
when the forward RF output power level drops
below a preset level.
J1-15 J11-8 REJ PWR
WARNING
J1-16 J11-21 REJ PWR FAULT Provides ground connection through 200 Ohms
J1-17 J11-9 TX ON STATUS Provides ground connection through 200 Ohms
J1-18 J 11-22 TX LOW POWER
STATUS
J1-19 J11-10 N/C J1-20 J11-23 N/C J1-21 J11-11 N/C J1-22 J11-24 N/C
Provides ground connection through 200 Ohms
when the forward RF output power to the
combiner reject load exceeds a preset lev el.
when the forward RF output power to the
combiner reject load exce eds the safe operating
level and the system controller has terminated
transmitter operation.
when either transmitter is in the ON mode.
Provides ground connection through 200 Ohms
when either transmitter is in LOW POW ER ON
mode. Can sink 25mA to ground and is s uitable fo r
use with circuits up to 15 VDC.
J1-23 J11-12 GROUND Provides connection to circuit ground. J1-24 J11-25 GROUND Provides connection to circuit ground. J1-25 +15 VDC Provides connection to a current limited +15 VDC
used for external interlock and fail-safe signaling.
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Section II Parts List
2.1 Parts List
Replaceable Parts List Index
Table 2-1 XMTR, Z3-48HD+ HYB, FORMAT - - - - - - - - - - - 994 9712 005 2-2 Table 2-2 CABLE PKG, EXTENDER CABLES SYS CTRL - - - - 917 2332 878 (A) 2-2 Table 2-3 CABLE PKG, RF & CTLR, Z3-XX - - - - - - - - - - - 917 2332 993 (A) 2-2 Table 2-4 ASSY, DIR COUPLER- - - - - - - - - - - - - - - - - 927 8096 010 (E) 2-3 Table 2-5 ASSY, DIR COUPLER- - - - - - - - - - - - - - - - - 927 8096 012 (A) 2-3 Table 2-6 ASSY, DETECTOR - - - - - - - - - - - - - - - - - - 928 5652 003 (A) 2-3 Table 2-7 CONTROLLER, SYSTEM - - - - - - - - - - - - - - - 992 8850 005 (F) 2-3 Table 2-8 DISPLAY BD, DUAL TX CNTRL - - - - - - - - - - 992 8388 005 (E) 2-4 Table 2-9 PWA, SYSTEM CONTROLLER - - - - - - - - - - - 992 8853 001 (M) 2-5 Table 2-10 XMTR, ZD24/32HD+HYB, FORMAT - - - - - - - - - 994 9712 003 (A) 2-7
2
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Page 32
Z3-48HD+
Section II Parts List
Table 2-1 XMTR, Z3-48HD+ HYB, FORMAT - 994 9712 005
Harris PN Description Qty UM Reference Designators 250 0129 000 CORD, 3C 16AWG TYPE SJ 0 FT 250 0626 000 CORD, AC, IEC PLUG TO IEC RECP 2 EA #SYS CNTRLS 358 3197 000 SLIDES 10" PAIR 0 PR 384 0357 000 DIODE, RECT 1N4004 1 EA 612 1291 000 PLUG, 3 WIRE FEMALE AC 0 EA 620 0498 000 ADAPTOR 3-1/8 5 EA 620 0544 000 CONN, ANCHOR INS 3-1/8; 50 OHM 1 EA 620 0581 000 COUPLING, SLEEVE, 3-1/8 3 EA 620 1563 000 SPLITTER, 2-WAY-0, BNC 1 EA SP2 620 2275 000 ELBOW, EQUAL, 3-1/8, 90 DEG 3 EA 700 1408 000 LOAD, 10KW 230VAC 50 OHM 1 EA 901 0207 021 PWA, D/A FILTER 0 EA 901 0207 271 PWA, CAN ADAPTER 1 EA 917 2332 280 SPACER SYS CTLR MOUNTING 0 EA 917 2332 878 CABLE PKG, EXTENDER CABLES SYS CTRL1 EAW4A,W5A 917 2332 993 CABLE PKG, RF & CTLR, Z3-XX 1 EA W4,W28,W30,W31,W32,W33,W35 917 2435 098 STRAP, SHIPPING 2 EA 922 1346 015 CABLE, CONTROL, W4A 1 EA 927 8096 010 ASSY, DIR COUPLER 1 EA 927 8096 012 ASSY, DIR COUPLER 1 EA 928 5652 003 ASSY, DETECTOR 3 EA 939 8013 089 TUBE, COAX 3.125 X 26.5LG 1 EA 939 8013 180 TUBE, COAX 3.125 X 49.25 LG 1 EA 939 8014 089 TUBE,COAX 1.315 X 24.97LG 1 EA 939 8014 180 TUBE, COAX 1.315 X 47.72 LG 1 EA 971 0027 006 FLEXSTAR BOOST AMP 0 EA 988 2621 001 DP, Z3-48HD+ 1 EA 992 8850 005 CONTROLLER, SYSTEM 1 EA 992 9854 012 KIT, PLAT Z MOUNTING, HDX-FM 0 EA 994 9712 003 XMTR, ZD24/32HD+HYB, FORMAT 0 EA 995 0034 016 ! XMTR, Z16HD+, FORMAT 0 EA DIE98694-4-77DBCOMBINER, IBOC 4.77DB 38KW 1 EA
Table 2-2 CABLE PKG, EXTENDER CABLES SYS CTRL - 917 2332 878 (A)
Harris PN Description Qty UM Reference Designators 922 1346 015 CABLE, CONTROL, W4A 1 EA 922 1346 016 CABLE, CONTROL, W5A 1 EA
Table 2-3 CABLE PKG, RF & CTLR, Z3-XX - 917 2332 993 (A)
Harris PN Description Qty UM Reference Designators 922 1203 425 CABLE, COAX, W30 1 EA 922 1203 426 CABLE, COAX, W31 1 EA 922 1203 427 CABLE, COAX, W32 1 EA 922 1203 432 CABLE, CONTROL W28 1 EA 922 1203 908 CABLE, CONTROL, W4 1 EA 952 9238 087 CABLE, CONTROL, W35/W33 1 EA
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Z3-48HD+
Section II Parts List
Table 2-4 ASSY, DIR COUPLER - 927 8096 010 (E)
Harris PN Description Qty UM Reference Designators 358 0498 000 CLAMP, HOSE DIA 2.563 MIN 3.50 MAX 2 EA 620 0581 000 COUPLING, SLEEVE, 3-1/8 1 EA 827 8096 010 ASSY INSTR, DIR COUPLER 0 DWG 839 7900 147 INNER COND. 3-1/8 1 EA 939 8118 901 OUTER CONDUCTOR 2 HOLES, 1 EA 992 9701 002 ASSY, DIRECTIONAL COUPLER,42DB 1 EA 992 9701 005 ASSY, DIRECTIONAL COUPLER,49DB 2 EA
Table 2-5 ASSY, DIR COUPLER - 927 8096 012 (A)
Harris PN Description Qty UM Reference Designators 358 0498 000 CLAMP, HOSE DIA 2.563 MIN 3.50 MAX 2 EA 620 0581 000 COUPLING, SLEEVE, 3-1/8 1 EA 827 8096 011 ASSY INSTR, DIR COUPLER 0 DWG 839 7900 147 INNER COND. 3-1/8 1 EA 939 8118 902 OUTER CONDUCTOR, 1 HOLE, 1 EA 992 9701 002 ASSY, DIRECTIONAL COUPLER,42DB 1 EA
Table 2-6 ASSY, DETECTOR - 928 5652 003 (A)
Harris PN Description Qty UM Reference Designators 516 0781 000 CAP 220PF 5% 100V C0G 1 EA C3 548 2400 382 RES 6.98K OHM 1/2W 1% 1 EA R5 817 2332 769 ASSY INSTR, DETECTOR ASSY 0 DWG 817 2332 770 SCHEM, DETECTOR ASSY 0 DWG 448 0875 000 BOX SHIELDED 1 EA 516 0375 000 *CAP 0.010UF 20% 50V Z5U 1 EA C1 508 0261 000 CAP .022UF 200V 10% 1 EA C2 384 0321 000 *DIODE, SCHOTTKY, 5082-2800 1 EA CR1 540 1600 208 RES 200 OHM 3W 5% 4 EA R1,R2,R3,R4 254 0003 000 WIRE, BUS CU 18AWG 0.100 FT
Table 2-7 CONTROLLER, SYSTEM - 992 8850 005 (F)
Harris PN Description Qty UM Reference Designators 250 0274 000 CORD, AC, 3C, NEMA/IEC PLUG 1 EA 358 3223 000 FEMALE SCREWLOCK .56"4-40 1 EA 398 0081 000 FUSE,SLO CART 2A 250V 1 EA 472 1693 000 XFMR, PWR, DP241-6-28 1 EA 484 0296 000 * FILTER RFI POWER LINE 1 EA 813 4999 023 STDOFF 6-32X5/16 1/4 HEX 14 EA 839 8118 218 SCHEM, OVERALL PTD SYS 0 DWG 917 2435 050 HANDLE, CTLR/DIGIT 2 EA 922 1085 071 CABLE, PT CONTROLLER 1 EA 922 1200 002 CABLE ASSY, RIBBON, 25C 1 EA 922 1203 113 WINDOW, SYSTEM CONTROLLER 1 EA 939 8118 180 COVER, SYSTEM CONTROLLER 1 EA 943 5293 071 FRAME, FRONT PANEL MTG. 1 EA 943 5293 072 REAR PNL, SYSTEM CONTROL 1 EA 943 5293 075 CHASSIS, SYSTEM CONTROL 1 EA 943 5293 646 FRONT PANEL, SYSTEM CONTROL, 1 EA 992 8388 005 DISPLAY BD, DUAL TX CNTRL 1 EA 992 8853 001 PWA, SYSTEM CONTROLLER 1 EA
888-2621-001 2-3
WARNING: Discon nect primar y power prior t o servicing .
Page 34
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Table 2-8 DISPLAY BD, DUAL TX CNTRL - 992 8388 005 (E)
Harris PN Description Qty UM Reference Designators 000 0000 010 B/M NOTE: 0 DWG 358 1928 000 JUMPER 1/4 LG 1/8H 7 EA JP1,JP4,JP10,JP11,JP12,JP13,JP14 358 3383 000 JUMPER, 0.1" LG, 0.125" H 5 EA JP015,JP016,JP17 380 0125 000 XSTR, NPN 2N4401 ES D 1 EA Q003 380 0189 000 *XSTR, NPN, MMBT3904 1 EA Q002 380 0190 000 *XSTR, PNP, MMBT3906 2 EA Q001,Q005 382 0401 000 *IC, CD4028B 1 EA U003 382 0523 000 *IC, CD4066 2 EA U009,U010 382 1207 000 IC CD4076B ESD 1 EA U002 382 1208 000 IC CD4070B ESD 4 EA U005,U006,U007,U008 382 1209 000 IC CD4532B ESD 1 EA U001 382 1210 000 IC CD4538B ESD 1 EA U004 382 1211 000 IC ICL7136 ESD 1 EA U011 384 0205 000 *DIODE, RECT 1N4148/914 30 EA
384 0826 000 LED LIGHT BAR, RED ESD 4 EA DS004,DS005,DS006,DS011 384 0827 000 LED LIGHT BAR, GREEN ESD 2 EA DS009,DS010 384 0849 000 LED LIGHT BAR, GREEN ESD 1 EA DS007 384 0850 000 LED LIGHT BAR, RED ESD 2 EA DS003,DS008 384 0858 000 LED LIGHT BAR, YELLOW ESD 1 EA DS013 386 0135 000 *ZENER 1N4733A 5.1V 5% 1W 1 EA CR032 404 0824 000 SOCKET, DIP14, LO PROFILE 6 EA
404 0825 000 SOCKET, DIP16, LO PROFILE 4 EA XU001,XU002,XU003,XU004 404 0828 000 SOCKET, SIP18, STRAIGHT 4 EA 406 0529 000 DISPLAY, LCD 3.5 DIGIT CUSTOM 1 EA DS012 500 1274 000 CAP 51PF 100V 5% 1 EA C003 506 0262 000 CAP, 0.047UF 100V 5% 1 EA C006 516 0484 000 CAP 0.100UF 10% 100V X7R CK06 20 EA
522 0581 000 CAP 10UF 35V 20% 2 EA C002,C026 540 1485 000 RES NETWORK 100K OHM 2% 2 EA R001,R016 548 2400 234 RES 221 OHM 1/2W 1% 1 EA R008 548 2400 242 RES 267 OHM 1/2W 1% 1 EA R034 548 2400 301 RES 1K OHM 1/2W 1% 1 EA R027 548 2400 312 RES 1.3K OHM 1/2W 1% 10 EA
548 2400 366 RES 4.75K OHM 1/2W 1% 1 EA R033 548 2400 401 RES 10K OHM 1/2W 1% 10 EA
548 2400 466 RES 47.5K OHM 1/2W 1% 2 EA R004,R011 548 2400 526 RES 182K OHM 1/2W 1% 1 EA R003 548 2400 601 RES 1MEG OHM 1/2W 1% 1 EA R002
CR001,CR002,CR003,CR004,CR005,CR0 06,CR007,CR008,CR009,CR010,CR011, CR012,CR013,CR014,CR015,CR016,CR0 17,CR019,CR020,CR021,CR022,CR023, CR024,CR025,CR026,CR027,CR031,CR0 33,CR034,CR035
XU005,XU006,XU007,XU008,XU009,X U010
C001,C004,C005,C007,C008,C009,C010, C011,C012,C013,C014,C015,C016,C017, C018,C019,C020,C021,C022,C023
R017,R018,R019,R020,R021,R022,R023, R024,R031,R032
R006,R007,R010,R012,R013,R014,R015, R025,R026,R035
2-4 888-2621-001
WARNING: Disconnect prim ary power prior to servic ing.
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548 2400 626 RES 1.82MEG OHM 1/2W 1% 1 EA R009 550 0953 000 TRIMPOT 20K OHM 1/2W 10% 1 EA R005 604 1111 000 SW PB GRAY MOM W/O LED 5 EA S001,S003,S005,S009,S010 604 1119 000 SW PB RED MO M W/O LED 1 EA S011 604 1261 000 SW PB GRAY ALT-ACTION W/O LED 1 EA S008 610 0933 000 TEST POINT, OVAL-LOOP THRU 12 EA
TP001,TP002,TP003,TP004,TP005,TP006 ,TP007,TP008,TP009,TP010,TP011,TP01
2 610 1106 000 HDR, 8PIN, 1ROW, STRT,POL 1 EA J014 610 1441 034 HDR, 34C 2ROW VERTICAL 1 EA J001 839 8025 004 SCHEM, DISPLAY BD 0 DWG 843 5215 004 PWB, DISPLAY 1 EA
Table 2-9 PWA, SYSTEM CONTROLLER - 992 8853 001 (M)
Harris PN Description Qty UM Reference Designators 000 0000 010 B/M NOTE: 0 DWG 354 0309 000 TERM SOLDER 25 EA
358 1214 000 SCREWLOCK, M/F 4-40X3/16" 5 EA 380 0189 000 *XSTR, NPN, MMBT3904 15 EA
380 0190 000 *XSTR, PNP, MMBT3906 7 EA Q008,Q012,Q013,Q019,Q020,Q021,Q022 382 0184 000 IC, 340T-5/7805 +5V REG ESD 1 EA U019 382 0359 000 IC, 7815 ESD 1 EA U016 382 0360 000 IC, 7915 ESD 1 EA U017 382 0465 000 IC, 74C74 ESD 1 EA U012 382 0605 000 IC 7905C ESD 1 EA U018 382 0711 000 *PRECISION IC MULTIPLIER ESD 1 EA U009 382 0719 000 *IC, LM324A (DIP-14) 4 EA U005,U006,U007,U008 382 1016 000 *IC, 74C240 (DIP-20) 2 EA U004,U011 382 1017 000 *IC, 74C244 (DIP-20) 2 EA U003,U013 382 1070 000 IC, ILQ1 1 EA U001 382 1084 000 IC, LP339 (DIP-14) 1 EA U010 384 0205 000 *DIODE, RECT 1N4148/914 38 EA
384 0321 000 *DIODE, SCHOTTKY, 5082-2800 15 EA
384 0357 000 DIODE, RECT 1N4004 14 EA
384 0610 000 LED, GRN T1-3/4 VERT 4 EA DS001,DS002,DS003,DS004 384 0719 000 DIODE, TVS (UNIDIR), SA5.0A ESD 1 EA CR063
TP001,TP002,TP003,TP004,TP005,TP006
,TP007,TP008,TP009,TP010,TP011,TP01
2,TP013,TP014,TP015,TP016,TP017,TP0
18,TP019,TP020,TP021,TP022,TP023,TP
024,TP025
Q001,Q002,Q003,Q004,Q005,Q006,Q007
,Q009,Q010,Q011,Q014,Q015,Q016,Q017
,Q018
CR002,CR003,CR004,CR005,CR006,CR0
09,CR010,CR012,CR016,CR017,CR018,
CR019,CR020,CR021,CR034,CR035,CR0
39,CR040,CR041,CR042,CR043,CR044,
CR045,CR047,CR048,CR051,CR052,CR0
53,CR054,CR055,CR056,CR057,CR058,
CR059,CR060,CR069,CR071,CR073
CR022,CR023,CR024,CR025,CR026,CR0
27,CR028,CR029,CR030,CR031,CR032,
CR033,CR036,CR037,CR038
CR007,CR008,CR013,CR014,CR049,CR0
50,CR061,CR062,CR064,CR065,CR066,
CR067,CR072,CR075
WARNING: Discon nect primar y power prior t o servicing .
888-2621-001 2-5
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384 0720 000 DIODE, TVS (UNIDIR), 1.5KE15A 3 EA CR068,CR074,CR077 384 0743 000 DIODE ARRAY DUAL 8 ESD 3 EA U002,U014,U015 384 0838 000 DIODE, TVS (UNIDIR), 1.5KE36A 2 EA CR070,CR078 384 0854 000 DIODE ARRAY, 8 ISOLATED ESD 2 EA CR001,CR046 386 0085 000 *ZENER 1N4740A 10V 5% 1W 1 EA CR015 404 0303 000 SOCKE T IC 10 PIN 1 EA XU009 404 0513 000 HEAT SINK PA1-1CB 4 EA #U016,#U017,#U018,#U019 404 0674 000 SOCKET, DIP, 14 PIN (DL) 9 EA
XU002,XU005,XU006,XU007,XU008,X
U010,XU012,XU014,XU015 404 0675 000 SOCKET, DIP, 16 PIN (DL) 3 EA CR001,CR046,XU001 404 0767 000 SOCKET, DIP, 20 PIN (DL) 4 EA XU003,XU004,XU011,XU013 494 0218 000 CHOKE, WIDE BAND 2.5 TURN 2 EA 506 0230 000 CAP .001UF 100VAC 5% 36 EA
516 0453 000 CAP 0.100UF 10% 100V X7R 23 EA
516 0511 000 CAP 0.47UF 100V 20% 1 EA C075 522 0524 000 CAP 10 UF 100V 20% NON-POLAR 1 EA C076 522 0548 000 CAP 10UF 50V 20% (5X11) 6 EA C026,C029,C049,C053,C070,C071 522 0586 000 CAP 3300UF 50V 20% 2 EA C050,C069 526 0109 000 CAP 22UF 25V 20% 2 EA C024,C027 526 0349 000 CAP 2.2UF 50V 20% 4 EA C052,C055,C057,C073 540 0618 000 *RES 2K OHM 2W 10% 2 EA R216,R217 540 1357 000 RES NETWORK 1000 OHM 2% 4 EA R001,R004,R005,R006 540 1366 000 RES NETWORK 100 OHM 2% 6 EA R002,R003,R007,R008,R009,R010 548 2051 000 RES ZERO OHM 5 EA R038,R048,R076,R099,R140 548 2400 201 RES 100 OHM 1/2W 1% 2 EA R020,R163 548 2400 209 RES 121 OHM 1/2W 1% 2 EA R207,R208 548 2400 268 RES 499 OHM 1/2W 1% 1 EA 548 2400 273 RES 562 OHM 1/2W 1% 2 EA R220,R221 548 2400 281 RES 681 OHM 1/2W 1% 4 EA R016,R017,R226,R227 548 2400 301 RES 1K OHM 1/2W 1% 13 EA
548 2400 318 RES 1.5K OHM 1/2W 1% 3 EA R058,R218,R219 548 2400 327 RES 1.87K OHM 1/2W 1% 5 EA R044,R064,R079,R096,R144 548 2400 330 RES 2K OHM 1/2W 1% 5 EA R154,R164,R166,R174,R176 548 2400 335 RES 2.26K OHM 1/2W 1% 5 EA R036,R054,R069,R106,R117 548 2400 336 RES 2.32K OHM 1/2W 1% 1 EA R130 548 2400 338 RES 2.43K OHM 1/2W 1% 1 EA R057 548 2400 358 RES 3.92K OHM 1/2W 1% 4 EA R071,R089,R104,R135 548 2400 366 RES 4.75K OHM 1/2W 1% 7 EA R019,R034,R056,R067,R108,R111,R187 548 2400 368 RES 4.99K OHM 1/2W 1% 12 EA
548 2400 385 RES 7.5K OHM 1/2W 1% 2 EA R160,R171 548 2400 393 RES 9.09K OHM 1/2W 1% 2 EA R128,R131
C001,C002,C003,C004,C005,C006,C007,
C008,C010,C012,C013,C014,C015,C017,
C018,C020,C021,C023,C030,C031,C032,
C033,C034,C035,C036,C037,C038,C039,
C040,C041,C043,C044,C045,C046,C047,
C048
C009,C011,C016,C019,C022,C025,C028,
C051,C054,C056,C058,C059,C060,C061,
C062,C063,C064,C065,C066,C067,C068,
C072,C074
R012,R015,R018,R022,R023,R025,R027,
R029,R121,R122,R129,R159,R170
R035,R049,R055,R066,R068,R075,R086,
R087,R107,R110,R114,R133
2-6 888-2621-001
WARNING: Disconnect prim ary power prior to servic ing.
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548 2400 401 RES 10K OHM 1/2W 1% 45 EA
R013,R014,R030,R043,R046,R050,R053,
R059,R065,R074,R077,R098,R100,R101,
R109,R118,R138,R139,R141,R142,R153,
R155,R156,R157,R167,R168,R177,R179,
R182,R185,R188,R193,R195,R196,R198,
R200,R203,R204,R206,R209,R210,R211,
R213,R215,R222 548 2400 430 RES 20K OHM 1/2W 1% 1 EA R152 548 2400 439 RES 24.9K OHM 1/2W 1% 5 EA R051,R061,R073,R102,R137 548 2400 447 RES 30.1K OHM 1/2W 1% 5 EA R031,R041,R082,R093,R147 548 2400 466 RES 47.5K OHM 1/2W 1% 22 EA
548 2400 468 RES 49.9K OHM 1/2W 1% 5 EA R042,R062,R081,R094,R146 548 2400 493 RES 90.9K OHM 1/2W 1% 5 EA R032,R040,R083,R092,R148 548 2400 501 RES 100K OHM 1/2W 1% 27 EA
548 2400 526 RES 182K OHM 1/2W 1% 5 EA R033,R039,R084,R091,R149 548 2400 566 RES 475K OHM 1/2W 1% 2 EA R162,R172 548 2400 601 RES 1MEG OHM 1/2W 1% 1 EA R194 550 0858 000 TRIMPOT 5K OHM 1/2W 10% 6 EA R080,R088,R095,R145,R158,R197 550 0947 000 TRIMPOT 1K OHM 1/2W 10% 1 EA R132 550 0956 000 TRIMPOT 2K OHM 1/2W 10% 5 EA R037,R045,R078,R097,R143 550 0958 000 TRIMPOT 10K OHM 1/2W 10% 2 EA R161,R169 550 0981 000 TRIMPOT 50 OHM 1/2W 10% 4 EA R070,R090,R105,R134 560 0060 000 MOV, 40WVAC, 3J, 7MM DISC 1 EA RV001 574 0366 000 RELAY, DPDT 12VDC 2A 4 EA K001,K002,K003,K004 610 0828 000 *HEAD ER, 26C TWO ROW VERTICAL 1 EA J011 610 0900 000 HDR, 3C VERT 1ROW UNSHR 9 EA
610 1106 000 HDR, 8PIN, 1ROW, STRT,POL 1 EA J012 610 1441 034 HDR, 34C 2ROW VERTICAL 1 EA J013 612 1180 000 *D RECP 15C RT ANGLE 4 EA J002,J003,J004,J005 612 1181 000 *D RECP 25C RT ANGLE 1 EA J001 612 1184 000 SHUNT JUMPER 0.1" CENTERS 9 EA
612 1268 000 RECEPTACLE RT ANG BNC 5 EA J006,J007,J008,J009,J010 839 8118 181 SCHEM, PTD SYS CONTROLLER 0 DWG 843 5293 076 PWB, PTD SYS CONTROLLER 1 EA
R165,R173,R175,R178,R181,R183,R184,
R186,R189,R190,R191,R192,R199,R201,
R202,R205,R212,R214,R223,R224,R225,
R228
R011,R021,R024,R026,R028,R047,R052,
R060,R063,R072,R085,R103,R112,R113,
R115,R116,R119,R120,R123,R124,R125,
R126,R127,R136,R150,R151,R180
JP001,JP002,JP003,JP004,JP005,JP006,JP
007,JP008,JP009
#JP001,#JP002,#JP003,#JP004,#JP005,#J
P006,#JP007,#JP008,#JP009
Table 2-10 XMTR, ZD24/32HD+HYB, FORMAT - 994 9712 003 (A)
Harris PN Description Qty UM Reference Designators 2520003000A *WIRE, MIL, 20AWG 1000V WHITE 0.3 FT #J2,#J3 354 0384 000 CONTACT, PIN 4 EA J2,J3 358 2635 000 CABLE TIE, PUSH MOUNT SNAP IN 7 EA 358 3197 000 SLIDES 10" PAIR 1 PR 384 0357 000 DIODE, RECT 1N4004 2 EA 408 0212 000 BACKSHELL, D-SUB 15C NO-SHIELD 2 EA #J2,#J3 606 0866 000 BREAKER, CIRCUIT 10A 1 EA A1CB2
WARNING: Discon nect primar y power prior t o servicing .
888-2621-001 2-7
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610 0538 000 PLUG, DSUB 15PIN CRIMP-POKE 2 EA J2,J3 614 0048 000 TERM BLK, 2ROW 4-TERM 20A 1 EA A1TB7 620 0498 000 ADAPTOR 3-1/8 6 EA 620 0544 000 CONN, ANCHOR INS 3-1/8; 50 OHM 2 EA 620 0581 000 COUPLING, SLEEVE, 3-1/8 11 EA 620 0675 000 COUPLER, PI/2 HYBRID 1 EA 620 2275 000 ELBOW, EQUAL, 3-1/8, 90 DEG 10 EA 646 0972 000 *LABEL 117V 0 EA #A1TB7 646 0973 000 *LABEL, 230V 0 EA #A1TB7 700 1414 000 LOAD, 8898-315, 115VAC 0 EA 700 1415 000 LOAD, 5KW 230VAC 3-1/8 0 EA 822 1346 014 XMTR LAYOUT, ZD24/32HD+, HYBRID, W/FLEXSTAR0 DWG 822 1346 073 XMTR LAYOUT, ZD-HYB 1PH 0 DWG 901 0207 271 PWA, CAN ADAPTER 2 EA 917 2332 280 SPACER SYS CTLR MOUNTING 8 EA 917 2332 741 CABLE PKG, RF & CTLR 1 EA W4,W5,W28,W30,W31,W32 917 2332 879 CABLE PKG, COAX, ZDHD+ 1 EA W147,W902,W903,W901A,W901B 917 2435 098 STRAP, SHIPPING 2 EA 922 1203 406 SHIELD 4POS TERM BLK, 1 EA #A1TB7 922 1260 239 CABLE, RIBBON W211B 0 EA 922 1260 240 CABLE, RIBBON W212B 0 EA 927 8096 010 ASSY, DIR COUPLER 1 EA 927 8096 012 ASSY, DIR COUPLER 1 EA 928 5652 003 ASSY, DETECTOR 3 EA 939 8013 022 TUBING COAX 1 EA 939 8013 120 TUBE, COAX 3.125 X 34.25 LG 1 EA 939 8013 254 TUBE, COAX 3.125 X 67.75 LG 1 EA 939 8014 022 TUBE, COAX 1.315 X 8.22LG 1 EA 939 8014 120 TUBE, COAX 1.315 X 32.72 LG 1 EA 939 8014 254 TUBE, COAX 1.315 X 66.22 LG 1 EA 971 0027 006 FLEXSTAR BOOST AMP 1 EA 988 2514 003 DWG PKG, ZD24/32HD+, HYBRID 1 EA 988 2515 001 DP, SYSTEM ZDHD 1 EA 992 8850 005 CONTROLLER, SYSTEM 1 EA 992 9854 012 KIT, PLAT Z MOUNTING, HDX-FM 1 EA 995 0034 012 ! XMTR, Z12HD+, FORMAT 0 EA 995 0034 016 ! XMTR, Z16HD+, FORMAT 0 EA
2-8 888-2621-001
WARNING: Disconnect prim ary power prior to servic ing.
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