Larcan MXI101V User Manual
TSM21Q-365
MXi101V AMPLIFIER
TECHNICAL SERVICE MANUAL
LARCAN INC.
228 AMBASSADOR DRIVE
MISSISSAUGA, ONTARIO
CANADA L5T 2J2
PHONE: (905) 564-9222
FAX: (905) 564-9244
EMAIL: techservices@larcan.com
TSM21Q-365 Rev 0
July 17, 2009
1
MXI101V TECHNICAL SERVICE MANUAL
CONTENTS
TSM20-365 MXi201U TECHNICAL SERVICE MANUAL
1 MXi201U AMPLIFIER–INTRODUCTION..................................................................................................................3
2 SAFETY NOTICES..........................................................................................................................................................4
2.1 BERYLLIUM OXIDE WARNING ......................................................................................................................................4
2.2 OTHER TOXIC MATERIALS ...........................................................................................................................................4
2.3 DANGEROUS VOLTAGES...............................................................................................................................................4
2.3.1 Switch to Safety....................................................................................................................................................5
3 LARCAN PARTS, ASSEMBLIES, ASSEMBLY DRAWINGS AND SCHEM ATIC NUMBERS...........................7
3.1 VENDOR STANDARD PART NUMBERS...........................................................................................................................7
3.2 LARCAN NUMBERS FOR PARTS, ASSEMBLIES AND DOCUMENTATION .......................................................................7
3.3 LEADED RESISTORS......................................................................................................................................................8
3.4 SURFACE MOUNT RESISTORS 1/4W AND LESS .............................................................................................................8
3.5 SURFACE MOUNT CAPACITORS ....................................................................................................................................9
3.6 PARTS LISTS .................................................................................................................................................................9
3.6.1 Production Changes.............................................................................................................................................9
FIGURES
FIGURE 1 MXI AMPLIFIER HEATSINK ASSEMBLY ........................................................................................................................3
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MXI101V TECHNICAL SERVICE MANUAL
1 MXI101V AMPLIFIER–INTRODUCTION
This Technical Service Manual contains publications (PUBs) describing the technical details of the MXi101V
amplifier, as well as the overall operating instructions, including the bench test procedures of the amplifier stages
incorporated in this unit. It also covers the transmitter’s start-up operation, and troubleshooting, as well as basic
transmitter maintenance guidelines.
The RF section of the MXi101V Amplifier consists of a heatsink assembly that includes three cascaded
broadband amplifier modules and a directional coupler.
MXi101V utilizes one of these output amplifiers only.
Figure 1 shows the layout of an MXi201 assembly. The
Figure 1 MXi Amplifier Heatsink Assembly
Also mounted on the heatsink is a thermal switch that protects the amplifier from over temperature conditions.
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MXI101V TECHNICAL SERVICE MANUAL
2
SAFETY NOTICES
This section provides general guidance and information for the operation, maintenance, and service personnel
who are familiar with the hazards of working with high-powered electronic circuits. This manual does not detail all
of the safety precautions which should be observed when servicing this or any other electronic equipment.
Service by inadequately trained or inexperienced personnel can result in personal injury or death and/or
damage to the equipment.
Important: All personnel concerned with the servicing of this equipment should be thoroughly familiar with
standard first aid procedures for the treatment of electrical burns and shock, including cardio-pulmonary
resuscitation (CPR).
Use the “buddy” system, with one person performing the actual service and a colleague observing. The observer
must be familiar with the work being performed and within sight and sound of the person doing the work. The
observer should not be engaged in any other work or be otherwise distracted; he must be available instantly in
case of accident.
Always have the observer with you when you work on the transmitter.
2.1
BERYLLIUM OXIDE WARNING
Internal thermal management in certain RF devices in this equipment is accomplished through the use of
Beryllium Oxide ceramic material. Do not break open any RF power transistors, or otherwise dismantle them.
Beryllium Oxide is a hard white ceramic used as insulation for heatsinking of RF power semiconductors. Beryllium
Oxide is a poison. In case of accidental breakage of devices, do not inhale the resulting beryllium dust and
avoid getting beryllium dust in your mouth. Do not let beryllium into your blood stream through cuts or
open wounds. Seek immediate medical attention if the dust enters your body in any manner. Avoid cuts by
wearing gloves while picking up the broken pieces. Be careful – do not inhale dust while replacing or emptying
vacuum cleaner filter bags and wash your hands thoroughly afterward. Wash your hands thoroughly after
replacing RF power devices. Dispose of defective RF power devices only through approved toxic waste facilities.
Wear gloves when picking up the pieces. Wash your hands thoroughly after replacing devices. Dispose of defective
devices only through approved toxic waste facilities.
When cleaning up after an accidental breakage, remember to wear a respirator mask to avoid inhaling the dust while
replacing or emptying vacuum cleaner filter bags and to wash your hands well after servicing the vacuum cleaner. If
possible, use a wet vacuum, in which the dust gets trapped in water.
2.2
OTHER TOXIC MATERIALS
The non-metallic coverings of some coaxial cables used in this equipment are flammable and can transmit fire
when ignited. Other wire coverings are not capable of supporting combustion but any non-metallic covering when
heated sufficiently can emit dense smoke and acid gases, which can be highly toxic and often corrosive.
Solvents and glues can emit toxic vapors and can be flammable. Read and understand the directions on the
containers and ensure that they are used only in well ventilated locations.
2.3
DANGEROUS VOLTAGES
This equipment has been designed to protect operating personnel from accidental contact with dangerous voltages,
by means of shields and covers. It is extremely important that any protective covering devices be kept in place at all
times.
While all practical safety precautions have been adopted to safeguard personnel from possible injury, both
supervisory and operating personnel are urged to ensure that the safety rules detailed below are followed as an
established routine at all times. The following four Rules are the standard safety guidelines for working with and
around transmitters.
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MXI101V TECHNICAL SERVICE MANUAL
Rule #1 KILL THE AC POWER BEFORE IT KILLS YOU
Under no circumstances should any person reach within the cabinets for the purpose of servicing or
adjusting the equipment without first disconnecting the AC power or without the immediate presence of
another person capable of rendering aid. The “buddy” system is encouraged for transmitter work.
Rule #2 DO NOT TAMPER WITH INTERLOCKS OR SAFETY SHIELDS
Under normal circumstances, no safety shield should be removed.
Rule #3 REMOVE PERSONAL JEWELRY WHEN WORKING ON THE EQUIPMENT
The mains AC power to this transmitter can deliver high currents capable of melting metallic tools or
personal jewelry, such as watch bands, bracelets, or rings. Accidental short circuits from such metallic
objects can cause an explosive shower of molten metal which can result in serious personal injury.
Rule #4 KNOW FIRST AID AND KEEP FIRST AID SUPPLIES AVAILABLE
Illustrated first aid instructions for the treatment of electrical shock and burns and CPR procedures should
be displayed in a prominent location adjacent to the equipment. In rendering first aid, the timeliness and
effectiveness of the treatment are vitally important to the recovery of the injured person.
Always have a colleague with you when you work on the transmitter and make sure both of you know first
aid, including cardio-pulmonary resuscitation (CPR). This is most important.
Without exception, all personnel should thoroughly familiarize themselves with the procedures involved. One
person, whose normal duties place him or her at the transmitter site often, should be given complete
responsibility and authority to ensure that first aid supplies are kept onsite and maintained. Prominently
display a list of emergency phone numbers. This list should include the numbers of the nearest police,
ambulance, hospital, doctor, fire department, paramedics, poison control center, public works (roads)
department, and the utility (power and phone) companies.
Do not try to work on the transmitter if you are tired or drowsy; you could make a fatal error in judgment.
2.3.1 Switch to Safety
Here are some safety suggestions, based partially on the knowledge of experts familiar with high-powered tubed
equipment, and partially on the procedures used at a typical utility company and at a company which makes and
tests high voltage devices. A few of these suggestions apply primarily to factory environments and require some
modification to be applied in transmitter settings.
Our thanks to the Varian Corporation for sharing its "Electrical Safety Training Program" notes. Our thanks also to
Ontario Hydro for its information booklets dealing with high voltage.
Have in place a comprehensive safety program, with defined procedures. Know First Aid and CPR.
Use the “buddy” system, with one person performing the actual service and a colleague observing. The observer
must be familiar with the work being performed and within sight and sound of the person doing the work. The
observer should not be engaged in any other work or be otherwise distracted; he must be available instantly in
case of accident. Always have the observer with you when you work on the transmitter.
Pay attention to emergency communications requirements. This could even include a voice channel on the STL
so that constant communication with the studio can be maintained. Headset-equipped phones connected on this
voice channel should be installed in locations near hazardous areas or everyone on site should carry fully
charged cell phones. When you are administering CPR, you might not be able to leave your patient for the length
of time it could take to call paramedics, especially if phone service is poor, or lines are down, and/or you are in a
rural area without emergency telephone service (e.g., 911 in North America).
Do not defeat the interlock switches on access doors unless it is absolutely necessary and you know exactly
what you are doing.
Keep the area neat and tidy, free of any interfering conductive material and free of any sharp objects. Remember
that reaction to a shock could cause you to strike nearby objects.
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MXI101V TECHNICAL SERVICE MANUAL
Avoid wearing loose clothing and personal jewelry such as rings, watches, and chains when working near
energized circuits. Make a habit of removing all jewelry and storing it in a safe place as soon as you enter the
transmitter building.
Before beginning work, shut off all AC to the transmitter power supplies. Tag and lockout the switches.
Your safety routine must ensure that the person placing the tag and locking the switch is the only person who
removes it and reactivates the switch. You might want to include the AC to the remote control as well, if there is
any possibility that a studio worker could unknowingly activate the transmitter while you are working on it. One
way of ensuring that the lockout "placer and remover" are the same person is to issue individual padlocks to each
person on the transmitter technical staff.
You might want to include your tower contractor's rigging crew in the list of people who are allowed to use tags
and padlocks. As an alternative, Dielectric™ makes a transmission line lockout switch that is intended for riggers
to turn off and lock out any RF before climbing over the antenna to replace light bulbs, etc.
Proper grounding is vital. Make ground inspection a part of your maintenance program; someone's life could
depend on it.
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MXI101V TECHNICAL SERVICE MANUAL
3
LARCAN PARTS, ASSEMBLIES, ASSEMBLY DRAWINGS AND SCHEMATIC NUMBERS
3.1
VENDOR STANDARD PART NUMBERS
Vendor or original manufacturer part numbers are indicated for most components.
3.2
LARCAN NUMBERS FOR PARTS, ASSEMBLIES AND DOCUMENTATION
An index of LARCAN specified number are used to define and specify the following:
• parts made by a manufacturer to LARCAN specification;
• an assembled unit or “group” such as a PC Board or completed cabinet;
• assembly drawings and schematics;
• standards.
Depending on the application, AutoCAD drawing or Microsoft Word document format is used.
Document numbers have the format YYZXXXXKn Rev m where:
YYZ Prefix denoting drawing size and Product type. Can be 10A, 11A, 20B, 21B, 30C, 31C, 40D, 41D, 50E, 51E
– describes drawing or document size, VHF or UHF application
XXXX Drawing Index number. Between 0000 to 9999.
K Refers to the type of drawing / document:
• “no suffix” for drawing of part (assembly or schematic)
• P = Part
• G = Group of parts
• A = Assembly drawing
• F = PC board fabrication films and
• S = Schematic
n Index number for drawing type. Part, group, assembly drawing or schematic next number and may be
one or more digits
Rev Revision (sometimes denoted as R or R–)
m Revision number and may be one digit or more. May contain a decimal (e.g., Revision 3.2)
Drawings may consist of one or more sheets. Generally multiple sheets are used if one sheet is not enough to
show all necessary information. Sometimes, especially with older drawings, multiple sheets are used to show
more than one part or assembly.
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MXI101V TECHNICAL SERVICE MANUAL
3.3 LEADED RESISTORS
Generic carbon composition resistors with leads are numbered as follows:
nnnx
3R
P
- or -
nnx
Power Rating Resistance Value * Tolerance
152 = 1/4W nn - first digits of K =10%
77 = 1/2W resistance (5, 10% tol.) J =5%
78 = 1W nnn - first digits of H =1%
79 = 2W resistance (1% tol.)
x - x10 multiplier
For values between 1Ω and 10Ω, a letter “R” will appear in the resistance value to indicate the decimal place.
For vendor leaded resistors a generic drawing describing basic specifications, but having many “parts”, will often
be used.
“3R152P5R6J” is 5.6Ω, 1/4W, ±5%
“3R152P470K” is 47Ω, 1/4W, ±10%
“3R152P1022H” is 10.2kΩ, 1/4W, ±1%
“3R152P102J” is 1kΩ, 1/4W, ±5%
3.4 SURFACE MOUNT RESISTORS 1/4W AND LESS
There is no specified recommended supplier of these parts. The Philips numbering system is employed with the
following parameters/designations (example follows):
9C
SIZE LxW POWER
nn=first 2 digits
x=multiplier
nnnx tolerance<5%
nnn=first 3 digits
nRnx or nnRnx or nRnnx
R inserted as decimal point
0000 - four zeros for jumper
RATING
0603=1.6x08mm 1 = 1/16W
0805=2x1.25mm 2 = 1/10W
1206=3.2x1.6mm 2 = 1/8W
(1% tol.)
3 =1/4W
(5% tol.)
A nnnx
RESISTANCE VALUE
nnx tolerance>=5%
x=multiplier
where required
TOLERANCE TEMP COEF
D=0.5% C=50ppm/°C
F=1% K=100ppm/°C
J=5% L=200ppm/°C
M=300ppm/°C
The pairs of parameters enclosed in boxes are normally mutually selected; for example, a resistor having 1%
tolerance normally is selected as having a temperature coefficient of 100ppm/°C.
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MXI101V TECHNICAL SERVICE MANUAL
Example: 9C08052A1001F K
(Size 0805, Power Rating 1/10W, Resistance 1kohm, Tolerance 1%, Temperature
Coefficient 100ppm/°C)
3.5 SURFACE MOUNT CAPACITORS
There is no specifically recommended supplier of these parts. The part numbering system being used is based on
a Philips (now Yageo/Phycomp) numbering system with the following parameters/designations (example follows):
SIZE LxW DIELECTRIC
MATERIAL
0603=1.6x08mm CG = NPO nn =first 2 digits B=0.10pF 7=16VDC B=Ni/Sn
0805=2x1.25mm 2R = X7R
1206=3.2x1.6mm 2F = Y5V * x =multiplier as
9=x0.1
0=x1
1=x10
2=x100
3=x1000
4=x10000
5=x100000
* (infrequent use)
2E = Z5U *
shown below
8=x0.01
Nnx
CAPACITANCE
VALUE
(in Pico farads)
C=0.25pF 8=25VDC
D=0.50pF 9=50 VDC
F=1% 0=100VDC
G=2% B=200VDC
J=5% D=500VDC
K=10%
M=20%
TOLERANCE
VOLTAGE
RATING
TERMINATION
A=Ag/Pd
C=Ni/Sn-Pb
e.g., 0805CG102J9B
SIZE =0805
DIELECTRIC MATERIAL =NPO
VALUE =1000pF
TOLERANCE =5%
VOLTAGE RATING =50V
TERMINATION =Ni/Sn
PACKAGING =Not Specified
MARKING =None
Note that “u” appears in most cases instead of the correct symbol “μ” whenever a “micro” is required. Electronic
parts list data, when imported by our PC publication program, allows us to substitute the correct “μ” when
checking and editing.
3.6
PARTS LISTS
Parts lists for all assemblies in the transmitter are provided on CD-ROM, in PDF format. The CD-ROM is packed
inside the transmitter cabinet for shipping.
Parts lists are generated in a hierarchical structure, beginning with major assemblies, then the subassemblies of
each major assembly, and so forth.
3.6.1
Production Changes
From time to time, it may become necessary to make changes in the equipment described in this manual. Such
changes are usually made either to provide improved performance or to accommodate component substitutions.
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MXI101V TECHNICAL SERVICE MANUAL
A revision letter or number may follow the model or group number marked on the nameplate, chassis, or circuit
board; or on the parts list (where it is an "R" followed by a dash and a number). Whenever a revision letter or
number appears, it should be quoted in any communication regarding the equipment.
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MXiV DUAL PALLET OPERATIONS AND MAINTENANCE
CONTENTS
1 MXi CONTROLLER.....................................................................................................................................................12
2 AMPLIFIER INSTALLATION AND STARTUP.......................................................................................................14
2.1 BEFORE APPLYING AC TO THE UNIT ..........................................................................................................................14
2.2 APPLYING AC TO THE UNIT........................................................................................................................................14
2.3 BEFORE TURNING THE AMPLIFIER ON .......................................................................................................................15
2.4 AMPLIFIER ON SEQUENCE..........................................................................................................................................16
2.4.1 Turning ON MXi Amplifier..............................................................................................................................166
3 TEST AND TROUBLESHOOTING ............................................................................................................................17
3.1 BASIC TROUBLESHOOTING TECHNIQUES ....................................................................................................................17
3.1.1 Amplifier Completely OFF.................................................................................................................................17
3.1.2 No RF Output.....................................................................................................................................................17
3.1.3 Output Reduced to 25%.....................................................................................................................................17
4 MAINTENANCE............................................................................................................................................................18
4.1 DAILY.........................................................................................................................................................................18
4.2 MONTHLY...................................................................................................................................................................18
4.3 SEMI-ANNUALLY AND ANNUALLY .............................................................................................................................18
4.4 TRANSMITTER COOLING SYSTEM ...............................................................................................................................18
5 SERVICE.......................................................................................................................................................................119
5.1 REMOVING THE FAN ARRAY.......................................................................................................................................19
5.2 REPLACING THE ENTIRE FAN ARRAY .........................................................................................................................20
5.3 REPLACING A SINGLE FAN..........................................................................................................................................20
6 TEST EQUIPMENT SETUP.........................................................................................................................................21
7 SPECIFICATIONS ........................................................................................................................................................22
7.1 ELECTRICAL ...............................................................................................................................................................22
7.2 ENVIRONMENTAL.......................................................................................................................................................22
7.3 COOLING ....................................................................................................................................................................22
7.4 DIMENSIONS ...............................................................................................................................................................22
7.5 SHIPPING WEIGHT ......................................................................................................................................................22
FIGURES
FIGURE 2 MXI CONTROLLER......................................................................................................................................................12
FIGURE 3 MXI FRONT PANEL .....................................................................................................................................................12
FIGURE 4 MAIN MENU SCREEN ..................................................................................................................................................12
FIGURE 5 AMPLIFIER (AMP) SUBMENU ..................................................................................................................................... 13
FIGURE 6 REAR PANEL SHOWING INTERLOCK TERMINAL BOARD..............................................................................................14
FIGURE 7 MAIN MENU................................................................................................................................................................15
FIGURE 8 INTERLOCKS STATUS ..................................................................................................................................................15
FIGURE 9 AGC OFF...................................................................................................................................................................15
FIGURE 10 TRANSMITTER ON ....................................................................................................................................................16
FIGURE 11 BOTTOM VIEW OF MXI.............................................................................................................................................19
FIGURE 12 FAN ARRAY ..............................................................................................................................................................20
FIGURE 13 FAN ATTACHMENT TO MOUNTING PLATE.................................................................................................................20
FIGURE 14 TEST EQUIPMENT SETUP ...........................................................................................................................................21
TSM21Q-365 Rev 0 July 17, 2009 MXiV Dual Pallet Operations and Maintenance 11
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