EasyManua.ls Logo

Harris Maxiva ULX User Manual

Default Icon
308 pages
To Next Page IconTo Next Page
To Next Page IconTo Next Page
Page #1 background imageLoading...
Page #1 background image
Maxiva ULX COFDM
Series Digital Transmitter
This manual applies to the following modulation types:
DVB-T/H
ISDB-T/H
FLO
CTTB
CMMB
TECHNICAL MANUAL
888-2629-200
Maxiva ULX COFDM Series
Digital Transmitter
Oct. 5, 2010
Rev: B
T.M. No. 888-2629-200
© Copyright Harris Corporation 2010
All rights reserved

Table of Contents

Question and Answer IconNeed help?

Do you have a question about the Harris Maxiva ULX and is the answer not in the manual?

Harris Maxiva ULX Specifications

General IconGeneral
BrandHarris
ModelMaxiva ULX
CategoryTransmitter
LanguageEnglish

Summary

Technical Assistance

Replaceable Parts Service

Details on obtaining replacement parts from Harris Service Parts Department.

Unpacking Procedures

Instructions for carefully unpacking equipment and conducting a visual inspection.

Returns And Exchanges Policy

Information regarding the process for returning or exchanging equipment.

Manual Revision History

Guide to Using Harris Parts List Information

First-Aid Procedures

Treatment of Electrical Burns

Guidance on how to treat electrical burns, distinguishing between extensive and less severe cases.

Section 1 Introduction

Purpose of This Manual

Outlines the information covered in the technical manual for the Maxiva ULX Series transmitter.

General Description

Provides an overview of the Maxiva ULX Series COFDM digital television transmitters.

Maxiva COFDM Series Transmitter Models

Details the various liquid-cooled power levels and models available in the Maxiva COFDM Series.

System Block Diagram

Presents a basic system block diagram showing signal flow and configuration.

Transmitter Control System

Explains the simplified control system architecture, TCU, and communication buses.

Transmitter RF Power Control

Describes how transmitter RF output power is controlled via the Phase and Gain Board.

Graphical User Interface

Details the touchscreen GUI, its software and hardware buttons for monitoring and control.

Control System Communications

Explains the CAN bus system for control, status, and analog monitoring.

Software Updates

Information on updating the transmitter's software via a serial port connection.

Remote Control

Details discrete wired parallel remote control and web-enabled GUI interface.

PA Module

Describes the Maxiva ULX Series PA Module utilizing LDMOS amplifiers.

Module Control

Explains the primary method for control and monitoring of PA modules via ribbon cable bus.

Transmitter Power Supplies

Details the three-phase AC mains input requirements and configurations for the transmitter.

Cooling System

Provides an overview of the transmitter's liquid cooling system and its components.

Cooling System Control Panel

Describes the controls and indicators on the cooling system control panel for operation.

Pump Module/Heat Exchanger

Details the control panel, pump module, and heat exchanger units.

Heat Exchanger Fan Control

Explains how heat exchanger fans are controlled electronically based on temperature.

Pump Operation/Control Logic

Describes the automatic pump operation modes (LOCAL and REMOTE) and control logic.

PA Module and Combiner Cold Plates

Information on liquid-cooled cold plates for PA modules, combiners, and splitters.

M2X Multimedia Exciter

Describes the M2X exciter used with the Maxiva ULX Series transmitter.

General Specifications

Lists general specifications for the transmitter, including performance and physical characteristics.

Section 2 Installation

Introduction

Overview of installation and initial turn-on procedures for the Maxiva ULX Series transmitter.

Documentation

Lists the documentation that ships with the transmitter and provides document package numbers.

Installation Drawings

Recommends reviewing the drawing package for installation and planning information.

Installation Steps

Provides numbered steps for the installation process, with primary goals indicated by bold letters.

Transmitter Cabinet Placement

Details the required clearance and steps for placing the transmitter cabinet.

Cooling System Installation

Outlines the major components of the cooling system and installation procedures.

Heat Exchanger and Pump Module Installation

Provides restrictions and considerations for installing the heat exchanger and pump module.

Calculation of Cooling System Capacities

Explains how to calculate cooling system capacities for coolant and distilled water needs.

Rigging Heat Exchanger & Pump Module

Provides guidance on handling and setting the heat exchanger and pump module units.

Initial Inspection

Instructions for immediately inspecting equipment and accessories upon receipt for shortages or damage.

Placement of Heat Exchanger and Pump Module

Details the proper placement of the heat exchanger and pump module units.

Liquid Cooling System Plumbing Installation

Provides guidelines for installing the liquid cooling system plumbing, including valve usage and pipe sizing.

Pump Module & Heat Exchanger Electrical

Covers the electrical installation of the heat exchanger and pump module unit.

Transmitter AC Connection

Details the AC inputs to the top of the cabinet and AC connection procedures.

Safety Ground

Explains the requirement for a safety ground wire for each AC mains input.

AC Connections Procedure

Provides step-by-step instructions for routing and connecting the primary AC conduit and wires.

Checking AC Configuration

Details how to compare voltage specifications and verify jumpers in various panels.

Signal and Ground Connections

Provides guidelines for connecting RF inputs and ensuring proper conduit separation for signal/control cables.

Intercabinet Connections

Instructions for installing inter-cabinet connections for multi-cabinet transmitter models.

External Interlock Connections

Describes external interlock connections and the interlock connector on the customer I/O panel.

Interlock Connector on Customer I/O Panel

Details the interlock connector's pins and their functions for external interlocks.

Fault-Off Interlocks (Safety Interlocks)

Explains the function of fault-off interlocks for personnel and cabinet safety.

RF Mute External Interlock Connections (J2)

Describes RF mute interlock connections used for temporary RF mute conditions.

3 Port Patch Panel Connections

Refers to electrical installation drawings for patch panel connections.

Initial Cooling System Turn ON

Provides steps for the initial turn-on of the liquid cooling system components.

Heat Exchanger & Pump Module Start-up and Maintenance

Covers electrical installation, motor rotation checks, and cleaning procedures.

Starting Pumps & Checking Pump Rotation

Details the procedure for verifying pump rotation and addressing incorrect rotation.

Starting Fans & Checking Fan Rotation

Explains how to verify heat exchanger fan rotation and correct improper rotation.

Initial System Leak Tests

Provides steps for checking static pressure and performing visual leak checks on the cooling system.

Initial System Cleaning

Describes the process for creating and using a cleaning solution to clean the cooling system.

System Flushing

Outlines the procedure for flushing the system with distilled water to remove cleaning solution residue.

Final Cooling System Fill

Details the procedure for filling the cooling system with the required glycol/water mixture.

Install PA Modules

Provides instructions for installing PA modules into the transmitter cabinet.

Initial Turn-On

Details the critical steps for the initial powering on of the transmitter and its systems.

Final Cooling System Turn ON

Guides the user through the final steps to turn on the cooling system.

Setting the Transmitter Flow Rate

Explains how to check and adjust the transmitter's flow rate to match nominal values.

Normal Pump and Fan Operation

Describes the normal operating conditions for pumps and fans in the cooling system.

Operational Pressure Values (typical)

Lists typical operational pressure values for various points in the cooling system.

Setting Exciter Parameters

Directs the user to the M2X Exciter manual for setting exciter parameters.

RF Initial Turn ON

Provides critical steps for the initial RF turn-on of the transmitter.

Individual Transmitter Parallel Remote Control Connections

Details connections for parallel remote control units to the Customer I/O Board.

Individual Transmitter Commands J3, J4 and J5

Lists the pin functions for remote control connectors J3, J4, and J5.

Individual Transmitter Outputs J6, J7& J8

Lists the pin functions for remote status output connectors J6, J7, and J8.

Individual Transmitter Metering, J9

Details the connections for analog metering output J9 on the External I/O Board.

External RF Switch

Describes the external RF switch connector J10 for controlling motorized switches.

Install Battery in TCU PCM Card

Provides instructions for installing the real-time clock battery on the TCU PCM card.

Section 3 Operation

Introduction

Provides detailed operational information for the Maxiva ULX Series transmitter.

Transmitter Control Panel

Describes the front panel interface, including the touchscreen display and hardware buttons.

Hardware Control Buttons

Details the six pairs of hardware control buttons for main transmitter functions.

Graphical User Interface (GUI)

Explains the GUI's design for intuitive transmitter control and navigation.

Global Status and Navigation

Describes the global areas of the touchscreen display showing transmitter status and navigation.

GUI Home Screen

Identifies the HOME screen as the primary operator screen displaying general operational information.

Drive Chain Main Menu

Details the Drive Chain screen for exciter, pre-driver, and IPA control and monitoring.

Drive Chain Faults

Describes the screen that displays faults for exciters and pre-driver/IPA units.

Drive Chain Meters

Explains the screen displaying input and output information for exciters and pre-driver/IPA units.

Power Amp Main Menu

Details the Power Amps screen showing current and forward power for individual PA modules.

PA Faults

Lists all faults monitored in each PA module, highlighting active faults in red and warnings in yellow.

Output Main Screen

Provides total system Forward and Reflected power, VSWR, and Foldback status.

Output Faults

Displays faults considered Cabinet or System level such as VSWR and Power High.

Power Supply Main Menu

Shows the power supply metering screen for low voltage units and AC Mains.

PS Faults

Lists monitored power supply faults for AC mains and low voltage power supplies.

System Main Menu

Provides overall status information and access to additional System screens.

System Faults

Displays system faults, highlighting active conditions in red and warnings in yellow.

System Fault Log

Provides a complete listing of transmitter and system faults in the order they occurred.

System Service

Allows modification of station name, model number, and serial number used throughout the GUI.

Admin Setup (Local GUI Only)

Details admin setup parameters accessible via the System Service Admin screen.

System Setup

Guides setting system nominal power, center frequency, modulation type, and AC line voltage.

Cabinet Setup

Covers setting cabinet output power, number of PA's, IPA's, and cooling pumps.

System and Cabinet Power Calibrate

Refers to Section 5 for procedures utilizing these calibration screens.

System Version Screen

Displays software revision information for TCU controllers.

System Network Screen

Provides information on network settings like MAC, IP, Netmask, and Gateway.

GUI Menu Structures

Shows the menus accessible on the GUI, serving as a navigation guide.

Section 4 Theory of Operation

Introduction

Provides detailed descriptions of transmitter sub-assemblies and external assemblies.

Active Logic Symbols

Explains the system for differentiating between active high/low logic states on schematics.

Block Diagram Descriptions

References block diagrams for transmitter overview, signal flow, and model configurations.

AC Distribution

Details the three-phase AC mains supply to PA cabinets and jumper configurations.

Transmitter Control System

Explains the advanced yet simple control system, including cabinets, modules, and buses.

Graphical User Interface (GUI)

Describes the GUI as a touchscreen interface for operator control and monitoring.

Transmitter RF Power Control

Explains how RF output power is controlled via the Predriver modules and ALC loop.

TCU Control

Details the TCU's role as the heart of the control system, acting as master or slave.

MCM Card

Describes the MCM card as a microprocessor-based controller for critical transmitter functions.

PCM Card

Explains the PCM card for enhanced monitoring, control, and data collection.

RF Detector/Pump Control/Interlocks Card

Details the card containing RMS detectors, pump control, and interlock wiring.

PA Interface Card

Explains the PA interface card's role in connecting TCU, Predriver, IPA, and PA backplanes.

Predriver and IPA Drive A and B Busses

Describes the buses providing control and monitoring for predriver and IPA modules.

Customer I/O Card

Details the I/O card's function for interfacing with external devices.

Exciter Switcher Card

Explains the exciter switcher card's function in controlling exciter switching.

PS Monitor Card

Describes the PS monitor card's function in monitoring AC power, fuses, and temperatures.

PA Monitor Board

Details the PA monitor board's role in controlling and monitoring PA module operation.

CPLD (Complex Programmable Logic Device)

Explains the CPLD device within PA modules for fault reporting and action.

Life Support Functions

Describes functions active when the main control system is not functioning properly.

Controller Area Network (CAN) Bus

Explains the CAN bus as a high-speed serial link for transmitter control boards.

System Bus

Describes the system bus as a ribbon cable distributing CAN and parallel control lines.

Cabinet Bus

Explains the cabinet bus connecting the TCU (MCM card) to IPA and PA backplanes.

Customer I/O Board

Details the I/O board's function for interfacing with external devices and provides connection information.

Transmitter RF System

Provides an overview of the transmitter's RF system components.

Apex M2X Exciter(s)

Describes the M2X exciter and its role in signal generation for the transmitter.

Predriver

Explains the predriver's function in redundant power and phase adjustment of RF drive signals.

IPA (driver) and PA Module

Details the IPA and PA modules' function in amplifying modulated RF signals.

AC Distribution Board

Describes the AC distribution board's function in AC line filtering and transient protection.

AC/DC Converter Interface Board

Explains the AC/DC converter board as a switching power supply for module operation.

PA PS (AC/DC) Voltage Select Path

Details the path for the PA voltage select signal controlling power supply output voltage.

PA Monitor Board

Describes the PA monitor board's role in controlling and monitoring PA module operation.

J1 - PA or IPA Connector I/O Board

Details the pins and functions of the PA/IPA connector I/O board.

Signal Distribution Board

Explains the board's function in routing analog and digital control and monitoring data.

PA Module Phase Alignment

States that PA modules are phase optimized at the factory and do not require field alignment.

PA Module Splitter

Describes the splitter's function in dividing RF signals equally among PA pallets.

PA Module Pallet Combiner

Explains the combiner's function in combining RF signals from PA pallets.

RF Pallets

Describes the PA pallet as a single stage of amplification in the Triton module.

FET Bias

Notes that LDMOS FETs maintain factory bias characteristics without field re-biasing.

Module Combiner

Describes the module combiner's function in optimizing across the UHF frequency band.

Cooling System

Provides references for information on the Maxiva ULX cooling system.

Heat Exchanger/Pump Module Diagrams

Shows block and schematic diagrams of the heat exchanger/pump module system.

Leak Detector and Cabinet Drains

Explains the function of the leak detector and cabinet drains in the cooling system.

Maxiva 16 Module Transmitter Diagrams

Refers to block diagrams for the Maxiva 16 Module transmitter configuration.

RF Block Diagram

Presents a block diagram of the Maxiva 16 Module transmitter RF signal path.

Section 5 Maintenance and Alignments

Introduction

Outlines maintenance, alignment, replacement, and calibration procedures for the transmitter.

PA Module Removal and Replacement

Provides detailed instructions and cautions for removing and replacing PA modules.

PA Slot Locations

Outlines the slots containing PA modules in various transmitter model configurations.

PA Module Removal

Details the step-by-step procedure for safely removing PA modules from the rack.

PA Module Installation

Provides step-by-step instructions for installing PA modules correctly into the rack.

Operation With Inoperative PA Modules

Explains how the transmitter continues to produce RF power with some modules removed.

PA Module/Rack Alignment

Outlines the procedure for aligning the rack if difficulty is encountered during module installation.

PA Module Bias

States that PA module re-biasing is not required on Maxiva ULX transmitters.

PA Module Phasing

Notes that PA module phasing is factory controlled and requires no field adjustment.

PA Module Component ID

Emphasizes identifying faulty components before attempting field repairs.

PA and IPA (driver) Pallet Replacement

Provides instructions for replacing PA and IPA (driver) pallets.

PA Module AC/DC Converter (PS) Board

Covers the PA Module AC/DC Converter (PS) Board and its replacement.

PS Board Removal and Replacement

Details the steps for removing and replacing the PS board.

AC/DC Converter (PS) Board Output Voltage

Explains how the PS board output voltage changes with modulation type and adjustment.

Setting Voltage:

Guides the user through setting the PS board output voltage using a test fixture.

Power Calibrations

Lists required power calibrations such as system and cabinet forward/reflected power.

Forward Power Calibration

Details the procedure for calibrating forward power using a local GUI screen.

Calibrate Forward Cabinet Power:

Describes repeating the forward power calibration using internal cabinet samples.

Reflected Power Calibrate

Establishes values for VSWR protection thresholds for foldback and fault events.

Calibrate Reflected Total Power

Guides the calibration of system reflected power using the GUI screen.

Calibrate Reflected Cabinet Power

Describes calibrating reflected power at the cabinet output using internal samples.

Exciter Output Calibration

Details the procedure for calibrating exciter output levels using the GUI and web browser.

PDU Calibration

Explains the calibration procedure for the predriver unit's input power measurement.

Threshold Settings

Guides the user to the CALIBRATE screen to adjust various system thresholds.

Exciter A & B Threshold Settings

Describes setting exciter A and B detector and threshold levels for fault indication.

Cabinet Reject Load Thresholds

Specifies setting cabinet reject loads to approximately 3V thresholds at 100% reject power.

System Reflected Thresholds

Details setting system reflected threshold voltage relative to detected voltage levels.

System Foldback Power

Explains setting system foldback power to a maximum of 2.8% of nominal output power.

FWD Pwr Warn

Sets the kW level at which the power bar turns yellow.

Fwd Pwr Flt

Sets the kW level at which the power bar turns red and a fault is logged.

PA Cabinet Fan Replacement

Details the procedure for replacing the two 230V AC fans in the Maxiva cabinet.

Cabinet Fan Removal

Provides steps for removing the fan assembly from the cabinet.

PA Cabinet RF System Removal

Explains when RF system removal is required and the initial steps for removal.

RF System Removal

Details the process of removing the cabinet fan assemblies and output coax.

Miscellaneous Maintenance

Covers various maintenance tasks including cooling system checks and filter cleaning.

Cooling System Checks

Routine inspection of the cooling system for leaks and coolant level.

Heat Exchanger Cleaning

Instructions for cleaning heat exchanger and pump motor housing fins.

Alternate Pumps

Recommends switching pumps every three months to maintain proper working state.

Pump Module Strainer Cleaning

Details the inspection and cleaning of the pump module strainer.

Coolant Level Management

Explains how to check and manage the coolant level in the closed pressurized system.

Cooling System Maintenance Notes

Provides notes on coolant checks, changing pumps, and general maintenance.

Coolant Checks

Guidelines for checking the pH level and 50/50 glycol/water mixture.

Changing Pumps

Provides steps for changing pumps, including disconnecting fittings and maintaining flow direction.

Pump Module Operation Without Transmitter

Describes how to operate the pump module independently using LOCAL mode.

Air Filter Replacement

Recommends monthly inspection and cleaning of the air filter.

LCD Screen Adjustments

Explains how to adjust LCD display contrast via the GUI System Service screen.

LCD Screen Contrast

Details accessing the GUI screen to adjust the LCD contrast setting.

Touch Screen Calibration

States that the GUI touchscreen is calibrated at the factory and requires no further calibration.

Date and Time Settings

Explains how to perform date and time settings using the local GUI screen.

Changing the Battery on the PCM Card

Provides instructions for installing the real-time clock battery on the TCU PCM card.

TCU Card Replacement

Outlines the procedure for changing cards within the TCU, noting revision levels.

MCM Card Replacement

Provides instructions for replacing the MCM card, including component settings.

Typical Test Equipment

Lists recommended test equipment for maintenance and alignment procedures.

Section 6 Diagnostics

Introduction

Contains diagnostic and troubleshooting information for the ULX series UHF transmitter.

GUI System Log

Lists all faults that have occurred, including fault type, time, date, and active/inactive status.

Maxiva Three-Strike Fault Actions

Details the three-strike fault policy for reflected power faults and transmitter actions.

Reflected Power Faults

Identifies reflected power faults that initiate a three-strike procedure.

Module Faults

Lists module faults that trigger a three-strike action, affecting only the specific PA module.

Maxiva Drive Chain Fault List

Provides a listing of drive chain faults, descriptions, fault levels, and transmitter actions.

PA and IPA Module Fault List

Lists faults related to PA and IPA modules, including temperature, VSWR, and power overload.

Power Supply Faults List

Details power supply faults for AC mains and low voltage supplies, including voltage failures and fuse issues.

Output Faults List

Lists output faults such as VSWR, power overload, and foldback conditions.

System Faults List

Provides a list of system faults including ambient temperature, coolant flow, and leaks.

Section 7 Parts List

Replaceable Parts List

Lists replaceable parts with Harris PN, description, quantity, and reference designators.

Heat Exchanger/Pump Module Replacement Parts

Details replacement parts specifically for the heat exchanger and pump module.

Appendix A Cutting & Soldering Transmission Line

Suggested Cutting And Soldering Procedure

Provides guidelines for field cutting and soldering RF transmission line for system interconnection.

Cutting The Transmission Line

Describes various methods for making a square, smooth cut on transmission line.

Soldering Flanges

Details the procedure for soldering silver solder type transmission line flanges.

Soldering Procedure

Step-by-step guide for preparing and soldering transmission line flanges.

Cleaning The Soldered Joint

Describes methods for cleaning soldered joints using acid solutions or Naval Jelly.

Alternate Cleaning Method

Provides an alternative procedure for cleaning soldered transmission lines.

Appendix B Cooling System Help

Coolant and Water Recommendations

Recommends a 50% mixture of deionized water and industrial grade ethylene glycol.

Plumbing System Installation

Provides guidelines for pipe sizing, routing, and installation techniques.

Materials needed

Lists necessary materials for plumbing system installation, including tools and supplies.

Standard Coolant Plumbing Practices

Outlines good plumbing practices for ensuring system integrity and quality soldering.

Routine System Operation and Maintenance

Covers routine inspections for leaks, pump operation, and system analysis.

Operating Environment

Specifies ambient air temperature limits for heat exchanger dry coolers.

Measuring Specific Gravity

Describes using a hydrometer or refractometer to verify the 50/50 glycol/water mixture.

Example

Provides an example to help understand the process of determining Ucartherm percentage.

Determining Percent of Ucartherm

Guides on reading a chart to determine the glycol percentage in the coolant solution.

Appendix C Grounding Considerations, Surge & Lightning Protection

Surge and Lightning Protection

Discusses protection against transients from lightning and the effectiveness of surge protectors.

System Grounding

Explains the importance of low-impedance ground wiring for noise reduction.

Ground Wires

Details requirements for ground wires, including impedance, length, and insulation.

AC Ground

Describes the grounding method for AC power input and equipment cabinets.

DC Ground

Explains DC ground connections routed to a common cabinet ground and earth ground.

Earth Ground

Specifies requirements for connecting to earth ground, including impedance limits.

RF Ground

Covers effective grounding and shielding for reliable equipment operation.

Appendix D Lightning Protection Recommendation

Introduction

Discusses the destructive nature of lightning strikes and their impact on electronic equipment.

Environmental Hazards

Lists and defines anomalies like over/under voltage, single phasing, RFI, and EMP.

What Can Be Done?

Provides recommendations for minimizing lightning risk and maximizing system efficiency.

Conclusion

Summarizes protection strategies against lightning strikes and emphasizes surge protection.

Related product manuals