Harris ZX2500 - Dual-Drive; Main-Alternate Switcher

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12/20/11 888-2595-001 1-19

WARNING: Disconnect primary power prior to servicing.

Section 1 Introduction

ZX Series

1.9.4 Dual-Drive / Main-alternate Switcher

A second exciter and exciter switchover controller are sometimes provided. The

operation of the main alternate switcher is addressed in a separate manual.

Main Page

Table of Contents15
Manual Contents19
Features / Benefits20
General Product Description21
- Exciter21
- Amplifier22
Transmitter Nomenclature22
Tri-Mode Operation23
ZX Transmitter General Construction23
Simplified Block Diagrams26
Major Subassemblies31
Transmitter Accessories36
- Customized Rack Integration36
- AC Distribution & Signal Monitor Chassis36
- Directional Coupler or Wattmeter36
- Dual-Drive / Main-Alternate Switcher37
- Section 1 Introduction38
Specifications38
Field Services45
- Installation45
- Commissioning46
Unpacking46
Returns and Exchanges46
Transmitter Documentation46
- Installation and Outline Drawings47
Site Selection47
AC Mains Requirements48
- Transmitters with AC Distribution Chassis48
- Transmitters Without AC Distribution Chassis49
Surge Suppression Devices51
Ground Requirements51
- Overview of RF Grounding Practices52
Cooling System Requirements53
Personnel and Equipment Protection55
- Safety Circuits55
Remote Control Installation56
- Exciter Connections61
System Bus Connections64
Initial Start-Up Procedure64
- Operation69
Introduction69
Controls and Indicators69
- Front Panel69
- Controller Board71
- Internal Leds74
System Metering Assembly75
Basic Operational Procedures76
- ON/OFF Procedure76
- Power Raise/Lower Procedure77
- Switch Operating Mode Procedure (Flexstar HDX Exciter)77
- Basic Functional Check Procedure78
- Theory of Operation81
Introduction81
RF Interconnect Wiring Diagram81
Output Assembly82
AC-DC Interconnect Wiring Diagram84
PA Backplane85
- PA Reverse Power Alarm85
- PA Temperature Alarm86
- PA Current Alarm86
- Socket Interlock Module Fault Sensor87
IPA Backplane87
I/O Filter PCB88
PS Interface PCB89
Fan Monitor PCB90
Load PCB91
Pa, Iboc Pcb91
Transmitter Controller PCB92
- On/Off Control92
- Auto Restart93
- APC Circuit and Power Level Adjust94
- Operating Mode and Bias Level Control96
- Metering97
- Fault and Status Signaling99
- Load Temperature Fault Sensor100
- Ambient Temperature Sensor100
- Drain Voltage Adjust100
System Metering Assembly100
System Interconnect101
- Command Sharing101
- Power Control Sharing103
- Maintenance and Alignments105
Introduction105
General Maintenance Guidelines106
- Personnel Training106
- Recommended Tools and Equipment107
- Spares Holding109
- Safety Precautions109
- Transmitter Logbook110
- Maintenance Logbook110
- Routine Maintenance111
- MTBF Estimates111
Basic Maintenance Procedures112
- Power Amplifier (PA) Module Swap112
- Procedure113
- Power Supply (PS) Module Swap Procedure114
- Air Filter Replacement Procedure115
- PA Module Cleaning Procedure116
Advanced Maintenance Procedures117
- Advanced Functional Check117
- Forward Power Meter Calibration120
- Precision Directional Coupler121
- Reverse Power Meter Calibration122
- Set Transmitter Power Level (Case 1: Internal Transmitter APC Control)123
- Set Transmitter Power Level (Case 2: Exciter APC Control with Flexstar HDX)125
- APC Setup for Multiple PA Chassis127
- Set User Reverse Power Foldback Threshold (ZX2500 / ZX3750 / ZX5000)128
- Set User Reverse Power Foldback Threshold (ZX7.5, ZX10)129
- Periodic Cleaning and Inspection130
- Service One PA Chassis While Transmitter Is on Air (ZX7.5/ZX10)132
- Service One PA Chassis While Transmitter Is Appendix A - FM Web Remote132
- Check Balance by Disconnecting Load (ZX7.5/ZX10)132
Special Part Replacement Notes134
- PA Module (992-9992-041G or Otherwise)134
- PA Amplifier Assembly (PWA, PA)134
- PS Module (736-0445-000)136
- Transmitter Controller PCB (901-0203-541)137
- PA Backplane PCB (901-0203-381)137
- IPA Backplane PCB (901-0203-581)137
- PS Interface PCB (901-0203-531)137
- RF Output Assembly (971-0023-026/027/028)138
- Output Assembly Ballast Load (700-1225-000)142
- RF Splitter (901-0203-511/561/571)143
- I/O Filter PCB (901-0203-551)144
- Web Remote PCB (901-0203-391T)144
- Fan Monitor PCB (901-0203-441)144
- Cooling Fans (430-0458-000)144
- Front Panel Multimeter (632-1201-000)144
- AC Mains Filter (476-0528-000 or 609-0125-000)145
- Front Panel Filter (943-5567-408)145
- IPA Splitter (901-0203-591)145
- Input 3Db Attenuator (971-0023-050)145
- System Metering Assembly145
- Output Combiner (3Db Hybrid)145
- Kw RF Load146
- Troubleshooting147
Contacting Harris Service147
Troubleshooting Table148
- Parts List163
ZX5000 Replaceable Parts List164
ZX10 Replaceable Parts List169
- Appendix A - FM Web Remote Option175
Introduction175
- General Product Description175
Installation177
- Internet Security177
- Installation Procedure178
Operation179
- Access Main Page179
Theory of Operation185
Maintenance186
- Access Configuration Page186
- Configuration Settings189
- Perform Simple Reset191
- Perform Expert Reset192
- Change Clock Battery193
- Calibrate Clock Speed193
- Use Microchip Discoverer Utility194
Troubleshooting195
USB Flash Drive196

Harris ZX2500 - Dual-Drive; Main-Alternate Switcher

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