Power CD. IOT Transmitter

Transcription

1 TECHNICAL MANUAL Power CD Power CD IOT Transmitter T.M. No Copyright Harris Corporation 2006, 2007, 2011, 2012 All rights reserved Printed: 4/13/2012 Revision D

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3 Technical Assistance Technical and troubleshooting Technical assistance for Assistance HARRIS Transmission products is available from HARRIS Field Service (factory location: Quincy, Illinois, USA) during normal business HARRIS technical and troubleshooting assistance is available from HARRIS Field hours (8:00 AM - 5:00 PM Central Time). Telephone to contact the Field Service during normal business hours (8:00 AM - 5:00 PM Central Time). Service Department; FAX ; or questions to tsupport@harris.com. Emergency service is available 24 hours a day by telephone only. Telephone 217/ Emergency service is available 24 hours a day, seven days a week, by telephone only to contact the Field Service Department. Online assistance, including technical manuals, white papers, software downloads, and HARRIS Service may also be contacted via FAX at 217/ service bulletins, are available at (from there, click on non-urgent support questions to tsupport@harris.com. Customer Support Portal under the Services & Support tab dropdown menu). Other on-line assistance, including technical manuals, white papers, software Address written correspondence to Field Service Department, HARRIS Broadcast downloads, and service bulletins is available for no charge at Communications Division, P.O. Box 4290, Quincy, Illinois , USA. For other premier.harris.com/broadcast/ (log-in required). global service contact information, please visit: Address written correspondence to Field Service Department, HARRIS Broadcast NOTE: For all service and parts correspondence, you will need to provide the Sales Order Communications Division, P.O. Box 4290, Quincy, Illinois , USA. number, as well as the Serial Number for the transmitter or part in question. For future For global contact information, please visit: reference, record those numbers here: / contact. Please provide these numbers for any written request, or have these numbers ready in the event you choose to call regarding any Service, or Parts requests. For warranty claims it will be required, and for out of Replaceable warranty products, Parts this Service will help us to best identify what specific hardware was shipped. Replacement parts are available from HARRIS Service Parts Department from 7:00 AM to 11:00 PM Central Time, Replaceable seven days Parts a week. Service Telephone 217/ or servicepartsreq@harris.com to contact the Service Parts Department. Replacement parts are available from HARRIS Service Parts Department 7:00 AM to 7:00 Emergency replacement parts are available by telephone only, 24 hours a day, PM Central Time, Monday through Friday, and 8:00 AM to 1:00 PM Central Time on seven days a week by calling 217/ Saturday. Telephone or servicepartsreq@harris.com to contact the Service Parts Dept. Emergency replacement parts are Unpacking available by telephone only, 24 hours a day, seven days a week by calling Carefully unpack the equipment and preform a visual inspection to determine if any apparent damage was incurred during Unpacking shipment. Retain the shipping materials until it has been verified that all equipment has been received undamaged. Locate and retain Carefully all PACKING unpack the CHECK equipment LISTs. and Use perform the PACKING a visual inspection CHECK LIST to determine to help locate if any and apparent damage identify was any incurred components during shipment. or assemblies Retain which the shipping are removed materials for shipping until it has and been must verified be that reinstalled. all equipment Also has remove been received any shipping undamaged. supports, Locate straps, and and retain packing all PACKING materials prior CHECK to LISTs. initial Use turn the on. 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. Returns And Exchanges Returns And Exchanges No equipment can be returned unless written approval and a Return Authorization is No equipment received from can HARRIS be returned Broadcast unless written Communications approval and Division. a Return Special Authorization shipping is received from instructions HARRIS Broadcast and coding Communications will be provided Division. to assure Special proper handling. shipping instructions Complete details and coding regarding will be circumstances provided to assure and reasons proper handling. for return Complete are to be included details regarding the request circumstances for and return. reasons Custom for return equipment are to be or included special order in the equipment request for is return. not returnable. Custom equipment In those or special instances order where equipment return is or not exchange returnable. of In equipment those instances is at the where request return of the or customer, exchange or of equipment convenience is at the of the request customer, of the a customer, restocking or fee convenience will be charged. of the customer, All returns a will restocking be sent fee will freight be charged. prepaid All and returns properly will be insured sent freight by the prepaid customer. and When properly communicating insured by the with customer. When communicating with HARRIS Broadcast Communications Division, specify the HARRIS Order Number or Invoice Number. 4/13/ iii

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5 MANUAL REVISION HISTORY Power CD Transmitter Rev. Date ECN Pages Affected Draft 01/27/05 Created Rev 0 02/02/06 Manual Sent to Review Rev A 01/19/04 P24295 Manual Released Rev B 11/21/ Revised Figure 6-24, PowerCD Logic Block Diagram, on page Section 4.3.8, Checking Flow Meter Calibration, on page added definition of flow meter K value to step 1 A. Added Flow Meter instruction manual to Appendix G. Added list of items to Appendix G. Added list of Appendix G items to Table of Contents. Added Section , Materials Needed for UV Lamp and Filter Change, on page 5-7. Rewrote Section , Installing Barnstead Filters., on page 5-8. Added Section 5.4, Flow Meter Parts Lists, on page 5-9. Expanded Section 5.5.1, Cooling Cabinet Flow Meter Calibrations, on page Section , Constructing the Fine Matcher, on page 3-14, rewrote the fine matcher construction instructions, and modified Figure 3-6, Probe Installation for Fine Matcher, on page Modified Section 4.5.3, The Conditioning Process, on page Rewrote Section 4.7.1, HPA Output Forward Power Calibration And Setup, on page 4-28 to reflect a better gird voltage setup procedure Rewrote Section , Adjustment of Grid BIas and Idle Current, for FCC Mask Compliance, on page Added Section , Checking IOT Dissipation and Efficiency, on page Added Section , Checking Heat Dissipation In The DI Water System, on page 5-37 Figure 5-23, RFU Chassis Rear Panel and Chassis Top View, With Single HPA Cabling, on page 5-51, moved cable from RF PA board J11 to J6. Figure 3-8, IOT Directional Coupler Cabling, on page 3-21, added notes giving coupling of couplers. Figure 6-1, RF Block Diagram for PowerCD Transmitter with One HPA Cabinet, on page 6-2 and Figure 6-2, Block Diagram for PowerCD Transmitter with Two HPA Cabinets, on page 6-3. Added ALC blocks and IPA gain control to both drawings. Table 6-2, Signal Levels For The Single HPA RFU System, on page 6-5 and Table 6-2, Signal Levels For The Single HPA RFU System, on page 6-5. Added a column of average signal levels in dbm. Continued on Next Page. 4/13/ MRH-1

6 MANUAL REVISION HISTORY Power CD Transmitter Rev. Date ECN Pages Affected Figure 6-6, Phase and Gain Board Block Diagram, on page 6-10, Added input from envelope detector to back porch level detector. Added Figure 6-8, Single Collector IOT Structure, on page Added filament voltage notes to Figure 6-9, Multi-collector IOT Showing DC Supplies, on page Added Section , Energy Flow From Electron Bunches To Primary Cavity, on page 6-17, this section includes four figures. Figure 6-23, HPA Output Couplers (Part of HPA Breakaway Assembly), on page 6-29, added IOT cabinet right sidewall couplers, to show connections to breakaway section. Table 6-5, HPA RF Coupler, on page 6-29, revised definitions of front bottom and rear couplers. Added notes to bottom of Figure 6-29, ALC System Block Diagram, on page Added Section 6.5.1, Grid Voltage Normal And Idle Modes, on page 6-50, which includes one figure. Figure 6-32, Idle Current Changes With Time (IOT Temperature), Eb and Eg Held Constant, on page 6-52, added the word temperature to the horizontal axis description. Figure 6-33, Idle Current Changes With Eb, Eg and Operating Temperature Held Constant, on page 6-52, removed reference to Eb from caption of drawing. Added Figure 5-1, Cooling Cabinet Lower Interior View, Showing New Cavity Blower Filter Location, on page 5-4, and modified Figure 5-2, Cooling Cabinet Lower Interior View, Showing Old Cavity Blower Filter Location, on page 5-4 Revised Table 6-6, System Bus Connector Pin Out, on page 6-32, and Table 6-7, IPA Module System Bus Pin Out, Backplane Board J7, J9, J11, J13, J15, on page Rev C 3/23/ Section 6.5.2, Effect of Grid Voltage and Idle Current on Spectrum Response, on page Re wrote text. Rev D 4/13/ Tables 7-3 and 7-5, changed Fuse, Slow Cart 0.5A250V PN to Fuse, Slow Cart 1.0A 250V PN , per request Kevin Novinger. Replaced all references to APEX Exciter with references to M2X Exciter. Removed all references to Ucartherm, replace with references to Dow SR1 for ethylene glycol and DowFrost for propylene glycol. Revised Chapter 7, Parts Lists, removing references to Ucartherm. Replaced Appendix G3, Ucartherm Brochure with Dowtherm SR-1 Brochure. MRH /13/2012

7 Guide to Using Harris Parts List Information 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 Cabinet, PA Cabinet, and Output Cabinet show up one indentation level below the Transmitter 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 Transmitter Table 7-1. Transmitter Table 7-2. Control Cabinet Table 7-3. Controller Board Table 7-4. PA Cabinet Table 7-5. PA Amplifier Table 7-6. PA Amplifier Board Table 7-7. Output Cabinet Control Cabinet Controller Board PA Cabinet PA Amplifier PA Amplifier Board Output Cabinet 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: 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.). NOTE: 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 three numbers are 000, the item is a part that Harris has purchased 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 the description column implies 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. 4/13/ vii

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11 ! WARNING: THE CURRENTS AND VOLTAGES IN THIS EQUIPMENT ARE DANGEROUS. PERSONNEL MUST AT ALL TIMES OBSERVE SAFETY WARNINGS, INSTRUC- TIONS 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 Halogenated Fire Extinguishing Agent Systems, No. 12A! WARNING: ALWAYS DISCONNECT POWER BEFORE OPENING COVERS, DOORS, ENCLO- SURES, 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. Keep away from live circuits, know your equipment and don 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 DEFEC- TIVE CAPACITOR. DO NOT ATTEMPT TO SERVICE A DEFECTIVE CAPACITOR WHILE IT IS HOT DUE TO THE POSSIBILITY OF A CASE RUPTURE AND SUBSE- QUENT INJURY. 4/13/ xi

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13 FIRST-AID Personnel engaged in the installation, operation, maintenance or servicing of this equipment are urged to become familiar with first-aid theory 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 STANDARD FIRST AID AND PERSONAL SAFETY MANUAL (SECOND EDITION) 4/13/ xiii

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15 Table of Contents 2533mainTOC.fm Table of Contents 1 Introduction Organization of Technical Manual General Description The GUI Display Driver Cabinet High Power Amplifier System (HPA) Block Diagram Transmitter Sub Assemblies Driver Cabinet Display Unit RFU Drive Control Power Supply Cabinet Display Unit HPA controller board LV power supplies Floating Power Supply Step Start Unit Transmitter Control System Organization of Transmitter Documentation Packages Major Transmitter System Components (Cabinets) Driver Cabinet HPA Assembly HPA System IOT Circuit Assembly Types e2v Multi-collector IOT Circuit Assembly Specifications General Specifications Performance Specifications Environmental Specifications Building Heat Load Physical Dimensions Power Cabinet Keylock System Power Cabinet Rear Door Unlocking Procedure Power Cabinet Front Door Unlocking Procedure Key Management Key Management, Key Reorder Form /13/ Page: xv

16 Table of Contents 3 Transmitter Installation HPA IOT Circuit Assembly Types Fuses or Breakers For AC Distribution Chain Planning a Successful Installation Delivery and Storage Returns and Exchanges Unpacking High Voltage Power Supplies Equipment Placement Beam Supplies and Cooling Units Pump Module Automatic Voltage Regulator (AVR) RF System RF System Mounting Height RF System Placement PowerCD Driver and HPA System Cabinet Installation Procedure Interconnecting Transmission Line and Waveguide Preparation For Installing Transmission Line Installation of Fine Matcher Sections for RF Line Optimization Constructing the Fine Matcher RF Sample Cables Plumbing System Installation Guidelines For Installing the Cooling System Cooling System Checkout RF System Optimization Reinstalling The IOT Trolley Conduit and Electrical Installation Fuses or Breakers Conduit Conduit For High Voltage From Beam Supply HPA Power Cabinet Branch Circuits HPA Power Cabinet to Beam Supply Wiring AC Mains Conduits and Connections HPA Internal Assembly Cable and Wire Connections e2v 5130w IOT Umbilical Cord Connections Page: xvi /13/12

17 Table of Contents 2533mainTOC.fm IPA Installation Driver Cabinet Control and Signal Interconnections Transmitter Control Interconnections External Interlock Connections Transmitter Parallel Remote Control Connections Mode Controller Setup Transmitter System Dip Switch Settings Power Supply Cabinet Dip Switches Cooling Cabinet Dip Switch Settings Driver Cabinet Dip Switch Settings External I/O Board RFU Controller board Power Supply Controller Transmitter Checkout Automatic AC Voltage Regulator Commissioning Driver Cabinet Power Up Power Up and Checkout of HPA(s) Verifying AC and LVPS in Power Supply Cabinet Bringing Up Display Unit Installing Barnstead Filters Fill Water Cooling Tank In Cooling Cabinet Bleeding Barnstead Filters Cooling Cabinet Power Up and Check Out Setting Flow Through Barnstead Filters Checking Flow Meter Calibration Setting Liquid Cooling Flow Rates Reconnecting The Mezzanine Ribbon Cable First Application of Lower IOT Voltages Checking RF System Exciter Setup ISO Supplies and Step Start Controller Checkout Conditioning A New MSDC IOT The ION Pump Precautions Taken With A New IOT The Conditioning Process PowerCD Transmitter IOT Tuning /13/ Page: xvii

18 Table of Contents IOT Tuning Cautions Power Levels Used For IOT Tuning Tuning At Low Power Tuning At Medium Power e2v Multi-collector IOT Input Tuning Interaction of Input and Output Tuning and Power Level Basic IOT Output Tuning Bandwidth Measurement Methods Measuring Depth Saddle and Height of Haystack Measuring Bandwidth The Four Output Tuning Controls Primary Tuning Interstage Coupling Changes Secondary Tuning Loading (output Coupling) Changes Setup and Procedures For the Multi-collector IOT Output Tuning Typical Low Power Output Tuning Results First Operation at Full Output Power HPA Output Forward Power Calibration And Setup HPA Output Reflected Power Setup System and HPA Automatic Level Control (ALC) Setup Warm Cavity Medium Power Tuning Reject Load Calibration, For Transmitters With Two or More PAs Combining HPAs in a Multiple Tube System System Level Forward Power Calibration System Level Reflected Power Setup Verifying RTAC RF Sample Levels Activating RTAC Correction Output Shoulders Fails FCC Mask Test RF System/Mode Controller Checkout Hour Transmitter Operation Test Maintenance Recommended Test Equipment Equipment Cleaning Scheduled Maintenance Weekly Maintenance Page: xviii /13/12

19 Table of Contents 2533mainTOC.fm Electrical Performance Monthly Maintenance Electrical Performance Transmitter Room Biannual Maintenance IOT Inspection Interior Transmitter Cleaning Fiberglass Insulators (G-10) and 50 Meg Ohm Resistors Electrical Performance Power Cabinet and Beam Supply Annual Maintenance DI Water System Materials Needed for UV Lamp and Filter Change Barnstead Micron Filter Cartridge Barnstead ION Exchange Cartridge The UV Lamp Conductivity Meter Sensor Installing Barnstead Filters IOT Ceramic Cleaning Cavity Inspection Beam Supply Glycol System Flow Meter Parts Lists Flow Meter Models Used In PowerCD Flow Meter Rebuild Parts Water Flow Rate Check Cooling Cabinet Flow Meter Calibrations Cavity Air Flow IOT Removal/Replacement e2v Multi-collector IOT Removal/Replacement Cabinet Power Down Disconnecting IOT Circuit Assembly From PA Cabinet Transmission Line Breakaway Disassembly /Assembly Removing IOT Circuit Assembly From PA Cabinet Tube Removal and Replacement Reinstallation of IOT Circuit Assembly /13/ Page: xix

20 Table of Contents 5.8 Full Heater Voltage Adjustment BG Heater Voltage Adjustment Focus Current Adjustment IOT Conditioning Following Replacement The ION Pump Precautions Taken With A New IOT The Conditioning Process IOT Beam Idle Current IOT Tuning and Setup After Tube Conditioning IOT Tuning Cautions Power Levels Used For IOT Tuning Tuning At Low Power Tuning At Medium Power e2v Multi-collector IOT Input Tuning Interaction of Input and Output Tuning and Power Level Basic IOT Output Tuning Bandwidth Measurement Methods Measuring Depth Saddle and Height of Haystack Measuring Bandwidth The Four Output Tuning Controls Primary Tuning Interstage Coupling Changes Secondary Tuning Loading (output Coupling) Changes Setup and Procedures For Multi-collector IOT Output Tuning Typical Low Power Output Tuning Results Warm Cavity Medium Power Tuning IOT Setup following Tube Tuning Adjustment of Grid BIas and Idle Current, for FCC Mask Compliance Checking IOT Dissipation and Efficiency Checking Heat Dissipation In The DI Water System Combining HPAs in a Multiple Tube System Activating RTAC Correction Output Shoulders Fails FCC Mask Test Negative IOT Grid Current Increases Over A Several Month Period Explanation of Grid Current Page: xx /13/12

21 Table of Contents 2533mainTOC.fm 5.15 HPA Forward Power Calibration And Setup HPA Reflected Power Setup System Level Forward Power Calibration System Level Reflected Power Setup Reject Load Calibration, For Transmitters With Two or More PAs HPA ALC Setup IPA Module Gain Setup ARC Overload Parameter Limits Set By Software HPA Faults Warnings and Limits RFU Chassis Layout Theory of Operation Introduction to the IOT RF Section Power CD Transmitter RF System Block Diagrams Overview of Major RF Components of Block Diagram Radio Frequency Unit (RFU) The Exciter Switcher RFU Operation for Single HPA Systems Small Signal Board, for Multiple HPA Systems IPA Module Phase and Gain Board Automatic Level Control (ALC) RF Pallets Auto Bias Circuit Pallet Splitters and Combiner Module Controller PS Front End Board Power Supply Board The Multi-collector IOT Beam Current, Collector and Cathode Assembly Voltages IOT Arc and Ground Current Protection IOT Collector and Body Current Energy in the IOT Beam Current Formation of Electron Bunches Energy Flow From Electron Bunches To Primary Cavity Single Collector IOT Beam Current, For Reference Only /13/ Page: xxi

22 Table of Contents e2v Multi-collector IOT Beam Current MEDC IOT Collector Currents Verses Output Power IOT RF Output Circuits HPA Output RF Coupler Samples PowerCD Control System The System Bus IPA Module Modified System Bus Connections In-System Programming or ISP The Local Bus Display Unit Switch Panel (Switch Board, or Control Panel) Introduction Modes of Operations Button Presses Button / Indicator lighting Button States Error Messages and Indicators FP Error Com Error, Main Controller COM ERROR, MODE CONTROLLER COM ERROR, RFU CONTROLLER COM ERROR, CONTROL SYSTEM Power Indicators (DS5 and DS63) RFU Controller Critical Life Support Functionality Status Indicators Switches Test Points External I/O Functionality Driver Cabinet Functionality Cooling Cabinet Functionality Critical Life Support Functionality Status Indicators Switches Test Points Page: xxii /13/12

23 Table of Contents 2533mainTOC.fm Micro Uses External I/O IPA Module Controller RFU Controller Power Supply Monitor (Controller) Micros Mode Controller Automatic Level Control (ALC) System HPA ALC In The Remote Disabled Mode HPA ALC In The Remote Enabled Mode ALC Master and Control Signals VSWR Foldback Circuit Grid Voltage and Idle Current Adjustment Grid Voltage Normal And Idle Modes Effect of Grid Voltage and Idle Current on Spectrum Response IOT Idle Current Variation Parts List Appendix A Cutting and Soldering Transmission Line A-1 A.1 Suggested Cutting And Soldering Procedure A-1 A.2 Line Cutting and Flange Soldering Procedure A-1 A.3 Cutting The Transmission Line A-3 A.4 Soldering Flanges A-6 A.4.1 Soldering Procedure A-6 A.5 Cleaning The Soldered Joint A-7 A.5.1 Alternate Cleaning Method A-8 Appendix B Lightning Protection Recommendation B-1 B.1 Introduction B-1 B.2 Environmental Hazards B-2 B.3 What Can Be Done? B-5 B.4 AC Service Protection B-6 B.5 Conclusion B-7 Appendix C Grounding Considerations, Surge & Lightning Protection C-1 C.1 Surge and Lightning Protection C-1 C.2 System Grounding C-1 C.2.1 Ground Wires C-2 C.2.2 AC Ground C-2 04/13/ Page: xxiii

24 Table of Contents C.2.3 DC Ground C-2 C.2.4 Earth Ground C-3 C.2.5 RF Ground C-3 Appendix D External Heat Exchanger System D-1 D.1 Equipment Purpose D-1 D.2 General Description D-1 D.2.1 Major Hardware D-2 D.2.2 Equipment Characteristics D-2 D Electrical Requirements D-2 D Mechanical/Environmental Characteristics D-2 D.2.3 Recommended Coolants D-3 D During Checkout and Flushing D-3 D.3 Installation D-4 D.3.1 Unpacking D-4 D.3.2 Plumbing Layout Drawings D-5 D.3.3 Pump Module Location D-5 D.3.4 Externally Mounted Fluid Cooler D-5 D.3.5 Ice/Sun Shield D-5 D.3.6 Pipe Sizing and Routing D-6 D.3.7 Plumbing System Installation D-6 D.3.8 Reserve Coolant Supply D-6 D.3.9 Clean-Up Plan D-6 D.4 Startup Checkout and Operation D-6 D.4.1 Controls and Indicators D-6 D.4.2 Pump Rotation D-7 D Fan Rotation D-7 D.4.3 Start Up Procedure D-7 D.4.4 Flushing The Cooling System D-7 D.5 Theory of Operation D-10 D.5.1 External Fluid Cooler D-10 D.6 Maintenance D-11 D.7 Troubleshooting D-11 D.8 Fluid Cooler Parts Lists D-12 Appendix E Internal Pure Water System Setup and Maintenance E-1 E.1 Pure Water Loop Component Descriptions E-1 E.1.1 Supply Loop E-1 Page: xxiv /13/12

25 Table of Contents 2533mainTOC.fm E.1.2 Return Loop E-1 E.1.3 Purification Loop E-1 E.1.4 Collector Cooling Loop E-1 E.1.5 Anode Cooling Loop E-1 E.1.6 Glycol External Cooling Loop E-2 E.2 Cooling Cabinet Prestart Checklist E-2 E.3 Cooling Cabinet Pure Water Loop Service E-2 Appendix F Linear RF Amplifiers F-1 F.1 Review of Heterodyne Action F-1 F.1.1 Multiple-Order Intermodulation Products F-1 F Intermodulation Product Levels F-2 F.1.2 Modulation Crosstalk F-2 F.2 Classes of Operation F-3 F.2.1 Class AB F-3 F Class AB Bias F-3 Appendix G Vendor Data G-1 G.1 SeaMetrics S-Series Low Flow Meter Instructions G-1 G.2 IOT Breakaway Section G-5 G.3 DOWTHERM SR-1, Inhibited Ethylene Glycol, Product information g-6 G.4 NWL 80 kw, 3-Channel Beam Supply Manual G-6 G.5 NWL Solid State Step Start Manual G-6 G.6 e2v ESCIOT5130 Specifications Manual G-6 G.7 e2v 3-Electrode Spark Gap Manual G-6 04/13/ Page: xxv

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27 List of Figures 2533mainLOF.fm List of Figures Figure 1-1 Basic PowerCD Transmitter Cabinets Figure 1-2 Top View of a Three Tube Power CD Transmitter Figure 1-3 Power CD Transmitter RF BLock Diagram (One HPA) Figure 1-4 Power CD Transmitter RF BLock Diagram (Three HPAs) Figure 1-5 e2v Multi-collector IOT Circuit Assembly Figure 2-1 Power Supply Cabinet Rear Door Unlocking Sequence Figure 2-2 Power Supply Cabinet Front Door Unlocking Sequence Figure 3-1 Waveguide Tightening Sequence Figure 3-2 Setup for Lifting Cabinets off of Pallets Figure 3-3 Driver and HPA Cabinets of a 1-Tube Power CD Transmitter Figure 3-4 Top View of the 3-Tube PowerCD Transmitter Figure 3-5 Breakaway Assembly of the IOT Cabinet Figure 3-6 Probe Installation for Fine Matcher Figure 3-7 IOT Trolley Front View Showing Cavity Arc Detector Connectors Figure 3-8 IOT Directional Coupler Cabling Figure 3-9 Beam Supply to Step Start Control Board Wiring Figure 3-10 NWL A Beam Supply Wiring Figure 3-11 Top Front View of Power Cabinet Showing Cable Duct Access Panel Figure 3-12 Heater, Cathode, and Grid Bias Connections For e2v Multi-collector IOT Figure 3-13 HV Wiring, Cathode and Collectors 2-5, In Rear of Power Cabinet Figure 3-14 HV Wiring, Return Current and Ground Fault Senser, In Rear of Power Cabinet Figure 3-15 Isolated Supply Cable Entrance, In Rear of Power Cabinet Figure 4-1 Cooling Cabinet Pump Rotation and Coolant Flow Direction Figure 4-2 Rear View Cooling Cabinet Figure 4-3 Rear View of Cooling Cabinet Showing Flow Meters Figure 4-4 Cooling Cabinet Door, Showing Filters and Flow Meter Figure 4-5 IOT Cabinet Front View Showing DeIonized Water Flow Control Valves Figure 4-6 Beam Supply HV Tap and Output Voltages Switches Figure 4-7 e2v Multi-collector IOT Plug In Tube Input Match, Two Examples Figure 4-8 IOT Input Reflected Response When HPA Is At Full Power Figure 4-9 Bandwidth and Depth of Saddle (or Hay Stacked) Measurement Figure 4-10 Primary Tuning Figure 4-11 Coupling Figure 4-12 Secondary Tuning Figure 4-13 Loading (Output Coupling) /13/ Page: xxvii

28 List of Figures Figure 4-14 Low Power Tuning Starting Response Figure 4-15 M2X Exciter Showing RTAC Bypassed Figure 4-16 Spectrum Of HPA Output, Before High Power Filter, All RTAC Correction Bypassed Figure 4-17 IOT Input Reflected Response When HPA Is At Full Power Figure 4-18 Medium Power Tuning Warm Cavity Output Response Figure 4-19 HPA Output Showing Correct Adjacent Channel Shoulder Response Figure 4-20 IOT InpuT Match Response Before and After Readjustment of Input Tuning Figure 5-1 Cooling Cabinet Lower Interior View, Showing New Cavity Blower Filter Location Figure 5-2 Cooling Cabinet Lower Interior View, Showing Old Cavity Blower Filter Location Figure 5-3 Rear View of Cooling Cabinet Showing Flow Meters Figure 5-4 Beam Supply HV Tap and Output Voltages Switches Figure 5-5 e2v Multi-collector IOT Plug In Tube Input Match, Two Examples Figure 5-6 IOT Input Reflected Response When HPA Is At Full Power Figure 5-7 Bandwidth and Depth of Saddle (or Hay Stacked) Measurement Figure 5-8 Primary Tuning Figure 5-9 Coupling Figure 5-10 Secondary Tuning Figure 5-11 Loading (Output Coupling) Figure 5-12 Low Power Tuning Starting Response Figure 5-13 IOT Input Reflected Response When HPA Is At Full Power Figure 5-14 Medium Power Tuning Warm Cavity Output Response Figure 5-15 M2X Exciter Showing RTAC Bypassed Figure 5-16 Spectrum Of HPA Output, Before High Power Filter, All RTAC Correction Bypassed Figure 5-17 Upper Portion of the HPA GUI > Power Amp > Meters Screen Figure 5-18 HPA GUI > System > Meters >Cooling Screen Figure 5-19 HPA Output (Before Mask Filter) Showing Correct Adjacent Channel Shoulder Response Figure 5-20 IOT InpuT Match Response Before and After Readjustment of Input Tuning Figure 5-21 Graph of IOT Grid Voltage and Current Flow Figure 5-22 RFU Chassis Rear Panel and RFU Chassis Top View Figure 5-23 RFU Chassis Rear Panel and Chassis Top View, With Single HPA Cabling Figure 5-24 RFU Chassis Rear Panel and Chassis Top View, With Cabling For Three HPAs Figure 6-1 RF Block Diagram for PowerCD Transmitter with One HPA Cabinet Figure 6-2 Block Diagram for PowerCD Transmitter with Two HPA Cabinets Figure 6-3 Block Diagram of RFU, For System With One HPA Figure 6-4 Block Diagram of RFU, For System With Three HPAs Figure 6-5 IPA Module Simplified Block Diagram Page: xxviii /13/12

29 List of Figures 2533mainLOF.fm Figure 6-6 Phase and Gain Board Block Diagram Figure 6-7 Pallet Simplified Diagram Figure 6-8 Single Collector IOT Structure Figure 6-9 Multi-collector IOT Showing DC Supplies Figure 6-10 IOT Side View, Showing Development of Electron Bunches, Slide Figure 6-11 IOT Operation: Cathode Current, Primary Cavity Voltage, Electron Bunches, Slide Figure 6-12 IOT Operation: Cathode Current, Primary Cavity Voltage, Electron Bunches, Slide Figure 6-13 IOT Operation: Cathode Current, Primary Cavity Voltage, Electron Bunches, Slide Figure 6-14 IOT Operation: Cathode Current, Primary Cavity Voltage, Electron Bunches, Slide Figure 6-15 Drift Tube and Cavity Assemblies of a Single Collector IOT Figure 6-16 Drift Tube and Cavity Assemblies of a e2v multi-collector IOT Figure VSB Waveform, Low Signal Power Causes all Current to Flow to Collector Figure VSB Waveform, Peaks Reaching Collector 3 Zone, Some Collector 3 Current Flow Figure VSB Waveform, Peaks Reach Collector 1 Zone, Current Flow in collectors 1 through Figure 6-20 Maximum 8VSB Output, Collector 2 Current Equal To Or Greater Than Collector Figure 6-21 Significant Clipping Of 8VSB, Collector 1 Current Greater Than Collector 2 Current Figure 6-22 Expended Clipped Peak Showing Relative Current Flow For Collectors 1 Through Figure 6-23 HPA Output Couplers (Part of HPA Breakaway Assembly) Figure 6-24 PowerCD Logic Block Diagram Figure 6-25 Local Bus, Driver Cabinet Figure 6-26 Display Unit Block Diagram Figure 6-27 Front View of Control Panel Figure 6-28 Rear View of Control Panel Figure 6-29 ALC System Block Diagram Figure 6-30 Grid Bias Circuit Block Diagram Showing E Pot Control Figure 6-31 Spectrum Of HPA Output, Before High Power Filter, All RTAC Correction Bypassed Figure 6-32 Idle Current Changes With Time (IOT Temperature), Eb and Eg Held Constant Figure 6-33 Idle Current Changes With Eb, Eg and Operating Temperature Held Constant Figure A-1 Measurements When Elbows Are Used A-2 Figure A-2 Outer Conductor Measurements A-2 Figure A-3 Measurement for Cutback of Inner Conductor A-3 Figure A-4 Guide For Use With Hand Hack Saw A-4 Figure A-5 Cutting With a Hand Band Saw A-4 Figure A-6 Swing Arm Band Saw Cutting Tips A-5 Figure A-7 Use Of Tubing Cutter Results In Crimped Cut (Exaggerated) A-5 Figure A-8 Bevel Cut End and Remove Burs A-7 04/13/ Page: xxix

30 List of Figures Figure A-9 Torch Aiming Location A-7 Figure B-1 Map Showing Lightning Days Per Year B-1 Figure B-2 Lightning Incidents to Tall Structures B-2 Figure B-3 Regulators for Delta and 4-Wire WYE systems B-3 Figure B-4 EM Flux Field B-4 Figure B-5 Sample Surge Voltage as a Function of Distance From Stroke to Line B-4 Figure B-6 Surge Protectors and Ferrite Chokes B-5 Figure B-7 Basic Elements of a Properly Designed Antenna System B-6 Figure D-1 Block Diagram Heat Exchanger System D-1 Figure F-1 Spectrum Analyzer Display Showing Intermodulation Products F-2 Figure F-2 Class AB Amplifier Transfer Curves F-4 Page: xxx /13/12

31 List of Tables 2533mainLOT.fm List of Tables Table 1-1 Transmitter Model Numbers Table 1-2 e2v 5130w IOT Ratings Table 1-3 General Specifications Table 1-4 Tube Output Power and Transmitter Model Numbers Table 1-5 Specifications Table 1-6 AC Specifications for Various Models Table 1-7 Environmental Specifications Table 1-8 Building Heat Load for Various Transmitter Models Table 1-9 Physical Dimensions for Various Transmitter Models Table 3-1 Installation Tools and Materials Table 3-2 Shipping Weights and Measurements Table 3-3 Example of 1/8 Wavelength Calculation Table 3-4 Interlock Jumpers Table 3-5 ISO Supply HVPS monitor board S1 Settings Table 3-6 HPA Controller Board S1 Settings Table 3-7 Cooling Cabinet Dip Switch Settings Table 4-1 Beam Supply HV Tap Switches and Output Voltages Table 5-1 Recommended Test Equipment Table 5-2 Materials Needed for UV Lamp and DI Water Filter Changes Table 5-3 SeaMetrics Flow Meter Rebuild Parts Table 5-4 Beam Supply HV Tap Switches and Output Voltages Table 5-5 HPA Faults Warnings and Limits Table 5-6 RFU Chassis Connections Table 6-1 Signal Levels For The Exciter Switcher Table 6-2 Signal Levels For The Single HPA RFU System Table 6-3 Signal Levels For The Multiple HPA RFU System Table 6-4 e2v 5130w IOT Parameters, Left = Tube Data Sheet, RIght = Engineering Tx Table 6-5 HPA RF Coupler Table 6-6 System Bus Connector Pin Out Table 6-7 IPA Module System Bus Pin Out, Backplane Board J7, J9, J11, J13, J Table 6-8 Local Bus Function and Pinout Table 6-9 Switch Panel Operating Mode Selection Table 6-10 Cabinet ID Settings Table 7-1 FORMAT, SYSTEM, PWR30D (Z) Table 7-2 PUMP INTER ASSY - FOR SIGMA PUMP TO POWERCD (J) /13/ Page: xxxi

32 List of Tables Table 7-3 PWA, MULTI I/O FOR SIGMA PUMP MODULE W/ POWERCD T (A). 7-4 Table 7-4 FORMAT, XMTR, PWR30D (V) Table 7-5!FORMAT, POWERCD TANK BASE PUMP MODULE (A) Table 7-6 CONTROLLER, DUAL AC, POWER CD PUMP (D) Table 7-7 PA MODULE DIGITAL POWER CD (G) Table 7-8 MODULE, BASIC, RF AMP, UHF BAND (Z) Table 7-9 MK2 UHF BROADBAND PALLET (D) Table 7-10 PWA, PHASE & GAIN (F--) Table 7-11 PWA, PS FRONT END (D--) Table 7-12 PWA, POWER SUPPLY (F--) Table 7-13 PWA, PREDRIVER PALLET (B) Table 7-14 PWA, MODULE CONTROLLER (C) Table 7-15 PWA, 8-WAY COMBINER (B--) Table 7-16 KIT, SPARE BOARDS (K) Table 7-17 ASSY, FOCUS SUPPLY, TESTED T (A) Table 7-18 FOCUS SUPPLY (C) Table 7-19 ASSY, GRID SUPPLY, TESTED T (A) Table 7-20 ASSY, GRID SUPPLY (B) Table 7-21 ASSY, FILAMENT SUPPLY, TESTED T (A) Table 7-22 ASSY, FILAMENT SUPPLY (C) Table 7-23 *PWA, SWITCH BOARD, TESTED T (A) Table 7-24 *PWA, ISO SUPPLY MONITOR, TESTED T (A) Table 7-25 *PWA, ISO SUPPLY MONITOR (E) Table 7-26 PWA, SPARK GAP INTERFACE, TESTED T (A) Table 7-27 PWA, SPARK GAP INTERFACE (D-) Table 7-28 PWA, COOLING CONTROL BOARD, TESTED T (A) Table 7-29 PWA, COOLING CONTROL BOARD (E) Table 7-30 *PWA, EXTERNAL I/O, TESTED T (A) Table 7-31 *PWA, EXTERNAL I/O (C) Table 7-32 *PWA, HPA CONTROLLER, TESTED T (A) Table 7-33 *PWA, HPA CONTROLLER (C) Table 7-34 PWA, STEP START CONTROL, TESTED T (A) Table 7-35 PWA, STEP START CONTROL (C-) Table 7-36 PWA, HIGH VOLTAGE METERING, TESTED T (A) Table 7-37 *PWA, HIGH VOLTAGE METERING (H-) Table 7-38 PWA, ION SUPPLY, TESTED T (A) Page: xxxii /13/12

33 List of Tables 2533mainLOT.fm Table 7-39 *PWA, ION SUPPLY (D-) Table 7-40 KIT, SPARE PARTS (F) Table 7-41 KIT, SPARE PARTS, ADVANCED (H) Table 7-42 PWA, ISO SUPPLY AC INTERFACE (B-) Table 7-43 PWA, ISO SUPPLY TRANSIENT INTF (A-) Table 7-44 KIT, SPARE PARTS, BEAM SUPPLY (C) Table 7-45 KIT, SPARE PARTS, NWL STEP START (B) Table 7-46 KIT,SPARES,POLY TANK BASE, 2IN PUMP MODULE (A) Table 7-47 FORMAT, SYSTEM, PWR60D (AA) Table 7-48 FORMAT, XMTR, PWR60D (T) Table PH, 400V, MOV PKG (DELTA) (B) Table 7-50 *PWA, MOV/AC SAMPLE AA, 400VDELTA (C--) Table 7-51 MOV BD, 480 VAC (A) Table 7-52 PWA, MOV/AC SAMPLE, PH (D--) Table 7-53 DRIVER CAB, BASIC, POWER CD (AA) Table 7-54 *ASSY, DISPLAY UNIT W/ GUI P-CD (A) Table 7-55 ASSY, DISPLAY UNIT MINUS GUI POWER-CD (B) Table 7-56 PWA, MODE CONTROLLER (E--) Table 7-57 PWA, CUSTOMER INTERFACE BOARD (D-) Table 7-58 PS CABINET, POWER CD (U) Table 7-59 TOWER, RESISTOR - GND SWITCH (A) Table 7-60 SUPPLY, ISO (E) Table 7-61 ASSY, CONTROL PANEL (115VAC) (G) Table 7-62 IOT CABINET, POWER CD (C) Table 7-63 KIT, EARTH WAND (C) Table 7-64 POWER SUPPLY 480 VAC (S) Table 7-65 *PWA, OVERVOLTAGE PROTECTION UNTESTED (H--) Table 7-66 POWER SUPPLY VAC (L) Table 7-67 PWA, MOV/AC SAMPLE,400 3 PH DE (C--) Table 7-68 FORMAT, SYSTEM, PWR90D (W) Table 7-69 FORMAT, XMTR, PWR90D (T) Table 7-70 DRIVER CAB, BASIC, POWER CD (AA) Table 7-71 PWA, MODE CONTROLLER (E--) Table 7-72 *PWA, PS MONITOR CONTROLLER UNTESTED (A--) Table 7-73 *PWA, PA BLOCK CONTROLLER UNTESTED (J) Table 7-74 *PWA, 376 MICRO MODULE G (A--) /13/ Page: xxxiii

34 List of Tables Table 7-75 COOLING CAB, POWERCD, DOOR FLTR (L) Table 7-76 ASSY, LIQUID LEVEL SWITCH (A) Table 7-77 KIT, POWERCD, RFU, 3 CABINET (F) Table 7-78 KIT, SPARES, 2-1/2 INCH FLANGE PUMP (A) Table A-1 Tools and Materials Needed For RF Feed Line Construction A-1 Table B-1 Significant Lightning Stroke Characteristics B-3 Table D-1 Cooling System Electrical Characteristics D-2 Table D-2 Cooling System Physical/Environmental Characteristics D-3 Table D-3 Recommended Coolants D-4 Table D-4 External Cooling Systems Capacities D-10 Table D-5 Cooling System Maintenance Schedule D-11 Table D-6 Pump Troubleshooting D-12 Table D-7 Fan and Thermal Troubleshooting D-12 Table D-8 Fluid Cooler Electrical Parts List For 2, 3, or 4 Fan Units D-13 Page: xxxiv /13/12

35 Organization of Technical Manual PowerCD Transmitter Introduction 1 Introduction This technical manual describes the Harris PowerCD UHF digital television transmitter series, which is designed around the high power, high efficiency multi-collector IOT. 2533s100.fm Multiple power levels are available by using system configurations of one to three HPAs (high power amplifier) systems, which are listed in Table 1-1. Table 1-1 Transmitter Model Numbers TX Models Number HPAs Tube Type Output Power level PWR30D1 1 e2v 5130w 30kW Average PWR60D2 2 e2v 5130w 60kW Average PWR90D3 3 e2v 5130w 90kW Average 1.1 Organization of Technical Manual 1.2 General Description The manual is divided into the following sections: Section 1: Introduction Section 2: Power Cabinet Keylock System Section 3: Transmitter Installation Section 4: Transmitter Checkout Section 5: Maintenance Section 6: Theory of Operation Section 7: Parts List In addition to this manual, three large books of drawings are also supplied, they are: PowerCD basic transmitter drawing package, consisting of two large books of drawings, which apply to all PowerCD transmitters. System specific drawing package, which contains cabinet outline drawings, system installation drawings, and cabinet interconnect drawings for your transmitter. Separate technical manuals and other documentation are also provided for: M2X exciters ecdi (User network interface, GUI) PowerCD Operator s Manual (via GUI) Output RF system High voltage power supply IOT amplifying tube Schematic drawings for the RF system accompany its manual. This section contains a general description of the PowerCD series of television transmitters. Included in this section will be descriptions of the control system, power amplifier system, block diagrams of the different models and system specifications. 04/13/ Page: 1-1

36 Introduction General Description All PowerCD transmitters include a driver cabinet, which supplies a medium level RF drive signal to each high power amplifier (HPA). One driver cabinet will support up to 3 HPA cabinets. The number of HPAs used depends on the desired power level and configuration. Figure 1-1 shows a typical PowerCD transmitter with one amplifier cabinet. Driver Cabinet M2X Exciters Control Unit GUI Display, Mounted on the Display Unit RF Unit (2RU) mounted under the Display Unit IPA Modules Figure 1-1 Basic PowerCD Transmitter Cabinets This transmitter features the e2v 5130 IOT, which requires an electrically non-conductive liquid cooling system and multiple beam supply voltage taps. Each HPA system has its own high voltage beam power supply. The beam power supply is normally an oil-filled outdoor unit. The AC supply voltage for the beam supply is routed through the PA assembly power supply cabinet, which houses the beam supply step start assembly. The driver and HPA cabinets uses both air, a water/glycol mixture and water for cooling. Internal air cooling is used to cool the tube cavities and other cabinet circuits. Water/glycol mixture is used to cool the IPA (intermediate power amplifier) driver modules and any reject/test loads. A deionized water loop, contained within the HPA system, cools the tube and a heat exchanger transfers the heat from the deionized water to the water/glycol loop. Page: /13/12

37 General Description PowerCD Transmitter Introduction The external liquid cooling system consists of one or more pump modules and one or more heat exchangers, based on transmitter size and customer preference. It is sized to cool the system under full operating power conditions at the highest expected ambient temperature. The water/glycol solution is used to prevent freeze damage during operation in cold climates. 2533s100.fm The GUI Display A water only cooling system can be used in areas where the temperature never drops below 32 F (0 C). When using the water only system, resistive loads must be substituted for the water column loads. The GUI (Graphical User Interface) touch screen systems are mounted in the front of the driver cabinet and each HPA system. The GUI screens are used to display all transmitter operating status and meter readings. The GUI screens can also be used as the transmitter s control panel. A panavise clamp allows the GUI display to swivel up and down as well as to the side for more convenient viewing. The mounting for the GUI display is on the front of the 2RU panel of the display unit. A series of nested screens is selected by pressing buttons which appear on the screen. All transmitter controls appear as push-buttons on the screens. The GUI screens allow the transmitter operator to view the transmitter metering and overall condition. It offers exceptional access and visibility to all areas of the transmitter, which allows the operator to focus on a specific area of the transmitter for detailed analysis or troubleshooting. Remote control software in the display unit permits the transmitter s GUI displays to be viewed and operated over an ethernet connection from a remote location Driver Cabinet The driver cabinet (on the left in Figure 1-1) contains the main transmitter control panel as well as the RF drive system. Included in the driver cabinet are: An M2X exciter Complete information on the M2X exciter assembly is supplied in a separate service manual. An optional second M2X exciter An RFU (RF Unit) to select the on-air exciter, provide low level RF drive signals for the IPA modules, provide RF phase adjustment provisions for proper HPA output power combining, and automatic level control (ALC) for each HPA and the RF output system. There is one IPA module, located in the driver cabinet, for each HPA assembly. Each IPA module supplies drive to one IOT. The IPA modules are Liquid cooled, with other components of the driver cabinet cooled with flushing air. Each IPA module is a self contained, self monitoring power amplifier module with built in power supplies and control logic. The module only requires AC input power, RF drive, on/off commands, and a liquid cooling system. 04/13/ Page: 1-3

38 Introduction General Description A 12" color touch screen GUI (graphic user interface) display unit. It is used for transmitter setup and too display detailed information for the operator. The display unit allows users to connect to the ethernet and run remote ecdi. A control unit which consists of the following two boards. External I/O, which provides remote control provisions for parallel and series remote control. This board also stores system information. A mode controller to control, monitor and protect the high power filter, the antenna/load switch and also the RF output combining system 9for two or more HPAs. The power supply monitor board provides monitoring for the driver cabinet power supply and cooling (liquid and air) systems. Redundant DC power supplies for the driver cabinet sub assemblies. Step down transformer to provide the necessary driver cabinet AC voltages from the AC mains High Power Amplifier System (HPA) Each HPA receives a medium-level RF drive from the driver cabinet and amplifies it to the desired output level. The high power amplifier system consists of three joined cabinets and one beam supply, which are as follows: IOT Cabinet, Refer to Figure 1-2. This cabinet sits in the recessed area between the driver cabinet and power supply cabinet for single tube systems, or between its power supply cabinet and the power supply cabinet for an adjacent HPA system. It houses the multi-collector IOT, the RF breakaway section, and other IOT interface components. Power Supply Cabinet, Refer to Figure 1-2. The power supply cabinet, sitting on the right side of the IOT cabinet, houses all the components necessary to power and monitor the multi element IOT. This includes the interface for the AC power used by the high power amplifier system and the beam supply, the HPA control system, a touch screen GUI, an interface to the driver cabinet system controller, as well as the various required low voltage power supplies for the HPA system. Cooling Cabinet, Refer to Figure 1-2. This cabinet is located behind the IOT cabinet and is flanked by the driver and power supply cabinets. It houses the deionized water cooling components for the tube, which provides a means to exchange heat between this cooling system and external glycol system, and provides the necessary control and monitoring for the cooling systems. It also includes the air cooling components for the IOT and power supply cabinets, and an external customer interface for remote control of the HPA system. Beam supply This is a separate, sealed assembly typically placed outside. It is a linear supply with multiple taps to accommodate the multi-collector IOT. Page: /13/12

39 General Description PowerCD Transmitter Introduction 2533s100.fm Driver Cabinet Cooling Cabinet IOT Cabinet Power Cabinet Cooling Cabinet IOT Cabinet Power Cabinet Cooling Cabinet IOT Cabinet Power Cabinet HPA System 1 HPA System 2 HPA System 3 Figure 1-2 Top View of a Three Tube Power CD Transmitter Block Diagram Refer to Figures 1-3 and 1-4 for RF system block diagrams for single tube and three tube Power CD transmitters. The HPA and transmitter system ALC (automatic level control) system is shown in Figures 1-3 and 1-4, and is discussed in detail in Section 6.4, Automatic Level Control (ALC) System, on page M2X Exciter Driver Cabinet RF Unit IPA HPA HPA Controller High Power (FCC Mask) Sharp Tuned Filter Optional RF Switch or Patch Panel M2X Exciter ALC Control ALC Reference ALC RF Sample Fwd Fwd Test Load 2 Way Splitter 2 Way Splitter HPA Feedback Sample HPF Feedback Sample Use good quality RF cable to avoid signal ingress. Figure 1-3 Power CD Transmitter RF BLock Diagram (One HPA) 04/13/ Page: 1-5

40 Introduction Transmitter Sub Assemblies Driver Cabinet ALC Control M2X Exciter IPA 1 HPA 1 RF Unit ALC Control IPA 2 HPA 2 RF System Combiner Including Test Load High Power (FCC Mask) Sharp Tuned Filter M2X Exciter IPA 3 HPA 3 Fwd Fwd ALC Control ALC Reference See Note 1 2 Way Splitter 2 Way Splitter HPA Feedback Sample HPF Feedback Sample Use good quality RF cable to avoid signal ingress. Note 1. The ALC (automatic level control) reference comes from a digital pot in the driver cabinet. It controls the power of all HPAs. Each HPA has its own ALC system, similar to the one shown in Figure 1-3, which sends an ALC control signal to the RFU to control its output power. The ALC system is described in Section 6.4, Automatic Level Control (ALC) System, on page Transmitter Sub Assemblies Figure 1-4 Power CD Transmitter RF BLock Diagram (Three HPAs) This overview covers the key components that make up the front panel user interface for the transmitter system. They are located in the driver cabinet and in each high power amplifier system in the power supply cabinet. This section also covers the key control boards for each of the other cabinets in the system. While there are other means to interface to the transmitter, this section covers only the front panel user interfaces Driver Cabinet The driver cabinet contains the 2RU control panel. From this panel the user can put the transmitter system in the On, Standby, Background Heat or Off state, Raise or Lower system power, Enable or Disable system remote control and get a fault status of the six major subsystems in the transmitter (drive chain, power amplifier, output, power supply, system and performance). This control and status is via illuminated push buttons on a control panel. The fault status indicators are also push buttons that will function as hot keys for the display. The control panel is hinged on the bottom to allow easy access to the back of the panel as well as better access to the UPS located behind it. In life support (loss of CAN bus) mode, the 2RU control panel generates commands for transmitter on or off, power raise or lower, exciter switch or mode controller changes. It also indicates lack of communication or possible fault within each sub assembly. Page: /13/12

41 Transmitter Sub Assemblies PowerCD Transmitter Introduction Display Unit 2533s100.fm The display unit is a 2RU assembly that is mounted below the control unit. Access to the unit is obtained by removing it from the transmitter. It contains a single board computer (SBC), harddrive, power supply, network interface board, CAN interface and a distribution board. This unit functions both as a display driver for the GUI and as a network interface unit (using the ecdi program) to allow the transmitter to be connected to an ethernet for remote control and monitoring. The CAN interface board allows the SBC to collect data from the transmitter control system. The graphical user interface (GUI) is a 12" touchscreen LCD flat panel display used for overall monitoring and control of the transmitter. The software for this display is basically the same for both local and remote control of the transmitter. The GUI display is mounted to the front of the display unit, which contains the appropriate hardware for driving the display RFU Drive Control The RFU (radio frequency unit) is responsible for selecting the exciters in dual exciter configurations, monitoring exciter drive, providing low level RF drive signals for the IPA modules, automatic level control for each HPA, the detection RF samples from the reject loads and the detection of RF forward and reflected power samples for the overall system. It also has provision for controlling the RF phasing for multiple HPA systems Power Supply Cabinet The power supply cabinet contains a low voltage compartment that houses some of the control components and other items that can be serviced with the unit powered up. This cold compartment is the top section of the front of the power supply cabinet behind a removable access panel. The control panel is mounted in the cold compartment below the access panel. It is used to control the HPA. The control panel is hinged on the bottom to allow easy access to the back of the panel as well as better access to the UPS located behind it. The control panel allows each HPA to be individually controlled from the front. From this panel the user can put the associated HPA cabinet into the On, Standby, Background Heat or Off state. It also allows the user to Raise and Lower cabinet power and Enable or Disable remote control of the HPA cabinet from driver/system control or remote control through the external cooling cabinet. This panel will also provide fault status of the five major subsystems in the HPA system (drive chain, power amplifier, output, power supply and system). Control and status is via illuminate push buttons on a 2RU high control panel. The fault status indicators are also push buttons that will function as hot keys for the display Display Unit The display unit is 2RU high and is mounted (without slides) at the very bottom of the cold compartment. Access to the unit is obtained by removing it form the transmitter. The display unit contains a single board computer (SBC), harddrive, power supply, network interface board, CAN interface and a distribution board. This unit functions both as a display driver for the GUI and as a network interface unit (using the ecdi program) to allow the HPA to be connected to an ethernet for remote control and monitoring. The CAN interface board to allow the SBC to collect data from the HPA control system. 04/13/ Page: 1-7

42 Introduction Transmitter Control System The graphical user interface (GUI) is a 12" touchscreen LCD flat panel display used for overall monitoring and control of the HPA cabinet. The GUI display is mounted to the front of the display unit, which contains the appropriate hardware for driving the display. The software for this display is basically the same for both local and remote control of the transmitter. While this display is capable of monitoring the entire system, it has tailored screens for showing the status of the HPA cabinet HPA controller board The HPA controller board is located in the center of the back wall of the cold compartment, with the bottom of the board lined up with the top of the control panel. This mounting is most convenient for servicing and cabling, since it allows servicing of the board with the front panel removed. The back wall of the cold compartment is a false wall, which, along with another wall in the hot portion of the power supply cabinet forms the AC supply conduits for the beam power supply contactors LV power supplies Identical Vicor power supplies are located on the left and right walls of the cold compartment. Because each supply has a separate AC supply circuit breaker, failed unit to be easily and safely replaced while the other power supply is still on Floating Power Supply The floating power supply looks like a metal suitcase, and is located in the rear (high voltage) compartment of the power supply cabinet. It supplies the IOT filament voltage, grid bias voltage, and ion pump voltage. Since these supplies are referenced to the IOT cathode, they and their metal enclosure float at the cathode potential (-36 to -38kV) Step Start Unit 1.4 Transmitter Control System The step start unit is located in the AC compartment, which is located behind a locked door in the lower front side of the power supply cabinet. This unit is responsible for bringing up the beam supply in two steps. This is necessary to limit the AC inrush current, which is caused by the charging of the beam supply filter capacitors as it is energized. The transmitter uses a distributed architecture control system. This means that each transmitter sub-system is responsible for its own monitoring and protection and simply reports back to the display unit for display on the GUI (graphical user interface) or to the remote interface. The heart of the system are the micro modules. These are micro processors which are used for control, monitoring and protection throughout the transmitter control system. Page: /13/12

43 Organization of Transmitter Documentation Packages PowerCD Transmitter Introduction 1.5 Organization of Transmitter Documentation Packages 2533s100.fm One of the most difficult tasks for a transmitter engineer is to trace a circuit through the various schematics in the schematic pack. This task is simplified by understanding that the transmitter is a group of assemblies and sub assemblies and that each has its own drawing. Some major assemblies, such as the pump module, have only one wiring diagram, while others such as the HPA system consist of many interconnected sub assemblies, each with its own schematic, with their interconnection shown by an overall wiring diagram. This paper is intended to show the hierarchy of the PowerCD transmitter drawings Major Transmitter System Components (Cabinets) Driver Cabinet HPA Assembly The major components (cabinets) of the PowerCD transmitter system include the following. Driver Cabinet (one for each transmitter system) HPA assemblies, up to three for digital, which include: IOT Cabinet (subcabinet of the HPA system) Power Supply Cabinet (another subcabinet of the HPA system) Cooling Cabinet (the third subcabinet of the HPA system) Beam Supply (one for each HPA) Pump Module (one or more for each transmitter system) Heat Exchanger Module (one or more for each transmitter system) RF system, with its manufacturer supplied technical manual, is referred to in the transmitter system interconnection drawings and some driver cabinet drawings. To trace a path between these cabinets, refer to the system interconnection diagram for the specific transmitter system in question. They are identified by schematic number, which relates to the transmitter model number and number of HPAs. In current schematic packs they are found in the system specific installation manuals and not in the two transmitter schematic packs, which contains the remainder of the driver and HPA system schematics. To trace a path between sub assemblies of the driver cabinet, refer to the driver cabinet wiring diagram for that transmitter system. This diagram, along with the schematics for the other driver cabinet subassemblies, is located in section 100 of the two transmitter schematic packs. Some driver cabinet drawings, which are common to more than one section of the schematic pack, appear in Section 500. To trace a path between the three sub cabinets of the HPA assembly, refer to the system interconnection diagram for the specific transmitter system in question. To trace a path between individual assemblies within an HPA system subcabinet, refer to the appropriate HPA sub cabinet wiring diagram. Within the two transmitter schematic packs the HPA system drawings are divided into the following sections. Section 200 contains the power supply cabinet wiring diagram and the schematics for the other sub assemblies within the power supply cabinet. 04/13/ Page: 1-9

44 Introduction HPA System IOT Circuit Assembly Types Section 300 contains the cooling cabinet wiring diagrams and the diagrams for the subassemblies within the cooling cabinet. Section 400 contains the IOT cabinet wiring diagrams the diagrams for the subassemblies located in the IOT cabinet. This is the enclosed portion of the power supply cabinet which contain the high voltage connections. Section 500 contains the schematics common to more than one section of the schematic pack. This avoids needless duplication and reduces the size of the schematic pack. Section 600 contains the IPA module schematics. 1.6 HPA System IOT Circuit Assembly Types The IOT amplifier tube for the HPA system is mounted in a roll-out assembly which contains the tuned input and output RF circuits together with magnet coils which focus the electron beam within the drift tube section of the tube. The assembly may be easily removed from the transmitter for maintenance purposes. Each tube requires a beam supply with three voltage taps that range from -18 to -36 kv. The HPA system is designed to accept the multi-collector IOT and its circuit assembly. The IOT and circuit assembly used in this transmitter is described in Section 1.6.1, e2v Multi-collector IOT Circuit Assembly, on page Page: /13/12

45 HPA System IOT Circuit Assembly Types PowerCD Transmitter Introduction e2v Multi-collector IOT Circuit Assembly The e2v multi-collector IOT circuit assembly is shown in Figure 1-5. The tubes used in this circuit assembly are listed in Table s100.fm Model e2v 5130w Table 1-2 e2v 5130w IOT Ratings Digital TV Peak and (Average) Power 135 kw (30 kw) Figure 1-5 e2v Multi-collector IOT Circuit Assembly 04/13/ Page: 1-11

46 Introduction Specifications 1.7 Specifications Specifications for the Power CD series of transmitters are printed below. Specifications are subject to change without notice General Specifications Table 1-3 General Specifications Parameter RF output (each HPA) Output frequency range Data input Data input connector PFC input AC input AC phase symmetry AC power factor Description Impedance = 50 Ohms 1.1 to 1 (or better) VSWR over standard TV channel Connector: = 6-1/8 EIA flanged for all Power CD models FCC Channels 14-51, MHz SMPTE-310M, Mb/s BNC, 75 ohms 10 MHz, -10 to +10 dbm, BNC, 50 ohms 480 volts ±2%, 3-phase, 60 Hz, 3 or 4 wire. For other voltages consult Harris ±2% maximum 0.9 or better Performance Specifications Table 1-4 Tube Output Power and Transmitter Model Numbers Tube Output Power Tube Type 1 Tube 2 Tubes 3 Tubes 135 kw peak (30 kw average) e2v 5130w IOT PWR30D1 PWR60D2 PWR90D3 For total power output, multiply tube power output by number of tubes (one tube per HPA system). Average power outputs are after FCC mask filter and typical RF combining systems, if present. Average power specifications listed above are for the sharp tuned filter (STF) Table 1-5 Specifications Parameter Stability of output power Frequency stability Frequency offsets Signal to noise (modulation error ratio) Harmonic & spurious radiation Sideband performance Specification ±2% or better ±200 Hz per month, after initial aging of 60 days. 3 Hz or better with external precision frequency control option Per FCC requirements 27 db (> 30 db typical) Compliant with FCC requirements Compliant with FCC mask, with optional Harris specified output filter Page: /13/12

47 Specifications PowerCD Transmitter Introduction 2533s100.fm Table 1-6 AC Specifications for Various Models Model Power Consumption PWR30D1 92kW PWR60D2 184kW PWR90D3 276kW These values represent typical power consumption for an average output of 30kW per HPA and includes cooling Environmental Specifications Table 1-7 Environmental Specifications Ambient temp. range 0 C to +45 C (+32 to +113 F) Maximum temperature rating is 45 C at sea level, derated 2 C per 1,000ft above sea level. Ambient humidity range 0 to 90% relative humidity Maximum altitude 7,500 feet (2,286 meters) For higher altitude operation, consult Harris Building Heat Load Typical heat load, assuming standard layout, and beam supply located outside of the building. Table 1-8 Building Heat Load for Various Transmitter Models Model PWR30D1 PWR60D2 PWR90D3 kw All coolant pipes inside kbtu/hr building insulated kw All coolant pipes inside kbtu/hr building uninsulated Note: Add 3.4 kw (11.7 kbtu) per beam supply if located inside building. 04/13/ Page: 1-13

48 Introduction Specifications Physical Dimensions Table 1-9 Physical Dimensions for Various Transmitter Models Model PWR30D1 PWR60D2 PWR90D3 Transmitter Height (in) Width (in) Depth (in) Weight (lbs) Oil-filled beam supply 1 each 2 each 3 each Height (in) Width (in) Depth (in) Weight (lbs) Fan unit 1-2 fan unit 1-4 fan unit 2-3 fan units Height (in) Width (in) x 132 Depth (in) Weight (lbs) x 946 Indoor Pump module 1 each Minimum of 1 Minimum of 1 Height (in) Width (in) Depth (in) Weight (lbs) Individual Cabinet weights: Driver cabinet IOT cabinet Power supply cabinet Cooling cabinet 705 lbs. 753 lbs. 774 lbs. 562 lbs. Page: /13/12

49 Power Cabinet Rear Door Unlocking Procedure PowerCD Transmitter Power Cabinet Keylock System 2 Power Cabinet Keylock System This section includes the procedure for unlocking the rear and front doors of the power cabinet and also provides information for reordering the keys needed to unlock the doors. 2533s200.fm Matching keys and locks have colored button on them for ease of identification. Matching keys and locks also have individual serial numbers stamped into them. 2.1 Power Cabinet Rear Door Unlocking Procedure Follow the steps in Figure 2-1 to unlock the power supply cabinet rear door. Warning AFTER OPENING EITHER DOOR OF THE POWER SUPPLY CAB- INET OR BEAM SUPPLY, ALWAYS TOUCH EACH ELECTRICAL CONNECTION WITH THE GROUNDIN STICK. 04/13/ Page: 2-1

50 Power Cabinet Keylock System Power Cabinet Rear Door Unlocking Procedure 6. Insert key in upper most lock on rear door and turn it counter clockwise to unlock the rear door. The key will be trapped in the lock as long as the door is open. 5. Remove a key from any of the three three ganged locks below. These three keys are identical. Any key can be used in any position or can be used to unlock any of the items listed below: Power Supply Cabinet Rear Door Power Supply Cabinet Front Door For Unlocking Beam Supply 4. Rotate any of this set of three keys counter clockwise to lock the grounding switch in the grounded position. These three locks are ganged together so rotating one rotates all of them. Removing any or all of the three keys Prevents the grounding switch from being rotated off of the ground position. 3. Rotate grounding switch handle counter clockwise to ground the beam voltages 2. Insert the key in lowest lock on rear door and turn it counter clockwise. This unlocks the grounding switch from the locked open position. 1. Set HPA system to Standby, BG Heat, or Off, turn Off beam supply AC disconnect, and remove the key. The AC disconnect cannot be switched on while the key is removed from its lock. Figure 2-1 Power Supply Cabinet Rear Door Unlocking Sequence Page: /13/12

51 Power Cabinet Front Door Unlocking Procedure PowerCD Transmitter Power Cabinet Keylock System 2.2 Power Cabinet Front Door Unlocking Procedure 2533s200.fm Follow the steps in Figure 2-2 to unlock the power supply cabinet front door. Since this compartment contains both the beam supply and the HPA system AC feeds, both disconnects must be locked in the off position and therefore this door requires two keys to be opened. 1. Set HPA system to Off and wait for the cool down cycle to finish. 2. Follow steps 1 through 4 in Figure Remove a key from one of the three ganged shorting switch locks in Figure 2-1. This is one of the two keys required to open the power supply cabinet front door Use a key from one of the three ganged shorting switch locks. Use key from the HPA system AC disconnect 3. Insert the key in upper most lock on front door. 4. Turn Off HPA system AC disconnect, lock it and remove the key. This disconnect cannot be switched on while the key is removed. 5. Insert the key in lower lock on front door and turn it counter clockwise. The locks are ganged together so both keys will turn at the same time. These two keys will be trapped in their locks as long as the front power supply cabinet door is open. Figure 2-2 Power Supply Cabinet Front Door Unlocking Sequence 04/13/ Page: 2-3

52 Power Cabinet Keylock System Key Management 2.3 Key Management THIS PAGE IS TO BE KEPT WITH TECHNICAL MANUAL COPY PAGES 2-5 AND 2-6 TO ORDER KEYS! Attn: General Manager Harris Corporation, in compliance with IEC-215, has designed the multi-collector IOT UHF transmitter with an interlock system that requires the use of unique keys operated in an exact procedure in order to gain access to potentially harmful portions of the transmitter during maintenance functions. This system, if used properly, will provide full protection to the user by disconnecting lethal voltages from cabinets to be serviced. It is the responsibility of the user not to deviate from the Key Lock System operating procedure. Harris Corporation urges that you accept our recommendations for the safety of your service personnel. Harris Corporation provides, with each transmitter shipped, one full complement of keys for that transmitter. In addition, Harris retains one duplicate set of keys for the transmitter. To have that duplicate set of keys shipped separately to you or a designated representative of the station, Harris requires that the attached authorization form be completed and forwarded to Harris Corporation, Broadcast Communications Division. There is no charge for the one duplicate set. These duplicate keys are to be utilized by authorized service personnel only if keys in the original set become lost or misplaced. It is the responsibility of the designated representative at the station to control the utilization of these keys. If the original key is damaged and not lost, the damaged key can be replaced by returning the faulty part and a new one will be issued. Warning USE OF DUPLICATE KEYS TO GAIN ACCESS TO THE INTERIOR OF THE TRANSMITTER BY BYPASSING THE NORMAL KEYLOCK OP- ERATING PROCEDURE IS DANGEROUS AND COULD RESULT IN INJURY OR DEATH TO THE PERSONNEL INVOLVED. Replacement keys can be ordered only through Harris Corporation with written authorization from the designated representative stating specific keys are lost and must be replaced. It will be necessary that you supply to Harris, the serial numbers of the specific locks requiring keys at the time of order. By signing the attached form, the signer accepts the responsibility for proper utilization of any duplicate interlock keys and authorizes Harris Corporation to forward the duplicate set of keys, or replacement keys as required, to the signer. Should you have any questions please feel to call or write. Please address any correspondence to: Television Contract Administrator Harris Corporation, Broadcast Communications Division 3200 Wismann Lane P.O. Box 4290 Quincy, IL Phone: (217) FAX: (217) Page: /13/12

53 Key Management PowerCD Transmitter Power Cabinet Keylock System THIS PAGE IS TO BE KEPT WITH TECHNICAL MANUAL COPY PAGES 2-5 AND 2-6 TO ORDER KEYS! 2533s200.fm AUTHORIZATION FORM: SPARE/REPLACEMENT KEY TO: Harris Corporation, Broadcast Communications Division 3200 Wismann Lane P.O. Box 4290 Quincy, Il Attn: Television Contract Administrator I accept the responsibility as the designated representative for the control and management of any duplicate keys used to access the interior of the Harris Television transmitter. In the event a key or keys are lost, Harris Corporation will require written authorization from me before any key will be provided. General Manager Date Designated Representative (if other than General Manager) Station Call: Address: KEYS NEEDED: ( ) Complete spare set for entire transmitter (First spare set available at no charge). ( ) Replacement keys as follows: QTY LOCK SERIAL NUMBER BUTTON COLOR CODE THIS PAGE IS TO BE KEPT WITH TECHNICAL MANUAL - COPY PAGES 2-5 AND 2-6 TO ORDER KEYS! 04/13/ Page: 2-5

54 Power Cabinet Keylock System Key Management, Key Reorder Form 2.4 Key Management, Key Reorder Form Attn: General Manager Harris Corporation, in compliance with IEC-215, has designed the multi-collector IOT UHF transmitter with an interlock system that requires the use of unique keys operated in an exact procedure in order to gain access to potentially harmful portions of the transmitter during maintenance functions. This system, if used properly, will provide full protection to the user by disconnecting lethal voltages from cabinets to be serviced. It is the responsibility of the user not to deviate from the Key Lock System operating procedure. Harris Corporation urges that you accept our recommendations for the safety of your service personnel. Harris Corporation provides, with each transmitter shipped, one full complement of keys for that transmitter. In addition, Harris retains one duplicate set of keys for the transmitter. To have that duplicate set of keys shipped separately to you or a designated representative of the station, Harris requires that the attached authorization form be completed and forwarded to Harris Corporation, Broadcast Communications Division. There is no charge for the one duplicate set. These duplicate keys are to be utilized by authorized service personnel only if keys in the original set become lost or misplaced. It is the responsibility of the designated representative at the station to control the utilization of these keys. If the original key is damaged and not lost, the damaged key can be replaced by returning the faulty part and a new one will be issued. Warning USE OF DUPLICATE KEYS TO GAIN ACCESS TO THE INTERIOR OF THE TRANSMITTER BY BYPASSING THE NORMAL KEYLOCK OP- ERATING PROCEDURE IS DANGEROUS AND COULD RESULT IN INJURY OR DEATH TO THE PERSONNEL INVOLVED. Replacement keys can be ordered only through Harris Corporation with written authorization from the designated representative stating specific keys are lost and must be replaced. It will be necessary that you supply to Harris, the serial numbers of the specific locks requiring keys at the time of order. By signing the attached form, the signer accepts the responsibility for proper utilization of any duplicate interlock keys and authorizes Harris Corporation to forward the duplicate set of keys, or replacement keys as required, to the signer. Should you have any questions please feel to call or write. Please address any correspondence to: Television Contract Administrator Harris Corporation, Broadcast Communications Division 3200 Wismann Lane P.O. Box 4290 Quincy, IL Phone: (217) FAX: (217) Page: /13/12

55 Key Management, Key Reorder Form PowerCD Transmitter Power Cabinet Keylock System AUTHORIZATION FORM: SPARE/REPLACEMENT KEY 2533s200.fm TO: Harris Corporation, Broadcast Communications Division 3200 Wismann Lane P.O. Box 4290 Quincy, Il Attn: Television Contract Administrator I accept the responsibility as the designated representative for the control and management of any duplicate keys used to access the interior of the Harris Television transmitter. In the event a key or keys are lost, Harris Corporation will require written authorization from me before any key will be provided. General Manager Date Designated Representative (if other than General Manager) Station Call: Address: KEYS NEEDED: ( ) Complete spare set for entire transmitter (First spare set available at no charge). ( ) Replacement keys as follows: QTY LOCK SERIAL NUMBER BUTTON COLOR CODE THIS PAGE IS TO BE KEPT WITH TECHNICAL MANUAL - USE THE FOLLOWING COPY TO ORDER KEYS! 04/13/ Page: 2-7

56 Power Cabinet Keylock System Key Management, Key Reorder Form Page: /13/12

57 HPA IOT Circuit Assembly Types PowerCD Transmitter Transmitter Installation 3 Transmitter Installation 2533s300.fm This section provides the information and instructions necessary for the installation of the Harris PowerCD series television transmitter. The instructions are intended as guidelines, to minimize the installation time required. Notes, cautions and warnings are included as precautionary measures, to alert the installer to possible problems and hazards. 3.1 HPA IOT Circuit Assembly Types The PowerCD HPA (high power amplifier) cabinet is designed to accept the e2v 5130w IOT. For a view of this circuit assemblies refer to Section 1.6.1, e2v Multi-collector IOT Circuit Assembly, on page Fuses or Breakers For AC Distribution Chain It is important to use time delay RK5 fuses or a fuses with equivalent transient rating throughout the transmitter AC power distribution chain, from each beam supply through the building AC service entrance. A circuit breaker can be used for the beam supply as long as it has a 125 amp nominal rating with a surge rating of 1500 amps for 1/2 cycle. For more information concerning the AC power system, consult the transmitter system specific drawings. 3.3 Planning a Successful Installation Planning and preparation are the most important factors in a successful, efficient, and safe installation phase of a new transmitter. Study equipment manuals beforehand and become thoroughly familiar with the installation requirements for each piece of equipment. The transmitter equipment installation phases should be planned carefully before the equipment arrives and a detailed plan worked out and written down. Know what installation equipment and materials Harris is supplying with the transmitter and what equipment and materials the station must supply. In general, a transmitter installation requires that the following areas be addressed: 1. Have a clear plan for transmitter system monitoring and make provision for any needed RF monitoring samples. Make sure the monitoring equipment will be suitably located for convenient operation and monitoring. STL and remote control equipment should also be planned early. While not part of the transmitter, monitoring and control equipment (and the STL) must be available when installation is completed to test the transmitter and to put it into service. 2. Plan a star point grounding system for the building and equipment cabinets. This grounding system should incorporate the grounding system for the AC service entrance and the grounding system for the tower. 3. When considering the sequence of events during an installation, it is important to approach the transmitter, its peripherals, and the building as a system. typical drawings are used as references. It must be assumed special requirements will cause deviations from the published installation drawings in order to accommodate a particular configuration or building requirement. 4. In a new installation, interior walls should be in place, ceiling work should be complete, concrete floors should be aged and well sealed, and all painting be completed before arrival of the equipment or the transmitter is placed in the room. Transmitters 04/13/ Page: 3-1

58 Transmitter Installation Planning a Successful Installation and other electronic equipment can be damaged or made inoperable by dust and dirt entering the equipment. Even a plastic covering placed over the transmitter rarely keeps out concrete dust and plaster dust created from drywall installation. 5. Concrete pads for the beam supplies and cooling units should be poured and cured before arrival of equipment. If possible, plan to unload them from the truck directly onto their concrete mounting pad. For more information see Section 3.7.1, Beam Supplies and Cooling Units, on page In a new installation, will electrical power be available when needed? Often transmitter installation and checkout is held up because primary power is not available. 7. In an existing facility, must an existing transmitter remain on the air during installation of the new equipment? Plan how this is to be done to minimize off-air time. 8. A staging area should be chosen and set aside to place the boxes and crates that contain all the smaller parts and assemblies not shipped attached to the transmitter. A separate area should be used to stage all installation materials (plumbing materials, wire, conduit and accessories, loose hardware, etc.) 9. Each piece of equipment should be inspected for shipping damage. Inventory all equipment and the contents of each box and compare to the packing check list that comes with the equipment. 10. Think about how the equipment will be unloaded. Will the proper lifting and moving equipment be there when the truck containing the transmitter arrives? Will there be enough workers there to help? 11. Equipment placement must be worked out carefully. Use a station layout drawing to determine equipment placement and the order in which the equipment should be set in place. If possible, lay out equipment location with lines marked on the floor. 12. When planning placement of the output RF system, make certain the ceiling or overhead framing will support the weight of the RF components. If not, structure modification or floor-mounted components may be required. 13. The electrical and plumbing work should begin at the start of the installation in order not to delay completion, however the transmitter, RF output system and cooling system plumbing should be installed prior to running electrical conduits or air handling ducts in the transmitter space. 14. Hanging hardware must be on-hand to avoid delays. Ensure that all pipe hangers, conduit hangers, threaded rod, beam clamps, Unistrut and Unistrut hardware are on site. 15. Ensure that all necessary tools are on site and in good shape when needed. Check transmitter and other equipment technical manuals to see if any specialized tools are required. Make arrangements to obtain them if necessary. A list of installation tools and materials is shown in Table 3-1. Table 3-1 Installation Tools and Materials Welding torch set Oxygen and acetylene tanks Welder s mask or goggles Power band saw (can be rented) and extra blades Silver solder, 1/16 inch diameter, 30 to 45%, such as Hard Stay Silv #45, or Aladdin #45, Harris part number Paste flux (Engelhard Ultra-Flux, 1 lb jar) Harris part number Page: /13/12

59 Planning a Successful Installation PowerCD Transmitter Transmitter Installation Table 3-1 Installation Tools and Materials 2533s300.fm Stay Clean Flux, 16 oz bottle, Harris part number Muratic acid, 1 quart Baking soda, two 1-pound boxes Three plastic 5-gallon buckets or containers with open tops Scotch Brite Steel wool Emery cloth, roll type, 1 to 1.5 inch wide Framing square Level Plumb bob Chalk line Hacksaw and extra blades Swing arm band saw or abrasive wheel type cutoff machine (for cutting transmission line) Tubing cutters with extra cutting wheel (for water pipe and conduit, not for transmission line) Various wrenches Torque Wrench (for RF flanges and the IOT breakaway) Crowbar Rope Saw horses or cutting table Come-along or chain-fall hoist Ladders Files Garden hose 25-ft tape measure Hole saw, 1-7/8 inches, for installing directional couplers Rubber hammer Claw hammer Gloves Safety glasses 1-5/16 x 18 tap and 1 - tap handle, for fine matcher thread cleaning. Note: All-thread rod, hangers, angle iron, or channel will be needed to support the transmission line, dummy load, RF system, and etc. 04/13/ Page: 3-3

60 Transmitter Installation Delivery and Storage 3.4 Delivery and Storage 3.5 Returns and Exchanges 3.6 Unpacking The Power CD series transmitter is normally delivered with the larger units mounted on shipping skids. Smaller components are shipped in cardboard cartons. Any obvious damage should be noted at the time of receipt and claims filed with the carrier. In unloading the equipment, suitable equipment capable of handling a 5000 pound load (2268 kg) will be needed. Extreme care should be taken during the unloading operation to prevent injury to personnel or damage to the equipment. The beam power supply and heat exchanger are usually installed outside the building. These items are large and heavy. If possible, unload them from the truck directly onto their concrete mounting pad. If storage of the equipment is necessary, store it inside in a protected area until it is to be installed. The storage area should be dry and clean, and the lighting should be adequate to make it possible to quickly locate any needed part during the installation. The oil filled high voltage power supply and cooling unit may be stored outside. Do not stack items. Doing so can result in damage to the lower boxes and their contents, and stacking makes it difficult to access those parts in the bottom boxes. Leave the larger units mounted on their skids for ease of storage and movement. When it is time to install the equipment, move each unit close to its final position; then remove it from its skid and slide it into position. Occasionally a part is found to have been damaged during shipping and handling and must be returned for replacement. Information on returns and exchanges is printed on the reverse side of the title page of this manual. The following guidelines are provided for ease of unpacking the equipment. Several parts of the transmitter system are large and heavy and will require special handling equipment. Table 3-2 lists weights and dimensions for the major components. Note To prevent equipment damage by dust and dirt, concrete floors should be aged and well sealed and all painting be completed before the transmitter is placed in the room. Page: /13/12

61 Equipment Placement PowerCD Transmitter Transmitter Installation Table 3-2 Shipping Weights and Measurements 2533s300.fm Net Weight Size (width x depth x height) Item kg lb cm in Driver Cabinet x 125 x x 49 x 79.5 Power Supply Cabinet x 125 x x 49 x 79.5 IOT Cabinet x 82 x x x 79.5 Cooling Cabinet x 61 x x x 82.5 Beam Supply NWL x 159 x x 62.5 x Pump Module x 178 x x 70 x Heat Exchanger, two fans (1 each for 1 IOT system) x 111 x x 43.6 x 43.2 Heat Exchanger, three fans (2 each for 3 IOT system) x 111 x x 43.6 x 43.2 Heat Exchanger, four fans (1 each for 2 IOT system) x 111 x x 43.6 x 43.2 Dimensions refer to outside clearance. Refer to installation drawings for detailed equipment dimensions. Dependent upon type of system installed, RF systems will typically ship directly from the manufacturer. NWL beam supply, Harris part number , NWL part number A High Voltage Power Supplies 3.7 Equipment Placement Each high voltage power supply weighs approximately 4400 pounds, necessitating the use of suitable lifting equipment. When handling the power supply, keep the plastic envelope in place for protection in storage unless the equipment can be installed soon after its arrival. Do not tip the power supply more than 10 degrees. To remove from the truck, a forklift can be used (winching the equipment to the rear edge of a loading platform is not advisable), or the equipment can be lifted using the lugs provided on the sides. When inserting the lifting hooks into the lugs, keep any tearing of the plastic envelope to a minimum. Use spreaders on the slings, if necessary. Provide padding as necessary to protect the painted surfaces from the sling. The recommended equipment placement depends somewhat on the operating channel. Refer to the typical station layout and plumbing drawings in the system specific and cabinet interconnection drawing set for details. These drawings provide useful information regarding floor plan, RF transmission line layout, and the cooling system Beam Supplies and Cooling Units It is recommended that the beam power supplies and heat exchanger cooling units be mounted on a concrete pad in a secure area outside the building. Consult local electrical codes for proper physical distance of items from walls and other equipment. Also, allow for proper placement of ground straps. 04/13/ Page: 3-5

62 Transmitter Installation Equipment Placement Plan location of the cooling units to allow free and unimpeded inlet and outlet air flow. Avoid low ceilings or overhead structures which might cause reduced air flow. Additional information about liquid cooling systems is available in Appendix D, External Heat Exchanger System. Provisions for ice bridge protection should be made, if required due to geographic location. When ready for installation, use a fork lift or other suitable equipment to carefully remove the fan unit from its skid and set it in place on its pad. The beam supply must be lifted off of its skid using the lugs provided on the sides. Provide padding as necessary to protect the painted surfaces from the sling. Do not tip or swing the supply while moving it Pump Module The pump module is placed inside the transmitter building to keep the temperature of the bulk of the glycol coolant above 32 degrees F (0 degrees C.) This caution is necessary since the IOT is cooled by water, and the water is cooled by the glycol coolant through a heat exchanger. If the coolant temperature is below 32 degrees F (0 degrees C) it could freeze the water in the heat exchanger. When ready for installation, use a fork lift or other suitable equipment to carefully remove the pump module from its skid and set it in place Automatic Voltage Regulator (AVR) A primary power voltage regulator is recommended for this transmitter. Place the AVR according to the floor plan. Caution The AVR or UPS system must be capable of maintaining +/-2% output regulation at the specified line voltage. Over voltage could possibly void the IOT warranty. Voltage should adjust in a linear manner with no sharp rise-time step functions RF System The RF system is the assembly that connects the RF output lines from one or more HPAs to the input of the antenna feed line. Study the typical station layout drawings or any custom layout drawings before beginning installation of the RF system. For a single tube configuration, the RF system consists of a filter and possibly a patch panel or motorized RF switch. For a multiple tube configuration, the RF system includes one or more combiners, one filter, and possibly one or more motorized RF switches. These larger RF systems may be shipped disassembled in two or more sections, which must be reassembled on site. The horizontal and vertical placement of the RF system in relation to the transmitter is crucial to the successful installation of the interconnecting lines and the antenna transmission line. Page: /13/12

63 Equipment Placement PowerCD Transmitter Transmitter Installation Phasing of multiple-hpa transmitters is accomplished by controlling the relative length and height of the RF lines that connect the HPA to the RF system. Refer to the Typical Station Layout drawing for your transmitter system in the installation drawing set and to literature supplied by the RF system vendor. 2533s300.fm RF System Mounting Height The mounting height of the RF system is determined by many factors, which include: The height of the ceiling Available floor area inside the transmitter room Whether the input and output RF lines enter from above or below the RF system. (this is determined by the site requirements.) The length of the phasing lines If a patch panel is to be used, Depending on the required phasing length of the HPA to RF system lines (for multiple HPA systems) and the mounting height of the RF system, the HPA inputs can be arranged (on site) to enter the RF system from above or below. Also, the RF system antenna output can go above or below, depending on the RF system height and the height of the transmission line or wave guide run to the antenna RF System Placement If two or more HPAs are included in the transmitter, some transmission line lengths in the RF output system are critical. In multiple-hpa transmitters using nonstandard output systems, output line length information should be provided in the installation drawing set or by the RF system manufacturer. Identify the RF system input ports on the layout drawing and determine its location with respect to the transmitter. Locate the same point on the floor of the room and mark it. Support the center sections of the filter above the floor and orient the section so the inputs of the RF system, when attached, will be close to being directly over the previously made marks on the floor. The filter can be supported by setting it on the interconnecting flanges. Do not support the assembly on the wave guide sections of the filter or on the protruding filter tuners. Use care not to bump the tuners or dent or deform the wave guides or filter sections. If the RF system arrived in two or more sections, and each section is very heavy, or the entire system is too bulky or heavy to hang as a unit, the system can be hung one section at a time and the sections joined after they are hung. If used, install the magic tee phase shifter assembly to the filter section using marking or labeling on the pieces as a guide. Support the magic tee section carefully to avoid denting or deforming it, and to assist in aligning the connecting flanges. Alignment pins are provided and should be used in diagonal corners to assure proper seating of flanges. The flange bolts should be used to hold the two flanges together and not to correct flange misalignments. Tighten the bolts in the sequence shown in Figure 3-1; then torque each to 15 ft. lbs. 04/13/ Page: 3-7

64 Transmitter Installation Equipment Placement Figure 3-1 Waveguide Tightening Sequence Position the input ports of the assembled combiner/filter directly over the mark on floor using a plumb bob. Also using the plumb bob, locate the proper placement and install the all-thread rods from the overhead support system. Locate the rods so they are directly over the hanging brackets on the RF system. Raise the RF system using suitable hoists and pulleys. Level the RF system when its proper height is reached and it has been attached to the all-thread rods. Note The length of the threaded rods hanging the RF system should be as short as possible to minimize objectionable lateral movement. If the RF system equipment is to be supported from a high ceiling, an intermediate metal frame grid should be constructed. The frame normally hangs from the ceiling and in turn provides the structure from which the RF system is suspended. Where necessary, lateral bracing may be used to reduce sway PowerCD Driver and HPA System Cabinet Installation Procedure. This section covers the assembly of the PowerCD transmitter cabinets. Refer to drawing to guide the assembly.the cabinet assembly steps are listed below. 1. Uncrate an un skid transmitter cabinets. A. Use spreader bar, steel rods, and chain fall to lift cabinet from pallet, see Figure 3-2. While cabinet is still elevated, screw in the adjustable feet to the bottom of the cabinet. Page: /13/12

65 Equipment Placement PowerCD Transmitter Transmitter Installation Cabinet lifting spreader bar with lifting hook 2533s300.fm Eye bolts screwed into each corner of the cabinet top. Top of cabinet Thread steel bars through the eye bolts and the spreader bar holes and use the spreader lifting hook to lift the cabinet off of the pallet. Top of cabinet Figure 3-2 Setup for Lifting Cabinets off of Pallets 2. Install spacer plates, they may have already been installed. A. Install 4 spacers on cooling cabinet. B. Install 4 spacers on IOT cabinet. C. Install 2 L brackets to top of driver cabinet. D. Install 2 studs to bottom of driver cabinet. 3. Bolt IOT cabinets to cooling cabinets, see Figure Slide cabinets in place, one at a time, see Figure 3-3., the driver cabinet must go on the left side facing the front of the transmitter. A. As cabinets are slid into place, route interconnect cables through holes to adjacent cabinet. 1. place the power supply cabinet first, then slide the cooling cabinet next to it being careful not to pinch the wires which pass through the walls of the cabinets. These cables, from the power supply cabinet, are in two bundles. The cable from the top hole terminates in 8-pin and 12-pin connectors, and an AC power cable (consisting of wires 97, 98 and 99) passes through the bottom holes in the cabinet walls. 2. Next, slide the HPA cabinet in place and then the driver cabinet. B. Using the adjustable leveling feet, level each cabinet as it is set in place then bolt it to the next. C. For driver cabinet slip 2 inch ground strap through cabinet into cooling cabinets as they are set into place. 5. Connect cabinet interconnects. A. Cooling cabinet, J20 and J21. Yellow to yellow, green to green. B. Cooling cabinet, 480 VAC, wires, 97, 98, 99 to S1. C. Connect 2 air hose to pump outlet. D. Route air sensor tube along side 2 air hose into IOT cabinet. 04/13/ Page: 3-9

66 Transmitter Installation Equipment Placement Driver Cabinet IOT Cabinet Cooling Cabinet Power Cabinet HPA System Figure 3-3 Driver and HPA Cabinets of a 1-Tube Power CD Transmitter Driver Cabinet Cooling Cabinet IOT Cabinet Power Cabinet Cooling Cabinet IOT Cabinet Power Cabinet Cooling Cabinet IOT Cabinet Power Cabinet HPA System 1 HPA System 2 HPA System 3 Figure 3-4 Top View of the 3-Tube PowerCD Transmitter Page: /13/12

67 Equipment Placement PowerCD Transmitter Transmitter Installation 2533s300.fm 6. Ground straps. A. Connect 4 straps between cooling and power supply cabinets. Four inch by six inch ground straps with 1/4 inch holes are used to connect the inter cabinet ground front to rear (IOT cabinet to cooling cabinet) and side to side (PS cabinet to cooling cabinet and PS cabinet to IOT cabinet. B. Connect 4 inch straps between cooling and IOT cabinets. C. Connect 2 strap between driver and cooling cabinet. D. Connect 4 strap to station ground. 7. PS cabinet. A. If not already installed at the factory, install the floating bias supply (also called the isolated supply). 1. Open ISO supply suitcase and route the fiber optic cables through the grommeted hole in the lower center right half of the suit case. Connect fiber optic cables W7, W5, W9, and W10 to sockets 21, 22, 23, and 24 respectively on the IOS supply controller board A5. Refer to drawing sheet 3 of Route the floating AC input leads into the two banana jacks on the ISO supply AC interface board A6. It is located on the lower right side toward the rear. 8. IOT cabinet. A. Install top halve of break away, see Figure Connect wires 182 and 183 to break away interlock switch. They come from J25 pins 1 and 2 of HPA controller board in power supply cabinet. B. Slip the cabinet interconnection RF cables, into IOT cabinets. C. Unpack and assemble tube and trolley, refer to e2v manual supplied with tube. 1. The IOT circuit assembly should be kept in a safe and secure area until needed. It should be kept covered to prevent dust and dirt contamination. 2. It will be necessary to install the IOT magnet assembly into the amplifier cabinet to determine the height and centering of the RF transmission line breakaway. Caution The IOT circuit assembly is top heavy, use caution when rolling it across the floor. The area should be smooth surface which is free of any debris which might interfere with the wheels and cause the IOT and magnet to tip over. D. Install bottom halve of breakaway to tube trolley output coupler. E. Roll tube and trolley into IOT cabinet close enough to check the alignment of the two halves of the breakaway assembly, see Figure The interconnecting cables and hoses will not be installed at this time because the trolley will have to be removed when the RF system is optimized. F. Align breakaway sections and roll trolley into place. 04/13/ Page: 3-11

68 Transmitter Installation Equipment Placement G. Install transmission line bolts to join the flanges of the two sections of the breakaway. One flange bolt is longer then the others and will reach the interlock micro switch mounted on the rear of the breakaway support bracket, see Figure 3-5. Six tuner fine matcher, used to match breakaway and output line to the IOT. Fixed portion of IOT breakaway section. This is the flange where the movable and fixed portions of the breakaway section are joined. This is the area which must be aligned. Movable breakaway section, attached to the IOT circuit assembly secondary cavity. Customer Sample, Forward Directional Coupler Probe Reflected Directional Coupler Probe, to two way directional coupler splitter DC6. Note: For the three breakaway couplers, the coupling is 45 db and the directivity is 30 db. IOT Circuit Assembly Secondary Cavity The remainder of the IOT circuit assemblies attached but not shown. Forward Directional Coupler Probe, to two way directional coupler splitter DC7. Saddles mounted to rear wall. Hose clamps hold line assembly to saddle clamps. The flange of the fixed section of the breakaway sits on this movable bracket. This bracket is adjusted to match the height of the fixed to the movable sections of the breakaway assembly. The breakaway interlock switch is mounted on the inside of the opposite side of this bracket. One of the flange bolts used to join the two halves of the breakaway is long enough to engage the interlock switch. Rear Wall of IOT Cabinet This drawing is not to scale. Figure 3-5 Breakaway Assembly of the IOT Cabinet 9. Cabinet interconnect cables, see interconnection diagram A. Connect LAN system interconnection cables between driver cabinet customer I/O panel and power supply cabinet display unit interface board. Wire W610 from customer I/O panel (on top of driver cabinet) to HPA 1 J18 Wire W611 from customer I/O panel (on top of driver cabinet) to HPA 2 J18 Wire W612 from customer I/O panel (on top of driver cabinet) to HPA 3 J18 Page: /13/12

69 Interconnecting Transmission Line and Waveguide PowerCD Transmitter Transmitter Installation B. The system bus ribbon cable W607 is run from the driver cabinet external I/O panel J3 and loops through each power cabinet HPA controller at J8, starting with HPA1. No termination is required at the last HPA. 2533s300.fm Note Each HPA interface is identified by its cabinet ID. Cabinet IDs are selected using individual GUIs via the configuration screen. C. The ALC coaxes are run from each power cabinet HPA controller J15 and terminate at the driver RF I/O panel as follows: Wire W603 from HPA1 J15 goes to driver RF I/O J1. Wire W604 from HPA2 J15 goes to driver RF I/O J2. Wire W605 from HPA3 J15 goes to driver RF I/O J7. D. Install interlock cable W606 between driver cabinet external I/O and power cabinet HPA controllers. 1. Interlock starts and ends in the power cabinet controller. J23. Pin 1 is a +12V source, pin 2 is a relay coil to ground (the return load), and pin 3 is a ground. 2. In the driver cabinet customer interface board, W606 ends at J32. J32 pin 1 is the HPA1 +12V supply. J32 pin 2 is the HPA1 return to the relay coil. J32 pin 3 is the HPA1 ground reference. J32 pin 4 is the HPA2 +12V supply. J32 pin 5 is the HPA2 return to the relay coil. J32 pin 6 is the HPA2 ground reference. J32 pin 7 is the HPA3 +12V supply. J32 pin 8 is the HPA3 return to the relay coil. J32 pin 9 is the HPA3 ground reference. E. Install RF drive heliax between cabinets. 1. Each RF drive cable terminates in J1 on the top of its IOT cabinet. 2. The other end of the heliax comes from the top of the driver cabinet as follows: Heliax W600, from J20 to HPA 1 Heliax W601, from J21 to HPA 2 Heliax W602, from J22 to HPA Interconnecting Transmission Line and Waveguide Find the proper system interconnection drawings for your system in the system specific and cabinet interconnection drawing set. Because of the relative routing inflexibility of transmission line and wave guide connections and components, it is recommended that transmitter to RF system transmission line be installed before the plumbing and conduit are installed. This will allow some movement 04/13/ Page: 3-13

70 Transmitter Installation Interconnecting Transmission Line and Waveguide of the RF system or the transmitter cabinets for needed alignment without having to disconnect plumbing or conduit lines. The typical station layout drawing shows one method of proper installation of the transmission line. See Appendix A, Cutting and Soldering Transmission Line for specific instructions on how to cut and fit rigid transmission lines. All PowerCD transmitters will use 6 1/8 inch transmission line between each HPA and the RF system Preparation For Installing Transmission Line Before cutting any transmission line, verify that the transmitter and RF system components are correctly positioned and are level and the transmission line vertical height at the top of each amplifier cabinet is established. See the applicable typical layout drawings in the system specific installation drawing package. If it has not already been done, temporarily install each IOT/magnet assembly in it s cabinet.and adjust the height and centering of each breakaway. This procedure was covered in Step 8., IOT cabinet. on page This will help compensate for slight variations in the floor level. Note When installing the transmission lines between the HPA cabinets and the RF system, make sure that it is well supported above the cabinet to keep its weight from pushing down on the breakaway system and the IOT trolley Installation of Fine Matcher Sections for RF Line Optimization A fine matcher is included in the IOT cabinet, but one may be required elsewhere in the RF system. The RF system needs to be optimized for at least a 30 db return loss looking from the break away assembly to the system load after the RF system is complete and the liquid cooling plumbing system has been installed. This optimization is accomplished with one or more fine-matcher line sections, which must be constructed and installed at the time the transmission line is installed. The fine matcher must be within 10 wavelengths of the unwanted reflection. If the distance is greater than 10 wavelengths, the bandwidth of the correction will be too narrow, and the correction will be unstable as the temperature of the line changes Constructing the Fine Matcher A fine matcher is a short section of rigid line with four adjustable tuning probes installed in it, see Figure 3-6. Tuning probes, used for fine matcher construction, are provided with the installation kit. Four probes are installed at 1/8 wavelength intervals along the length of a short section of line. The distance for 1/8 wavelength is calculated using the formula: 1/8 Wavelength (inches) = 1476 / F MHz Where: F MHz = center frequency of the channel. Table 3-3 provides 1/8 wavelength calculations for channels 14, 41, and 69. The spacing between the probes is given to the nearest 1/16 of an inch. The small rounding error, or even rounding to the nearest 1/8 inch would not hinder the operation of the fine matcher. Page: /13/12

71 Interconnecting Transmission Line and Waveguide PowerCD Transmitter Transmitter Installation Table 3-3 Example of 1/8 Wavelength Calculation 2533s300.fm Channel Center Frequency 1/8 Wavelength in decimal 1/8 Wavelength to nearest 1/16 inch MHz inch 3 1/8 inch MHz inch 2 5/16 inch MHz inch 1 13/16 inch When constructing a fine matcher, drill four holes in the outer conductor of the line, using a inch (F) tap drill, and solder brass nuts over the holes (using 3% to 5% silver solder). Do not use 50/50 solder. If the brass nuts are plated, sand the plating off of the bottom of the nuts to allow the solder to adhere to it. Chase the threads of the nuts and thread the outer line using a 5/16 x 18 tap. Four sizes of probes are provided for 6-1/8 inch line. The larger probes are used for lower frequencies, the limiting factor being that the spacing must be greater than the probe disk diameter. The available probes are listed by Harris part number in Figure 3-6. Figure 3-6 Probe Installation for Fine Matcher The probes provide adjustable shunt capacity every 90 electrical degrees and are used to cancel out reflections that occur a short distance down the line toward the load. Larger probes provide more capacity and can cancel larger reflections. The exact size of probe to use for 6-1/8 inch line is determined by trial. Generally, the smallest size probe capable of achieving the correction is the correct size RF Sample Cables A number of RF sample cables must be routed to the driver cabinet RF I/O panel from the RF Output system, these include: RF forward and reflected power samples used for metering and VSWR protection RF reject load samples in transmitters with two or more HPAs RTAC sample cables taken before and after the reject load. 04/13/ Page: 3-15

72 Transmitter Installation Plumbing System Installation 3.9 Plumbing System Installation Refer to drawing to determine the exact RF sample cable requirements. Use the RG223 cable provided with the transmitter to make these connections. If the installation requires added cable, obtain additional RG223 - do not substitute other types of cable. Refer to the system interconnect drawing for your transmitter to identify the proper connections for these cables. The liquid cooling plumbing system consists of two loops. The main loop carries a water/glycol mixture between the outside heat exchanger, inside pump module, HPA cooling cabinets, driver cabinet, and RF system loads. The second loop is located within the IOT and cooling cabinets of the HPA system. It consists of a pump and heat exchanger which is used to circulate deionized water through the IOT. The heat exchanger transfers the heat removed from the IOT via the deionized water to the water/glycol mixture of the main loop. The second loop also contains purifying equipment to keep the resistance of the deionized water above one megohm per centimeter. Use the following information for assistance during installation: Refer to typical plumbing layout drawings in system specific documentation packages, in conjunction with the list of plumbing kit parts. A custom plumbing layout drawing, if provided. Appendix D, External Heat Exchanger System provides specific information and instructions for cooling system installation, initial startup, flushing, and checkout. Install plumbing system per drawings. Take care to ensure each solder joint is well sealed. Extra time spent making sure solder joints are leak-free will save hours of time later Guidelines For Installing the Cooling System The following tools and materials are needed: Mapp gas torch set Extra Mapp gas tanks Welders mask or goggles Tubing cutter for 2.5 inch tubing Flux (Stay Clean Flux) or equivalent (Harris part number ; one 16 oz bottle provided with plumbing kit) Soft silver solder (96.5% tin; 3.5% silver) such as Aladdin #450 (Harris part number ) is needed. Three 1 lb rolls of 1/16 inch soft silver solder is supplied with plumbing kit. 1/8 inch silver solder (Harris part number ) is also available. Wire brush and rags Water hose All thread rod, unistrut and pipe clamps will be needed to support the plumbing. The copper plumbing lines should be cut with a tubing cutter. Always de-bur the line (remove any rough points or flared-in edges at the cut). Page: /13/12

73 Plumbing System Installation PowerCD Transmitter Transmitter Installation Warning Temperature of the heated line in the following steps is quite high. precautions must be taken to avoid contact with exposed skin. 2533s300.fm It is recommended that Aladdin 450 soft silver solder (Harris part number for 1/16 inch diameter, or for 1/8 inch diameter) be used to assemble all plumbing joints. The line, elbows and tees should be cleaned with emery cloth or Scotch Bright before the recommended liquid flux is applied for soldering. Since considerable heat is necessary to make the solder flow, some torch black and flaking may develop inside the pipe. Before hanging the line, it is recommended that a hose and wire brush or rag be used to clean and flush the inside of the line. This will avoid future problems with plugged filters and fittings due to dirty internal line. When connecting threaded plumbing fittings, use three wrap layer of teflon tape and some pipe dope on the male fittings. When applying the teflon tape, do not let it extend beyond the end of the threads of the male fitting, as these scraps will sheer off when installed and will end up inside the pipe. Do not use pipe dope on the female fittings because it will bunch up on the inside surface of the plumbing and interfere with normal cooling system operation. It is difficult to remove excess pipe dope and teflon tape scraps from inside the liquid cooling system. Additional cooling system information is given in Appendix D, External Heat Exchanger System, with initial startup and checkout information about the cooling cabinet given in Appendix E, Internal Pure Water System Setup and Maintenance Cooling System Checkout. When the cooling system has been completely installed, and before the plumbers leave the site, the cooling system should be flushed and checked out. If the AC installation is not complete, provide a temporary, but safe, AC installation to the pump and heat exchanger modules to allow the cooling system checkout to proceed. To prepare for flushing and checking out the cooling system, bypass the following: The entire driver cabinet, by opening the valved bypass and closing the driver cabinet supply and return valves. Temporarily replace the plugs at the bottom of the driver cabinet cooling lines with a pipe extensions and valves to assist in draining the system. Reinstall the plugs after the flushing is completed. Each HPA cabinet A. By opening the valved bypass and closing the HPA cooling cabinet supply and return valves. B. If a bypass valve is not provided, bypass the external cooling loop side of the cooling cabinet heat exchanger with a hose and open the cooling cabinet supply and return valves. Each liquid cooled load by using a hose type bypass connection between the liquid supply and return lines. 04/13/ Page: 3-17

74 Transmitter Installation Plumbing System Installation Proper direction of rotation of the cooling system pumps and fans should also be checked before flushing is attempted. The pumps can be momentarily powered while dry to check rotation, but do not operate them for more then 5 seconds when dry. If the pump rotation of both pumps is wrong, power down the unit and swap any two AC phases at the safety disconnect switch on the pump module. If the pump rotation of only one pump is wrong, power down the unit and swap any two AC phases at the pump or at the contactor for the pump. After AC power is connected to the pump module, the notes below explain how to temporarily operate the pumps. For the Sigma pumps, temporarily connect TB2-1 to TB2-8. When checking rotation with the system dry, do not keep this jumper connected (pump running) for more than 5 seconds. Use the alternate pump command on the front of the pump module to check the other pump. For the Transcool pumps, each pump has a control switch. To operate pump A, place the pump A switch in manual and the pump B switch to off. Reverse the two switches to operate pump B. When checking rotation with the system dry, do not keep the pump running for more than 5 seconds. After AC power has been connected to the heat exchanger, the fans can be temporarily operated by connecting a jumper between heat exchanger terminals 70 and 71. Thermostats AQ1 and AQ2 will have to be set to a lower temperature to operate the fans if the outside temperature is too low. The fans on the heat exchanger should blow upwards. If all fans blow air down, open the AC disconnect and reverse any two of the three AC supply wires at the AC input to the heat exchanger. If some fans (but not all) are blowing down, power down the unit and reverse any two of the three phase ac wires at the input to the offending fan motor or at its contactor (FA1 or FA2).When finished, reset AQ1 and AQ2 to 95 and 115 Fahrenheit respectively. The pump tank empty and tank low float assembly operation can be checked while the system is being filled for either a flush or the final fill. For the Sigma pumps, the pump control panel tank empty and tank low indicator LEDs should extinguish as the tank is being filled. For the Transcool pumps, the pump control panel tank empty and tank low indicator LEDs should extinguish as the tank is being filled. the tank empty level is 9 gallons, the tank low level is 24 gallons, normal running level is 46 gallons, and the overfull warning occurs at 53 gallons. Information for flushing and filling the external glycol cooling loop is given in Appendix D, External Heat Exchanger System. Page: /13/12

75 RF System Optimization PowerCD Transmitter Transmitter Installation 3.10 RF System Optimization 2533s300.fm After the RF system is complete and the liquid cooling system has been installed, flushed, and filled with coolant, the RF system return loss must be measured, and adjusted if necessary. It is necessary to delay the RF system optimization until after the cooling system has been installed because the presence of the liquid coolant will affect the impedance of the liquid cooled waveguide (water column) loads. It is necessary to remove the IOT trolley assembly to perform the RF system optimization. Remove the transmission line bolts from the breakaway assembly flange and carefully separate the two halves of the flange as the trolley is rolled out of the IOT cabinet. If the IOT cabinet interconnecting lines and hoses are still connected to the trolley, remove them Reinstalling The IOT Trolley The system should be optimized for at least a 1.05 VSWR (32dB return loss) looking into each load and looking through the break away assembly and RF system into to the system load. System return loss can be adjusted with the fine-matcher line section which should have already been installed, some liquid cooled waveguide loads include a built in fine matcher, if not, one should have been installed at the input of the load. See Section 3.8.2, Installation of Fine Matcher Sections for RF Line Optimization, on page A fine matcher is already installed in the IOT breakaway, but if necessary additional fine matchers may be installed. First check and adjust the return loss of the system loads. This will ensure that they will match the RF system. Next, check and adjust the return loss looking into the RF system from the breakaway in the IOT cabinet. This will ensure that the IOT will see a good match into the RF system. It is assumed that the antenna and its transmission line or wave guide was adjusted for a good return loss at the time of its installation. Looking through the input to the transmission line or waveguide, an older antenna system should have a 1.1 VSWR (-26dB return loss) across the channel, and with careful installation and optimization, a newer antenna system can have a 1.05 VSWR (-32dB return loss) across the channel. The system should have a minimum VSWR of 1.1 (-26dB return loss) looking at the antenna through the breakaway and RF system. This is a necessity since the transmitter will be adjusted and checked out with test loads, and performance will not be optimum if the antenna presents a poor match to the RF system. After the RF system has been optimized, the IOT trolley assembly must be reinstalled and fully interconnected with the IOT cabinet. Use the procedure below for the reinstallation. 1. Roll tube and trolley into IOT cabinet close enough to check the alignment of the two halves of the breakaway assembly, see Figure 3-5, on page A. Prior to engaging RF transmission line, connect 2 air hose and cavity air pressure sensor. B. Connect anode cooling lines to rear of cabinet. Connection is made with hanson fittings. Water flow direction is not critical. 2. Align breakaway sections and roll trolley into place. 3. Install transmission line bolts to join the flanges of the two sections of the breakaway. One flange bolt is longer then the others and will reach the interlock micro switch mounted on the rear of the breakaway support bracket, see Figure 3-5, on page /13/ Page: 3-19

76 Transmitter Installation Reinstalling The IOT Trolley 4. Connect the yellow wires to the breakaway interlock switch. Wire 183 to the common switch terminal and wire 182 to the normal open terminal. 5. Connect collector cooling hoses to tube. Connection is made with hanson fittings to the matching connectors on the rear wall of the IOT cabinet. The hose labeled input connects to the top connector. 6. Connect focus magnet connection, cavity arc detectors and ground cable to tube trolley. The connectors for the cavity arc sensor cables are labeled primary cavity are and secondary cavity are. They are connected as shown in Figure 3-7. IOT Collector Assembly Output Transmission Line Connect Secondary Cavity Arc Cable Connector Here Primary Resonant Cavity Connect Primary Cavity Arc Cable Connector Here Secondary Resonant Cavity Figure 3-7 IOT Trolley Front View Showing Cavity Arc Detector Connectors 7. Connect forward RF sample line (W7) to the coupler on rear of breakaway and the reverse sample line (W6) to lower coupler on front of breakaway, see Figure 3-8. A. The other end of cable W7 is connected to coupler DC7 on the right side of the IOT cabinet, and the other end of cable W6 is connected to coupler DC6 on the right side of the IOT cabinet. 8. Install RF cable W8 between circulator (located on the top left hand wall of the IOT cabinet) and reject load in cooling cabinet, see Figure 3-8. The reject load is clamped to the glycol supply line in the cooling cabinet. 9. Connect cable W2 from the forward output of the IPA directional coupler (located on the top left hand wall of the IOT cabinet) to coupler DC5 (located on the right hand wall of the IOT cabinet). 10. Install IOT RF input cable W3 between the directional coupler output connector and the IOT input connector (located on the lower left side of the IOT trolley on the input impedance matching adjustment), see Figure The grid/cathode umbilical cord is secured to the right wall of the IOT cabinet in the lower hole. The collector umbilical cord assembly secured to the right wall of the IOT cabinet in the upper hole. The wires from the umbilical cords enter into the rear compartment of the power supply cabinet. These wires will be connected later, in Section , e2v 5130w IOT Umbilical Cord Connections, on page Page: /13/12

77 Reinstalling The IOT Trolley PowerCD Transmitter Transmitter Installation 2533s300.fm IOT Cabinet Left Wall, Circulator and IPA Input Coupler. Input From IPA W2 In DC 5 Coupled IOT Cabinet Right Wall, Sample Couplers W6 In DC 6 Coupled W7 In DC 7 Coupled Out Out Out Circulator Forward To Reject Load (Via Cable W8) 102 Side View IOT Breakaway Assembly To Power Cabinet HP Controller Reflected IOT Input Directional Coupler Customer Sample J 12 J13 J14 Forward Output to IOT Input Connector (Via Cable W3) Reflected Note: For the IPA coupler assembly, the forward coupling is 37 db and the reflected coupling is 43 db. IOT Secondary Cavity Note: For the three breakaway couplers, the coupling is 45 db and the directivity is 30 db. Figure 3-8 IOT Directional Coupler Cabling 04/13/ Page: 3-21

78 Transmitter Installation Conduit and Electrical Installation 3.12 Conduit and Electrical Installation Warning Ensure ground straps are connected between transmitter cabinets, high voltage power supplies, pump modules, cooling modules, and other transmitting equipment. Bond the straps to station ground at a central point. The straps should be silver soldered or cadwelded together. For additional information on lightning protection and system grounding refer to Appendix B, Lightning Protection Recommendation and Appendix C, Grounding Considerations, Surge & Lightning Protection. The AC Power Flow drawing for the transmitter, in the system specific Installation drawing set, provides ac distribution, routing and circuit sizing information. The drawing numbers are as follows: for a 1-tube system for a 2-tube system for a 3-tube system. For protection of all personnel on site, a lock-out tag-out procedure should be documented and implemented for all personal on site, including outside contract personnel Fuses or Breakers It is important to use time delay RK5 fuses or a fuses with equivalent transient rating throughout the AC power distribution chain from each beam supply through the building AC service entrance. A circuit breaker can be used for the beam supply as long as it has a 125 amp nominal rating with a surge rating of 1500 amps for 1/2 cycle Conduit Metal conduit (not supplied with the transmitter) must be used to support and enclose wires connecting each piece of equipment. Any outdoor conduit must be weatherproof. EMT is acceptable for interlocks and other AC signals indoors. Refer to the site specific/installation drawings and the standard schematic package for information on conduit installation for the HV beam supplies and HPA power cabinets. These drawings should also be used to help determine conduit sizes, length of wire runs and fuse/circuit breaker ratings. Warning Label all conduit covers with appropriate voltage markings, such as Vac Primary or 38 kvdc. Number power cabinets and corresponding beam supplies to ensure removal of power to the correct unit during service. Page: /13/12

79 Conduit and Electrical Installation PowerCD Transmitter Transmitter Installation Conduit For High Voltage From Beam Supply 2533s300.fm The three high voltage supply lines and the ground return line should be run in a single 1.5 inch rigid steel conduit. Plastic, aluminum or thin wall conduit is not an acceptable substitution. This conduit should use only sweep bends, no L bends. Ensure that the ends of the conduit are well de-burred, as sharp edges encourage corona and increase the likelihood of cable breakdown. Article in the National Electrical Code requires a pull box (L bend) after the equivalent of 360 of sweep bends (four 90 bends). L bends should be avoided in the high voltage conduit because sharp bends encourage the formation of corona, which increases the possibility of insulation breakdown over time. Pull boxes should also be avoided because they can be easily opened and the high voltage wiring exposed. If pull boxes are required, they should be labeled with DANGER HIGH VOLTAGE and referred to the HPA power cabinet that it powers. The three high voltage and one ground return cables are clad in zipper tubing when shipped. The purpose of the zipper tubing is to prevent cable damage during installation. If local electrical codes require a ground wire to be included in the conduit, it is to be run outside the zipper tubing. After installing the cable apply the supplied duct seal to the rigid conduit entrance and exit points to prevent moisture intrusion HPA Power Cabinet Branch Circuits The branch circuits feeding the HPA power cabinet must be fused as specified in the ac wiring diagram HPA Power Cabinet to Beam Supply Wiring The step start control board , is wired to the beam supply as shown in Figure 3-9. The internal Wiring of the NWL A beam supply is shown in Figure The high voltage dc connections from beam supply to the power cabinet are shown in Figures 3-10 and Four high voltage cables are pulled between the beam supply and the HPA system power supply cabinet. They are as follows: The high voltage return wire, from the ground strap via U6 and U7 on Figure 3-12 to the beam supply HV return terminal on Figure The -38 kv cathode wire, from the cathode ground switch on Figure 3-12 to the beam supply HV 60 terminal on Figure The -18 kv wire, from the collector 4 switch on Figure 3-12 to the beam supply HV 3 terminal on Figure The kv wire, from the collector 3 switch on Figure 3-12 to the beam supply HV 2 terminal on Figure See Figure 6-9, on page 6-15 for a block diagram of a multi-collector IOT shown with current sensors and three-tap beam supply. See Figure 4-6, on page 4-15 for a photo of the beam supply tap and output voltage switches along with Table 4-1, which lists the output voltages for each switch position. 04/13/ Page: 3-23

80 Transmitter Installation Conduit and Electrical Installation Beam Supply TB Black Brown Red Orange Yellow Green Blue White Black Brown Blue White Yellow Green Red Orange Step Start Control Board J Figure 3-9 Beam Supply to Step Start Control Board Wiring 26.6kV Supply - + Beam Supply Sealed Compartment kV Supply kV Supply 40 HVR 100 HV2 HV3 HV-60 HV-100 Choke HV6 Bypass 0.125uF 0.125uF 0.125uF 0.125uF HVR HV2 HV3 HV VAC to Return Collector 3 Collector 4 Cathode L1 L2 L3-11,4kV -19kV -38kV Beam Supply Compartment, Front Panel Access Figure 3-10 NWL A Beam Supply Wiring Page: /13/12

81 Conduit and Electrical Installation PowerCD Transmitter Transmitter Installation AC Mains Conduits and Connections 2533s300.fm Refer to the following diagrams when pulling and connecting the AC mains cables for a 1-tube system for a 2-tube system for a 3-tube system. A duct between the front (cold) compartment and the rear (high voltage dc) compartment is provided to fasten the AC conduits and run the AC cables to their terminals. Access to this duct is gained through the following procedure. 1. Remove HPA controller cables 2. Remove the cable duct access panel, Refer to Figure The HPA controller is mounted on this panel. 3. Fasten the conduits to the ceiling of the AC duct and pull the following AC wires. A. 3 phase from AC mains B. 3 Phase from PS cabinet to beam supply 4. Replace cable duct access panel (with the HPA controller board). 5. Reconnect the HPA controller cables. HPA Control Board Cable Duct Access Panel Figure 3-11 Top Front View of Power Cabinet Showing Cable Duct Access Panel 04/13/ Page: 3-25

82 Transmitter Installation HPA Internal Assembly 3.13 HPA Internal Assembly The three cabinets that comprise the HPA system should already be joined together. The following paragraphs will complete the assembly of all internal modules and interconnecting wiring Cable and Wire Connections Refer to HPA cabinet wiring diagram for all tubes e2v 5130w IOT Umbilical Cord Connections The e2v multi-collector IOT collector and grid cathode umbilical cord assemblies are part of the IOT circuit assembly. At this time the IOT circuit assembly should already be installed in the IOT cabinet with the collector umbilical cord secured to the upper hole and the grid/cathode umbilical cord secured to the lower hole in the right wall of the IOT cabinet. The wires from the umbilical cords and the beam supply are in the rear compartment of the power cabinet. The high voltage supply and return wires from the beam supply enter via the conduit at the top of the rear compartment of the power cabinet. These wires are run and connected as shown in Figures 3-12 through 3-15 and drawing # Note Banana plugs for the cathode and collectors 2 and 3 grounding switches are not plugged in order to bring up the HPA for testing without applying high voltage to the IOT. These connections will be made in the next chapter after the filament, bias, focus, ion, and beam supplies have been tested. Secure these three loose leads away from the high voltages at the grounding switches and temporarily ground them. Connect the wires to the Isolated Supply as shown in Figure 3-15, refer to drawing # Page: /13/12

83 HPA Internal Assembly PowerCD Transmitter Transmitter Installation U7 Conduit From Beam Supply (In Ceiling) 2533s300.fm 3 Power Cabinet, Wall Opposite Rear Door U6 Return Wire 4 Right Wall of Rear Power Cabinet Compartment H.V. Metering Board Ground Strap T1 Arc Detector T1 Upper (Collector) Umbilical Cord Cathode Col. 5 Col. 4 Col. 3 Col. 2 Cathode (-38 kv) U5A U5B U4 U3 U2 Col.4 Lower (Cathode) Umbilical Cord Col.3 Col.2 Top View, Grounding Switch Cathode (-38 kv) Collector 5 Filament + Large Red Fil. Sense + Small Red Large Blk, Fil.- Cathode Fil. Sense Small Blk Isolated Supply Suitcase Grid Yellow. Ion Pump Figure 3-12 Heater, Cathode, and Grid Bias Connections For e2v Multi-collector IOT 04/13/ Page: 3-27

84 Transmitter Installation HPA Internal Assembly Collector 2 Collector 3 Collector 4-38 kv from Beam Supply Cathode + - Note: the current flow through this sensor is reversed from the others. Collector Collector Collector Collector Note: Electron current flow through the sensors is shown by the arrows. This end of wire comes from the supply via the shorting switch. This end of wire goes to the IOT via the upper umbilical cord. Figure 3-13 HV Wiring, Cathode and Collectors 2-5, In Rear of Power Cabinet Page: /13/12

85 HPA Internal Assembly PowerCD Transmitter Transmitter Installation 2533s300.fm U7 Ground Fault Sensor U6 Return Current + - Figure 3-14 HV Wiring, Return Current and Ground Fault Senser, In Rear of Power Cabinet Cathode Filament Sense + p/n Ground Stud Collector 5 Grid Sense - Ion Pump Figure 3-15 Isolated Supply Cable Entrance, In Rear of Power Cabinet 04/13/ Page: 3-29

86 Transmitter Installation Driver Cabinet Control and Signal Interconnections IPA Installation The IPA module is shipped separately from the driver cabinet assembly. After the transmitter system has been assembled, the IPA module can be installed. All connectors will match when the module is slid into place from the front. The liquid cooling hoses will have to be connected to the rear of each module. If the IPA is inadvertently operated without the cooling hoses connected, it will protect itself with a thermal shutdown. Due to the tight tolerances used in the hanson fittings, they will not mate if the module is hot. They will engage when the module is allowed to cool. Do not attempt to force a hanson fitting on a hot module Driver Cabinet Control and Signal Interconnections Connections to the driver cabinet from the HPAs and other equipment are located on an I/O panel in the upper center of the driver cabinet, see interconnection drawing Transmitter Control Interconnections Control, monitoring, and interlock connections between the driver cabinet and the rest of the transmitter system connect at the customer I/O board on the top of the driver cabinet External Interlock Connections External interlock connections terminate at the customer I/O board on the driver cabinet and are cabled to the other parts of the transmission system which must inhibit or be controlled by the transmitter. Check the transmitter system interconnect diagrams for the appropriate number of HPAs for the proper external interlock cabling for the transmitter. The following interlocks are jumpered as shown in Table 3-4. If the function is used, wires will be run from the terminals to the appropriate connections on the mode controller. If the function is not used, the terminals listed will be jumpered. Table 3-4 Interlock Jumpers PC Board Function I/O Panel J5-3 J6-3 Reject 1 Flow / Thermal Interlock J5-4 J6-4 Reject 2 Flow / Thermal Interlock J5-5 J6-5 Reject 3 Flow / Thermal Interlock J5-6 J6-6 Reject 4 Flow / Thermal Interlock J5-7 J6-7 Test Load Flow / Thermal Interlock J5-8 J6-8 HP Filter Thermals. J5-9 J6-9 Antenna. J5-10 J6-10 External interlock. Page: /13/12

87 Driver Cabinet Control and Signal Interconnections PowerCD Transmitter Transmitter Installation Table 3-4 Interlock Jumpers 2533s300.fm I/O Panel HPA Controller J32-1 J23-1 HPA 1, External. Interlock from Mode Controller. J32-2 J23-2 J32-4 J23-1 HPA 2, External. Interlock from Mode Controller. J32-5 J23-2 J32-7 J23-1 HPA 3, External. Interlock from Mode Controller. J32-8 J Transmitter Parallel Remote Control Connections See the driver cabinet customer interface board (drawing number ) for the parallel remote control connections. Customer interface board connections are also shown on sheet 1 of the appropriate transmitter systems interconnection diagram mentioned above Mode Controller Setup The mode controller is set up at the factory during final test, connection information between mode controller and the RF system (via the customer interface board) is given in the appropriate system interface drawing Transmitter System Dip Switch Settings Several circuit boards have dip switches which must be set to assign HPA cabinet IDs and other functions Power Supply Cabinet Dip Switches Power Supply Cabinet Dip Switch Settings Verify that the ISO Supply HVPS monitor board has S1 set as shown Table 3-5. MSB to LSB (1 to 8) runs left to right when viewing this board with the isolated supply suitcase sitting open in the rear of the power cabinet. Switch position down is off and up is on. This switch determines which HPA the isolated supply is residing in. Table 3-5 ISO Supply HVPS monitor board S1 Settings MSB LSB HPA HPA HPA Note: On = 1, Off = 0, and switch position up is on. 04/13/ Page: 3-31

88 Transmitter Installation Driver Cabinet Control and Signal Interconnections Verify that the HPA Controller board has S1 set as shown Table 3-6. MSB to LSB (1 to 8) runs right to left when viewing this board in the power cabinet. Switch position up is off and down is on. This switch determines the HPA Identity. Table 3-6 HPA Controller Board S1 Settings LSB MSB HPA HPA HPA Note: On = 1, Off = 0, and switch position down is on Cooling Cabinet Dip Switch Settings Verify that the cooling cabinet external interface board has S1 set as shown Table 3-7. MSB to LSB (1 to 8) runs right to left when viewing this board in the cooling cabinet. Switch position down is on and up is off. This switch determines which HPA the isolated supply is residing in. Table 3-7 Cooling Cabinet Dip Switch Settings LSB MSB Cooling Cabinet Cooling Cabinet Cooling Cabinet Note: On = 1, Off = 0, and switch position down is on. XXX Add note for HPA External I/O board interlock jumpers, see sheet Driver Cabinet Dip Switch Settings The driver cabinet has four boards which have dip switched to set. They are the external I/O board, the RFU controller board, the power supply controller board, and the mode controller board External I/O Board Driver Cabinet, this board is the Main controller board. HPA System, this board is the Cooling control board Verify that the driver cabinet external I/O board has all S1 sections in the off (down) position. This board is located on the upper side of the left wall of the rear section of the driver cabinet. Page: /13/12

89 Driver Cabinet Control and Signal Interconnections PowerCD Transmitter Transmitter Installation XXX Add note for Driver External I/O board interlock jumpers, see Customer I/O Panel connector J27, pins 1 to 8 and 9 to RFU Controller board. 2533s300.fm This board is located at the center rear of the RFU chassis when facing it from the front. This board has two switches. S2 is a 4 position switch with all sections off. S3 is an 8 position switch with all sections off. XXX Need S3 positions for 2 and 3 PA systems Power Supply Controller The driver cabinet power supply controller board, located on the shelf in the rear of the driver cabinet, has two dip switches, S2 and S3 all are off except S3 position 5, which is on. S3 position 5 settings are as follows: On = Dual low voltage power supplies. Off = Single low voltage power supply. 04/13/ Page: 3-33

90 Transmitter Installation Driver Cabinet Control and Signal Interconnections Page: /13/12

91 Automatic AC Voltage Regulator Commissioning PowerCD Transmitter Transmitter Checkout 4 Transmitter Checkout 2533s400.fm At this point, the following items must have been completed, this should have been done in chapter 3 or this manual. The transmitter and support systems have been installed. All of the interconnecting transmission lines have been installed. The external liquid cooling system plumbing lines have been installed. The conduit runs have been installed. Wires have been pulled into the conduit and connected to the equipment. The various RF sample cables have been run and connected. The external cooling system has been checked for proper rotation of pumps and fans and the system has been checked for leaks, flushed and filled with the proper coolant, The RF system has been optimized back to the IOT output. This transmitter checkout and turn on procedure is to be performed following installation of the system, and the checkout portion can be performed as a part of periodic maintenance to check transmitter interlocks, overload settings, calibrations, and other safety devices. Warning Before applying primary power for the first time, turn off all circuit breakers and disconnect switches on the power distribution system, AVR, HPA power cabinet, cooling cabinet, driver cabinet, pump module and heat exchanger. Warning 4.1 Automatic AC Voltage Regulator Commissioning 4.2 Driver Cabinet Power Up Proper procedure for measuring voltages which exist within locked or interlocked cabinets in the following steps requires prior removal of all power, and grounding of all locations where test leads are to be attached or removed. The test meter is to be located outside the transmitter cabinet and all doors are to be closed and locked prior to applying any power. Follow the vendor supplied automatic voltage regulator commissioning procedure. Check that bypass mode is operational and correct output voltages are present. Place the unit online and ensure that the regulation correction window is better than +/- 2%, and measure the output voltage phase to phase, as well as phase to ground to make certain front panel metering is correct. If required recalibrate the AVR metering circuitry. This driver cabinet power up and check out procedure assumes that the system installation is completed and is terminated into a suitable test load. 04/13/ Page: 4-1

92 Transmitter Checkout Driver Cabinet Power Up Warning Before energizing the driver cabinet AC disconnect at the distribution panel, be sure all driver cabinet connections are installed correctly in the terminal block, and check all terminals for tightness. 1. Ensure all driver cabinet circuit breakers are off. Remove the cover from the mains AC access panel located on top of the driver cabinet. Apply primary power from the AC distribution panel (30 amp fused disconnect). Measure phase to phase voltage (480 VAC) and phase to ground (277 VAC) at TB5 N, L1, L2, L3. Remove primary power at the main distribution panel and replace the mains AC access panel. 2. Energize CB9 20 amp circuit breaker on the lower front panel of the driver cabinet. Next energize LVPS breakers CB11 and CB12 located on the left hand side of the rear of the driver cabinet. 3. Refer to DWG sheet 3 of 5. Measure LVPS DC output voltages on the controller board A7 as follows: A. LVPS 1 - Output 1, +7.5VDC, at A7J6-2 to A7J6-1 (ground). B. LVPS 1 - Output 2, +15VDC, at A7J6-4 to A7J6-3 (ground). C. LVPS 1 - Output 3, -15VDC, at A7J6-6 to A7J6-5 (ground). D. LVPS 2 - Output 1, +7.5VDC at A7J7-2 to A7J7-1 (ground). E. LVPS 2 - Output 2, +15VDC, at A7J7-4 to A7J7-3 (ground). F. LVPS 2 - Output 3, -15VDC, at A7J7-6 to A7J7-5 (ground). 4. Energize IPA breakers, one for each IPA module, located center shelf rear of the driver cabinet. 5. Open the control unit panel and turn on the UPS unit. The cabinet LCD display/ computer should boot up and after a short diagnostic sequence, the PowerCD GUI software will load. GUI Software is described in the PowerCD Operator s Manual (pn ) A. Select the Home tab B. Select Local UI tab C. Select Security Management D. Login as an Engineer (Password = Engineer) There is a programable time out window that limits engineering access time. Note: After a predetermined period the GUI will log out of the engineer mode and revert to the operator mode. E. Select Power Supply tab, Driver button, Meter and verify nominal PSU voltages. F. Select Fault button and check for indicated faults. You may have some spurious faults (within this screen due to initial turn on). Reset by depressing the Beam On command on the control panel. 1. After a few seconds, depress the Beam Off button. G. Continue by starting the HPA cabinet turn on sequence. Page: /13/12

93 Power Up and Checkout of HPA(s) PowerCD Transmitter Transmitter Checkout 4.3 Power Up and Checkout of HPA(s) Complete this procedure for each HPA in the system. 2533s400.fm Warning Before energizing the HPA power cabinet and beam power supply AC disconnects, be sure all HPA power cabinet AC connections are installed correctly and all terminals are checked for tightness Verifying AC and LVPS in Power Supply Cabinet The procedure verifies the 480V 30 amp AC wiring to the HPA power cabinet. 1. Insure all breakers on the power supply cabinet are off 2. Unlock 30 amp HPA power cabinet disconnect, turn it off and remove the key 3. Insert key into correct lock of front door of power supply cabinet and go through the key interlock sequence described in Section 2.2, Power Cabinet Front Door Unlocking Procedure, on page Verify the 480 VAC wiring and safety ground between the 30 amp disconnect and TB3-6, 8, 10 for the AC connections and TB3-12 for the safety ground connection. TB3 is located on the front left corner of the floor of the power supply cabinet. A. This wiring can be tested with an ohmmeter or an audio continuity tester. A long insulated wire with clips at each end can be run between the disconnect and the power cabinet to provide a return for the ohmmeter. 5. When the 480 VAC wiring has been verified, secure the power cabinet front and rear doors by following in reverse order the key interlock procedures described in Section 2.2, Power Cabinet Front Door Unlocking Procedure, on page 2-3 and Section 2.1, Power Cabinet Rear Door Unlocking Procedure, on page 2-1. A. After the two doors are secure, energize the HPA power cabinet disconnect The procedure below verifies correct operation of the low voltage power supplies (LVPS) in the HPA power cabinet. 1. Turn on CB2, CB3 (LVPS1,3), CB4 (LVPS 2,4) 2. Measure DC voltages for LVPS 1, 2, 3, and 4 at the following locations: LVPS1 and 2 are measured at the HPA Controller A7 J1 and J2 respectively. A. LVPS 1, -15VDC, at A7J1-5 and 6 LVPS 1, +15VDC, at 7J1-3 and 4 LVPS 1, +7.5VDC, at A7J1-1 and 2 B. LVPS 2, -15VDC, at A7J2-5 and6 LVPS 2, +15VDC, at A7J2-3 and 4 LVPS 2, +7.5VDC, at A7J2-1 and 2 3. LVPS 2 and 4, +48 Vdc Measured at the HPA Controller A7J42 A. LVPS 3, +48 VDC, at A7J42-3,4 B. LVPS 4, +48 VDC, at A7J42-1,2 04/13/ Page: 4-3

94 Transmitter Checkout Power Up and Checkout of HPA(s) Bringing Up Display Unit 1. Open control panel and turn UPS on. 2. Turn on CB5 (Display) on power supply cabinet. 3. The computer should run and the display should come up. 4. Login as an engineer, password = Engineer. 5. Verify no phase sequence or phase imbalance faults are present on GUI. If needed correct the AC phase rotation on 30 Amp AC input TB3-6,8, Verify the above LVPS readings taken in Section 4.3.1, Verifying AC and LVPS in Power Supply Cabinet Installing Barnstead Filters. 1. Shut off the filter loop flow control and return shut off valves, shown in Figure 4-2, while installing or changing filters. 2. Install the barnstead filters located on the cooling cabinet door, see Figure 4-4. A. The micron filter comes with two flat black O-rings already installed on it. It also comes with a bag with two adapters in it. Remove the two flat black o-rings from the filter, they are not used. One of the adapters is a plug, place it into one end of the filter. Be sure that it seats all of the way in, it can be pretty tight. The other adapter allows the filter to attach to the filter head, seat it into the other end of the micron filter. The small O-ring fits into a grove on the inner assembly of the filter head. The large O-ring is used to seal the outer filter cartridge casing to the filter head. B. The larger ION exchange filter cartridge is already made with the proper connections on it, it only needs the O-rings. The small O-ring fits into a grove on the inner assembly of the filter head. The large O-ring is used to seal the outer filter cartridge casing to the filter head. C. Be careful when changing the UV lamp. It sits in a quartz sleeve. The quartz sleeve may pull out with the light bulb and is only held in place with an o-ring. It may be worth having a spare quartz sleeve on hand in case it breaks. Be sure to clean this quartz sleeve while you have it out Fill Water Cooling Tank In Cooling Cabinet Fill water cooling tank, located at the top of the cooling cabinet. It requires approximately 12 gallons of deionized water. 1. Bleed the air from the pump using the bleed valve on the pump housing. Ensure tank is still full prior to turning on pump. The bleed valve is a small hex head screw threaded into a larger plug. It is on the opposite side of the pump from the prime plug shown in Figure An internal bypass valve is located on the bottom of the pump. Its appearance is similar to the air bleed valve mentioned above. Make sure the small hex head screw is fully inserted, turns clockwise, to cut off bypass flow. 3. Before starting pump, make sure the filter loop flow control and return shut off valves, shown in Figure 4-2, are shut off. Page: /13/12

95 Power Up and Checkout of HPA(s) PowerCD Transmitter Transmitter Checkout 4. Manually press contactor K3, shown in Figure 4-2, to momentarily energize water pump. The arrow on housing of pump, shown in Figure 4-1, shows motor rotation. Verify rotation direction by watching blades on top of pump. The blades should turn counter clockwise. 2533s400.fm Bleeding Barnstead Filters. 1. Turn on the filter loop flow control and return shut off valves. 2. Bleed the air from the filter housings using the air bleed levers located on top of each filter manifold, see Figure Cooling Cabinet Power Up and Check Out Before continuing the cooling cabinet power up and checkout, it is necessary to explain the functions of switches S1 through S4 on the cooling control board. Disconnecting the mezzanine ribbon cable between cooling control board and external I/O board, see Figure 4-2, allows the cooling control board switches S1 through S4 to control the cavity air blower and the DI water pump respectively. Pressing S3 for three seconds turns the system on, both the cavity air blower and the pump. Pressing S1 for three seconds toggles the cavity air blower between on and off, assuming the system was activated by S3. Pressing S2 for three seconds toggles between pumps A and B. The pump B option is not installed at this time, it will be available at a later date. Therefore, if S2 is pressed for 3 seconds it will alternately turn pump A off and on. Pressing S4 sets the system off (turns off the cavity air blower and pump) and resets the system to pump A. Continue with the cooling cabinet power up and checkout. 1. Turn on CB1 on front of power supply cabinet. 2. Turn on S1 in cooling cabinet, see Figure Disconnect the mezzanine ribbon cable between cooling control board and external I/O board, see Figure 4-2. A. This cable will be reconnected when checkout of the cooling cabinet is completed. 4. Depress S3 for three seconds.to turn the system on. 5. Verify correct rotation of blower- air should be sucking in on input side of cooling cabinet (lower left side towards rear of cabinet, see Figure 4-4). 6. Remove small white air tube from the trolley and verify cooling fault on display unit. 7. Depress S4 to shut off the pump and the blower Setting Flow Through Barnstead Filters. 1. Turn on the filter loop flow control and return shut off valves. 2. Bleed the air from the filter housings using the air bleed levers located on top of each filter manifold, see Figure Depress S3 on cooling control board to energize water pump. 04/13/ Page: 4-5

96 Transmitter Checkout Power Up and Checkout of HPA(s) 4. Turn DI flow valve so flow through filter is at approx. 2 gal per min. 5. The water purity meter in IOT cabinet will typically read low, often less than 1 meg ohm. After the pump has run for a period of time and the water has stabilized, the water purity meter should read between 1 and 3 meg ohms. Reduce DI loop flow to approximately ½ gallon per minute. A. Depending on the initial purity level of the water, it could take 30 minutes or longer for the purity to reach the minimum threshold of 1 meg ohm. B. While the water is being purified, the remainder of DI water checkout can be performed. Pump prime plug. This plug is not used since the tank is located above the pump The air bleed valve is located on the opposite side of the pump. It is the small hex head screw threaded into the larger plug. Rotation Indicator Coolant Flow Direction Figure 4-1 Cooling Cabinet Pump Rotation and Coolant Flow Direction Page: /13/12

97 Power Up and Checkout of HPA(s) PowerCD Transmitter Transmitter Checkout Cooling Control Board External IO Board 2533s400.fm Mezzanine Cable DI Water Filter Loop Control Valve DI Water Filter Loop Return Shut Off Valve S1 and CB1 Locations K3 Location DI Water Pump Cavity Air Blower Figure 4-2 Rear View Cooling Cabinet Checking Flow Meter Calibration Follow the procedure below to check calibration the collector, anode, and external glycol flow meters: 1. Obtain the K factor from each sensor, see Figure 4-3. A. K factor is the number of pulses per gallon from the flow meter. 2. Go to the HPA GUI system > service > calibrate screen and check the recorded K factor against the value showing in the appropriate field. A. If the value is different, enter the recorded value and press the calibrate button to the right of the entry. 04/13/ Page: 4-7

98 Transmitter Checkout Power Up and Checkout of HPA(s) External Flow Meter Anode Flow Meter Collector Flow Meter Figure 4-3 Rear View of Cooling Cabinet Showing Flow Meters Setting Liquid Cooling Flow Rates Set the cooling cabinet liquid cooling flow rates as follows. Collector loop, DI water, set flow to 12 gallons per minute, see Figure 4-5. Anode cooling loop, DI water, set flow to 2 gallons per minute. Check to ensure that the DI loop flow remains at ½ gallon per minute. This flow is not displayed on the GUI screen. Check the flow meter, it is located on the cooling cabinet door above the barnstead filters, see Figure 4-4. Set the cooling cabinet glycol loop flow to 22 gallons per minute. The fault level is 17.5 gallons per minute, warning level is 18 gallons per minute Reconnecting The Mezzanine Ribbon Cable The mezzanine ribbon cable between cooling control board and external I/O board, shown in Figure 4-2, was disconnected earlier in the cooling cabinet checkout procedure. It must be reconnected now using the procedure below. 1. Press S4 to reset and system and shut off cavity air blower and pump. 2. Reconnect the mezzanine ribbon cable between cooling control board and external I/O board, see Figure 4-2. Page: /13/12

99 Power Up and Checkout of HPA(s) PowerCD Transmitter Transmitter Checkout 2533s400.fm DI Water Flow Meter Filter Air Bleed Levers UV Filter (Algaecide) Barnstead Filters UV Lamp Controller Cavity Blower Air Intake On Other Side Of Wall Figure 4-4 Cooling Cabinet Door, Showing Filters and Flow Meter Collector Flow Valve Anode Flow Valve Figure 4-5 IOT Cabinet Front View Showing DeIonized Water Flow Control Valves 04/13/ Page: 4-9

100 Transmitter Checkout First Application of Lower IOT Voltages 4.4 First Application of Lower IOT Voltages This portion of the checkout procedure will progress to the first application of beam voltage to the IOT Checking RF System Exciter Setup Before the HPAs can be checked too thoroughly, the output RF system phase shifters and RF switches must be checked out from the driver cabinet. Caution Checking out the RF system and the RF system to transmitter interface requires a person with knowledge of and experience with the RF system and its interface to the transmitter due to the complexity and variety of RF systems. Check the operation of the RF switches, phase shifters, temp and flow to each load, AC and temp to mask filer, any other optional external interlocks. Use the driver control panel to check all switches and phase shifters in RF system. Verify interlocks are functioning correctly by observing the LEDs on the mode controller board and by observing the driver GUI Output > Faults > Driver > Mode Controller section of the screen. The exciter setup should have been performed at the final test, but will be included here. Exciter setup includes setting channel number, modulation mode, frequency offset, output power, maximum power, normal power, and minimum power. The exciter setup process is as follows: 1. In the driver GUI > Service > Exciters screen click in the white boxes and enter the channel number, frequency offset, and modulation (only ATSC at this time). 2. On the M2X exciter GUI screen, enter the following: A. In the main screen the output power should be set at 100 mw. B. In the M2X GUI Home Screen > Setup > UDC/Output screen, click in the white box and set the power limit to 100 mw. 3. This sub routine is used to calibrate the input power to the RFU, from the exciters. A. Slide the RFU out and remove the outer in inner covers. This will expose the circuit boards. B. The right rear board is the switch board. On that board 20 db pads are connected to J1 and J2. These are the exciter inputs. Cable W4 is the input from exciter A and connects to the pad in J1, and W3 is the input from exciter B and connects to the pad in J2. Remove these cables from the pads. C. In the driver GUI > Service > Calibrate screen press the save power offset soft keys for exciters A and B. D. Reconnect Cables 104 and 103 to the pads in J1 and J2 respectively. E. In the driver GUI, tough the white exciter A window, a key pad will appear. F. Enter the output power shown in exciter A main screen. G. Press the calibrate soft key. Page: /13/12

101 First Application of Lower IOT Voltages PowerCD Transmitter Transmitter Checkout 2533s400.fm H. In the driver GUI, tough the white exciter B window, a key pad will appear I. Enter the output power shown in exciter B main screen. J. Press the calibrate soft key. K. This completes the RFU power calibration procedure. 4. This subroutine is used when the system has two exciters. It sets the minimum exciter output power, the point where the RFU will switch the other exciter on the air. The point at which the exciter switch occurs is user dependant. The exciter leaves the factory with the minimum exciter power set to 50%. A 50% to 80% range is practical. A. In the driver GUI > Service > Exciters screen the dual exciters yes soft key should be lit green. If not, press the yes soft key. B. In the driver GUI > Control screen, press the manual soft key. The manual soft key should light up yellow. C. In the driver GUI > Service > Exciters screen, touch the exciter A minimum power setting white box. A key pad will appear. D. Enter the desired exciter minimum power level in mw. E. Press the store soft key. F. Repeat steps C through E for exciter B. 5. To test the exciter minimum power setting perform the following. A. In the driver GUI > Control screen, press the auto soft key. The auto soft key should light up green. B. Lower the power of the on air exciter below the minimum power limit. The other exciter should become the on air exciter. C. Return the exciter to its normal power. This completes the exciter setup procedure ISO Supplies and Step Start Controller Checkout In this section the operation of ISO Supplies and Step Start Controller will be checked 1. Ensure the beam supply Disconnect is open. 2. Energize 200 Amp disconnect after following the key sequence. 3. Turn on CB6 Step start control, CB7 Focus Supply, CB8 ISO Supply. 4. Verify that no phase imbalance or phase rotation errors are indicated on the GUI. 5. Check all of the following interlocks by observing the System > Faults > Cabinet screen on the HPA GUI. Tube in place, called Tube on the GUI screen. This interlock switch is located behind the breakaway, see Figure 3-5, on page The bolt which activates the interlock switch can be unscrewed slightly to test the interlock. Tube lifting handle, called Handle on the GUI screen. The hold down allen screw can be loosened to check this interlock. Rear door power supply cabinet. Open the rear power supply cabinet door to check this interlock. Follow the instructions in Section 2.2, Power Cabinet Front Door Unlocking Procedure, on page 2-3. Beam supply door, stick, oil. The beam supply door can be opened to check these interlocks. Follow the instructions in Section 2.2, Power Cabinet Front Door Unlocking Procedure, on page 2-3 to access the key which opens the beam supply door. 04/13/ Page: 4-11

102 Transmitter Checkout First Application of Lower IOT Voltages The door interlock can be checked by leaving the beam supply door open and checking the GUI screen. The grounding stick interlock can be checked by removing it from its holder, closing the beam supply door, and checking the GUI screen. The oil interlock can be checked by disconnecting the external (red) wire from the beam supply terminal board (TB1-7), closing the beam supply door, and checking the GUI screen. If the external (black or brown) wire is disconnected from the beam supply terminal board (TB1-1 or 2)and the beam supply door is closed, the beam supply cannot be energized because the interlock string for the 480 VAC contactor is open. The 480 VAC contactor supplied power to the beam supply step start controller. 6. Glycol pump tank low, tank empty status by observing the System > Faults > Cooling screen on the HPA GUI. The basic operation of the tank low and empty float switches have been checked while the cooling system was being flushed and filled, now it is necessary to check the tank status wiring from the pump to the transmitter. For the Sigma pumps, ground TB2-3 at the pump assembly and check for the tank low fault on the GUI. and ground TB2-4 at the pump assembly and check for the tank empty fault on the GUI. At the present time, the system must be shut down and restarted after a Sigma pump tank empty fault. For the Transcool pumps, it is possible to reach into the tank and manually operate the float while another person checks for proper tank low and empty faults on the GUI. 7. Select Standby from the HPA control panel. This will energize I/P filter blowers, cavity blowers, glycol pump module, DI water pump and the ISO supplies. A 10 minute time delay will start it s countdown to quiescent verify. Note If the water purity is below the threshold (1 to 1.2 meg ohms) the warm-up timer will not time out until the purity is above the threshold. Depending on the contamination, this could take up to 30 minutes. Note A new IOT may have an ion current in excess of 20 ua when first installed. This current should reduce in time and go to zero. If it does not, the IOT may have been damaged in shipment. 8. Verify that the power supplies are set to the tube data sheet settings. Full Filament Volts, see HPA GUI > Power Supply > Service. Full Filament Current, fixed parameter, but should be close to value stated on the IOT data sheet, see HPA GUI > Power Supply > Service. BG Filament Volts, see HPA GUI > Power Supply > Service. Focus (Magnet) Current, see HPA GUI > Power Supply > Service. Grid Voltage, see HPA GUI > Power Supply > Service. Ion Pump Voltage, fixed parameter, see HPA GUI > Power Supply > Summary. Ion Pump Current, fixed parameter, see HPA GUI > Power Supply > Summary. Page: /13/12

103 Conditioning A New MSDC IOT PowerCD Transmitter Transmitter Checkout 2533s400.fm 4.5 Conditioning A New MSDC IOT A new IOT is very likely to be gassy when it is first turned on, also, an old tube can become gassy if it is unused and un-powered for a month or longer. Gassy tubes are likely to arc if operated at full power, but the tube can be safely degassed by a process of conditioning, which takes advantage of the tube s internal ion pump. Gas is trapped within the metal of a new tube and is liberated over a period of time. This liberation process is accelerated if the metal is heated, such as when the tube is first operated. The higher temperatures encountered if a new tube is immediately operated at full power will accelerate the liberation of trapped gas and will increase its tendency to arc. The conditioning process liberates and removes much of this trapped gas and which allows the tube to be operated at full power. If any gassy tube (new or old) is brought up to full power without conditioning, it may develop internal arcs which could damage the tube. When a tube arcs, it generates ions due to the vaporization of metal or other material in the vicinity of the arc, and it can also liberate gas which is trapped within the metal in the vicinity of the arc. This can have a tendency to cause additional arcs, especially if the tube is new. If this happens the tube must be conditioned The ION Pump An IOT contains a special circuit called an ion pump. Its function is to remove gas (and ions) within the tube Vdc +/-500V is applied to the ion pump. This ionizes the gas atoms, and accelerates the resultant ions toward a target of special material within the ion pump. These ions are imbedded and trapped in the ion pump target. The ion pump is in operation while the IOT filaments are on. The presences of gas within the tube is indicated by ion pump current. A gassy tube will have high ion pump current, in excess of 5 ua when turned on. This current will typically drop to less than 1 ua after the filament has been in operation for about 15 minutes, although some tubes may take much longer. Transmitter beam voltage will be inhibited when ion pump current is 5 ua or greater. For a new tube, beam voltage should not be applied if the ion current is 5 ua or greater. If the ion current does not drop below 1 ua after one hour of filament operation, contact the tube manufacturer. A new IOT may still have considerable gas (ions) even though the ion current may be as low as 1 ua Precautions Taken With A New IOT Certain precautions should be taken with a new IOT to decrease the likelihood its premature failure. They include the following items. Avoid mechanical shock Avoid repeated raising and lowering of high voltage. Keep the filament voltage, idle current, and focus current set at the specified value or within the allowable range indicated on the data sheet which accompanies the tube. Allow some time for conditioning the tube before application of full beam voltage. In addition to the problem of a gas, as indicated above, particles may collect on the internal structures of the tube. These particles can have sharp edges which will increase the chances of an arc When an arc occurs within the tube, it can burn away some of the attached particles and clean that area of debris, but it will cause more ions to be generated. After an arc, it is common to observe several microamperes of ion pump current flow for a short time while the newly released ions are being removed. 04/13/ Page: 4-13

104 Transmitter Checkout Conditioning A New MSDC IOT The Conditioning Process The conditioning should be performed when a new tube is installed, or if a tube starts arcing excessively, for instance if a new tube had been installed and the conditioning process were skipped or minimized. If arcing persists after conditioning, contact technical support. During this process, the RF should be prohibited, so that only idle current can flow through the tube. The HPA should be in Standby, and when the 10 minute warm-up timer has timed out, perform the following: 1. On the HPA GUI select Power Amp Tab > Service Button > Drive Prohibit Button. This will prevent the application of drive when bringing up the IOT beam voltage. 2. Using the HPA GUI > Power Supply > Service screen, set the filament voltages as follows: A. In the Standby mode, set the full filament voltage to the value specified on the data sheet which was shipped with the tube. B. In the settings section of the Service screen, enter the nominal (standby) filament voltage. This is the value specified on the IOT data sheet. This entry defines the 0.3 volts filament voltage regulation limit. C. Check the full filament current. This is a fixed parameter, but should be close to value stated on the IOT data sheet. D. In the BG Heat mode, set the BG filament volts to value stated on the IOT data sheet. 3. When a new IOT is installed, it should be allowed to operate with full (standby) filaments energized for about 30 minutes. During this time the ION current should drop to less than 1 ua as the gas and ions are removed from the tube. If high ion current continues for over one hour, contact the tube manufacturer. 4 After 30 minutes of filament operation and after the ion current has decreased to 1 ua or less perform the following setup. A Set the grid voltage idle setting, as outlined in steps 1 through 3, in reference to the values specified on the tube data sheet (which was shipped with the IOT). 1. In the Standby mode, on the HPA GUI > Power Supply > Service screen, the grid voltage mode can be switched between the idle and the normal modes. 2. Set the normal mode grid voltage to 2 volts more negative than the grid voltage on the tube data sheet. 3. Set the idle grid voltage 5 volts more negative than the normal grid voltage. Example: Data sheet grid voltage = -121V, normal voltage = -123V, idle voltage (initial setting) = -128V. Note: With beam on and without drive, or with the HPA output power below 5 kw, the grid voltage, on the HPA > Power Supply > Service screen, will be in the idle mode. When HPA output power is greater than 5 kw, the grid voltage will be in the normal mode. B Set the beam supply to the lowest full tap voltage setting, see Figure Following the procedure in Section 2.1, Power Cabinet Rear Door Unlocking Procedure, on page 2-1, remove the beam supply door key and open the access door on the beam supply. Page: /13/12

105 Conditioning A New MSDC IOT PowerCD Transmitter Transmitter Checkout 2533s400.fm 2. Use the ground stick to discharge all beam supply connections. 3. Adjust the tap switches for lowest full tap output voltages. 4. Close and seal the beam supply, make sure the ground stick is positioned in its holder on the beam supply access door. 5. Reverse the procedure in Section 2.1, Power Cabinet Rear Door Unlocking Procedure, on page 2-1 to reenergize the transmitter AC. 5 Energize the transmitter and let it operate with beam on and a cathode (idle) current of 0.2 A for 30 minutes. A. If the tube arcs, set the beam supply the maximum half tap voltage and allow the tube to operate for 30 minutes. 6 Following all safety precautions, set the beam supply to the next higher full tap beam voltage and repeat step 5. 7 Repeat step 6 until the beam voltage is set to the desired value. A. At the desired beam voltage, set the idle mode grid voltage for 0.55 A of idle current. 8. Check cavity arcs, test buttons are located on the HPA controller board. A. Depress each cavity arc test button and verify H.V. drops out. Press and hold S2 (for primary cavity are test) or S3 (for secondary arc test.), located on the HPA control board, in the upper front compartment of the power cabinet. 9. After the tube has operated for 10 to 15 minutes at the desired beam voltage, set the transmitter to Standby or BG Heat. 10 The IOT can now be tuned. Y = 19.6 kv = 34 kv Y = WYE Y = 18.5 kv = 32 kv 6 kv 34 kv = DELTA Y = 17.3 kv = 30 kv Y = 21.9 kv = 38 kv Figure 4-6 Beam Supply HV Tap and Output Voltages Switches. Table 4-1 Beam Supply HV Tap Switches and Output Voltages Voltage Adjust Switch Position Delta Wye Switch (Delta = Full Tap / Wye = Half Tap) HV5-60 Output To Cathode and Collector 5 HV3 Output To Collector 4 HV2 Output To Collector 3 38 kv -38 / kv -19 / kv / -6.6 kv 36 kv -36 / kv -18 / kv / -6.2 kv 34 kv -34 / kv -17 / -9.8 kv / -5.9 kv 32 kv -32 / kv -16 / -9.3 kv -9.6 / -5.6 kv 30 kv -30 / kv -15 / -8.6 kv -9.0 / -5.2 kv Collectors 1 and 2 return to the supply via current sensors U2 and U6 through the +38 kv return lead. 04/13/ Page: 4-15

106 Transmitter Checkout PowerCD Transmitter IOT Tuning 4.6 PowerCD Transmitter IOT Tuning Read and understand this entire section before attempting to tune the PowerCD transmitter. The input and output circuit of an IOT must be tuned to the operating channel for the tube to operate correctly. The many effects caused by incorrect input and/or output tuning include higher dissipation and lower efficiency, and also higher EVM, lower digital signal to noise ratio, and excessive adjacent channel sideband intermodulation levels. Before any IOT tuning is attempted, the RTAC linear and nonlinear correctors must be turned off, and the IOT idle current must be set at 0.55 A. For the e2v multi-collector IOT, the idle current flow is through collector 4, but is best to measure it at the cathode IOT Tuning Cautions To prevent possible damage to the IOT or RF output system, read and understand all of the caution statements listed below and the tuning instructions before attempting to tune the IOT. Caution Never apply drive to the tube when the transmitter is in Standby. Caution The tube can be damaged if there is high RF power at the tube input (100Wor greater) if the tube is detuned or the beam is off. Caution Care should be taken when performing a high power wide band sweep when there are RF filters in the transmitter output system. RF filters in the transmitter output often have 1 kw reject loads which can be damaged by the out of channel energy of a high power sweep. Caution A new IOT tube must be conditioned before applying full beam voltage. Do not start the tuning process until the tube has been conditioned and full beam voltage is applied Power Levels Used For IOT Tuning Two methods of IOT tuning can be performed. The methods are tuning at low power and tuning at medium power. Page: /13/12

107 PowerCD Transmitter IOT Tuning PowerCD Transmitter Transmitter Checkout Tuning At Low Power The first is at low power, applying the output of the tracking generator through the IPA output (HPA input) directional coupler which takes the signal directly into the input of the IOT. 2533s400.fm The tracking generator output should be set at a low level such as 0 to +3 dbm (1 or 2 mw). This results in an output signal of a few hundred milliwatts. Using low power tuning, the tube cannot be damaged by improper tuning, and when correctly tuned, the response will change very little when brought up to full power. The IPA must be disabled when tuning at low power because the IPA output is disconnected from the IOT. 1. Set the HPA to drive disable using the HPA GUI > Power Amp > Service > Drive Prohibit. A. This sets the ALC for that HPA to zero, the effect is to set the HPA power control to minimum. B. When tuning is complete and drive is enabled, driver cabinet set to transmit, the power raise arrows, on the right side of the HPA GUI, must be used to bring the HPA to full power. This power raise procedure must performed twice, once when the HPA is in remote disable and again when the cabinet is in remote enable Tuning At Medium Power Tuning at medium power is rarely used, except for troubleshooting. This method of tuning involves applying the output of the tracking generator to the input of the IPA, see procedure below. Refer to drawing , sheet 3 of 5. Medium power tuning is accomplished by connecting the output of the tracking generator to coax 76 (for HPA1), 152 (for HPA2), or 153 (for HPA3). These cables connect to the rear output connectors of the RFU. The IOT input and output must have been preset or tuned at low power before attempting to tune at medium power. The tracking generator must be started at a low output level, such as -30 dbm to avoid over driving the IPA or HPA. With the HPA cabinet set to beam. Slowly increase the tracking generator output level until the collector 4 current reaches 1 amp. The HPA output should be below 1.5 kw. A relatively low HPA output power level is mandatory, especially if the IOT output must be routed through the high power mask filter. The reject loads on the high power (mask) filter typically have a rating of 1 kw, and a high power wide band sweep signal could damage them e2v Multi-collector IOT Input Tuning Either low or medium power tuning mentioned above can be used to tune the IOT input. IOT input tuning is critical, as the input tuned response will effect the output response. The IOT input is tuned by monitoring the reflected power from the input of the tube. 04/13/ Page: 4-17

108 Transmitter Checkout PowerCD Transmitter IOT Tuning The e2v plug in IOT has two input tuning controls built into the circuit assembly. They take the form of two rings which surround the input section of the circuit assembly and are located at the bottom of the assembly. The two controls are labeled impedance adjustment and frequency adjustment. These controls move up and down to perform the adjustment. The lower of the two controls is labeled frequency adjustment. It determines the input tuning, or center of the input response. The upper control is labeled impedance adjustment. It determines the bandwidth and flatness of the input response. Note If the IOT input is severely detuned, it should be pretuned or low power tuned to get the input tuning close. 1. The HPA cabinet should be in Standby. 2. Using the HPA GUI > Power Amp > Service screen, disable the drive. 3. If severely detuned, the input can be pretuned by setting the impedance and frequency adjustments according to the measurements given in the IOT assembly manual which accompanied the IOT circuit assembly. 4. Connect the output of the tracking generator to either of the following: A. For low power tuning, to the HPA input directional coupler (at the output of the circulator located on the left wall of the IOT cabinet) which takes the signal directly into the input of the IOT. Tracking generator output level should be set within the 1 to 3 dbm range. B. For medium power tuning to coax 76 (for HPA1), 152 (for HPA2), or 153 (for HPA3). These cables connect to the output of the RFU. Tracking generator output level should be set to -30 dbm. 5. Set the spectrum analyzer as follows: A. Center frequency to the center of the channel. B. Span to 10 MHz. C. Markers to center, +3MHz from center, and -3MHz from center. D. Resolution and video bandwidths to 30KHz. E. Vertical sensitivity to 10dB/cm. F. Set the tracking generator output level to -30dBm. 6. Connect the spectrum analyzer input to the IOT input cavity reflected directional coupler port. 7. Set the HPA cabinet to beam on. 8. Set the tube idle current to 0.55 A using the HPA GUI > Power Supply > Service screen. The cathode current can also be viewed on this screen. 9. For medium power tuning, start with the tracking generator output set at -30 dbm, increase tracking generator output in 1 db steps and stop just before the collector 4 current reaches 1 A. For low power tuning, the tracking generator output should be set at a low level such as 0 to +3 dbm (1 or 2 mw). Page: /13/12

109 PowerCD Transmitter IOT Tuning PowerCD Transmitter Transmitter Checkout 2533s400.fm Note: The beam supply ripple may impress some noise on the input and output tuning responses. This noise may be minimized by using a small amount of display averaging, but this will slow down the response of the display. 10. Adjust the frequency ring so that a notch appears at the center frequency, see Figure Use the impedance adjustment, with slight changes in the frequency adjustment to achieve a response similar to those of Figure 4-7, see sub step A. A. At the edges of the channel, the return loss of the response should range from -12 to -16 db with the return loss at the center of the channel ranging from -14 to -25 db. The return loss at the center of the channel is not as important as it is at the edge of the channel, center channel maximum return need not exceed 25 db. Strive for a symmetrical response with the greatest possible return loss at the edge of the channel. 12. Be sure to tighten the frequency and impedance lock knobs when the input match adjustments are finished, watch for response changes as the lock knobs are tightened. 13. Set HPA cabinet to standby. 0 db Ref. 3 2 Typical High Frequency Response 25 db maximum dip at center. Scale 10 db/div 1 1_-25 db 2_-17 db 3_-17 db Center Frequency = Center of Channel Span 10 MHz 0 db Ref. Typical Low 3 2 Frequency This response Response is better at high power. Scale 10 db/div 1 1_-16 db 2_-12 db 3_-12 db Center Frequency = Center of Channel Span 10 MHz Figure 4-7 e2v Multi-collector IOT Plug In Tube Input Match, Two Examples Interaction of Input and Output Tuning and Power Level Input tuning errors, such as non-symmetrical response or input response tilt, have a great effect on output tuning even though the output tuning is perfect. If input tuning errors are bad enough, it may be impossible to correctly tune the output. 04/13/ Page: 4-19

110 Transmitter Checkout PowerCD Transmitter IOT Tuning IOT output power level will also effect input tuning. When the IOT is passing the DTV signal at full power level, after tuning, the input tuning can change causing the output response to tilt. Therefore, when the amplifier is operating at full power after tuning, and after it has operated long enough to achieve temperature stability, recheck the input tuning by observing the 8-VSB signal at the reflected port of the IOT input directional coupler. The reflected response should be symmetrical with a dip at the center of the channel, see Figure 4-8. Caution Be careful to make very small changes in the frequency and impedance adjustments when rechecking the input match under power. Significant changes can reduce the output power to zero by reflecting all of the input back to the IPA circulator. Be sure to tighten the frequency and impedance lock knobs when the IOT input tough up adjustments are finished. 0 db Ref. Scale 10 db/div Center Frequency = Center of Channel, Span 20 MHz Figure 4-8 IOT Input Reflected Response When HPA Is At Full Power Basic IOT Output Tuning The IOT output circuit is a double-tuned over-coupled circuit. This section will cover the rules used to tune this type of circuit. A double-tuned over-coupled output stage has four tuning controls. They are the: Primary Tune, see Section on page Coupling, see Section on page Secondary tune, see Section on page Loading, see Section on page Page: /13/12

111 PowerCD Transmitter IOT Tuning PowerCD Transmitter Transmitter Checkout Bandwidth Measurement Methods Before the subject of tuning is attempted, a discussion of bandwidth measurements is needed for the double-tuned over coupled amplifier. 2533s400.fm Measuring Depth Saddle and Height of Haystack Depth of Saddle is the distance (measured in db) between lines A and B in Figure 4-9. Line A is drawn so that it just touches the upper peaks of the response waveform. The two peaks should be at the same level (line A should be horizontal). Line B is drawn so that it just touches the lowest point of the saddle and is parallel to line A. Height of Haystack is the distance (measured in db) between lines A and D in Figure 4-9. Line A is drawn so that it just touches the upper peak of the response waveform. Line D is drawn so that it crosses the response at the edge of the channel (6 MHz) and is parallel to line A. Saddle depth is typically 0.5 db, a hay stacked response is not used with the multi-collector IOT. Use 1.0 db vertical log scale on analyzer Measuring Bandwidth The following methods of bandwidth measurement are used for the IOT amplifier output. The method used depends in part on the customers preference and in part of the amount of saddle tuned into the output of the amplifier. Bandwidth is measured using lines B or C of Figure 4-9. Both of these lines are referenced to line A. Line A is drawn so that it just touches the upper peaks of the response waveform. If tuning is correct, line A should be horizontal. Line B is drawn so that it just touches the lowest point of the saddle and is parallel to line A. Line C is drawn parallel to line A and 1.0 db below it. Method 1, Depth of Saddle Bandwidth is defined as the frequency difference between the two vertical lines that cross the response where it intersects horizontal line B. This method of bandwidth measurement can be used if a measurable amount of saddle is tuned into the tube. Method 2, -1 db Bandwidth is defined as the frequency difference between the two vertical lines that cross the response where it intersects horizontal line C. This method of bandwidth measurement is useful if the response has no saddle (flat response) or up to 0.1 db of haystack. Note A 1dB tilt across the bandpass of the DTV signal increases the EVM (error vector magnitude) by 6 to 7%. 04/13/ Page: 4-21

112 Transmitter Checkout PowerCD Transmitter IOT Tuning 1.0 db Saddled Response Depth of Saddle Bandwidth 1.0 db Bandwidth Depth of Saddle A B C 1.0 db Hay stacked Response 6 MHz Haystack A D C 1.0 db Bandwidth Figure 4-9 Bandwidth and Depth of Saddle (or Hay Stacked) Measurement Note: A good starting point for tuning is a response with a 0.5 db saddle and a 1 db bandwidth of 8 MHz Page: /13/12

113 PowerCD Transmitter IOT Tuning PowerCD Transmitter Transmitter Checkout The Four Output Tuning Controls 2533s400.fm A spectrum analyzer and tracking generator are used to tune the IOT output. The tracking generator is setup and connected following either of the two tuning methods mentioned earlier, see See Tuning At Low Power on page 1-17., or See Tuning At Medium Power on page The IOT forward output sample, located on the IOT breakaway section, is connected to the input of the spectrum analyzer. Once the spectrum analyzer and tracking generator are connected and the HPA cabinet set to beam, output tuning is simply a matter of knowing what each of the four output controls do the HPA response. The tuning control rules are given below. Note: The beam supply ripple may impress some noise on the input and output tuning responses. This noise may be minimized by using a small amount of display averaging, but this will slow down the response of the display Primary Tuning Primary Tuned Higher Reference Response Primary Tuned Lower Figure 4-10 Primary Tuning Primary tuning rules. Desired effect: Desired effect: Undesired effect: Response tilts (in the direction of tuning) Response slides up or down the band (center of pass band changes) None. 04/13/ Page: 4-23

114 Transmitter Checkout PowerCD Transmitter IOT Tuning Interstage Coupling Changes Note: The beam supply ripple may impress some noise on the input and output tuning responses. This noise may be minimized by using a small amount of display averaging, but this will slow down the response of the display. Coupling Increased Reference Response Coupling Decreased Knob pulled outward, higher number on scale. Knob pushed inward, lower number on scale. Figure 4-11 Coupling Coupling rules. Desired effect: Bandwidth changes. Undesired effect: Center of pass band changes (one edge of response stays in place but the other edge moves). Undesired effect: Response tilts. Action for both undesired effects: Adjust primary and secondary tuning controls as necessary to flatten the response and center it in the passband. Coupling (bandwidth) has the following effect on IOT beam load impedance. Wider bandwidth = lower IOT beam load impedance. Narrower bandwidth = higher IOT beam load impedance. Setting the bandwidth too wide makes the tube more linear, but has the following effects. Lowers tube gain, which requires more drive power from the IPA. Lowers the efficiency of the amplifier, which causes higher beam current (I b ) and higher collector dissipation. Page: /13/12

115 PowerCD Transmitter IOT Tuning PowerCD Transmitter Transmitter Checkout Secondary Tuning Note: The beam supply ripple may impress some noise on the input and output tuning responses. This noise may be minimized by using a small amount of display averaging, but this will slow down the response of the display. 2533s400.fm Secondary Tuned Higher Reference Response Secondary Tuned Lower Figure 4-12 Secondary Tuning Secondary Tuning rules. Desired effect: Response tilts in opposite direction to that of primary tuning. Undesired effects None. 04/13/ Page: 4-25

116 Transmitter Checkout PowerCD Transmitter IOT Tuning Loading (output Coupling) Changes Note: The beam supply ripple may impress some noise on the input and output tuning responses. This noise may be minimized by using a small amount of display averaging, but this will slow down the response of the display. Output Loaded Lighter Reference Response Output Loaded Heavier Knob pulled outward, lower number on scale. Knob pushed inward, higher number on scale. Figure 4-13 Loading (Output Coupling) Loading rules. Desired effect: Saddle changes (light loading more saddle, heavier loading, less saddle or haystacked response). Undesired effect: Response tilts Action: adjust secondary tune to flatten response. Undesired effect: Bandwidth changes. Action: adjust coupling to correct bandwidth Output loading (depth of saddle) has the following effect on IOT beam load impedance. Heavier loading (less saddle or hay stacked response) = lower IOT beam load impedance. Lighter loading (more saddle) = higher IOT beam load impedance. Heavier Loading (less saddle) makes the tube more linear, but has the following effects. Lowers tube gain, which requires more drive power from the IPA. Lowers the efficiency of the amplifier, which causes higher beam current (I b ) and higher collector dissipation. Page: /13/12

117 PowerCD Transmitter IOT Tuning PowerCD Transmitter Transmitter Checkout 2533s400.fm Setup and Procedures For the Multi-collector IOT Output Tuning 1. Set HPA cabinet to Standby. 2. Using the HPA GUI > Power Amp > Service screen, disable the drive. 3. Connect the output of the tracking generator to either of the following: A. For low power tuning, to the HPA input directional coupler (at the output of the circulator located on the left wall of the IOT cabinet). This takes the signal directly into the input of the IOT. Tracking generator output level should be set within the 1 to 3 dbm range. B. For medium power tuning to coax 76 (for HPA1), 152 (for HPA2), or 153 (for HPA3). These cables connect to the output of the RFU. Tracking generator output level should be set to -30 dbm. 4 Set spectrum analyzer as follows: A. Center frequency to the center of the channel. B. Start with 20 MHz span and when tuning gets close switch to 10 MHz. span. C. Markers to center, +3MHz from center, and -3MHz from center. D. Resolution and video bandwidths to 30KHz. E. Vertical sensitivity to 1dB/cm. F. Set the tracking generator output level to -30dBm. 5. Connect the spectrum analyzer input to the customer sample forward directional coupler on the IOT output breakaway assembly. 6. If severely detuned, the four IOT output tuning controls can be preset. Preset tuning information can be obtained from IOT circuit assembly manual, transmitter final test data, or from customer s prior tuning records. 7. Set the HPA cabinet to beam. 8. Set the tube idle current to 0.55 A using the HPA GUI > Power Supply > Service screen. The cathode current can also be viewed on this screen. 9. For low power tuning, set the tracking generator output to 0 to +3 dbm (1 or 2 mw). 10. For medium power tuning, start with the tracking generator output set at -30 dbm, increase tracking generator output in 1 db steps and stop just before the collector 4 current reaches 1 A. 11. Perform the output tuning 12. Be sure to record the tuning results and IOT circuit assembly settings when finished. 13. Set HPA cabinet to standby Typical Low Power Output Tuning Results Two parameters indicate the IOT is correctly tuned. They are the swept bandwidth and amount of saddle. Correct saddle ranges from a 0.25 to 0.5dB saddle to a 0.1 db haystack. The top response of Figure 4-9, on page 4-22, is saddled, the bottom response is hay stacked. The correct bandwidth for the multi-collector IOT is 8 MHz, measured at the -1 db bandwidth. 04/13/ Page: 4-27

118 Transmitter Checkout First Operation at Full Output Power Correct bandwidth depends on the method of measurement. If measured at the depth of saddle, shown in Figure 4-9, the bandwidth appears to be more narrow than the same response measured at the -1.0 db bandwidth. The -1.0 db bandwidth measurement is necessary for a flat or hay stacked response. One low power tuning starting point response is shown in Figure This response will get the amplifier tuned close enough to allow tuning at medium power. Saddle = 1/4 to 1/2 db 1.0 db 1.0 db Bandwidth = 7.5 to 8.5 MHz 4.7 First Operation at Full Output Power Figure 4-14 Low Power Tuning Starting Response At this time, all transmitter cabling has been returned to normal. The transmitter is about to be brought up to full power for the first time HPA Output Forward Power Calibration And Setup This is the procedure for the first time setup of the forward power and the forward power calibration. The tube should have already been tuned. Note: For multiple HPA systems, this procedure refers to all HPAs combined or to a selected HPA. For a single HPA system, ignore the all or selected indications and preform that operation on the HPA. 1. On the driver GUI > Output > Service > Setup screen; enter the nominal forward power required at the output of the mask filter. This number may have already been entered. It tells the software what the normal 100% output power level should be. 2. On all HPA cabinets, verify that the remote is disabled. 3. Press standby on all HPA cabinets. Depending on what power output is required from each HPA, set the beam supply full tap switch on all HPAs appropriately. EXAMPLE: 30kW to 36kW start with 38kV 25kW to 34kW start with 36kV The final beam voltage setting depends on the performance of the tube. It should be set as low as acceptable tube output shoulder response will allow, this will provide the best IOT efficiency. Consider this while tuning the tube as the tuning can be affected by where beam voltage is set. The beam supply tap switch is accessed as follows. Page: /13/12

119 First Operation at Full Output Power PowerCD Transmitter Transmitter Checkout 2533s400.fm A. Following the procedure in Section 2.1, Power Cabinet Rear Door Unlocking Procedure, on page 2-1, remove the beam supply door key and open the access door on the beam supply. B. Use the ground stick to discharge all connections on the beam supply. C. Adjust the tap switches for the desired output voltages. D. Close and seal the beam supply, make sure the ground stick is positioned in its holder on the beam supply access door. E. Reverse the procedure in Section 2.1, Power Cabinet Rear Door Unlocking Procedure, on page 2-1 to reenergize the transmitter AC. 4. Connect a power meter to the output of the mask filter, use the calibrated port. Make sure the meter is properly set up, calibrated and the correct offset entered. 5. Verify that the driver cabinet beam is on. This enables the IPA. 6. On all HPA cabinets verify that the drive is prohibited. Use HPA GUI > Power Amp > Service 7. On the selected HPA, once the HPA cabinet time out has completed, press beam. 8. In the upper left hand corner of the selected HPA GUI > Power Supply > Service screen set the grid mode to Normal Adjust the grid voltage for 0.55 A of cathode current, the cathode current can be read on this screen. Note the grid voltage. 9. On the selected HPA GUI > Power Amp > Service screen, enable the (IOT) drive. 10. In the transmitter control section of the driver GUI, the ALC setting should read between 850 and Raise the HPA power level, using the HPA GUI transmitter control section ALC up and down arrows, so that the reading on the meter at the output of the mask filter indicates the following: A. For a single HPA system, the meter should indicate the power level required at the output of the mask filter. B. For a multiple HPA system, only one HPA will be operated at a time, with the selected HPA being the only one connected to the output. In this case the HPA power should be set so that the meter indicates the required mask filter output power divided by the number of HPAs. For example, if the required mask filter output power is 33kW and the system contained 3 HPAs, the power at the mask filter would be set at 11kw. C. The power level at the selected HPA will be higher than the mask filter output due to mask filter and combiner loss. 12. After the HPA output power has been established, set all M2X exciter RTAC correction to BYPASS as shown in Figure A. In the BG Heat, Standby, or Beam On in the drive prohibit mode, or Beam On where the HPA output power level is set below 3.0kW, the M2X exciter will be in the Hold mode. B. When the HPA output power raises above the threshold (approximately 4kW) the exciter RTAC mode changes from Hold to the preselected RTAC operating mode. 04/13/ Page: 4-29

120 Transmitter Checkout First Operation at Full Output Power M2X RTAC -Front Panel.jpg (500), and M2X RTAC - 1.jpg (400) Front Panel Gui Screen Figure 4-15 M2X Exciter Showing RTAC Bypassed 13. When the output power level has been set (greater than 4 kw) the upper left hand corner of the selected HPA GUI > Power Supply > Service screen should indicate the ISO PS Mode as Normal. A. Connect a spectrum analyzer to the forward output sample coupler located on the breakaway of the selected tube. Setup the spectrum analyzer per the data given in Figure B. The normal grid voltage will need to be lowered (set more positive) to a point where the HPA output adjacent channel shoulder intermod response (measured before the mask filter) indicates -30 to -32dB, as shown in Figure Grid bias, beam voltage, IOT tuning, and HPA output power level all combine to give -30 to -32 db shoulders and acceptable IOT efficiency. Check the efficiency and dissipation after the shoulder re- Page: /13/12

121 First Operation at Full Output Power PowerCD Transmitter Transmitter Checkout 2533s400.fm sponse is achieved. The IOT tuning and/or beam voltage can be changed in order to get a better compromise between efficiency and acceptable shoulders. 2. If this is one of the few PowerCD systems where the standard D mask filter is used, the shoulder response before the mask filter must be -37 db. If the sharp tuned mask filter is being used, the shoulder response can range from -34 to -37 db, strive for lowest practical shoulder levels. C. If the transmitter is going to operate at the same parameters as the e2v data sheet that came with the tube, then the normal grid voltage will probably be at a point within approximately 2 volts of the value on the tube data sheet. D. If the transmitter is operating at a lower power and lower beam voltage than what was on the e2v data sheet, experience has shown that the grid voltage will be lower (more positive) than the data sheet value by approximately 6 to 7 volts. 14. Record the power indication on the power meter, then lower the selected HPA power back down to zero from the HPA GUI. (ALC to zero) The grid voltage should have now stepped back to the Idle mode. This is indicated on the HPA GUI > Power Supply > Service screen in the upper left hand corner. The idle mode grid voltage will not be where it was originally set. This voltage tracks the normal gird voltage setting. The idle grid voltage has to be reset to 0.55 A of cathode current. The idle grid voltage is prohibited (by hardware) from being set more positive that the normal grid voltage. A. When finished, raise the power of the selected HPA to the power level recorded at the beginning of step 14. Figure 4-16 Spectrum Of HPA Output, Before High Power Filter, All RTAC Correction Bypassed 15. It the transmitter system has only one HPA, perform the following driver system forward power calibration. 04/13/ Page: 4-31

122 Transmitter Checkout First Operation at Full Output Power A. At the driver GUI > Output > Service > Calibrate screen select the white box by forward power and a key pad will appear. Enter the power level required at the output of the mask filter, this should also be the power indicated on the power meter which is connected to the calibrated port of the mask filter output. Select Enter, and select the calibrate button. For example, if the required power level is 29.5kW, enter If the system has multiple cabinets do not perform this calibration now. It must be performed after all cabinets have been combined. 16. For single or multiple HPA systems, move the power meter to the forward sample port on the breakaway of the selected HPA. Be sure to enter the correct offset for this coupler, and note the forward power reading. 17. On the selected HPA GUI > Output > Service > Calibrate screen enter the number displayed on the power meter into the Forward Power section and press Calibrate. A. This is the normal power calibration for power output displayed in kw. For example, if the meter reads 30.2kW, enter On the selected HPA GUI > System > Service > Configure screen enter the number displayed on the power meter into the Nominal Forward Power section and press Store. A. This calibration is used to establish the power level for 100% power, and also establishes the 110% output power limit for that HPA. 19. For multiple HPA systems, repeat steps 7 through 18 (skipping steps 11 and 15) for the other HPAs in the system HPA Output Reflected Power Setup 1. Remove the reflected sample cable from the reflected directional coupler on the IOT breakaway assembly. 2. Remove the load from the other (forward) port on the same directional coupler and place it on the reflected port. 3. Place a 20dB pad on the forward port 4. Connect the cable on to the 20 db pad. The reflected sample is now looking at a forward sample which has been reduced by 20dB. 5. On the HPA GUI > Output > Service > Calibrate screen enter 1% of the HPA forward power into the reflected power section and press Calibrate. If the Calibration box flashes Invalid after the Calibration button is pressed the calibration is no good. It is likely due to an RF level that is too low. Try decreasing the pad size from 20dB to raise the sample level then try recalibrating. Be sure to enter the correct percentage of power according to the level of pad inserted in to the sample line. Use a 16 db or larger pad, because the VSWR foldback point is set at 1.4:1. A. % Reduction = -100Antilog(-dB/10), where db represents the pad size. 6. Remove the pad and load from the directional coupler and remove the pad from the cable. 7. Place the load on the forward port of the coupler 8. Place the cable back the reflected port. 9. The HPA GUI should now indicate the actual reflected power of the system. Page: /13/12

123 First Operation at Full Output Power PowerCD Transmitter Transmitter Checkout 2533s400.fm 10. This sub routine will check or set the HPA VSWR overload and foldback settings on the HPA GUI. On the HPA GUI > Output > Service > Setup screen, the VSWR overload and trip points are shown in the blue boxes, they are typically set at 1.5:1 and 1.4:1. If they are not set correctly, they can be changed by: B. In the HPA GUI > Output > Service > Setup screen, click in the white window for the parameter to be changed. C. Enter the new VSWE setting. D. Click the store soft key System and HPA Automatic Level Control (ALC) Setup This procedure is to be performed with the transmitter off the air. At this point all disconnected cables should have been reconnected. The procedure for setting the PA cabinet output power depends on the transmitter configuration. Two possibilities exist, they are: The transmitter has a single HPA. In this case, the HPA should be in remote enable, drive disable and standby. The driver and HPA cabinets should be in standby. The transmitter has multiple HPAs. In this case, both HPAs should be in remote enable, drive disable and standby. The driver and HPA cabinet in question should be in standby. 1. On the driver GUI > Drive > Service > IPA Gain screen, reduce IPA Gain for each HPAs (by at least half) so that they cannot make 100% power. 2. Set the driver ALC to 1023, as viewed on the Control Tx window on the right side of the driver GUI screens. 3. Switch the driver cabinet to beam on. The HPAs should also go to beam on. 4. On all HPAs, enable the HPA drive. 5. For each HPA, slowly increase the HPA ALC to maximum, on the HPA Power ALC indication, on the right side of the HPA GUI screen. A. The HPAs should not be able to reach 100% power. If any HPA does, reduce its IPA gain further. B. Continue increasing each HPA ALC until its Master DAC number, on the HPA GUI > System > Meters > Control screen, stops increasing. Its maximum is 4095, but it will probably stop before that. 6. For each HPA in turn, slowly increase the IPA gain (10 or 15 steps at a time) until that HPA power reaches 110%. A. Observe the power on the HPA GUI > Full Screen > Summary, to see the power in percent. 1. This GUI can be turned so that it can be viewed from the driver cabinet. 7. Lower the driver ALC until the one HPA output power is at 100%. 8. Look at the output power level of each HPA, and tweak its ALC of that HPA to get 100% power from it. A. Only a small change should be needed. 9. Tweak the IPA gain of each HPA to get its ALC voltage indication (on the HPA GUI Power > ALC indication, on the right side of the screen) within the ideal operating range of 3.4 to 3.6 Vdc. 04/13/ Page: 4-33

124 Transmitter Checkout First Operation at Full Output Power A. Increase the IPA module gain to lower the ALC voltage and decrease the module gain to raise the ALC voltage. B. IPA gain number should fall within a typical range of 200 to 450, C. HPA cabinet drive power (HPA GUI > Drive > Meters, (or summary) should never exceed 250 watts. D. The IPA output is always greater than the drive power because of the cable loss between the IPA and IOT. The IPA output can be observed in the driver GUI > Drive > Meters, (or summary). On this screen it is called HPA1 (or 2 or 3) Input Power. 10. This completes the ALC setup procedure. Note: Pressing the drive disable button (HPA GUI > Power Amp > Service screen) resets both HPA remote and remote disabled ALC pots to zero. When leaving drive disable, the HPA output power will be zero. Therefore, both HPA power adjustments must be reset to 100% power for that HPA Warm Cavity Medium Power Tuning While operating at full power and after the cavity has had a chance to warm up, re-check the input tuning. The IPA input reflected response should be symmetrical about the center of the channel, similar to Figure If necessary, make slight adjustments to the IOT input frequency and impedance controls to correct the input response. 0 db Ref. Scale 10 db/div Center Frequency = Center of Channel, Span 20 MHz Figure 4-17 IOT Input Reflected Response When HPA Is At Full Power Within the space of 1 minute, to prevent the cavities from cooling too much, perform the following procedure: 1 Set the HPA to standby, 2 Restore the medium power tuning setup. 3 Set the HPA to transmit and check the idle current, it should be 0.55 A. Page: /13/12

125 First Operation at Full Output Power PowerCD Transmitter Transmitter Checkout 2533s400.fm 4 Sweep the HPA with collector 4 current at 1 A. 5 Figure 4-18 shows the resultant warm cavity medium power tuning response. A If necessary, adjust the output tuning controls to achieve desired results. 6 When tuning is complete, Set the HPA to standby and restore the IPA input cabling to normal. 6 MHz Saddle = 0.3 to 0.8 db 1.0 db 8.0 MHz Bandwidth Figure 4-18 Medium Power Tuning Warm Cavity Output Response Reject Load Calibration, For Transmitters With Two or More PAs 1. Verify that all other forward metering calibrations have been performed. 2. Lower power on all HPAs to zero, xxx using drive disable. 3. On the driver GUI > Output > Service > Calibrate screen press Save Reject Load Power Offsets. 4. Enable drive to all HPAs and set the power back to 100% with PA cabinets in remote enabled and remote disabled. 5. Switch the operation of the mode controller so that an HPA that is operating at full power is directed into the reject load to be calibrated. 6. On the driver GUI > Output > Service > Calibrate screen, select the white box next to the reject load to be calibrated and enter the power output of the HPA that is being directed to that load. 7. If this is a 3 HPA system, repeat steps 5 and 6 for the other reject load. A. It is not possible to route amplifiers A + B to either reject load in a 3 HPAsystem. 04/13/ Page: 4-35

126 Transmitter Checkout First Operation at Full Output Power Combining HPAs in a Multiple Tube System In multiple tube transmitter systems the outputs of the HPA cabinets must be combined into a single RF output. Therefore, all HPA cabinets must be operating within specification. If the performance of the other HPAs are in question, they should be checked, see Section 4.7.1, HPA Output Forward Power Calibration And Setup, on page The combining is done with either riblet or magic tee combiners. These combiners have two inputs and two outputs. The outputs of the tubes are connected to the combiner inputs, one combiner output is connected to a reject load, and the other (the useful output) is connected through the mask filter to the station test load or the antenna. If the phase and levels of the input signals are correct all of the signal will go to the useful output. Phase or level errors will cause some or all of the power to go to the reject load. For systems with more then two tubes, multiple combiners are used, but the rules for achieving the desired output at the desired port are the same. The combining process is as follows. 1. Carefully adjust and calibrate the outputs of all HPAs (into a resistive load) to the same output power. This should satisfy the level matching requirement. 2. Operate all HPAs at 100% power in the combined mode. 3. Monitor the reject load output on the driver GUI > Output > Service > HPA Phasing screen. 4. Press the HPA1 - HPA2 soft key and press the up or down arrow soft keys for the appropriate HPA to minimize power in the reject load. A. The larger of the two sets of arrow keys changes the phase by 90 degree increments and the smaller of the arrow keys varies the phase continuously over a 90 degree range. B. When reject power is minimized, should read below 5%, press the Save Phase Settings soft key. 5. For systems with more then two tubes, press the HPA1&2 - HPA3 soft key and press the HPA3 up and down arrow soft keys to minimize reject power. A. The larger of the two sets of arrow keys changes the phase by 90 degree increments and the smaller of the arrow keys varies the phase continuously over a 90 degree range. B. When reject power is minimized, should read below 5%, press the Save Phase Settings soft key. 6. When the combining is complete, the reject power meters should read below 5% power. The reject trip points are typically set at 12% reject power System Level Forward Power Calibration 1. Operate all cabinets at 100% power in the combined mode. 2. Connect a power meter to the output of the mask filter, use the calibrated port. Make sure the meter is properly set up, calibrated and the correct offset entered. 3. At the driver GUI Output > Service > Calibrate screen select the white box by forward power and a key pad will appear. Enter the number displayed on the power meter, select Enter, and select the calibrate button. 4. On the driver GUI > Output > Service > Setup screen; enter the nominal forward power required at the output of the mask filter. This number may have already been entered. It tells the software what the normal 100% output power should be. Page: /13/12

127 First Operation at Full Output Power PowerCD Transmitter Transmitter Checkout System Level Reflected Power Setup 2533s400.fm This is the system level reflected power setup and calibration procedure It can be used for the initial setup and for normal maintenance. If the system has multiple HPAs, all HPAs should have been calibrated and combined and operating at 100% power. 1. Remove the sample cable from the reflected directional coupler at the output of the mask filter. 2. Remove the load from the other (forward) port on the same directional coupler and place it on the reflected port, from which the cable was just removed. 3. Place a 20dB pad on the forward port 4. Connect the cable on to the 20 db pad. The reflected sample is now looking at a forward sample which has been reduced by 20dB. 5. On the driver GUI > Output > Service > Calibrate screen enter 1% of the system forward power into the reflected power section and press Calibrate. If the Calibration box flashes Invalid after the Calibration button is pressed the calibration is no good. It is likely due to an RF level that is too low. Try decreasing the pad size from 20dB to raise the sample level then try recalibrating. Be sure to enter the correct percentage of power according to the level of pad inserted in to the sample line. Use a 16 db or larger pad, because the VSWR foldback point is set at 1.4:1. A. % Reduction = -100Antilog(-dB/10), where db represents the pad size. 6. Remove the cable and load from the directional coupler and remove the pad from the cable. 7. Place the load on the forward port of the coupler 8. Place the cable back the reflected port. 9. The driver GUI should now indicate the actual reflected power of the system. 10. This sub routine will check or set the System VSWR overload and foldback settings on the driver GUI. On the driver GUI > Output > Service > Setup screen, the VSWR overload and trip points are shown in the blue boxes, they are typically set at 1.5:1 and 1.4:1. If they are not set correctly, they can be changed by: B. In the driver GUI > Output > Service > Setup screen, click in the white window for the parameter to be changed C. Enter the new VSWE setting. D. Click the store soft key Verifying RTAC RF Sample Levels Verify RTAC RF sample levels at Exciter. RTAC RF feedback sample levels should be set at -5 dbm for best RTAC operation. If required add or remove attenuation to obtain this level. Also, for multiple HPA systems, the RTAC sample levels must remain within the 0 to -10 dbm range when the mode controller is used to combine various combinations of HPAs (operating at 100% power) into the output. 04/13/ Page: 4-37

128 Transmitter Checkout First Operation at Full Output Power Activating RTAC Correction Connect a spectrum analyzer to the output of the mask filter, using one of the forward couplers. Set the spectrum analyzer as follows: A. Center frequency to the center of the channel. B. Span to 15 MHz. C. Resolution and video bandwidths to 30KHz. D. Vertical sensitivity to 10dB/cm. After the IOT has been tuned, forward power calibrated, and the correct warm channel response has been achieved, the transmitter system must be checked at full power with the M2X exciter Lin HPF and Non-Lin RTAC correction set to ADAPT. It takes RTAC a few minutes to correct the transmitter output signal when it is activated. Note: Non Linear RTAC usually gives a 5 to 6 db shoulder increase when activated. Non Linear RTAC is capable of better improvement, but in this case the IOT is being setup for better efficiency and not for best shoulder response. At this time, the most important specification to check is the adjacent channel shoulder response, which is -47 db or greater per the FCC DTV mask requirements. The -47 db FCC mask requirement is equivalent to -37 db shoulders when measured with respect to the response at the center of the channel. Figure 4-19 shows an output response that passed the FCC mask test. Its shoulders are approximately -49 db. Monitor the results of the nonlinear RTAC correction before the sharp tuned filter, because the transmitter will always pass the FCC mask specifications when monitored after the sharp tuned mask filter. This ensures that the shoulder level passes the FCC mask test before the sharp tuned filter, which ensures that the HPA is sufficiently linear. Poor HPA linearity will degrade both the shoulder response and the EVM. A very few PowerCD transmitters were setup using the standard D mask filter. For these transmitters, the shoulder response before the mask filter must measure -37 db with respect to the center of the channel (-47 db FCC mask specification). This is necessary because the standard D mask filter has minimum effect at the shoulders but has good adjacent channel attenuation after the beyond the shoulders. If the PowerCD system includes the sharp tuned filter (sometimes referred to as cool fuel) the transmitter output shoulders, measured before the sharp tuned mask filter, should measure -35 db or better (with respect to the center of the channel). After the mask filter the response should pass the FCC mask test by more than 10 db, sometimes by as much as 20 db. Monitor the results of the linear correction after the sharp tuned filter, because that is where most of the linear distortions (low EVM, poor digital signal to noise ration, and poor EYE pattern response) are generated. Usually, the EVM and digital SNR are ok, but if a problem exists, it may be that one or both adjacent channel shoulders will not meet the -47 db FCC specification when measured before the mask filter. Page: /13/12

129 First Operation at Full Output Power PowerCD Transmitter Transmitter Checkout 0 db Ref. 2533s400.fm -47 db Scale 10 db/div Center Frequency = Center of Channel Span 20 MHz Figure 4-19 HPA Output Showing Correct Adjacent Channel Shoulder Response Output Shoulders Fails FCC Mask Test A good test of the uncorrected linearity of the HPA is to observe the adjacent channel shoulders before the mask filter with the M2X exciter correction bypassed. If the transmitter has multiple HPAs, check the combined output. If the uncorrected shoulders measure -30 db or lower (more negative) with respect to the level at the center of the channel, the RTAC will be able to correct the HPA linearity and the shoulders will pass the FCC mask specification. If the shoulders do not make the -30 db adjacent channel mark, there is a problem with the HPA, such as, but not limited to input or output tuning problem, incorrect idle current, incorrect beam voltage for that power level (this can be caused by operating at a higher than the specified power level because of poor output power calibration or a change in the required output power), or other items. Note: Non Linear RTAC usually gives a 5 to 6 db shoulder increase when activated. Non Linear RTAC is capable of better improvement, but in this case the IOT is being setup for better efficiency and not for best shoulder response. If one or both output shoulders fail the FCC mask test, two corrective actions may be tried. The first is to broaden the IOT input match and the second is to change the output tuning bandwidth and/or saddle. 0 db Ref. IOT input match response before readjustment of IOT input tuning. IOT input match response after readjustment of IOT input tuning. Vertical Scale = 10 db/div Figure 4-20 IOT InpuT Match Response Before and After Readjustment of Input Tuning 04/13/ Page: 4-39

130 Transmitter Checkout First Operation at Full Output Power First, the IOT input response should be checked. The IOT input frequency control should be adjusted to place the response dip in the center of the channel and the impedance control adjusted to make the dip slightly more shallow, as shown in Figure This result will be a broader input match at the expense of a slightly reduced input return loss. The bandwidth at the IOT input must be as wide or wider than the shoulders it is expected to correct so that the RTAC Non-Lin pre correction signal can reach the IOT. A narrow IOT input bandwidth interferes with this corrective action. If the output shoulders still fail the FCC mask test, the IOT output will need to be retuned. Ensure that the when warm, the IOT output response is flat (not tilted) and centered within the channel. Also, a broader output bandwidth and/or less saddle will lower the beam load impedance and make the tube more linear. Three factors limit the amount of these adjustments, they are as follows: The gain of the IOT is decreased, requiring more IPA drive power. The efficiency of the IOT is decreased. The dissipation of the IOT is increased. First try increasing the 1 db bandwidth of the IOT output circuit from 8 to 9 MHz. while maintaining the saddle at 0.5 db. Caution It is possible to make the output bandwidth to wide, because the bandwidth is simply too wide, or limited input bandwidth may mask extra wide output bandwidth. The results are poor shoulder response, poor efficiency, high dissipation, and higher than normal IPA drive levels. If that doesn t succeed, try various combinations of saddle (0.3 to 0.8 db saddle) and bandwidth (1 db bandwidth range of 8 to 9 MHz). By its correct performance, the IOT will tell you what it wants RF System/Mode Controller Checkout If the transmitter system has more than one HPA, perform the mode controller checkout mentioned below. Ensure the RF system interconnects have been completed in accordance with the transmitter interconnect schematic, schematic number Test the appropriate mode command selections and ensure the RF system will switch to the selected positions and generate the appropriate status read backs Hour Transmitter Operation Test Allow the transmitter to operate for a 24 hour period and double check tube tuning and performance. Page: /13/12

131 Recommended Test Equipment PowerCD Transmitter Maintenance 5 Maintenance This section contains maintenance instructions for the PowerCD series of UHF television transmitters. Routine maintenance procedures, a recommended maintenance schedule, and a list of recommended test equipment is given. 2533s500.fm 5.1 Recommended Test Equipment See Table 5-1 for a list of recommended test equipment. Table 5-1 Recommended Test Equipment Equipment Type Manufacturer Model Number Options 8VSB Demodulator Tektronics RFA 300 OR Vector Signal Analyzer Optional: Network Analyzer Harris Part No. (if applicable) Agilent V or -A -AYA vector modulation analysis -AYH digital video modulation analysis -UFG 4 Mbyte RAM Agilent HP 8753C 041 Printer option and 099 H38W tracking generator LO (for sweep and tune) Spectrum Analyzer Agilent 8591E, or its replacement the, 4402B H38 LO output (for sideband adaptor) 010 tracking generator output 043 RS232 and parallel printer port Resolution: 30 Hz to 3 MHz Power measurement Agilent E4418B power meter with 8482Hsensor, 100 uw to 3 W Frequency measurement Agilent 53131A or 53181A Or Tektronics CMC251 Optional: High Pot Unit Hipotronics 860PL Optional: Tube Gas Tester e2v 4260A Miscellaneous Test Equipment Optional Adapters and connectors 010 high stability time base 015 range extension to 1.5 GHz, OR 030 range extension to 3.0 GHz 400 MHz dual trace Oscilloscope Camera or software package to record transmitter performance data Bird APM-16 wattmeter, with 1W to 1kW elements Narda Directional coupler Eagle RLB-150 RF bridge Eagle TNF-200 UHF RF notch filter Fluke 87 digital multimeter with current probe Or Any true RMS multimeter Power supply, 0-6 A constant current, 0 to 24 volt rang Myat 3-1/8 inch to 4-1/16 inch adaptor Dielectric 3-1/8 inch to 4-1/16 inch adaptor Myat 3-1/8 inch to 6-1/8 inch adaptor /8 inch to type N adaptor /13/ Page: 5-1

132 Maintenance Equipment Cleaning Table 5-1 Recommended Test Equipment Harris Part No. Equipment Type Manufacturer Model Number Options (if applicable) Adapters and connectors Type N to BNC, male to female Type N to BNC, female to male BNC barrel, female to female BNC barrel, male to male SMA to BNC, male to female SMA to N, male to female SMB (push on) to BNC SMC to BNC Adapter and connector kit Note: the analog adaptor and connector kit is Equipment Cleaning Cleaning the external surfaces of the transmitter can be done at any time without contacting dangerous voltages. A soft cloth and household type spray detergent should be used to remove fingerprints and dirt smudges from the painted surfaces. Do not spray cleanser into cracks, drawers or other crevices on the exterior of the transmitter or saturate hinges or latch assemblies. It is recommended that the cleaning cloth be sprayed and the equipment carefully wiped clean. For GUI screens non alcohol based LCD screen cleaners are available at any computer or office supply store. 5.3 Scheduled Maintenance A maintenance schedule must be established to ensure proper operation of the transmitter. Inspection and cleaning of the equipment should be performed at an interval no greater than that indicated in the schedule. Failure to perform maintenance invites costly and time consuming equipment breakdowns Weekly Maintenance 1. Water system leaks. Check the water system for leaks especially around the water connections to the IOT. Also check closely any water pipe joints and connections that may be located above the transmitter cabinets. All valves should be checked for leakage. 2. Glycol system leaks. By its nature, glycol has the ability to leak through a hole that water or air may not. Closely inspect the cooling systems for leaks including the piping to the outside cooling fans and pump module. With the pumps shut off, remove the side panels of the pump module and look for evidence of leaks on the floor of the pump module Electrical Performance It is recommended that the following be checked and adjusted only if out of specification. See system test/adjustment for details. 1. IOT heater voltages 2. IOT Idle current, refer to recorded value of grid voltage, shoulder response, and idle current settings recorded when the IOT was last tuned and set up. Page: /13/12

133 Scheduled Maintenance PowerCD Transmitter Maintenance 2533s500.fm 3. Verify driver and HPA cabinet GUI displays for output power metering calibrations 4. Amplitude response 5. Linearity 6. Group delay 7. Error vector magnitude 8. Intermod product suppression Monthly Maintenance 1. Check the pumps for excessive or unusual noises. Check for leaks around the pump seals. 2. Check fluid cooler fans for operation by bumping the contactor for each set of fans. Note any excessive noise, indicating possible bearing failure. (Make sure power is disconnected prior to accessing motors or fans.) 3. Remove and wash the filter on the back door of the power supply cabinet. Make sure filter is dry before reinstalling it. Filter part number is Check and/or replace the amplifier cabinet cavity blower filter on an as needed basis, Part number On current HPA cooling cabinets this filter is located in the lower left side of the back door of the cooling cabinet, see Figure 5-1. It is mounted on a bracket which is accessible when the back door is opened. A. On earlier HPA cooling cabinets this filter is located in the lower portion of the cooling cabinet inside the plenum where the two supply air hoses terminate, see Figure 5-2. It is an automotive type filter listed as follows: A. Fram, part number CA3916. B. Baldwin, part number PA Overload system. If not on air, and with beam on, check by pushing one of the Arc To Test buttons to see that beam is removed. the beams should turn off for two seconds then return. If the arc test sequence is performed three times within 30 seconds, the PA cabinet will fault off. Do not perform this test during broadcast day as transmitter will be removed from operation. 6. The air filter on the rear door of the power supply cabinet should be changed as needed. 7. Keep a running log of IOT grid current. A new IOT should operate at zero grid current. over a several month period the grid current may go more negative. A grid current warning will occur when the grid current reaches the -25 to -30 ma range. If a negative grid current increase trend becomes apparent, contact e2v for guidance in filament voltage management long before it reached the grid current warning level. For additional information, see Section 5.14, Negative IOT Grid Current Increases Over A Several Month Period, on page /13/ Page: 5-3

134 Maintenance Scheduled Maintenance CoolCabInsideFilterNew.jpg Cavity Blower Air Filter (New Location) Cooling Cabinet Rear Door With Filter Opening Figure 5-1 Cooling Cabinet Lower Interior View, Showing New Cavity Blower Filter Location CoolCabInsideOldFilter.jpg Cavity Blower Air Filter (Old Location, Behind Cover) Figure 5-2 Cooling Cabinet Lower Interior View, Showing Old Cavity Blower Filter Location Page: /13/12

135 Scheduled Maintenance PowerCD Transmitter Maintenance Electrical Performance 1. Check the pilot frequency and adjust if necessary. 2. Check the performance of the coolant flow interlocks. Operation of these interlocks will remove the transmitter from air. 2533s500.fm Transmitter Room Clean any filtration equipment associated with the maintenance of the transmitter room temperature and cleanliness Biannual Maintenance 1. Inspect and clean the fins of the outside fan unit. Clean fins of all debris that may inhibit air flow. This can be done with compressed air, water from a garden hose, or a commercial coil cleaner. Normally, water is sufficient to clean most dirt from the fins. A commercial cleaner is needed to remove grease or other imbedded dirt from the fins, but it must be rinsed off with water. Check for bent or damaged coil fins and repair as necessary. 2. All fan motors in the outside fan units have sealed bearings that do not require periodic lubrication, however some fan unit models have bearings equipped with pillow blocks that support the fan shaft. Check for the presence of pillow blocks on your unit and see if a lubrication fitting is installed. If so, these bearings require lubrication on a biannual basis. 3. Some models of pumps also have grease fittings. Check for the presence of grease fittings and inject grease as needed. Warning Ensure that all power is removed from the transmitter and high voltage power supply before performing the following steps. Always use a grounding stick to ensure that there are no residual voltages present IOT Inspection Remove IOT and magnet assembly from amplifier cabinet using the IOT removal procedure in Section on page 5-12, but do not remove the tube. Remove the air duct input to the primary cavity, as well as the dome on the secondary output cavity. Use a flashlight to inspect the IOT ceramic. Look for dirt on the ceramic, especially on the ceramic surface opposite the air inlet duct. Next check the primary and secondary cavities for cleanliness and any evidence of arcing. The amount of dirt will determine the cycle of cleaning Interior Transmitter Cleaning Cleaning the inside of the transmitter should be done using a vacuum cleaner and a clean soft paint brush. The paint brush should be a natural bristle brush with a wooden handle and a metal binding. Brushes made of plastic should be avoided because they cause static, which can damage modules and components on printed circuit boards. Ensure that all power to the transmitter is off and all high voltage circuits have been discharged. Be careful to not dislodge or damage wiring, components, or terminals. 04/13/ Page: 5-5

136 Maintenance Scheduled Maintenance Note Depending on the air quality in the transmitter room, interior transmitter cleaning may be required more often Fiberglass Insulators (G-10) and 50 Meg Ohm Resistors The G-10 fiberglass components, such as the shorting switch assembly, and the 50 meg ohm resistors in the power supply cabinet should be cleaned with denatured alcohol and a clean soft rag to prevent flash over. Depending on air quality, this may need to be done more often, but should be done at least once a year. Do not use rubbing alcohol or isopropyl alcohol to clean the transmitter because its high water content can cause high voltage leakage current to ground if it is absorbed into the insulating material Electrical Performance 1. Check power calibration. 2. Check each interlock and overload for proper operation Power Cabinet and Beam Supply Warning Ensure that all power is removed from the transmitter and high voltage power supply (by following the keylock procedures in chapter 2) before performing the following steps. Always use a grounding stick to ensure that there are no residual voltages present. 1. Check all wire connections for tightness of. 2. Check the lead dress of the incoming high voltage leads and the collector umbilical cord leads. Wires should not touch any sharp edges nor should any wire with low voltage insulation (such as the wires of the cathode umbilical cord) be allowed any closer than 6 inches to any high voltage terminal. 3. Check the lead dress of the beam supply wiring. Wires should not touch any sharp edges nor should any wire with low voltage insulation be allowed any closer than 6 inches to any high voltage terminal. 4. Check the feed through bushings for oil leaks. 5. Visually inspect the bleeder resistors and check with an ohmmeter. 6. Wipe off the high voltage insulators on the beam supply and filter capacitors with a clean dry cloth Annual Maintenance DI Water System The DI water system has several components in the filter loop which need to be changed periodically. They include the following items. Page: /13/12

137 Scheduled Maintenance PowerCD Transmitter Maintenance Materials Needed for UV Lamp and Filter Change Table 5-2 is a list of materials which are needed, or useful to have on hand, when changing the UV lamp or cartridge filters. 2533s500.fm Table 5-2 Materials Needed for UV Lamp and DI Water Filter Changes. Item Quantity Part Number UV lamp for water sterilization Quartz sleeve for UV lamp O-ring for quartz sleeve Filter cartridge, 0.45 micron High temp cartridge (ION) filter Large O-ring for filter cartridge casing Small O-ring for filter head assembly Note: The quartz sleeve does not need to be changed each time the UV lamp is changed, but one should be kept on hand in case of breakage Barnstead Micron Filter Cartridge The Micron filter, located on the door of the cooling cabinet, should be changed annually or more often if needed. The micron filter holder assembly includes a switch which closes when the pressure drop across the filter reaches 20 psi. This pressure drop indicated that the filter is getting dirty and should be replaced Barnstead ION Exchange Cartridge The ION exchange cartridge, located on the door of the cooling cabinet, should be changed annually or more often if needed. The normal flow rate of 0.5 gallons per minute should maintain water purity at 5 Meg ohms or greater. As the cartridge starts to loose its effectiveness, the water flow rate through the cartridge must be increased to maintain the 5 Meg ohm water resistance. The ION exchange cartridge is bad when a flow rate of 1 to 2 gallons per minute will not maintain the 5 Meg ohm water resistance The UV Lamp The UV lamp is used to kill any bacteria or algae which enters in the DI water. It should be changed annually Conductivity Meter Sensor The conductivity of the DI water should be checked once a year with an external meter to verify the accuracy of the transmitter conductivity meter. The the conductivity sensor of the DI water conductivity meter should be changed biannually. It can be corroded by the water and loose its sensitivity over an extended period of time. The part number for the conductivity sensor is /13/ Page: 5-7

138 Maintenance Scheduled Maintenance Installing Barnstead Filters. 1. Shut off the filter loop flow control and return shut off valves, shown in Figure 4-2, while installing or changing filters. 2. Install the barnstead filters located on the cooling cabinet door and change the UV lamp, see Figure 4-4. A. The micron filter comes with two flat black O-rings already installed on it. It also comes with a bag with two adapters in it. Remove the two flat black o-rings from the filter, they are not used. One of the adapters is a plug, place it into one end of the filter. Be sure that it seats all of the way in, it can be pretty tight. The other adapter allows the filter to attach to the filter head, seat it into the other end of the micron filter. The small O-ring fits into a grove on the inner assembly of the filter head. The large O-ring is used to seal the outer filter cartridge casing to the filter head. B. The larger ION exchange filter cartridge is already made with the proper connections on it, it only needs the O-rings. The small O-ring fits into a grove on the inner assembly of the filter head. The large O-ring is used to seal the outer filter cartridge casing to the filter head. C. Be careful when changing the UV lamp. It sits in a quartz sleeve. The quartz sleeve may pull out with the light bulb and is only held in place with an o-ring. It may be worth having a spare quartz sleeve on hand in case it breaks. Be sure to clean this quartz sleeve while you have it out. 3. Turn on the filter loop flow control and return shut off valves. 4. Bleed the air from the filter housings using the air bleed levers located on top of each filter manifold, see Figure Depress S3 on cooling control board to energize water pump. 6. Turn DI flow valve so flow through filter is at approximately 2 gal per min. The water purity meter in IOT cabinet should be between 1 and 3 meg ohms after water has stabilized. Reduce DI loop flow to approximately ½ gallon per minute. A. Depending on the purity level of the water, it could take 30 minutes or longer for the purity to reach the minimum threshold of 1 to 1.2 meg ohms IOT Ceramic Cleaning Cleaning of tube ceramics is only necessary if they are dirty. Dirt and foreign matter on the surface of the ceramic may cause local overheating or arcing and can lead to tube failure. 1. Remove IOT and magnet assembly from amplifier cabinet using the IOT Removal Procedure in Section on page Loosen the ejection lever allen screw and lift the lever. 3. Use a chain fall to lift the tube straight up out of the circuit assembly. 4. Inspect the finger stock and its mating surfaces. 5. Dust may be removed from the ceramic parts with a clean soft cloth or brush. More persistent spots may be removed with denatured alcohol applied to a clean cloth and then cleaning the ceramic. If arc marks or other contamination remain on the ceramic that rubbing alcohol will not remove, refer to the tube manufacturer s application data sheet that covers this subject. Page: /13/12

139 Flow Meter Parts Lists PowerCD Transmitter Maintenance Cavity Inspection 2533s500.fm Refer to the IOT circuit assembly manual for any needed instructions incase the cavities are dirty and need to be disassembled for cleaning and inspection of the fingerstock on the movable cavity tuning doors. 1. The cavities should be checked and cleaned any time the tube is removed The inside of the cavity should be cleaned with a soft clean dry cloth. A dry, soft brush is recommended to clean the contact fingers. More persistent dust may be removed with denatured alcohol. Do not use contact sprays. 2. The contact areas of the spring contacts inside and outside the cavity should be inspected for burn marks. If small burn marks are noticed, they should be carefully cleaned off using the green-scotch Brite pads. When cleaning metal cavity parts or finger stock, care must be taken to remove the oxide, but not the metal plating which is on some parts. Do not use crocus cloth or sandpaper. 3. Damaged spring contacts or contact fingers, particularly those that have been deformed, must be removed. Replace the finger stock if one or more fingers are missing, because missing fingers causes hot spots and arcing Beam Supply 1. Visually inspect the oil in the power supply and look for cloudy or contaminated oil. 2. Remove a small sample of oil from the bottom of the beam supply at the valve on the oil tank and have it checked for water or other contamination. 3. Check for bushing and drain valve oil leaks Glycol System 5.4 Flow Meter Parts Lists From the system drain valve located on the suction return lines to the pumps, take a sample of glycol for evaluation of the inhibitors and system acidity. The sample can be evaluated by Union Carbide/Dow, they will recommend any needed additives. Since the glycol does not touch the IOT, it should not need to be replaced every year. The glycol should have a PH of 8. If the PH drops below 7, the glycol is acidic and could damage the cooling system. The rotors in the flow meters, used to measure the glycol/water mix and pure water flow rates, can slow down or stick due to wear or other causes. These flow meters can be rebuilt using the parts listed in Table Flow Meter Models Used In PowerCD The following SeaMetrics flow meters are used in the PowerCD transmitters. SPX-100, used for 50/50 glycol solution, nickel tungsten carbide shaft, Harris part number , used in the PowerCD driver cabinet, flow rate 15 to 70 liters/min SPX , used for distilled water flow, ceramic shaft, Harris part number , used in the PowerCD anode return flow. Flow: 2 gallons/minute. 04/13/ Page: 5-9

140 Maintenance Water Flow Rate Check SPX , used for distilled water flow, ceramic shaft, Harris part number , used in the PowerCD collector return. Flow: 12 gallons/ minute. SPX , used for 50/50 glycol solution, nickel tungsten carbide shaft, Harris part number , used in the glycol return from cooling cabinet heat exchanger. Flow: 22 gallons/minute Flow Meter Rebuild Parts The moving parts for the above mentioned flow meters are listed in Table 5-3 and can be obtained from Harris Service Parts. For each flow meter to be rebuilt, the recommended parts are 1 O-ring, 1 rotor, and 2 bearings. If not already on hand, a bearing removal tool will be needed. Harris Part Number SeaMetrics Part Number Table 5-3 SeaMetrics Flow Meter Rebuild Parts Description O-Ring, used to seal the front panel to the flow meter body, used in the SPX-100, SPX , SPX , and SPX flow meters Bearing assembly, 2 required per meter, used with both the and rotors listed below Rotor with shaft, PVDF, Kynar /Ceramic, 2-magnet, used in the SPX and the SPX flow meters Rotor with shaft, PVDF, Kynar /Tungsten carbide, 2-magnet, used in the SPX-100 and the SPX flow meters Bearing removal tool (recommended), used to remove the bearings from all flow meters listed above. 5.5 Water Flow Rate Check The collector and body flow rates each have two parameters. They are the normal and the minimum flow rates. With the HPA in standby, adjust the collector and body coolant supply valves for the normal flow rate, observing the flow rate in the cooling window of the HPA GUI > System > Summary screen. Set the cooling cabinet liquid cooling flow rates as follows. Collector loop, DI water, set flow to 12 gallons per minute. Anode cooling loop, DI water, set flow to 2 gallons per minute. Check to ensure that the DI loop flow remains at ½ gallon per minute. This flow is not displayed on the GUI screen. Check the flow meter, it is located on the cooling cabinet door above the barnstead filters. Set the cooling cabinet glycol loop flow to 22 gallons per minute. The fault level is 17.5 gallons per minute, warning level is 18 gallons per minute. The minimum collector or body flow rate trip point is checked by the following procedure. 1. Operate the PA cabinet in standby. Page: /13/12

141 Water Flow Rate Check PowerCD Transmitter Maintenance 2533s500.fm 2. The collector and body coolant flow should be set (by the appropriate valve) to indicate normal flow. 3. Reduce the flow with the appropriate supply valve until a fault show in the flow window of the HPA GUI > System > Faults > Cooling screen. 4. The flow meter should indicate the minimum flow. 5. The normal flow rate for collector or body cooling should be set using the appropriate valve Cooling Cabinet Flow Meter Calibrations Follow the procedure below to check calibration the collector, anode, and external glycol flow meters: 1. Obtain the K factor from each sensor, see Figure 5-3. A. K factor is the number of pulses per gallon from the flow meter. B. To find the K-factor, look on the model-serial label of the sensor. The line reading K = xxxx is the desired number 2. Go to the HPA GUI system > service > calibrate screen and check the recorded K factor against the value showing in the appropriate field. A. If the value is different, enter the recorded value and press the calibrate button to the right of the entry. External Flow Meter Anode Flow Meter Collector Flow Meter Figure 5-3 Rear View of Cooling Cabinet Showing Flow Meters 04/13/ Page: 5-11

142 Maintenance Cavity Air Flow 5.6 Cavity Air Flow 5.7 IOT Removal/Replacement The cavity air pressure can be obtained from the HPA or driver GUI. HPA GUI > System > Meters > Cooling screen. Driver GUI > System > Meters > HPA > Select HPA (1-3) > Cooling screen. The air pressure fault point is 5.5 inches of water. This procedure covers removal and replacement of an e2v multiple collector IOT. It is divided into the following two sections. Section 5.7.1, e2v Multi-collector IOT Removal/Replacement, on page 5-12 After the tube has been replaced, the following two procedures must be performed. Section 5.11, IOT Conditioning Following Replacement, on page 5-15 Section 5.12, IOT Tuning and Setup After Tube Conditioning, on page 5-18 Note Prior to IOT replacement all overload/ protection circuitry and their calibration should be checked e2v Multi-collector IOT Removal/Replacement This procedure covers removal and replacement of an e2v multi-collector IOT. It is divided into the following sections. Cabinet Power Down Disconnecting IOT Circuit Assembly From PA Cabinet Transmission Line Breakaway Disassembly /Assembly Removing IOT Circuit Assembly From PA Cabinet Tube Removal and Replacement Cabinet Power Down 1. For multiple HPA transmitters, set mode controller to place operable IOTs on the air. 2. Place the defective PA cabinet in local control. 3. Depress OFF on the control panel of the defective HPA. Wait for automatic run down until blowers and pumps are off. 4. At rear of power supply cabinet follow the procedure to unlock the back door. It is given in Section 2.1, Power Cabinet Rear Door Unlocking Procedure, on page Disconnecting IOT Circuit Assembly From PA Cabinet 1. Remove IOT RF input cable from the IOT circuit assembly input cavity. 2. Disconnect the IOT collector umbilical lines from the rear compartment of the power supply cabinet Page: /13/12

143 IOT Removal/Replacement PowerCD Transmitter Maintenance 2533s500.fm 3. Undo and remove the IOT collector umbilical assembly locking ring from the inside of the power cabinet and remove the umbilical assembly with its cables from the IOT cabinet side. 4. Disconnect the IOT cathode umbilical lines from the rear compartment of the power supply cabinet 5. Undo and remove the IOT cathode umbilical assembly locking ring from the inside of the power cabinet and remove the umbilical assembly with its cables from the IOT cabinet side. 6. Remove air supply hoses from the cavity input flange. 7. Remove the air pressure switch sample hose (small white hose) from the air pressure manifold on the rear of the IOT circuit assembly. 8. Disconnect the four coolant hoses (Hansen fittings). 9. Disconnect the magnet, primary cavity and secondary cavity arc sensors on the IOT circuit assembly. 10. Disconnect the cabinet ground and the input cavity straps from top left corner of the IOT circuit assembly Transmission Line Breakaway Disassembly /Assembly For multiple PA transmitters, when an IOT is being replaced while another IOT in the transmitter continues to operate, a possibility of significant levels of RF energy may exist on the transmission line inner conductor of the breakaway being disassembled. Therefore, if other portions of the transmitter continue to operate, disassemble the breakaway transmission line on the failed IOT using the following procedure: Warning The following procedure exposes the breakaway center conductor. It may contain RF voltage that could cause RF burns to the skin. Wear electrically insulating rubber gloves when working with the center conductor. 1. Remove the eight transmission line bolts from the flange on the breakaway, see Figure 3-5, Breakaway Assembly of the IOT Cabinet, on page To re-assemble the breakaway assembly, perform the previous procedure in reverse order using the same precautions Removing IOT Circuit Assembly From PA Cabinet 1. Carefully roll the circuit assembly out of the cabinet. It may be necessary to assist in the separation of the breakaway flange Tube Removal and Replacement 1. For e2v multi-collector IOT tubes, move the circuit assembly into an area where the tube and input cavity assembly can be vertically hoisted. This requires 10 foot minimum floor to ceiling clearance when using the chain hoist supplied with the transmitter, and a fixed lifting point capable of supporting the weight of the tube and the hoist. 2. Refer to the e2v ESCIOT5130W circuit assembly manual for tube removal and replacement instructions. 04/13/ Page: 5-13

144 Maintenance Full Heater Voltage Adjustment Reinstallation of IOT Circuit Assembly 5.8 Full Heater Voltage Adjustment 5.9 BG Heater Voltage Adjustment 5.10 Focus Current Adjustment Reinstall the IOT circuit assembly in the reverse order from which it was removed. The full heater (also called filament) voltage adjustment is located on the filament window of the HPA GUI > Power Supply > Service screen. With the HPA cabinet set to standby mode, use the up/down arrows to set the filament voltage. The system will remember the setting. Check the filament voltage on the HPA GUI > Power Supply > Summary (or the meters) screen. Look up the exact filament voltage or current specification for each individual tube in the manufacturers tube data sheets. 1. In the settings section of the service screen, enter the nominal (standby) filament voltage. This is the value specified on the IOT data sheet which was shipped with the tube. This entry defines the 0.3 volts filament voltage regulation limit. At the time of this writing, e2v recommended operating the filament at 6.5 volts for the first 400 hours, then operating it at 6.25 volts after 400 hours. The purpose for this is to control the negative going grid current trend, which can occur over a several month period. For additional information, see Section 5.14, Negative IOT Grid Current Increases Over A Several Month Period, on page The filament voltage meter has been calibrated initially during manufacture of the transmitter. If calibration must be checked, take care to measure the voltage using an accurately calibrated reference meter, measuring as close as possible to the actual IOT filament terminals. Caution The IOT filament circuit is connected to the cathode, which operates at the IOT beam voltage. The beam power supply must be disabled and grounded prior to working on or connecting test equipment to these circuits. Verify the correct filament voltage in the standby mode. Switch to the BG heat mode and adjust the filament voltage to the BG filament voltage recommended on the data sheet which accompanied the IOT. The BG filament voltage adjustment is located on the filament window of the HPA GUI > Power Supply > Service screen. Use the up/down arrows to set the filament voltage. The system will remember this settings. e2v: Depending on tube type, the specification is 1.0 to 1.5 volts below the nominal heater voltage advised on the test record for the particular IOT. Under no circumstances should the BG heater voltage be less than the minimum specified heater voltage. Look up the exact BG heat specification in the manufacturers tube data. Adjust the focus current to the value specified on the IOT data sheet which accompanied the IOT. On the HPA GUI > Power Supply > Service screen, Use the up and down arrows in the focus voltage window to set the focus current. Page: /13/12

145 IOT Conditioning Following Replacement PowerCD Transmitter Maintenance 2533s500.fm 5.11 IOT Conditioning Following Replacement A new IOT is very likely to be gassy when it is first turned on, also, an old tube can become gassy if it is unused and un-powered for a month or longer. Gassy tubes are likely to arc if operated at full power, but the tube can be safely degassed by a process of conditioning, which takes advantage of the tube s internal ion pump. Gas is trapped within the metal of a new tube and is liberated over a period of time. This liberation process is accelerated if the metal is heated, such as when the tube is first operated. The higher temperatures encountered if a new tube is immediately operated at full power will accelerate the liberation of trapped gas and will increase its tendency to arc. The conditioning process liberates and removes much of this trapped gas and which allows the tube to be operated at full power. If any gassy tube (new or old) is brought up to full power without conditioning, it may develop internal arcs which could damage the tube. When a tube arcs, it generates ions due to the vaporization of metal or other material in the vicinity of the arc, and it can also liberate gas which is trapped within the metal in the vicinity of the arc. This can have a tendency to cause additional arcs, especially if the tube is new. If this happens the tube must be conditioned The ION Pump An IOT contains a special circuit called an ion pump. Its function is to remove gas (and ions) within the tube Vdc +/-500V is applied to the ion pump. This ionizes the gas atoms, and accelerates the resultant ions toward a target of special material within the ion pump. These ions are imbedded and trapped in the ion pump target. The ion pump is in operation while the IOT filaments are on. The presences of gas within the tube is indicated by ion pump current. A gassy tube will have high ion pump current, in excess of 5 ua when turned on. This current will typically drop to less than 1 ua after the filament has been in operation for about 15 minutes, although some tubes may take much longer. Transmitter beam voltage will be inhibited when ion pump current is 5 ua or greater. For a new tube, beam voltage should not be applied if the ion current is 5 ua or greater. If the ion current does not drop below 1 ua after one hour of filament operation, contact the tube manufacturer. A new IOT may still have considerable gas (ions) even though the ion current may be as low as 1 ua Precautions Taken With A New IOT Certain precautions should be taken with a new IOT to decrease the likelihood its premature failure. They include the following items. Avoid mechanical shock Avoid repeated raising and lowering of high voltage. Keep the filament voltage, idle current, and focus current set at the specified value or within the allowable range indicated on the data sheet which accompanies the tube. Allow some time for conditioning the tube before application of full beam voltage. In addition to the problem of a gas, as indicated above, particles may collect on the internal structures of the tube. These particles can have sharp edges which will increase the chances of an arc When an arc occurs within the tube, it can burn away some of the attached particles and clean that area of debris, but it will cause more ions to be generated. After an arc, it is common to observe several microamperes of ion pump current flow for a short time while the newly released ions are being removed. 04/13/ Page: 5-15

146 Maintenance IOT Conditioning Following Replacement The Conditioning Process The conditioning should be performed when a new tube is installed, or if a tube starts arcing excessively, for instance if a new tube had been installed and the conditioning process were skipped or minimized. If arcing persists after conditioning, contact technical support. During this process, the RF should be prohibited, so that only idle current can flow through the tube. The HPA should be in Standby, and when the 10 minute warm-up timer has timed out, perform the following: 1. On the HPA GUI select Power Amp Tab > Service Button > Drive Prohibit Button. This will prevent the application of drive when bringing up the IOT beam voltage. 2. Using the HPA GUI > Power Supply > Service screen, set the filament voltages as follows: A. In the Standby mode, set the full filament voltage to the value specified on the data sheet which was shipped with the tube. B. In the settings section of the Service screen, enter the nominal (standby) filament voltage. This is the value specified on the IOT data sheet. This entry defines the 0.3 volts filament voltage regulation limit. C. Check the full filament current. This is a fixed parameter, but should be close to value stated on the IOT data sheet. D. In the BG Heat mode, set the BG filament volts to value stated on the IOT data sheet. 3. When a new IOT is installed, it should be allowed to operate with full (standby) filaments energized for about 30 minutes. During this time the ION current should drop to less than 1 ua as the gas and ions are removed from the tube. If high ion current continues for over one hour, contact the tube manufacturer. 4 After 30 minutes of filament operation and after the ion current has decreased to 1 ua or less perform the following setup. A Set the grid voltage idle setting, as outlined in steps 1 through 3, in reference to the values specified on the tube data sheet (which was shipped with the IOT). 1. In the Standby mode, on the HPA GUI > Power Supply > Service screen, the grid voltage mode can be switched between the idle and the normal modes. 2. Set the normal mode grid voltage to 2 volts more negative than the grid voltage on the tube data sheet. 3. Set the idle grid voltage 5 volts more negative than the normal grid voltage. Example: Data sheet grid voltage = -121V, normal voltage = -123V, idle voltage (initial setting) = -128V. Note: With beam on and without drive, or with the HPA output power below 5 kw, the grid voltage, on the HPA > Power Supply > Service screen, will be in the idle mode. When HPA output power is greater than 5 kw, the grid voltage will be in the normal mode. B Set the beam supply to the lowest full tap voltage setting, see Figure Following the procedure in Section 2.1, Power Cabinet Rear Door Unlocking Procedure, on page 2-1, remove the beam supply door key and open the access door on the beam supply. Page: /13/12

147 IOT Conditioning Following Replacement PowerCD Transmitter Maintenance 2533s500.fm 2. Use the ground stick to discharge all beam supply connections. 3. Adjust the tap switches for lowest full tap output voltages. 4. Close and seal the beam supply, make sure the ground stick is positioned in its holder on the beam supply access door. 5. Reverse the procedure in Section 2.1, Power Cabinet Rear Door Unlocking Procedure, on page 2-1 to reenergize the transmitter AC. 5 Energize the transmitter and let it operate with beam on and a cathode (idle) current of 0.2 A for 30 minutes. A. If the tube arcs, set the beam supply the maximum half tap voltage and allow the tube to operate for 30 minutes. 6 Following all safety precautions, set the beam supply to the next higher full tap beam voltage and repeat step 5. 7 Repeat step 6 until the beam voltage is set to the desired value. A. At the desired beam voltage, set the idle mode grid voltage for 0.55 A of idle current. 8. Check cavity arcs, test buttons are located on the HPA controller board. A. Depress each cavity arc test button and verify H.V. drops out. Press and hold S2 (for primary cavity are test) or S3 (for secondary arc test.), located on the HPA control board, in the upper front compartment of the power cabinet. 9. After the tube has operated for 10 to 15 minutes at the desired beam voltage, set the transmitter to Standby or BG Heat. 10 The IOT can now be tuned. Y = 19.6 kv = 34 kv Y = WYE Y = 18.5 kv = 32 kv 6 kv 34 kv = DELTA Y = 17.3 kv = 30 kv Y = 21.9 kv = 38 kv Figure 5-4 Beam Supply HV Tap and Output Voltages Switches. Table 5-4 Beam Supply HV Tap Switches and Output Voltages Voltage Adjust Switch Position Delta Wye Switch (Delta = Full Tap / Wye = Half Tap) HV5-60 Output To Cathode and Collector 5 HV3 Output To Collector 4 HV2 Output To Collector 3 38 kv -38 / kv -19 / kv / -6.6 kv 36 kv -36 / kv -18 / kv / -6.2 kv 34 kv -34 / kv -17 / -9.8 kv / -5.9 kv 32 kv -32 / kv -16 / -9.3 kv -9.6 / -5.6 kv 30 kv -30 / kv -15 / -8.6 kv -9.0 / -5.2 kv Collectors 1 and 2 return to the supply via current sensors U2 and U6 through the +38 kv return lead. 04/13/ Page: 5-17

148 Maintenance IOT Tuning and Setup After Tube Conditioning IOT Beam Idle Current IOT beam idle current (quiescent current) must be operated within the limits specified by the tube manufacturer. Each manufacturer specifies a maximum idle current for the tube model. The following is recommended to ensure good tube life and performance: When first installed, set the tube idle current to 0.55 A. After tuning, when the tube is operating at the required power, the idle current will be set for a value, within the manufacture s limits, which provides the best adjacent channel intermodulation performance. Idle current is set by the following procedure: 1. Disable the RF drive to the IOT, using the drive prohibit soft key on the HPA GUI > Power Amp >Service screen. 2. Set the HPA to beam on, the IOT will be idling. 3. Monitor the IOT idle current by observing the cathode (current) window of the HPA GUI > Power Supply > Service screen. 4. In the same screen, use the grid voltage up and down arrow soft keys to set the IOT idle current to 0.55 A IOT Tuning and Setup After Tube Conditioning Very little tuning should be required following replacement of the IOT. This tuning procedure, which is used after replacing an IOT, assumes that the IOT cavity controls are at the same settings as they were before the tube was removed. These settings are close enough that just a medium power tuning touch up tuning is required. If these settings were changed, perform the entire IOT tuning procedure. This procedure also assumes that the PA cabinet was in proper adjustment before the IOT tube failed Read and understand this entire section before attempting to tune the PowerCD transmitter. The input and output circuit of an IOT must be tuned to the operating channel for the tube to operate correctly. The many effects caused by incorrect input and/or output tuning include higher dissipation and lower efficiency, and also higher EVM, lower digital signal to noise ratio, and excessive adjacent channel sideband intermodulation levels. Before any IOT tuning is attempted, the RTAC linear and nonlinear correctors in the M2X exciter must be set to bypass, and the IOT idle current must be set at 0.55 A. For the e2v multi-collector IOT, the idle current flow is through collector 4, but is best to measure it at the cathode IOT Tuning Cautions To prevent possible damage to the IOT or RF output system, read and understand all of the caution statements listed below and the tuning instructions before attempting to tune the IOT. Page: /13/12

149 IOT Tuning and Setup After Tube Conditioning PowerCD Transmitter Maintenance Caution Never apply drive to the tube when the transmitter is in Standby. 2533s500.fm Caution The tube can be damaged if there is high RF power at the tube input (100Wor greater) if the tube is detuned or the beam is off. Caution Care should be taken when performing a high power wide band sweep when there are RF filters in the transmitter output system. RF filters in the transmitter output often have 1 kw reject loads which can be damaged by the out of channel energy of a high power sweep. Caution A new IOT tube must be conditioned before applying full beam voltage. Do not start the tuning process until the tube has been conditioned and full beam voltage is applied Power Levels Used For IOT Tuning Two methods of IOT tuning can be performed. The methods are tuning at low power and tuning at medium power Tuning At Low Power The first is at low power, applying the output of the tracking generator through the IPA output (HPA input) directional coupler which takes the signal directly into the input of the IOT. The tracking generator output should be set at a low level such as 0 to 3 dbm (1 to 2 mw). This results in an output signal of a few hundred milliwatts. Using low power tuning, the tube cannot be damaged by improper tuning, and when correctly tuned, the response will change very little when brought up to full power. When tuning at low power the IPA output is disconnected from the IOT. The IPA should be disabled. 1. Set the HPA to drive disable using the HPA GUI > Power Amp > Service > Drive Prohibit. A. This sets the ALC for that HPA to zero, the effect is to set the HPA power control to minimum. B. When tuning is complete and drive is enabled, set the driver cabinet to transmit. The power raise arrows, on the right side of the HPA GUI, must be used to bring the HPA to full power. This power raise procedure must performed twice, once when the HPA is in remote disable and again when the cabinet is in remote enable. 04/13/ Page: 5-19

150 Maintenance IOT Tuning and Setup After Tube Conditioning Tuning At Medium Power Tuning at medium power is rarely used, except for troubleshooting. This method of tuning involves applying the output of the tracking generator to the input of the IPA, see procedure below. Refer to drawing , sheet 3 of 5. Medium power tuning can be accomplished by connecting the output of the tracking generator to coax 76 (for HPA1), 152 (for HPA2), or 153 (for HPA3). These cables connect to the output of the RFU. The IOT input and output must have been preset or tuned at low power before attempting to tune at medium power. The tracking generator must be started at a low output level, such as -30 dbm to avoid over driving the IPA or HPA. With the HPA cabinet set to beam. Slowly increase the tracking generator output level until the collector 4 current reaches 1 A. The HPA output should be below 1.5 kw. A relatively low HPA output power level is mandatory, especially if the IOT output must be routed through the high power mask filter. The reject loads on the high power (mask) filter typically have a rating of 1 kw, and a high power wide band sweep signal could damage them e2v Multi-collector IOT Input Tuning Either low or medium power tuning mentioned above can be used to tune the IOT input. IOT input tuning is critical, as the input tuned response will effect the output response. The IOT input is tuned by monitoring the reflected power from the input of the tube. The e2v plug in IOT has two input tuning controls built into the circuit assembly. They take the form of two rings which surround the input section of the circuit assembly and are located at the bottom of the assembly. The two controls are labeled impedance adjustment and frequency adjustment. These controls move up and down to perform the adjustment. The lower of the two controls is labeled frequency adjustment. It determines the input tuning, or center of the input response. The upper control is labeled impedance adjustment. It determines the bandwidth and flatness of the input response. Note If the IOT input is severely detuned, it should be pretuned or low power tuned to get the input tuning close. 1. The HPA cabinet should be in Standby. 2. Using the HPA GUI > Power Amp > Service screen, disable the drive. 3. If severely detuned, the input can be pretuned by setting the impedance and frequency adjustments according to the measurements given in the IOT assembly manual which accompanied the IOT circuit assembly. 4. Connect the output of the tracking generator to either of the following: Page: /13/12

151 IOT Tuning and Setup After Tube Conditioning PowerCD Transmitter Maintenance 2533s500.fm A. For low power tuning, to the HPA input directional coupler, which takes the signal directly into the input of the IOT. Tracking generator output level should be set within the 1 to 3 dbm range. B. For high power tuning to coax 76 (for HPA1), 152 (for HPA2), or 153 (for HPA3). These cables connect to the output of the RFU. Tracking generator output level should be set to -30 dbm. 5. Set the spectrum analyzer as follows: A. Center frequency to the center of the channel. B. Span to 10 MHz. C. Markers to center, +3MHz from center, and -3MHz from center. D. Resolution and video bandwidths to 30KHz. E. Vertical sensitivity to 10dB/cm. F. Set the tracking generator output level to -30dBm. 6. Connect the spectrum analyzer input to the IOT input cavity reflected directional coupler port. 7. Set the HPA cabinet to beam on. 8. Set the tube idle current to 0.55 A using the HPA GUI > Power Supply > Service screen. The cathode current can also be viewed on this screen. 9. For medium power tuning, start with the tracking generator output set at -30 dbm, increase tracking generator output in 1 db steps and stop just before the collector 4 current reaches 1 A. For low power tuning, the tracking generator output should be set at a low level such as 0 to +3 dbm (1 or 2 mw). Note: The beam supply ripple may impress some noise on the input and output tuning responses. This noise may be minimized by using a small amount of display averaging, but this will slow down the response of the display. 10. Adjust the frequency ring so that a notch appears at the center frequency, see Figure Use the impedance adjustment, with slight changes in the frequency adjustment to achieve a response similar to those of Figure 5-5, see sub step A. A. At the edges of the channel, the return loss of the response should range from -12 to -20 db with the return loss at the center of the channel ranging from -14 to -25 db. The return loss at the center of the channel is not as important as it is at the edge of the channel, center channel maximum return need not exceed 25 db. Strive for a symmetrical response with the greatest possible return loss at the edge of the channel. 12. Be sure to tighten the frequency and impedance lock knobs when the input match adjustments are finished. 13. Set HPA cabinet to standby. 04/13/ Page: 5-21

152 Maintenance IOT Tuning and Setup After Tube Conditioning 0 db Ref. 3 2 Typical High Frequency Response 25 db maximum dip at center. Scale 10 db/div 1 1_-25 db 2_-17 db 3_-17 db Center Frequency = Center of Channel Span 10 MHz 0 db Ref. This response is better at high power. 3 Scale 10 db/div 1 2 1_-16 db 2_-12 db 3_-12 db Typical Low Frequency Response Center Frequency = Center of Channel Span 10 MHz Figure 5-5 e2v Multi-collector IOT Plug In Tube Input Match, Two Examples Interaction of Input and Output Tuning and Power Level Input tuning errors, such as non-symmetrical response or input response tilt, have a great effect on output tuning even though the output tuning is perfect. If input tuning errors are bad enough, it may be impossible to correctly tune the output. IOT output power level will also effect input tuning. When the IOT is passing the DTV signal at full power level, after tuning, the input tuning can change causing the output response to tilt. Therefore, when the amplifier is operating at full power after tuning, and after it has operated long enough to achieve temperature stability, recheck the input tuning by observing the 8-VSB signal at the reflected port of the IOT input directional coupler. The reflected response should be symmetrical with a dip at the center of the channel, see Figure 5-6. Caution Be careful to make very small changes in the frequency and impedance adjustments when rechecking the input match under power. Significant changes can reduce the output power to zero by reflecting all of the input back to the IPA circulator. Be sure to tighten the frequency and impedance lock knobs when the input match tough up adjustments are finished. Page: /13/12

153 IOT Tuning and Setup After Tube Conditioning PowerCD Transmitter Maintenance 0 db Ref. 2533s500.fm Scale 10 db/div Center Frequency = Center of Channel, Span 20 MHz Figure 5-6 IOT Input Reflected Response When HPA Is At Full Power Basic IOT Output Tuning The IOT output circuit is a double-tuned over-coupled circuit. This section will cover the rules used to tune this type of circuit. A double-tuned over-coupled output stage has four tuning controls. They are the: Primary Tune, see Section on page Coupling, see Section on page Secondary tune, see Section on page Loading, see Section on page Bandwidth Measurement Methods Before the subject of tuning is attempted, a discussion of bandwidth measurements is needed for the double-tuned over coupled amplifier Measuring Depth Saddle and Height of Haystack Depth of Saddle is the distance (measured in db) between lines A and B in Figure 5-7. Line A is drawn so that it just touches the upper peaks of the response waveform. The two peaks should be at the same level (line A should be horizontal). Line B is drawn so that it just touches the lowest point of the saddle and is parallel to line A. Height of Haystack is the distance (measured in db) between lines A and D in Figure 5-7. Line A is drawn so that it just touches the upper peak of the response waveform. 04/13/ Page: 5-23

154 Maintenance IOT Tuning and Setup After Tube Conditioning Line D is drawn so that it crosses the response at the edge of the channel (6 MHz) and is parallel to line A. Saddle depth is typically 0.5 db, a hay stacked response is not used with the multi-collector IOT. Use 1.0 db vertical log scale on analyzer Measuring Bandwidth The following methods of bandwidth measurement are used for the IOT amplifier output. The method used depends in part on the customers preference and in part of the amount of saddle tuned into the output of the amplifier. Bandwidth is measured using lines B or C of Figure 5-7. Both of these lines are referenced to line A. Line A is drawn so that it just touches the upper peaks of the response waveform. If tuning is correct, line A should be horizontal. Line B is drawn so that it just touches the lowest point of the saddle and is parallel to line A. Line C is drawn parallel to line A and 1.0 db below it. Method 1, Depth of Saddle Bandwidth is defined as the frequency difference between the two vertical lines that cross the response where it intersects horizontal line B. This method of bandwidth measurement can be used if a measurable amount of saddle is tuned into the tube. Method 2, -1 db Bandwidth is defined as the frequency difference between the two vertical lines that cross the response where it intersects horizontal line C. This method of bandwidth measurement is useful if the response has no saddle (flat response) or up to 0.1 db of haystack. Note A 1dB tilt across the bandpass of the DTV signal increases the EVM (error vector magnitude) by 6 to 7%. Page: /13/12

155 IOT Tuning and Setup After Tube Conditioning PowerCD Transmitter Maintenance Saddled Response Depth of Saddle A 2533s500.fm 1.0 db Depth of Saddle Bandwidth 1.0 db Bandwidth B C Hay stacked Response Haystack 1.0 db A D C 6 MHz 1.0 db Bandwidth Figure 5-7 Bandwidth and Depth of Saddle (or Hay Stacked) Measurement 04/13/ Page: 5-25

156 Maintenance IOT Tuning and Setup After Tube Conditioning The Four Output Tuning Controls A spectrum analyzer and tracking generator are used to tune the IOT output. The tracking generator is setup and connected following either of the two tuning methods mentioned earlier, see See Tuning At Low Power on page 1-19., or See Tuning At Medium Power on page The IOT forward output sample, located on the IOT breakaway section, is connected to the input of the spectrum analyzer. Once the spectrum analyzer and tracking generator are connected and the HPA cabinet set to beam, output tuning is simply a matter of knowing what each of the four output controls do the HPA response. The tuning control rules are given below. Note: The beam supply ripple may impress some noise on the input and output tuning responses. This noise may be minimized by using a small amount of display averaging, but this will slow down the response of the display Primary Tuning Primary Tuned Higher Reference Response Primary Tuned Lower Figure 5-8 Primary Tuning Primary tuning rules. Desired effect: Desired effect: Undesired effect: Response tilts (in the direction of tuning) Response slides up or down the band (center of pass band changes) None. Page: /13/12

157 IOT Tuning and Setup After Tube Conditioning PowerCD Transmitter Maintenance Interstage Coupling Changes Note: The beam supply ripple may impress some noise on the input and output tuning responses. This noise may be minimized by using a small amount of display averaging, but this will slow down the response of the display. 2533s500.fm Coupling Increased Reference Response Coupling Decreased Knob pulled outward, higher number on scale. Knob pushed inward, lower number on scale. Figure 5-9 Coupling Coupling rules. Desired effect: Bandwidth changes. Undesired effect: Center of pass band changes (one edge of response stays in place but the other edge moves). Undesired effect: Response tilts. Action for both undesired effects: Adjust primary and secondary tuning controls as necessary to flatten the response and center it in the pass band. Coupling (bandwidth) has the following effect on IOT beam load impedance. Wider bandwidth = lower IOT beam load impedance. Narrower bandwidth = higher IOT beam load impedance. Setting the bandwidth too wide makes the tube more linear, but has the following effects. Lowers tube gain, which requires more drive power from the IPA. Lowers the efficiency of the amplifier, which causes higher beam current (I b ) and higher collector dissipation. 04/13/ Page: 5-27

158 Maintenance IOT Tuning and Setup After Tube Conditioning Secondary Tuning Note: The beam supply ripple may impress some noise on the input and output tuning responses. This noise may be minimized by using a small amount of display averaging, but this will slow down the response of the display. Secondary Tuned Higher Reference Response Secondary Tuned Lower Figure 5-10 Secondary Tuning Secondary Tuning rules. Desired effect: Response tilts in opposite direction to that of primary tuning. Undesired effects None. Page: /13/12

159 IOT Tuning and Setup After Tube Conditioning PowerCD Transmitter Maintenance Loading (output Coupling) Changes Note: The beam supply ripple may impress some noise on the input and output tuning responses. This noise may be minimized by using a small amount of display averaging, but this will slow down the response of the display. 2533s500.fm Output Loaded Lighter Reference Response Output Loaded Heavier Knob pulled outward, lower number on scale. Knob pushed inward, higher number on scale. Figure 5-11 Loading (Output Coupling) Loading rules. Desired effect: Saddle changes (light loading more saddle, heavier loading, less saddle). Undesired effect: Response tilts Action: adjust secondary tune to flatten response. Undesired effect: Bandwidth changes. Action: adjust coupling to correct bandwidth Output loading (depth of saddle) has the following effect on IOT beam load impedance. Heavier loading (less saddle) = lower IOT beam load impedance. Lighter loading (more saddle) = higher IOT beam load impedance. Heavier Loading (less saddle) makes the tube more linear, but has the following effects. Lowers tube gain, which requires more drive power from the IPA. Lowers the efficiency of the amplifier, which causes higher beam current (I b ) and higher collector dissipation. 04/13/ Page: 5-29

160 Maintenance IOT Tuning and Setup After Tube Conditioning Setup and Procedures For Multi-collector IOT Output Tuning 1. Set HPA cabinet to Standby. 2. Using the HPA GUI > Power Amp > Service screen, disable the drive. 3. Connect the output of the tracking generator to either of the following: A. For low power tuning, to the HPA input directional coupler (at the output of the circulator located on the left wall of the IOT cabinet). This takes the signal directly into the input of the IOT. Tracking generator output level should be set within the 1 to 3 dbm range. B. For medium power tuning to coax 76 (for HPA1), 152 (for HPA2), or 153 (for HPA3). These cables connect to the output of the RFU. Tracking generator output level should be set to -30 dbm. 4 Set spectrum analyzer as follows: A. Center frequency to the center of the channel. B. Start with 20 MHz span and when tuning gets close switch to 10 MHz. span. C. Markers to center, +3MHz from center, and -3MHz from center. D. Resolution and video bandwidths to 30KHz. E. Vertical sensitivity to 1dB/cm. F. Set the tracking generator output level to -30dBm. 5. Connect the spectrum analyzer input to the customer sample forward directional coupler on the IOT output breakaway assembly. 6. If severely detuned, the four IOT output tuning controls can be preset. Preset tuning information can be obtained from IOT circuit assembly manual, transmitter final test data, or from customer s prior tuning records. 7. Set the HPA cabinet to beam. 8. Set the tube idle current to 0.55 A using the HPA GUI > Power Supply > Service screen. The cathode current can also be viewed on this screen. 9. For low power tuning, set the tracking generator output between 0 to +3 dbm (1 or 2 mw). 10. For medium power tuning, start with the tracking generator output set at -30 dbm, increase tracking generator output in 1 db steps and stop just before the collector 4 current reaches 1 A. 11. Perform the output tuning 12. Be sure to record the tuning results and IOT circuit assembly settings when finished. 13. Set HPA cabinet to standby Typical Low Power Output Tuning Results Two parameters indicate the IOT is correctly tuned. They are the swept bandwidth and amount of saddle. Correct saddle ranges from a 0.25 to 0.5 db saddle. The top response of Figure 5-7, on page 5-25, is saddled, the bottom response is hay stacked. The correct bandpass for the multi-collector IOT is 8 MHz, measured at the -1 db bandwidth. Page: /13/12

161 IOT Tuning and Setup After Tube Conditioning PowerCD Transmitter Maintenance Correct bandwidth depends on the method of measurement. If measured at the depth of saddle, shown in Figure 5-7, the bandwidth appears to be more narrow than the same response measured at the -1.0 db bandwidth. The -1.0 db bandwidth measurement is necessary for a flat or hay stacked response. 2533s500.fm One low power tuning starting point response is shown in Figure This response will get the amplifier tuned close enough to allow tuning at medium power. Saddle = 1/4 to 1/2 db 1.0 db 1.0 db Bandwidth = 7.5 to 8.5 MHz Figure 5-12 Low Power Tuning Starting Response Warm Cavity Medium Power Tuning Normalize all of the cables that were changed for the tuning procedure and operate the HPA at 100% power with the normal digital signal. While operating at full power and after the cavity has had a chance to warm up, re-check the input tuning. The IPA input reflected response should be symmetrical about the center of the channel, similar to Figure If necessary, make slight adjustments to the IOT input frequency and impedance controls to correct the input response. 04/13/ Page: 5-31

162 Maintenance IOT Tuning and Setup After Tube Conditioning 0 db Ref. Scale 10 db/div Center Frequency = Center of Channel, Span 20 MHz Figure 5-13 IOT Input Reflected Response When HPA Is At Full Power Within the space of 1 minute, to prevent the cavities from cooling too much, perform the following procedure: 1 Set the HPA to standby, 2 Restore the medium power tuning setup. 3 Set the HPA to transmit and check the idle current, it should be 0.55 A. 4 Sweep the HPA with collector 4 current at 1 A. 5 Figure 5-14 shows the resultant warm cavity medium power tuning response. A If necessary, adjust the output tuning controls to achieve desired results. 6 When tuning is complete, Set the HPA to standby and restore the IPA input cabling to normal. 6 MHz Saddle = 0.25 to 0.5 db 1.0 db 8.0 MHz Bandwidth Figure 5-14 Medium Power Tuning Warm Cavity Output Response Page: /13/12

163 IOT Setup following Tube Tuning PowerCD Transmitter Maintenance 5.13 IOT Setup following Tube Tuning 2533s500.fm This procedure assumes the PA cabinet is in proper working order and that the IOT is correctly tuned. Combining HPAs Activating RTAC correction If the transmitter has only one HPA, skip the next section on combining multiple HPAs Adjustment of Grid BIas and Idle Current, for FCC Mask Compliance This procedure assumes that an IOT was replaced in a single HPA system or in one of the HPAs of a multiple HPA system. It further assumes that the transmitter is in proper calibration and was properly setup before changing the IOT. The procedure covers adjustment of gird bias to properly set the IOT idle current and ensure adjacent channel FCC mask compliance after the tube has been tuned. If the transmitter has multiple HPAs, the HPA being worked on will be referred to as the HPA. 1. On all HPA cabinets, verify that the remote is disabled. 2. On the driver cabinet GUI, use the mode controller to direct this HPA into a test or reject load. A. If this is a multiple HPA transmitter, the other HPAs may be on the air. B. If the other HPAs are not on the air, they should be in standby and remote disable. 3. Press standby on the HPA cabinet. 4. Verify that the driver cabinet beam is on. This enables the IPA. 5. On the HPA cabinet verify that the drive is prohibited. Use HPA GUI > Power Amp > Service 6. On the HPA, once the HPA cabinet time out has completed, press beam. 7. In the upper left hand corner of the HPA GUI > Power Supply > Service screen set the grid mode to Normal Adjust the grid voltage for 0.65 A of cathode current when the IOT is cold, or 0.55 A when it is hot. The cathode current can be read on this screen. Note the grid voltage. A. The idle current can vary by 0.1 A from a cold IOT to a hot IOT. 8. On the HPA GUI > Power Amp > Service screen, enable the (IOT) drive. 9. In the transmitter control section of the driver GUI, the ALC setting should read between 850 and 1023 A. Be careful not to adjust the driver ALC if other HPA cabinets are on the air. 10. Raise the HPA power level, using the HPA GUI transmitter control section ALC up and down arrows, until the HPA is at 100% power 11. After the HPA output power has been established, set all M2X exciter RTAC correction to BYPASS as shown in Figure A. If other HPAs are on the air, leave the M2X exciter Linear corrector set to adapt and the non-linear corrector set to bypass. B. When the HPA output power raises above the threshold (approximately 5kW) the exciter RTAC mode changes from Bypass or Hold to the preselected RTAC operating mode. 04/13/ Page: 5-33

164 Maintenance IOT Setup following Tube Tuning M2X RTAC -Front Panel.jpg (500), and M2X RTAC - 1.jpg (400) Front Panel Gui Screen Figure 5-15 M2X Exciter Showing RTAC Bypassed 12. When the HPA output power is set at 100%, the upper left hand corner of the HPA GUI > Power Supply > Service screen should indicate the ISO PS Mode as Normal. A. Connect a spectrum analyzer to the forward output sample coupler located on the breakaway of the selected tube. Setup the spectrum analyzer per the data given in Figure B. The normal grid voltage will need to be lowered (set more positive) to a point where the HPA output adjacent channel shoulder response (measured before the mask filter) indicates -30 to -32dB, as shown in Figure Note: Non Linear RTAC usually gives a 5 to 6 db shoulder increase when activated. Non Linear RTAC is capable of better improvement, but in this case the IOT is being setup for better efficiency and not for best shoulder response. C. If the transmitter is operating at the same parameters as the e2v data sheet that came with the tube, the normal grid voltage will probably be within approximately 2 volts of the value on the tube data sheet. Page: /13/12

165 IOT Setup following Tube Tuning PowerCD Transmitter Maintenance 2533s500.fm D. If the transmitter is operating at a lower power and lower beam voltage than what was on the e2v data sheet, the grid voltage will be lower (more positive) than the data sheet value by approximately 6 to 7 volts. E. Temporarily set the M2X exciter Non-linear RTAC corrector to Adapt mode. After 2 to 4 minutes, the shoulders should measure -35 db or better (with respect to the center of the channel) if the system includes the sharp tuned filter (sometimes referred to as cool fuel). A very few Power CD transmitters were setup using the standard D mask filter. For these transmitters, the shoulder response before the mask filter must measure -37 db with respect to the center of the channel (-47 db FCC mask specification). This is necessary because the standard D mask filter has minimum effect at the shoulders but has good adjacent channel attenuation beyond the shoulders. Figure 5-16 Spectrum Of HPA Output, Before High Power Filter, All RTAC Correction Bypassed 13. Lower the HPA power back down to zero from the HPA GUI. (ALC to zero) The grid voltage should have now stepped back to the Idle mode. This is indicated on the HPA GUI > Power Supply > Service screen in the upper left hand corner. The idle mode grid voltage setting will probably have changed, since it tracks the normal mode gird voltage setting. The idle grid voltage has to be reset to produce 0.55 A of cathode current. The idle grid voltage is prohibited (by hardware) from being set more positive that the normal grid voltage. 14. If this is a single HPA Transmitter, after checking IOT Dissipation and Efficiency in Section , Proceed to Section , Activating RTAC Correction, on page If this is a multiple HPA Transmitter, after checking IOT Dissipation and Efficiency in Section , use the driver cabinet GUI mode controller to direct all HPAs to the antenna or, if not on the air, to the test load. A. Proceed to Section , Combining HPAs in a Multiple Tube System, on page 5-39 B. Next, proceed to Section , Activating RTAC Correction, on page /13/ Page: 5-35

166 Maintenance IOT Setup following Tube Tuning Checking IOT Dissipation and Efficiency Dissipation should be checked periodically, and after the IOT has been changed, tuned, grid bias and idle current has been set, and the amplifier (or transmitter) has passed the FCC mask filter specifications and the EVM and digital signal to noise ratio are within specifications. Efficiency should be checked along with dissipation to keep a running tab on HPA operation. Significant changes in dissipation or efficiency are warnings to check the operation of the transmitter. HPA output power is needed, and can be found on the following screens, see Figure 5-17: The collector voltages and currents are given in the following screens: HPA GUI > Power Amp> Summary. HPA GUI > Power Amp > meters, see Figure The above mentioned parameters can also be found on the Drive GUI screens. IOT collector dissipation is calculated by subtracting the HPA average output power from the total IOT collector dc input power. Total IOT collector dc input power is calculated by adding the dissipations of each collector. The dissipations of each collector is calculated by multiplying that collector s dc current by its collector to cathode voltage drop, and the cathode voltage is the most negative beam supply voltage, typically -36kV or -38kV. The collector voltage given in all of the GUI screens is the collector voltage with respect to ground, which represents the most positive beam supply voltage. The simplified beam supply to IOT connections is shown in Figure 6-9, Multi-collector IOT Showing DC Supplies, on page The above problems are solved by creating the following equations. P In total = E C5 E C4 I C4 + E C5 E C3 I C3 + E C5 I C2 + I C1 Where: P In total = total dc input power for all collectors (in kw). E C5 = Collector 5 dc voltage, this is the same as the cathode voltage (in kv). This is also the collector 1 and 2 voltage with respect to the cathode. E C4 = Collector 4 dc voltage with respect to ground (in kv). E C5 E C4 = Collector 4 dc voltage with respect to the cathode. E C3 = Collector 3 dc voltage with respect to ground (in kv). E C5 E C3 = Collector 3 dc voltage with respect to the cathode. I C4 = Collector 4 dc current (in A). I C3 = Collector 3 dc current (in A). I C2 = Collector 3 dc current (in A). I C1 = Collector 3 dc current (in A). Note: Power dissipation in collector 5 is zero, since its collector to cathode voltage is zero. P Diss = P In total P out Page: /13/12

167 IOT Setup following Tube Tuning PowerCD Transmitter Maintenance Eff = P out P In total 2533s500.fm Where: P Diss = IOT total collector dissipation (in kw). P out = average HPA output power (in kw). Eff = IOT total collector efficiency. An example using the values in Figure 5-17 may be helpful: P In total = E C5 E C4 I C4 + E C5 E C3 I C3 + E C5 I C2 + I C1 P In total = P In total = P In total = P In total = 48.9kW P Diss = P In total P out = = 22.3kW P out 26.6 Eff = = = = 54% P In total 48.9 Figure 5-17 Upper Portion of the HPA GUI > Power Amp > Meters Screen Checking Heat Dissipation In The DI Water System Most of the power dissipated in the collector will be transferred to the liquid cooling system DI water. Using the formula provided below and the information obtained from the HPA GUI > System > Meters >Cooling Screen, see Figure 5-18, the power dissipated in the DI water can be calculated. Any significant changes in this data could indicate changes in the system, which should be investigated. 04/13/ Page: 5-37

168 Maintenance IOT Setup following Tube Tuning The power dissipation calculated preceding section will not be exactly equal to the power dissipated calculated in DI water due to rounding errors in the collected data, but the two calculated values should be close. The formula for power contained in a stream of flowing water is given below: P = T out T in GPM Where: P = Power dissipated in the water. This can be P C (for collector DI water) or P A (for anode DI water). Tout = Outlet water temperature, this can be Temperature Collector Out (T out C ) or Temperature Anode Out (T out A ) from Figure Tin = Inlet water temperature, (Temperature Tube In from Figure 5-18). GPM = Gallons per minute of water flow, this can be Flow Collector Out (GPM C ) or Flow Anode Out (GPM A ) from Figure Since separate DI water flow paths exist for both the collector and anode, two calculations can be made, one for collector DI water dissipation and the other for Anode DI water dissipation. An example using the data from Figure 5-18 is given below. P C = T out A T in GPM A P C = = = 22kW P A = T out A T in GPM A P A = = = 0.5kW If these answers are compared to the IOT collector dissipation calculated above (22.3kW), it can be seen that the collector DI water dissipation is 0.3kW lower, and the sum of the collector and anode DI water dissipation (22.5kW) is 0.2kW higher. Figure 5-18 HPA GUI > System > Meters >Cooling Screen Page: /13/12

169 IOT Setup following Tube Tuning PowerCD Transmitter Maintenance Combining HPAs in a Multiple Tube System In multiple tube transmitter systems the outputs of the HPA cabinets must be combined into a single RF output. Therefore, all HPA cabinets must be operating within specification. If the performance of the other HPAs are in question, they should be checked. 2533s500.fm The combining is done with either riblet or magic tee combiners. These combiners have two inputs and two outputs. The outputs of the tubes are connected to the combiner inputs, one combiner output is connected to a reject load, and the other (the useful output) to the station test load or the antenna (via the mask filter). If the phase and levels of the input signals are correct all of the signal will go to the useful output. Phase or level errors will cause some or all of the power to go to the reject load. For systems with more then two tubes, multiple combiners are used, but the rules for achieving the desired output at the desired port are the same. The combining process is as follows. 1. Carefully adjust and calibrate the outputs of all HPAs (into a resistive load) to the same output power. This should satisfy the level matching requirement. 2. Operate all HPAs at 100% power in the combined mode. 3. Monitor the reject load output on the driver GUI > Output > Service > HPA Phasing screen. 4. Press the HPA1 - HPA2 soft key and press the up or down arrow soft keys for the appropriate HPA to minimize power in the reject load. A. The larger of the two sets of arrow keys changes the phase by 90 degree increments and the smaller of the arrow keys varies the phase continuously over a 90 degree range. B. When reject power is minimized, should read below 5%, press the Save Phase Settings soft key. 5. For systems with more then two tubes, press the HPA1&2 - HPA3 soft key and press the HPA3 up and down arrow soft keys to minimize reject power. A. The larger of the two sets of arrow keys changes the phase by 90 degree increments and the smaller of the arrow keys varies the phase continuously over a 90 degree range. B. When reject power is minimized, should read below 5%, press the Save Phase Settings soft key. 6. When the combining is complete, the reject power meters should read below 5% power. The reject trip points are typically set at 12% reject power Activating RTAC Correction Connect a spectrum analyzer to the output of the mask filter, using one of the forward couplers. Set the spectrum analyzer as follows: A. Center frequency to the center of the channel. B. Span to 15 MHz. C. Resolution and video bandwidths to 30KHz. D. Vertical sensitivity to 10dB/cm. 04/13/ Page: 5-39

170 Maintenance IOT Setup following Tube Tuning After the IOT has been tuned, and the correct warm channel response has been achieved, the transmitter must be checked at full power with the M2X exciter Lin HPF and Non-Lin RTAC correctors set to ADAPT. It takes RTAC a few minutes to correct the transmitter output signal when it is first activated. Note: Non Linear RTAC usually gives a 5 to 6 db shoulder increase when activated. Non Linear RTAC is capable of better improvement, but in this case the IOT is being setup for better efficiency and not for best shoulder response. At this time, the most important specification to check is the adjacent channel shoulder response, which is -47 db per the FCC DTV mask requirements. Figure 5-19 shows an output response (before the mask filter) where the shoulders, but not the rest of the adjacent channel response, passed the FCC mask test. Its shoulders are approximately -49 db. Monitor the results of the nonlinear RTAC correction before the sharp tuned filter, because the transmitter will almost always pass the FCC mask specifications when monitored after the sharp tuned mask filter. This ensures that the shoulder level passes the FCC mask test before the sharp tuned filter, which ensures that the HPA is sufficiently linear. Poor HPA linearity will degrade both the shoulder response and the EVM. A very few PowerCD transmitters were setup using the standard D mask filter. For these transmitters, the shoulder response before the mask filter must measure -37 db with respect to the center of the channel (-47 db FCC mask specification). This is necessary because the standard D mask filter has minimum effect at the shoulders but has good adjacent channel attenuation beyond the shoulders. If the PowerCD system includes the sharp tuned filter (sometimes referred to as cool fuel) the transmitter output shoulders, measured before the sharp tuned mask filter, should measure -35 db or better (with respect to the center of the channel). After the mask filter the response should pass the FCC mask test by more than 10 db, sometimes by as much as 20 db. Monitor the results of the linear correction after the sharp tuned filter, because that is where most of the linear distortions (low EVM, poor digital signal to noise ratio, and poor EYE pattern response) are generated. Usually, the EVM and digital SNR are ok, but if a problem exists, it may be that one or both adjacent channel shoulders will not meet the -47 db FCC specification when measured before the mask filter. 0 db Ref. -47 db Scale 10 db/div Center Frequency = Center of Channel Span 20 MHz Figure 5-19 HPA Output (Before Mask Filter) Showing Correct Adjacent Channel Shoulder Response Page: /13/12

171 IOT Setup following Tube Tuning PowerCD Transmitter Maintenance Output Shoulders Fails FCC Mask Test 2533s500.fm A good test of the uncorrected linearity of the HPA is to observe the adjacent channel shoulders before the mask filter with the M2X exciter RTAC correction bypassed. If the transmitter has multiple HPAs, check the combined output. If the uncorrected shoulders measure -30 db or lower (more negative) with respect to the level at the center of the channel, the RTAC will be able to correct the HPA linearity and the shoulders will pass the FCC mask specification. If the shoulders do not make the -30 db adjacent channel mark, there is a problem with the HPA, such as, but not limited to input or output tuning problem, incorrect idle current, incorrect beam voltage for that power level, (this can be caused by operating at a higher than the specified power level because of poor output power calibration or a change in the required output power), or other items. Note: If beam voltage is too low for the power level, poor shoulder response will result. Increasing beam voltage will improve IOT linearity and shoulder response, but it will also result in higher IOT dissipation and lower efficiency. If power calibration is correct, and the output power has not been increased, low beam voltage is probably not the problem. If one or both output shoulders fail the FCC mask test, two corrective actions may be tried. The first is to broaden the IOT input match and the second is to change the output tuning bandwidth and/or saddle. First, the IOT input response should be checked. The IOT input frequency control should be adjusted to place the response dip in the center of the channel and the impedance control adjusted to make the dip slightly more shallow, as shown in Figure This result will be a broader input match at the expense of a slightly reduced input return loss. The bandwidth at the IOT input must be as wide or wider than the shoulders it is expected to correct so that the RTAC Non-Lin pre correction signal can reach the IOT. A narrow IOT input bandwidth interferes with this corrective action. If the output shoulders still fail the FCC mask test, the IOT output will need to be retuned. 0 db Ref. IOT input match response before readjustment of IOT input tuning. IOT input match response after readjustment of IOT input tuning. Vertical Scale = 10 db/div Figure 5-20 IOT InpuT Match Response Before and After Readjustment of Input Tuning 04/13/ Page: 5-41

172 Maintenance Negative IOT Grid Current Increases Over A Several Month Period Ensure that when warm, the IOT output response is flat (not tilted) and centered within the channel. Also, a broader output bandwidth and/or less saddle will lower the beam load impedance and make the tube more linear. Three factors limit the amount of these adjustments, they are as follows: The gain of the IOT is decreased, requiring more IPA drive power. The efficiency of the IOT is decreased. The dissipation of the IOT is increased. First try increasing the 1 db bandwidth of the IOT output circuit from 8 to 9 MHz. while maintaining the saddle at 0.5 db. Caution It is possible to make the output bandwidth to wide, because the limited input bandwidth may mask extra wide output bandwidth, or the bandwidth is simply too wide. The results are poor shoulder response, poor efficiency, high dissipation, and higher than normal IPA drive levels. If that doesn t succeed, try various combinations of saddle (0.3 to 0.8 db saddle) and bandwidth (1 db bandwidth range of 8 to 9 MHz). By its correct performance, the IOT will tell you what it wants Negative IOT Grid Current Increases Over A Several Month Period A new IOT should operate at zero grid current. Over a several month period the grid current may go more negative. A grid current warning will occur when the grid current reaches the -25 to -30 ma range. If a negative grid current increase trend becomes apparent, contact e2v for guidance in filament voltage management long before it reaches the grid current warning level. This problem occurs because of the close spacing between the IOT cathode and grid, and because the emissive material evaporates from the hot cathode to rapidly and condenses on the relatively cooler grid. Since the grid is also quiet hot, due to its close proximity to the hot cathode, it will emit electrons on the maximum negative grid voltage swing. As more emissive material collects on the grid over time, the resultant negative grid current increases. At the time of this writing, e2v recommends operating the filament at 6.5 volts for the first 400 hours, then operating it at 6.25 volts after 400 hours. The purpose for this is to control the negative going grid current trend, which can occur over a several month period. Sometimes the negative going trend of grid current still occurs, even with the filament voltage is set at 6.25 volts. If this happens, the filament voltage must be reduced more. Consult e2v it you encounter this problem and they will guide you through the filament voltage management procedure. Page: /13/12

173 HPA Forward Power Calibration And Setup PowerCD Transmitter Maintenance Explanation of Grid Current In the HPA GUI > Power Supply > Summary (or Meters) screens, the grid current indication is given in dc current in ma, but the current flow inside the grid is ac, see Figure The dc grid current is the average between the positive and negative grid currents. 2533s500.fm Positive voltage 0 volts Grid Bias Voltage Negative voltage Time Shaded areas represent grid current flow. Above zero volts, positive grid current flows, the grid accepts electrons form the electron stream. At the negative peaks negative grid current flows, the grid emits electrons to the electron stream. Figure 5-21 Graph of IOT Grid Voltage and Current Flow 5.15 HPA Forward Power Calibration And Setup This is the procedure for forward power calibration. The tube should have already been tuned. Note: If the HPAs are meeting specifications (and are properly combined, for multiple HPA systems) and the system level output power is set at 100% and properly calibrated, the output power of the HPA (each HPA, for multiple HPA systems) should be at the required output level for 100% output from that HPA. This HPA output level takes combiner and mask filter loss into account. 1. Connect a power meter to the customer forward directional coupler on the breakaway assembly. This port has a factory set coupling ratio of 45 db. Make sure the meter is properly set up, calibrated and the correct offset (directional coupler forward coupling ratio) entered. 2. Adjust the power of the HPA from the HPA GUI until the required HPA output level is reached at the breakaway. 3. On the HPA GUI > Output > Service > Calibrate screen enter the number displayed on the power meter into the Forward Power section and press Calibrate A. This is the normal power calibration for power output displayed in kw. 04/13/ Page: 5-43

174 Maintenance HPA Reflected Power Setup 5.16 HPA Reflected Power Setup 1. Remove the reflected sample cable from the reflected directional coupler on the IOT breakaway assembly. 2. Remove the load from the other (forward) port on the same directional coupler and place it on the reflected port. 3. Place a 20dB pad on the forward port 4. Connect the cable on to the 20 db pad. The reflected sample is now looking at a forward sample which has been reduced by 20dB. 5. On the HPA GUI > Output > Service > Calibrate screen enter 1% of the HPA forward power into the reflected power section and press Calibrate. If the Calibration box flashes Invalid after the Calibration button is pressed the calibration is no good. It is likely due to an RF level that is too low. Try decreasing the pad size from 20dB to raise the sample level then try re calibrating. Be sure to enter the correct percentage of power according to the level of pad inserted in to the sample line. Use a 16 db or larger pad, because the VSWR foldback point is set at 1.4:1. A. % Reduction = 100Antilog(-dB/10), where db represents the pad size. 6. Remove the pad and load from the directional coupler and remove the pad from the cable. 7. Place the load on the forward port of the coupler 8. Place the cable back the reflected port. 9. The HPA GUI should now indicate the actual reflected power of the system System Level Forward Power Calibration 1. Operate all cabinets at 100% power in the combined mode. 2. Connect a power meter to the output of the mask filter, use the calibrated coupler. Make sure the meter is properly set up, calibrated and the correct offset entered. 3. At the driver GUI > Output > Service > Calibrate screen select the white box by forward power and a key pad will appear. Enter the number displayed on the power meter, select Enter, and select the calibrate button. 4. On the driver GUI > Output > Service > Setup screen; enter the nominal forward power required at the output of the mask filter. This number may have already been entered. It tells the software what the normal 100% output power should be System Level Reflected Power Setup This is the system level reflected power setup and calibration procedure It can be used for the initial setup and for normal maintenance. If the system has multiple HPAs, all HPAs should have been calibrated and combined and operating at 100% power. 1. Remove the sample cable from the reflected directional coupler at the output of the mask filter. 2. Remove the load from the forward port on the same directional coupler and place it on the reflected port, from which the cable was just removed. 3. Place a 20dB pad on the forward port 4. Connect the cable on to the 20dB pad. The reflected sample is now looking at a forward sample which has been reduced by 20dB. Page: /13/12

175 Reject Load Calibration, For Transmitters With Two or More PAs PowerCD Transmitter Maintenance 2533s500.fm 5. On the driver GUI > Output > Service > Calibrate screen enter 1% of the system forward power into the reflected power section and press Calibrate. If the Calibration box flashes Invalid after the Calibration button is pressed the calibration is no good. It is likely due to an RF level that is too low. Try decreasing the pad size from 20dB to raise the sample level then try re calibrating. Be sure to enter the correct percentage of power according to the level of pad inserted in to the sample line.use a 16 db or larger pad, because the VSWR foldback point is set at 1.4:1. A. % Reduction = 100Antilog(-dB/10), where db represents the pad size. 6. Remove the pad and load from the directional coupler and remove the pad from the cable. 7. Place the load on the forward port of the coupler 8. Place the cable back the reflected port. 9. The driver GUI should now indicate the actual reflected power of the system. 10. This sub routine will check or set the System VSWR overload and foldback settings on the driver GUI. On the driver GUI > Output > Service > Setup screen, the VSWR overload and foldback trip points are shown in the blue boxes, they are typically set at 1.5:1 and 1.4:1 respectively. If they are not set correctly, they can be changed by: A. In the driver GUI > Output > Service > Setup screen, click in the white window for the parameter to be changed B. Enter the new VSWR setting. C. Click the store soft key Reject Load Calibration, For Transmitters With Two or More PAs 5.20 HPA ALC Setup 1. Verify that all other forward metering calibrations have been performed. 2. Lower power on all HPAs to zero using drive disable. 3. On the driver GUI > Output > Service > Calibrate screen press Save Reject Load Power Offsets. 4. Enable drive to all HPAs and set the power back to 100% with PA cabinets in remote enabled and remote disabled. 5. Switch the operation of the mode controller so that an HPA that is operating at full power is directed into the reject load to be calibrated. 6. On the driver GUI > Output > Service > Calibrate screen, select the white box next to the reject load to be calibrated and enter the power output of the HPA that is being directed to that load. 7. If this is a 3 HPA system, repeat steps 5 and 6 for the other reject load. This procedure is to be performed with the transmitter off the air. At this point all disconnected cables should have been reconnected. The procedure for setting the PA cabinet output power depends on the transmitter configuration. Two possibilities exist, they are: The transmitter has a single HPA. In this case, the HPA should be in remote enable, drive disable and standby. The driver and HPA cabinets should be in standby. 04/13/ Page: 5-45

176 Maintenance IPA Module Gain Setup 5.21 IPA Module Gain Setup The transmitter has multiple HPAs. In this case, all HPAs should be in remote enable, drive disable and standby. The driver and HPA cabinet in question should be in standby. 1. On the driver GUI > Drive > Service > IPA Gain screen, reduce IPA Gain for each HPAs (by at least half) so that they cannot make 100% power. 2. Set the driver ALC to 1023, as viewed on the Control Tx window on the right side of the driver GUI screens. 3. Switch the driver cabinet to beam on. The HPAs should also go to beam on. 4. On all HPAs, enable the HPA drive. 5. For each HPA, slowly increase the HPA ALC to maximum, on the HPA Power ALC indication, on the right side of the HPA GUI screen. A. The HPAs should not be able to reach 100% power. If any HPA does, reduce its IPA gain further. B. Continue increasing each HPA ALC until its Master DAC number, on the HPA GUI > System > Meters > Control screen, stops increasing. Its maximum is 4095, but it will probably stop before that. 6. For each HPA in turn, slowly increase the IPA gain (10 or 15 steps at a time) until that HPA power reaches 110%. A. Observe the power on the HPA GUI > Full Screen > Summary, to see the power in percent. 1. This GUI can be turned so that it can be viewed from the driver cabinet. 7. Lower the driver ALC until the one HPA output power is at 100%. 8. Look at the output power level of each HPA, and tweak its ALC of that HPA to get 100% power from it. A. Only a small change should be needed. 9. Tweak the IPA gain of each HPA to get its ALC voltage indication (on the HPA GUI Power > ALC indication, on the right side of the screen) within the ideal operating range of 3.4 to 3.6 Vdc. A. Increase the IPA module gain to lower the ALC voltage and decrease the module gain to raise the ALC voltage. B. IPA gain number should fall within a typical range of 200 to 450, C. HPA cabinet drive power (HPA GUI > Drive > Meters, (or summary) should never exceed 250 watts. D. The IPA output is always greater than the drive power because of the cable loss between the IPA and IOT. The IPA output can be observed in the driver GUI > Drive > Meters, (or summary). On this screen it is called HPA1 (or 2 or 3) Input Power. 10. This completes the ALC setup procedure. After the IOT has been turned on and operated at rated power, the IPA gain should be set so as to optimize the ALC loop and drive power limits. This optimum set point is reached when the HPA GUI transmitter screen ALC voltage is approximately 3.5 volts. Increase the IPA module gain to lower the ALC voltage and decrease the module gain to raise the ALC voltage. Page: /13/12

177 ARC Overload PowerCD Transmitter Maintenance ALC voltage is monitored in the ALC window, which is within the power window of the driver GUI > Transmitter Control Section > HPA screen. ALC voltage is monitored in the ALC window, which is within the power window of the HPA GUI > Control: Cabinet Section. 2533s500.fm During this process, IPA gain number should fall within a typical range of 200 to 450 and the HPA cabinet drive power (HPA GUI > Drive > Meters, (or summary) should never exceed 250 watts. If the drive power (at IOT input) exceeds 250 watts, the IOT tuning should be rechecked. The IOT input power (Drive) can also be observed on the driver GUI > Drive > Meters > Driver and on the HPA GUI > Output > Service > Calibrate screens. The IPA output is always greater than the drive power because of the cable loss between the IPA and IOT. The IPA output can be observed in the driver GUI > Drive > Meters, (or summary) ARC Overload Arc overload check is limited to the lamp test. The HPA must be in beam on with drive applied to test the arc overload. Press and hold S2 (for primary cavity are test) or S3 (for secondary arc test.), located on the HPA control board, in the upper front compartment of the power cabinet Parameter Limits Set By Software There is no need to set the following limits, they are set by software. Focus current over/under limits Collector current overload (all five collectors) Grid bias current overload Ion pump current overload Collector over temperature 5.24 HPA Faults Warnings and Limits A list of Power CD transmitter faults is given in Table 5-5. Table 5-5 HPA Faults Warnings and Limits Fault Warning Fault Limit Comments HPA ambient temperature limit N/A 55 degrees C Driver output power limit N/A 300 W HPA forward power limit N/A User selectable 110% above nominal setting. HPA reflected power limit Foldback Trip User selectable Cathode current N/A 3 A Collector 5 current limit N/A 0.1 A Collector 4 current limit N/A 1.5 A Collector 3 current limit N/A 1.5 A 04/13/ Page: 5-47

178 Maintenance HPA Faults Warnings and Limits Table 5-5 HPA Faults Warnings and Limits Fault Warning Fault Limit Comments Collector 2 current limit N/A 1.5 A Collector 1 current limit N/A 0.5 A Ground fault current limit N/A 0.05 A IOT quiescent current maximum N/A 800 ma IOT quiescent current minimum N/A 100 ma Collector 5 over voltage N/A 40 kv Collector 5 under voltage N/A 28 kv Collector 4 over voltage N/A 1/2 V5 + 2 kv 24 kv is absolute limit. Collector 4 under voltage N/A 1/2 V5-2 kv Collector 3 over voltage N/A 1/3 V5 + 2 kv 18 kv is absolute limit. Collector 3 under voltage N/A 1/3 V5-2 kv Collector 2 over voltage N/A 10 kv Collector 1 over voltage N/A 10 kv Grid voltage low N/A -80 V Grid voltage high N/A -250 V Grid current low -40 ma -150 ma Grid current high +50 ma +150 ma Filament voltage high N/A 6.8 V Nominal data sheet +/-0.3 V, Filament voltage low N/A 5.4 V range 5.7 to 6.5 V. Filament current high N/A 30A Filament current low N/A 25A Ion voltage high N/A 4.0 kv Ion voltage low N/A 3.0 kv Ion current high N/A 20 ua Focus voltage high N/A 6.8 V Focus voltage low N/A 5.4 V Focus current high N/A 30 A Focus current low N/A 25 A Cavity air pressure low N/A 5.5 inches water Cavity air temperature high N/A 60 degrees C IOT water pressure high 61 psi 64 psi IOT water pressure low N/A 25 psi DI water conductivity low 1.3 M ohm 1.1 M ohm Collector water flow high 14 gpm N/A Page: /13/12

179 RFU Chassis Layout PowerCD Transmitter Maintenance 2533s500.fm Table 5-5 HPA Faults Warnings and Limits Fault Warning Fault Limit Comments Collector water flow low 11.6 gpm 11.2 gpm DI water manifold temperature limit 50 degrees C 53 degrees C Collector water temperature limit out 65 degrees C 68 degrees C Anode water flow low 1.5 gpm 1.3 gpm External glycol flow high 30 gpm N/A External glycol flow low 18 gpm 17.5 gpm 5.25 RFU Chassis Layout The RFU rear panel and chassis layouts are shown in Figure 5-22, with the interconnections listed in Table 5-6 and shown in Figures 5-23, and Table 5-6 RFU Chassis Connections Source Destination Signal Name Jack Board or Rear Panel Jack Board or Rear Panel Exciter A Input J51 Rear Panel J1 RFU Switch Board Exciter A Input J52 Rear Panel J2 RFU Switch Board Reject 3 RF Sample Input J55 Rear Panel J32 RFU Switch Board Reject 4 RF Sample Input J56 Rear Panel J33 RFU Switch Board Exciter Switch RF Output J16 RFU Switch Board J6 RFU Switch Board Power For Fan J17 RFU PA Board RFU Chassis Fan Power and Control for RFU PA Board J7 RFU Control Board J16 RFU PA Board RF1 Output (to IPA1) J1 RFU PA Board J61 Rear Panel RF2 Output (to IPA2) J2 RFU PA Board J62 Rear Panel RF3 Output (to IPA3) J3 RFU PA Board J63 Rear Panel Single HPA System RFU Interconnection RFU Switch Board Output J5 RFU Switch Board J1 RFU PA Board For a single HPA system the small signal board is not installed. Multiple HPA System RFU Interconnection Exciter Switch RF Output J16 RFU Switch Board J5 RFU Small Signal Board 2-Way Splitter output (drive for Small J7 RFU Small Signal Board J8 RFU Small Signal Board Signal outputs 3 and 4. Small Signal Board Output 1 J1 RFU Small Signal Board J1 RFU PA Board Small Signal Board Output 2 J2 RFU Small Signal Board J2 RFU PA Board Small Signal Board Output 3 J3 RFU Small Signal Board J3 RFU PA Board Spare Low Level Amplifiers Input and Output Respectively J6 RFU Switch Board J5 RFU Switch Board Input and Output Respectively J9 RFU Small Signal Board J10 RFU Small Signal Board 04/13/ Page: 5-49

180 Maintenance RFU Chassis Layout RFU Rear Panel RF Switch Board Controller Board RFU PA Board J51 Exciter A J52 Exciter B J55 Reject 3 J56 Reject 4 J50 J65 RF5 out J64 RF4 out J63 RF3 out J62 RF2 out J61 RF1 out J20 Reject 1 J21 Reject 2 J22 Forward J23 Reflected J24 ALC 1 J25 ALC 2 J26 ALC 3 J27 ALC 4 J28 LVPS J29 RF Switch J30 System Bus RFU PA Board J16 J11 J12 J13 J6 J7 J8 J30 J29 J28 RFU Controller S4 Reset S3 8 Position 8 1 J S2 4 Pos. S1 JP1 J27 J26 J25 J24 J23 J22 J21 J20 RFU Switch Board J32 J33 J17 J18 R8 R7 J31 J10 J16 J1 J2 J3 J7 J11 J6 R2 R1 J8 J5 J6 J2 J1 J10 J9 J7 J5 RFU Small Signal Board Fan J4 J3 J2 J1 RFU Chassis, Front Figure 5-22 RFU Chassis Rear Panel and RFU Chassis Top View Page: /13/12

181 RFU Chassis Layout PowerCD Transmitter Maintenance RFU Rear Panel, View from the Back of the RFU RF Switch Board Controller Board RFU PA Board 2533s500.fm J51 Exciter A J52 Exciter B J55 Reject 3 J56 Reject 4 J50 J65 RF5 out J64 RF4 out J63 RF3 out J62 RF2 out J61 RF1 out J20 Reject 1 J21 Reject 2 J22 Forward J23 Reflected J24 ALC 1 J25 ALC 2 J26 ALC 3 J27 ALC 4 J28 LVPS J29 RF Switch J30 System Bus RFU PA Board J16 J11 J12 J13 J6 J7 J8 J30 J29 J28 RFU Controller S4 Reset S3 8 Position 8 1 J S2 4 Pos. S1 JP1 J27 J26 J25 J24 J23 J22 J21 J20 RFU Switch Board J32 J33 J17 J18 R8 R7 J31 J10 10 db J16 J1 J2 J3 J7 J11 R2 R1 10 db J5 J6 20 db J2 20 db J1 Fan RFU Small Signal Board Not Installed For Single HPA Units. RFU Chassis, Front Figure 5-23 RFU Chassis Rear Panel and Chassis Top View, With Single HPA Cabling 04/13/ Page: 5-51

182 Maintenance RFU Chassis Layout RFU Rear Panel, Viewed from the Back of the RFU Chassis RFU PA RF Switch Board Controller Board Board W14 W15 J51 Exciter A J52 Exciter B J55 Reject 3 J56 Reject 4 J50 J65 RF5 out J64 RF4 out J63 RF3 out J62 RF2 out J61 RF1 out W16 J20 Reject 1 J21 Reject 2 J22 Forward J23 Reflected J24 ALC 1 J25 ALC 2 J26 ALC 3 J27 ALC 4 J28 LVPS J29 RF Switch J30 System Bus W16 RFU PA Board W15 W14 J16 J11 J12 J13 J6 J7 J8 J30 J29 J28 RFU Controller S4 Reset S3 8 Position 8 1 J S2 4 Pos. S1 JP1 J27 J26 J25 J24 J23 J22 J21 J20 RFU Switch Board J32 J33 J17 J18 R8 R7 J31 J10 10 db J16 J1 J2 J3 J7 J11 J6 R2 R1 J8 J5 J10 J6 J9 J2 20 db 20 db J1 J7 J5 RFU Small Signal Board Fan J4 J3 J2 J1 Phasing Cables RFU Chassis, Front Figure 5-24 RFU Chassis Rear Panel and Chassis Top View, With Cabling For Three HPAs Page: /13/12

183 Introduction to the IOT RF Section PowerCD Transmitter Theory of Operation 6 Theory of Operation 2533s600.fm This section contains the theory of operation for the PowerCD transmitters. This section is divided into two parts, which are as follows. RF System Theory. Control Logic Theory. Automatic Level Control (ALC) System. Grid Voltage and Idle Current Adjustment Description 6.1 Introduction to the IOT RF Section The RF system includes the M2X exciter (can have one or two), the RFU (RF unit), the IPA (intermediate power amplifier, one for each HPA), the HPA (high power amplifier, the system can have up to three), the high power RF combining system (for more than one HPA) and the high power bandpass (mask) filter. These parts of the RF system will be covered in greater detail in the remainder of the RF theory section of this chapter Power CD Transmitter RF System Block Diagrams Figure 6-1 shows the block diagram of a PowerCD transmitter with two exciters and one HPA cabinet. Figure 6-2 shows the block diagram of a PowerCD transmitter with two exciters and two HPAs. PowerCD digital transmitters can have up to three HPA cabinets Overview of Major RF Components of Block Diagram Refer to Figures 6-1 and 6-2. The RF system starts in the M2X exciter at the output of the digital to analog converter (DAC) as a 140 MHz center frequency IF signal. All signal precorrection, both linear and nonlinear are performed in the digital section of the exciter, which occurs before the DAC. In the M2X exciter, the output of the DAC is a 140 MHz IF, which is up converted to the on channel RF output frequency in a single step. The output of the exciter is on channel with an adjustable output power of 100 mw maximum average power. The RFU (RF unit) module receives the output from both exciters and provides the exciter switcher functions. The RFU splits the output of the on air exciter into three signals, one for each HPA system. It provides an adjustable APC (automatic power control, also referred to as the ALC, automatic level control) for each HPA cabinet and for the combined transmitter RF output power, when more than one HPA is used. The APC circuitry provides an individual adjustment for the output power of each HPA cabinet and a master APC, the transmitter power control, which is capable of adjusting the output of all HPAs of the transmitter system together to control the output power of the transmitter. The RFU also performs the RF phasing function for multiple HPAs in the RF system. This ensures proper combining of HPAs with minimum power loss in the reject load. The IPA receives the low power output from the RFU and increases it up to the power level required to drive the IOT. The IPA is a water cooled amplifier which includes a logic system to monitor its output power and gain and which protects it for overloads and excessive VSWR. One IPA is provided for each HPA system in the transmitter. 04/13/ Page: 6-1

184 Theory of Operation Introduction to the IOT RF Section The HPA system centers about the liquid cooled multi-collector IOT. It raises the IPA output power to the required transmitter output power level. Each HPA system includes an IOT cabinet, a power supply cabinet, and a cooling cabinet. A separate beam supply is required for each HPA system, and a liquid cooling system is required to provide cooling for the IPAs and IOTs. An RF combiner system is required if the transmitter system includes more than one HPA. This system combines the output of the HPAs and provides a switching system to isolate one of the HPAs for maintenance purposes while the others continue to operate on the air. The last component of the RF system is the high power (mask) filter. It is used limit emissions outside the authorized channel to meet or exceed government regulations. M2X Exciter Control Cabinet IOT Cabinet RF Output RFU See Note 1 M2X Exciter IPA IPA Gain CIR1 FWD DC1 2-Way Splitter REF IOT Customer Samples HPA Breakaway Coupler FWD 2-Way Splitter REF 2-Way Splitter High Power Filter Customer Reflected Sample Output Coupler ALC Control Voltage RF Samples HPA Controller 2-Way Splitter RTAC HPA feedback sample 2-Way Splitter RTAC HPF feedback sample Note 1. The RFU provides automatic switching for the exciters and automatic output level control (ALC). Figure 6-1 RF Block Diagram for PowerCD Transmitter with One HPA Cabinet Page: /13/12

185 Introduction to the IOT RF Section PowerCD Transmitter Theory of Operation 2533s600.fm M2X Exciter RFU See Note 1 M2X Exciter Control Cabinet HPA1 IPA IPA Gain HPA2 IPA IPA Gain CIR1 ALC Control Voltage For HPA1 FWD HPA1 Cabinet DC1 2-Way Splitter REF RF Samples HPA Controller IOT Customer Samples HPA Breakaway Coupler FWD 2-Way Splitter REF 2-Way Splitter System Combiner Customer Reflected Sample DC FWD High Power Filter RF Output DC FWD HPA2 Cabinet CIR1 DC1 IOT HPA Breakaway Coupler FWD 2-Way Splitter REF Customer Samples FWD 2-Way Splitter REF 2-Way Splitter Customer Reflected Sample 2-Way Splitter 2-Way Splitter ALC Control Voltage For HPA2 RF Samples HPA Controller RTAC HPA feedback sample RTAC HPF feedback sample Note 1. The RFU provides automatic switching for the exciters, automatic output level control (ALC) for each HPA and for the transmitter system, and output phasing control for its HPAs. Figure 6-2 Block Diagram for PowerCD Transmitter with Two HPA Cabinets 04/13/ Page: 6-3

186 Theory of Operation Introduction to the IOT RF Section Radio Frequency Unit (RFU) The radio frequency unit (RFU) performs the following functions: Exciter Switcher. HPA phasing, when two or more HPAs are used in the transmitter system. Individual ALC (automatic level control) for each HPA of the system. Individual mute function for each HPA of the system. Provides required RF drive power (maximum of +23dBm peak, 200mW peak) for each HPA system IPA. The RFU controller is discussed in Section 6.3.6, RFU Controller, on page The Exciter Switcher Refer to Figures 6-3 and 6-4 and to the RFU switch board schematic ( ). The output from exciters A and B enter the RFU at connectors J51 and J52 respectively. They are connected to the RFU switch board at J1 and J2 respectively via 20dB pads. The on air exciter exits the RF switcher board at connector J16 where it is connected through a 10dB pad to one of two destinations. For single HPA transmitter systems it is connected to J6 on the RFU switch board, see Figure 6-3. For multiple HPA transmitter systems it is connected to J5 on the RFU small signal board, see Figure 6-4. Typical signal levels associated with the RF switcher are given in Table 6-1. Jack Number Table 6-1 Signal Levels For The Exciter Switcher Signal Level Peak Signal Level Peak Signal Level Average Signal Level Average J51 (from Exc. A) +25 dbm 316 mw +19 dbm 79 mw J52 (from Exc. B) +25 dbm 316 mw +19 dbm 79 mw J1 (from 20dB attenuator) +5 dbm 3.16 mw -1 dbm 0.79 mw J2 (from 20dB attenuator) +5 dbm 3.16 mw -1 dbm 0.79 mw J16 (from exciter switcher) -1 dbm 0.79 mw -7 dbm 0.2 mw RFU Operation for Single HPA Systems Refer to Figure 6-3 and to the RFU switch board schematic ( ). For single HPA systems, the RF reenters the RFU switch board (from the 10 db pad) at J6. It then passes through a voltage controlled attenuator, CR6 and CR5, then through amplifier U10, and leaves the small switch board at J5. A 10 db pad is connected to J5, and from there the signal goes to J1 of the RFU PA board. The voltage controlled attenuator cuts the signal off when mute is active (low at J10-37 on the switch board), and controls the signal level according to the ALC voltage (0 to +4.1 Vdc at J10-38 on the switch board). The attenuator RF output level is maximum when the ALC is at 4.1 Vdc and zero when the ALC is below 0.4 Vdc. Table 6-2 lists the typical RF signal levels for this section. Page: /13/12

187 Introduction to the IOT RF Section PowerCD Transmitter Theory of Operation 2533s600.fm Jack Number Table 6-2 Signal Levels For The Single HPA RFU System Signal Level Peak Signal Level Peak Signal Level Average Signal Level Average J6 (from switch board via 10 db pad) -11 dbm 80 uw -17 dbm 20 uw J5 (from U10) -8 dbm 160 uw -14 dbm 40 uw J1 (from U10 via 10 db pad) -18 dbm 16 uw -24 dbm 4 uw J6 (Output of RFU PA Board) +13 dbm 20 mw +7 dbm 5 mw Exciter A Input, J51 > > J52, Exciter B Input RF System Fwd Sample RF System Ref Sample 20dB Pad 20dB Pad HPA 1 ALC Reference Voltage From HPA Controller. RFU Switch Board Dwg. No J1 > J16 J6 Exciter > 10dB Pad > J2 Switcher > J22 > J23 > J24 > Exciter Detectors RF Detector RF Detector Exciter Select U10 ALC Control Voltage (0 to 12 V) J10 38 Mute J31 RFU PA Board J5 J1 J6 J61, RF > 10dB Pad > > > Output to HPA1 IPA Dwg. No Controller Dwg. No Figure 6-3 Block Diagram of RFU, For System With One HPA See Figure 5-23, on page 5-51 for the RFU chassis layout with cabling for a single HPA system. 04/13/ Page: 6-5

188 Theory of Operation Introduction to the IOT RF Section Small Signal Board, for Multiple HPA Systems Refer to Figure 6-4 and to the RFU small signal board schematic ( ). The small signal board is used for multiple HPA transmitter systems. The small signal board performs the following operations on the signal. It splits the signal into four paths, three for HPAs 1 through 3 plus one spare. It provides phase shifters for each path to facilitate proper combining for transmitter systems with two or more HPAs. Individual ALC (automatic level control) for each HPA of the system. Individual mute function for each HPA of the system. RF from the exciter switcher enters the small signal board at J5 (from the 10 db pad) and is divided into four signal paths by the in phase dividers U30, U31, and U33. From here, each signal passes through identical circuits to the output of the small signal board, therefore only the RF path 1 will be discussed. RF output from port 2 of the two way splitter enters the coarse phase shifter, which consists of HY5, U23, U19, and U15. This phase shifter is capable of phase shifts in increments of 90 degrees, from 45, to 135, to 225, to 315 degrees. The inputs of U23 and U19 are 90 degrees out of phase. The control input of U23 and U19 is capable of switching its output so that it is either in phase with or 180 degrees out of phase with its input. U15 is an in phase combiner which combines the output of U23 and U19. RF output from the coarse phase shifter enters the fine phase shifter, which consists of HY1 and varicap diodes CR9 and CR14. A voltage, which controls the output phase of this circuit, enters the phase shifter fromu32 via R89. This phase shifter is capable of a continuously variable phase shift of slightly over 90 degrees. The signal then passes through a voltage controlled attenuator, CR5 and CR1. The attenuator CR5 and CR1 has a -5 to -40 db range. The ALC control voltage (0 to volts) is amplified by U8 to a 0 to 12.3 volt range, which is then applied to attenuator CR5 and CR1. The attenuation is -5 db with a 12.3 volt control voltage and -40 db with a 0 volts control voltage. The mute signal is inverted by Q9 and applied to the input of U8. When the mute is active (low at J6-5 on the small signal board) it lowers the ALC control voltage to zero volts, which causes maximum attenuation. From attenuator CR5 and CR1, the signal is passed through amplifier U3 and leaves the small signal board at J1. The output at J1 is capable of 0 dbm peak power, but it normally operates at a much lower average power. The mute control, Q1 and Q5 cuts the signal off at the output of U3 when mute-1 is active (low at J6-5 on the small signal board). From J1 on the small signal board, the signal then goes to input J1 of the RFU PA board. Table 6-3 lists the typical RF signal levels for this section. Jack Number Table 6-3 Signal Levels For The Multiple HPA RFU System Signal Level Peak Signal Level Peak Signal Level Average Signal Level Average J6 (from switch board via 10 db pad) -11 dbm 80 uw -17 dbm 20 uw At the output of U30 and U31-19 dbm 12.6 uw -25 dbm 3.16 uw J1 (from the small signal board output) -18 dbm 15.9 uw -24 dbm 4 uw J6 (Output of RFU PA Board) +12 dbm 16 mw +6 dbm 4 mw Page: /13/12

189 Introduction to the IOT RF Section PowerCD Transmitter Theory of Operation 2533s600.fm Reject 1 RF Sample Reject 2 RF Sample RF System Fwd Sample RF System Ref Sample HPA 1 ALC HPA 2 ALC HPA 3 ALC HPA 4 ALC Exciter A Input, J51 > J52, > Exciter B Input 20dB Pad 20dB Pad J20 > J21 > J22 > J23 > J24 > J25 > J26 > J27 > J1 > J2 > RF Detector RF Detector RF Detector RF Detector Exciter Detectors Exciter Switcher RFU Switch Board, Dwg. No Exciter Select > J16 RF Output 10dB Pad J J31 J11 Controller Dwg. No Coarse Phase Control Inputs: Select-pin 9, MOSI-pin 10, MISI-pin 11, SCK-pin 12 Fine Phase Control Inputs: 1-pin 1, 2-pin 2, 3-pin 21, 4-pin 22 ALC Inputs: 1-pin 3, 2-pin 4, 3-pin 23, 4-pin 24 (0 to 12V) Mute Inputs: 1-pin 5, 2-pin 6, 3-pin 25, 4-pin 26 U30, U31, and U33 Are In Phase RF Splitters U31 J6 Phase Coarse Shifters Fine RF Signal Path 1 J1 > RFU PA Board J1 > J6 > J61 > RF Output to HPA1 IPA U33 J5 RF > Input Coax J7 Jumper J8 > > U30 Phase Coarse Phase Coarse Shifters Fine Shifters Fine RF Signal Path 2 RF Signal Path 3 J2 > J3 > J2 J7 J62 > > > RF Output to HPA2 IPA J3 J8 J63 > > > RF Output to HPA3 IPA Small Signal Board Dwg. No Phase Coarse Shifters Fine RF Signal Path 4 J4 > Dwg. No Figure 6-4 Block Diagram of RFU, For System With Three HPAs See Figure 5-24, on page 5-52 for the RFU chassis layout with cabling for a three HPA system. 04/13/ Page: 6-7

190 Theory of Operation Introduction to the IOT RF Section IPA Module The PowerCD IPA module is a wideband, high gain, liquid cooled RF amplifier. It utilizes LDMOS (laterally diffused metal oxide semi-conductor) amplifiers to produce up to 450W maximum average power (for 8VSB) with a liquid cooled heatsink. The gain of each module is manually set to a range of 50 to 52 db as part of the HPA ALC setup procedure. Each module weighs approximately 23.6kg and can be removed while the transmitter is running. A PowerCD driver cabinet has one IPA module for each HPA cabinet. The driver cabinet can hold up to five IPA modules. Each PowerCD IPA module is a self-contained 450W transmitter including power supply and its own internal control, monitoring and protection. The modules only receive basic on/off, mute, restart, and gain commands from the transmitter control system. This means that each module will protect itself without relying on the system controller. A simplified block diagram of the IPA module is shown in Figure 6-5. The primary method for communication between the IPA module and the rest of the transmitter is by the serial CAN (controller area network) bus. It is used for control, status and monitoring of all IPA module parameters. Commands are sent via the CAN bus to the module from the driver cabinet main controller, and any faults in the module will be reported over the CAN bus to the GUI. As a backup to the CAN bus, each IPA Module has dedicated hardware control lines for functions such as on, off, restart and RF mute. 3 phase full wave bridge rectifier, see drawing to 350 Vdc unregulated AB +250V 3Ø AC Front End Power Supply contains five Vicor dc to dc converters, see drawing RF IN Pin PA Power Supply PHASE & GAIN SWITCHED +28V Pre-driver A BIAS Driver A AB BIAS Splitter AB AB AB Pallets AB Pallet Combiner RFL FWD RF OUT PA PS MON Driver B AB BIAS Splitter AB AB AB TEMP CAN Bus ON/OFF CONTROL BOARD Auto Biasing TO MAIN CONTROLLER MODULE ENABLE/DISABLE Figure 6-5 IPA Module Simplified Block Diagram Page: /13/12

191 Introduction to the IOT RF Section PowerCD Transmitter Theory of Operation The IPA module is capable of 450 watts average digital (8VSB) output power, but the IPA module output limit is set at 300 watts. The usual IOT input power, supplied by the IPA, ranges between 140 to 210 watts, with the IPA input power ranging between 1 and 2 mw. 2533s600.fm Each IPA module consists of the following components: 1. IPA module controller board is responsible for all monitoring and protection of the module. It reports to the GUI via the CAN bus but is also connected to the parallel control lines in case the CAN bus is not operational. 2. Phase and gain board - Provides for module phase and gain adjustments. The phase adjustment is not used, but the gain adjustment is used in a manual mode to control the gain of the IPA module. 3. Pre-driver pallet (actually 1/2 of an amplifier pallet) - Provides enough power to drive the 2 way splitter and the 2 driver pallets. 4. Two (2) LDMOS driver pallets. 5. Two 4-way RF splitters - Each driven by an LDMOS driver pallet. 6. Eight LDMOS amplifier pallets - One for each output of the two 4-way RF splitters. 7. Eight way pallet combiner 8. Liquid cooled cold plate - Mounted directly to the eight LDMOS power amplifier pallets and power supplies for cooling. 9. RF output directional coupler - Samples both forward and reflected power for metering, module automatic level control (ALC) and module VSWR protection. 10. Integrated power supply - Receives 250 VAC and provides the dc power for the module Phase and Gain Board The RF enters the module and is routed directly to the phase and gain board. This board provides several functions which are key to operation of the module: 1. It acts as a gain block to increase the RF input to a level that is sufficient to drive the predriver pallet. 2. It has an RF input switch which is used to mute and un-mute the RF through the module. 3. Input power sampling for metering and input over-drive detection. 4. Receives I and Q vector control signals from the module controller board. These are used to control module insertion phase and gain. 5. Automatic level control (ALC) to keep the power output of the module constant. The RF output from the phase and gain board connects to the predriver pallet 04/13/ Page: 6-9

192 Theory of Operation Introduction to the IOT RF Section J1-5 RF_On J1-8 ALC_RFC J1-10 Phase_REF 2-Way Splitter J2 RF In Clamp J1-19 Back Porch Pulse -3dB Envelope Detector RF Mute Back Porch Level Detector Vector Modulator J1-6 RF_Off J1-17 Digital/Analog Comparator Mean Square Circuit J3 RF Out J1-3 Input Overdrive Reference J1-4 Input Power Overdrive J1-2 Input Power Sample Figure 6-6 Phase and Gain Board Block Diagram Automatic Level Control (ALC) Each IPA module uses an automatic level control or ALC circuit to keep the module power output constant. The IPA ALC is used in the manual mode in the PowerCD transmitter, it has the following two functions: To set the maximum IPA output power to 300 watts. To keep the HPA ALC in the correct range. The correct ALC range is 3.2 to 3.5 V at 100% HPA output power. When operating under this condition, the IPA output should be less than 300 watts The forward power output of the module is based on the factory calibration of the forward power sample from the pallet combiner inside the module RF Pallets The IPA module utilizes several LDMOS RF amplifier pallets. The pallet is actually made up of 2 push-pull amplifiers with a hybrid splitter on the input and a hybrid combiner on the output. Eight (8) pallets are used as the main power amplifiers, two (2) are used as driver pallets and 1/2 of one pallet is used for a predriver. A simplified diagram of the pallet is given in Figure 6-7. Page: /13/12

193 Introduction to the IOT RF Section PowerCD Transmitter Theory of Operation RF In 1 Side A Combiner Isolation Load 2533s600.fm 3dB Hybrid Bias +28 VDC 3dB Hybrid Splitter Isolation Load Side B RF Out 1 Figure 6-7 Pallet Simplified Diagram Auto Bias Circuit As LDMOS devices age, their biasing requirements change. To correct for this, the module controller has the ability to automatically re-bias the pallets for the correct idle current by adjusting the gate bias voltages. This auto bias procedure should be done at regularly scheduled intervals and is initiated manually using the GUI. Note When the biasing procedure is initiated, the module will be muted and transmitter RF output will be affected. This procedure takes about 5 seconds. The pallets get their gate bias voltages from 10 bit DACs (digital to analog converters) on the module controller. Each pallet is divided into a side A and side B with each side having one push-pull pair (PPP) LDMOS device. Each PPP has its own bias signal from a DAC output, but there is only one current sensor for each pallet. Therefore, the auto bias adjustment will be carried out on one side of all 8 pallets at a time, then it will do the other side to assure that each half is drawing its share of the idle current. To bias the module, the controller will disable the ALC and mute the RF by opening the RF switch on the phase and gain board. Then it will zero the bias for one side of all the pallets and adjust the bias for the desired idle current on the other half of each pallet. Then it will store these settings and repeat the procedure for the other half of the pallets. If during the bias procedure, one or more of the pallet currents does not fall within the acceptable margin of error, the procedure will be aborted and a warning of auto bias failure will be sent to the main controller and the fault log Pallet Splitters and Combiner The two 4-way drive splitters and the 8-way pallet combiner are strip line hybrid circuits. The pallet combiner also has a directional coupler to sense forward and reflected power at the output of the module. The forward power sample is used for power monitoring and module ALC (automatic level control). The reflected sample is used to protect the module from excessive VSWR. 04/13/ Page: 6-11

194 Theory of Operation Introduction to the IOT RF Section Module Controller The module controller uses the 376 micro module and is responsible for the following: Communicating with the main controller, for setup parameters, and reports its faults and status to the GUI via the CAN bus. Monitoring drain current to each of eight RF pallets, driver, pre-driver and phase and gain board in the module for over-current conditions and for pallet biasing. Monitoring the cold plate temperature at the pre-driver, and IPA power supply board temperature. Control and monitoring of IPA power supply, including over and under voltage fault warnings. The module is capable of performing phase adjustments, but that function is not used in the PowerCD transmitter. Phase adjustments, for proper combining, are performed in the RFU chassis. The module controller receives an output power reference level from the GUI via the CAN bus. This signal is used by the module controller ALC circuit to set the module gain by adjusting the level of I and Q signals to the phase and gain board. Fault monitoring and alarm generation, and control of module four strike process. Monitoring RF input and output power to/from the module. Determining when to use the backup analog ALC voltage. The IPA module systems bus pin out for the backplane board to IPA connectors J7,J9, J11, J13, and J15 is given in Section , IPA Module Modified System Bus Connections, on page PS Front End Board The PS front end board uses a three-phase, full-wave bridge rectifier to change the 3 phase AC entering the module to high voltage DC which is sent to the DC/DC converters. This board also serves to filter the power source of common mode noise Power Supply Board The power supply board is designed to connect the 5 DC/DC converters in parallel in order to provide sufficient DC power for one IPA module. This board accepts high voltage DC (335 to 350V) from the front end board. The high voltage DC is passed through a fuse to each converter. The primary or high-voltage side of the converters is floating with respect to earth ground. The converter outputs are low-voltage, ground referenced DC and are connected to a common bus through OR-ing diodes. This low voltage is used to supply the drain voltage requirements of the RF transistors on the IPA pallets, drivers, predriver and phase/gain boards. The power supply board provides input short-circuit protection for each DC/DC converter. It provides status monitoring for each converter and a single temperature sample for the circuit board. The power supply board provides a means to electronically adjust the converter output bus voltage, and provides current monitoring for each converter output with the ability to turn off any converter independently. Page: /13/12

195 Introduction to the IOT RF Section PowerCD Transmitter Theory of Operation The Multi-collector IOT 2533s600.fm The PowerCD series transmitters operate on the UHF band. The high power amplifying device is the high efficiency multi-collector IOT. This tube has a grid cathode assembly that resembles a tetrode and a multi-element depressed collector assembly that resembles that of a Klystron. Unlike the Klystron, which operates class A, the IOT operates class AB and is therefore more efficient. The multi-collector IOT is more efficient than the single collector IOT Beam Current, Collector and Cathode Assembly Voltages A simplified diagram of a multi-collector IOT is shown in Figure 6-9. This IOT has five collectors, with collector 1 at 0V (+36 kv with respect to the cathode), and collector 5 at -36 kv (0 Vdc with respect to the cathode). The dissipation of each collector is dependant not only on the current of each collector but also on the collector voltage, since each collector is operating at a different voltage with respect to the cathode IOT Arc and Ground Current Protection. Two sensors within the HPA system power cabinet protect against arcs and excessive ground current, see Figure 6-9, they are the spark gap interface SG1 and ground current sensor U7 respectively. Cathode current flows through pulse transformer T1 and the SG1. Any abrupt change in cathode current, which is usually the sign of an arc, induces a pulse into the secondary of the transformer shown on SG1 assembly, which causes the spark gap to fire, which grounds the beam supply. This induces a pulse into the secondary of transformer T1, which shuts down the step start controller (which removes the AC to the beam supply) and it also sends a command to the HPA controller which initiates a four strike sequence. The HPA controller reports the event to the GUI. Any leakage current to ground, which occurs in the beam supply side of U7, will return from ground to the positive side of the 38 kv section of the beam supply. This results in an unbalance of supply and return currents through U7, which creates an output from U7 via TB1. This signal returns to the HPA controller which initiated a four strike sequence. The HPA controller reports the event to the GUI. 04/13/ Page: 6-13

196 Theory of Operation Introduction to the IOT RF Section Collector Drift Tube Drift Tube IOT Beam Current kv Beam Supply Grid Cathode Heater - + Heater Supply - Grid Supply + Figure 6-8 Single Collector IOT Structure IOT Collector and Body Current For any IOT, the beam current flows from the cathode to the collector, see Figure 6-8. Electrostatic lenses and focusing electromagnets (not shown in Figure 6-8) cause the beam current to travel through the center of the drift tube and return to the collector and not to short cut into the drift tube. If a significant amount of the beam current returned to the drift tube, it would be damaged. The beam current is being pushed by -36 kv at the cathode. This represents considerable energy to the grounded drift tube, and if significant beam current were to flow into the drift tube, this is referred to as body current, it could melt a hole through the drift tube. Body current is avoided as long as the focus current, flowing through the IOT circuit assembly focus electromagnets, is within the range specified on the manufacturer data sheet included with the IOT Energy in the IOT Beam Current Two parameters control the energy contained in the beam current. They are the amount of electrons in the beam and the velocity of the electrons. The grid causes the beam current electrons to flow in bunches. Electron flow passed the grid increases when the RF makes the grid less negative with respect to the cathode, and the electron flow passed the grid decreases when the RF drives the grid more negative with respect to the cathode. Since the IOT is a class AB amplifier, the conduction angle for the beam current is between 180 and 360 degrees. The difference of potential between the cathode and drift tube cause the beam electrons to accelerate and gain energy. Page: /13/12

197 Introduction to the IOT RF Section PowerCD Transmitter Theory of Operation 2533s600.fm Voltage W/R to Cathode Voltage W/R to Ground 0 kv -38 kv +19 kv -19 kv Collector 5 Collector 4 U5B, Collector 5 Current U4, Collector 4 Current The arrow below shows the direction of beam voltage leakage current through U7. U7 full scale deflection is 100 ma, with a trip point set at 50 ma Beam Supply kv Supply kv kv +38 kv 0 kv +38 kv 0 kv Collector 3 Collector 2 Collector 1 Drift Tube Drift Tube U2, Collector 2 Current U3, Collector 3 Current U6, Return Current U7 Ground Current Sensor TB kv Supply 38 kv Supply See Note 1 0 kv -38 kv Grid Cathode Heater Note 1. The grid voltage (bias) typically ranges from -50 to -150 Vdc with respect to the cathode - + Heater Supply - Grid Supply + Part of Isolated Supplies Enclosure U5A, Cathode Current SG1 Spark Gap Spark Gap Interface J5 To J3 on HV Metering Board T1, Pulse Transformer Arc Detector Output (to Step Start Control Board) Note: Current (fall 2007) e2v recommendation for the e2v 5130w IOT filament voltage is 6.5 volts for the first 400 hours, than 6.25 volts thereafter. If the grid current becomes more negative over a several month period, filament voltage management is needed, contact e2v for specific instructions. Figure 6-9 Multi-collector IOT Showing DC Supplies Formation of Electron Bunches Figure 6-10 Shows a single collector IOT with cathode, grids, drift tube (greatly elongated, in order to better show the electron bunches), and the collector. The RF output circuit (primary and secondary resonant cavities and the coupling and loading loops) were left in place to improve the perspective of the drawing. The grid and cathode are spaced close together (approximately 1 mm) so that the distance between them is a small fraction of a wavelength at the highest UHF frequency used. The space between the grid and drift tube window is one or more wavelengths, so the normal RF grid drive and grid bias, operated in class AB, see upper half of Figure 6-10 for the 04/13/ Page: 6-15

198 Theory of Operation Introduction to the IOT RF Section cathode current waveform, causes the electrons to flow in bunches when traveling from the grid to the drift tube window. The bunches are approximately 1/2 wavelength long and the spacing between the bunches is 1/2 wavelength. The electrostatic lens (formed between the grid/cathode assembly and the lower portion of the drift tube), along with the current flowing in the focus coils (neither are shown here) cause the bunches to travel through the center of the drift tube. IOT Cathode Current I Bmax I B The numbers above and below represent time related beam current events. Drift tube (and primary resonant cavity) window Output Coupling Loop (Loading Control) Drift Tube 1 Bull Nose 2 Primary Resonant Cavity (Surrounds Drift Tube) Event numbers, relates to cathode current waveform shown above. Grid Drift Tube IOT Beam showing electron bunches, traveling towards the collector. - Secondary Resonant Cavity Interstage Coupling Loop (Coupling Control) kv Beam Supply Cathode Grid Supply Heater Heater Supply Figure 6-10 IOT Side View, Showing Development of Electron Bunches, Slide 1 Page: /13/12

199 Introduction to the IOT RF Section PowerCD Transmitter Theory of Operation Energy Flow From Electron Bunches To Primary Cavity 2533s600.fm As the bunches of electrons pass the window between the two halves of the drift tube, they impart some of their energy into the resonant cavity, this lost energy is the RF output. Figures 6-11 through 6-14 show four views of a bunch of electrons passing by the drift tube window. Each view shows the electron bunch in a different position in the window. In Figure 6-11, an electron bunch is in the lower window opening in the drift tube. Its negative charge repels electrons in the drift tube and lower inside surface of the cavity. This forces RF circulating currents to flow within the cavity, in the direction shown, which imparts energy from the electron bunch to the primary cavity. This action starts to de-bunch the electrons in the electron cloud. In Figure 6-12, the electron bunch is at the center of the window opening in the drift tube, its negative charge repels electrons equally from the upper and lower window opening. This stops the RF circulating current. Since the electron bunch is approaching the upper half of the window, the RF circulating current is getting ready to flow through the cavity in the opposite direction to that of Figure In Figure 6-13, the electron bunch is at the top of the window opening in the drift tube. Its negative charge repels electrons in the drift tube and upper inside surface of the cavity. This forces RF circulating currents to flow in the opposite direction (compared to Figure 6-11) within the cavity. This imparts more energy from the electron bunch to the primary cavity. By now, most of the RF energy in the bunch has been transferred to the primary resonant cavity. The de-bunched the electrons in the cloud are now spent electrons, which travel to the collector at varying energy levels. In Figure 6-14, The spent electron bunch is leaving the upper half of the window and a new electron bunch is approaching the bottom side of the window. Since no electron bunch is within the window, and the approaching bunch is still too far from the window, RF circulating current within the cavity is stopped. Since a fresh electron bunch is approaching the bottom half of the window, the circulating current is getting ready to flow through the cavity in the opposite direction to that of Figure 6-13, and in the direction of Figure Thus, the cycle is getting ready to repeat. The RF output energy lost from the electron bunches in the beam cause them to loose velocity and de-bunch. These electrons (leaving the upper half of the drift tube) are referred to as spent electrons. 04/13/ Page: 6-17

200 Theory of Operation Introduction to the IOT RF Section Primary Cavity Voltage Ep The numbers above and below represent time related primary cavity RF voltage and electron bunch events. Output Coupling Loop (Loading Control) Output Transmission Line Drift Tube RF Circulating Current Primary Resonant Cavity (Surrounds Drift Tube) Drift Tube Bull Nose Interstage Coupling Loop (Coupling Control) Secondary Resonant Cavity The event number centered within the bottom portion of the window marks the time position in the waveforms shown above IOT Beam showing electron bunches, traveling towards the collector. The time for this view is event 2. An electron bunch is in the lower window opening in the drift tube. Its negative charge repels electrons in the drift tube and lower inside surface of the cavity. This forces RF circulating currents to flow within the cavity, in the direction shown, which imparts energy from the electron bunch to the primary cavity. This action starts to de-bunch the electrons in the electron cloud. Figure 6-11 IOT Operation: Cathode Current, Primary Cavity Voltage, Electron Bunches, Slide 2 Page: /13/12

201 Introduction to the IOT RF Section PowerCD Transmitter Theory of Operation Primary Cavity Voltage 2533s600.fm Ep The numbers above and below represent time related primary cavity RF voltage and electron bunch events. Output Coupling Loop (Loading Control) Output Transmission Line Drift Tube 1 Primary Resonant Cavity (Surrounds Drift Tube) The event number centered within the bottom portion of the window marks the time position in the waveforms shown above Drift Tube IOT Beam showing electron bunches, traveling towards the collector. Bull Nose Interstage Coupling Loop (Coupling Control) Secondary Resonant Cavity The time for this view is event 3. The electron bunch is at the center of the window opening in the drift tube, its negative charge repels electrons equally from the upper and lower window opening. This stops the RF circulating current. Since the electron bunch is approaching the upper half of the window, the RF circulating current is getting ready to flow through the cavity in the opposite direction. The bunch of electrons shown here are starting to de-bunch (shown here by the lighter shading). Figure 6-12 IOT Operation: Cathode Current, Primary Cavity Voltage, Electron Bunches, Slide 3 04/13/ Page: 6-19

202 Theory of Operation Introduction to the IOT RF Section Primary Cavity Voltage Ep The numbers above and below represent time related primary cavity RF voltage and electron bunch events. Output Coupling Loop (Loading Control) Output Transmission Line Primary Resonant Cavity (Surrounds Drift Tube) RF Circulating Current The event number centered within the bottom portion of the window marks the time position in the waveforms shown above Drift Tube Drift Tube Bull Nose IOT Beam showing electron bunches traveling towards the collector. Interstage Coupling Loop (Coupling Control) Secondary Resonant Cavity The time for this view is event 4. The electron bunch is at the top of the window opening in the drift tube. Its negative charge repels electrons in the drift tube and upper inside surface of the cavity. This forces RF circulating currents to flow in the opposite direction (compared to event 2) within the cavity. This imparts more energy from the electron bunch to the primary cavity. By now, most of the RF energy in the bunch has been transferred to the primary resonant cavity. The de-bunched the electrons in the cloud are now spent electrons, which travel to the collector at varying energy levels. Figure 6-13 IOT Operation: Cathode Current, Primary Cavity Voltage, Electron Bunches, Slide 4 Page: /13/12

203 Introduction to the IOT RF Section PowerCD Transmitter Theory of Operation Primary Cavity Voltage 2533s600.fm Ep The numbers above and below represent time related primary cavity RF voltage and electron bunch events. Output Coupling Loop (Loading Control) Output Transmission Line Primary Resonant Cavity (Surrounds Drift Tube) The event number centered within the bottom portion of the window marks the time position in the waveforms shown above Drift Tube Drift Tube Bull Nose IOT Beam showing electron bunches traveling towards the collector. Interstage Coupling Loop (Coupling Control) Secondary Resonant Cavity The time for this view is event 5. The spent electron bunch is leaving the upper half of the window and a new electron bunch is approaching the bottom side of the window. Since no electron bunch is within the window, and the approaching bunch is still too far from the window, RF circulating current within the cavity is stopped. Since a fresh electron bunch is approaching the bottom half of the window, the circulating current is getting ready to flow through the cavity in the opposite direction to that of event 4, and in the direction of event 2. Thus, the cycle is getting ready to repeat. Figure 6-14 IOT Operation: Cathode Current, Primary Cavity Voltage, Electron Bunches, Slide 5 04/13/ Page: 6-21

204 Theory of Operation Introduction to the IOT RF Section Single Collector IOT Beam Current, For Reference Only The RF output energy lost from the electron bunches in the beam current cause causes them to loose velocity and de-bunch. These electrons (leaving the upper half of the drift tube) are referred to as spent electrons. The spent electron of the beam travel to the collector at varying velocities (energy levels), depending on how much energy they lost. The amount of energy given up by the electrons is dependant upon the position of the RF cycle when they travel passed the window. A low energy spent electron strikes the lower portion of the IOT collector, as shown in Figure Medium energy spent electrons strike higher on the collector, and high energy electrons strike the collector near the top. In a single collector IOT, the collector typically operates at +36 kv with respect to the cathode. The collector must be at this maximum potential in order to attract the low energy electrons. Collector to cathode voltage multiplied by the beam current yields collector input power, and collector dissipation is the difference between collector input and output power. Some collector dissipation cannot be avoided, but if the collector voltage could be reduced collector dissipation would decrease and tube operating efficiency would increase. For a single collector IOT, reducing collector voltage would result in failure to capture the low energy spent electron. Since the low energy electrons happen when the RF output cycle is at maximum negative (this is the point of maximum instantaneous beam current), the RF output signal would experience peak clipping or compression. High Energy Electrons Medium Energy Electrons Low Energy Electrons Single Collector IOT Collector Output Coupling Loop (Loading Control) Drift Tube Output Transmission Line Primary Resonant Cavity (Surrounds Drift Tube) Drift Tube Bull Nose Interstage Coupling Loop (Coupling Control) Secondary Resonant Cavity Figure 6-15 Drift Tube and Cavity Assemblies of a Single Collector IOT Page: /13/12

205 Introduction to the IOT RF Section PowerCD Transmitter Theory of Operation e2v Multi-collector IOT Beam Current 2533s600.fm Refer to Figure The construction of the e2v multi-collector IOT provides a method of applying multiple collector voltages (with respect to the cathode). Low energy spent electrons tend to flow to collectors 1 and 2. These collectors are operated at +36 kv with respect to the cathode. Medium energy spent electrons tend to flow to collector 3. This collector operates at kv with respect to the cathode. High energy spent electrons tend to flow to collector 4. This collector operates at +18 kv with respect to the cathode. A few very high energy electrons travel to collector 5, but this current flow is usually quite low. Collector 4 draws all of the current when the tube is idling. Since no RF energy is contained in the beam at idle, only high energy spent electrons exist. At approximately half RF output power, the beam current starts to divide up between collectors 1 through 4, with collector 5 drawing a small current at full power. Table 6-4 lists typical parameters for an e2v multi-collector IOT. These values illustrate how the currents distribute among the five collectors of the IOT. Table 6-4 e2v 5130w IOT Parameters, Left = Tube Data Sheet, RIght = Engineering Tx. IOT Element Current Voltage W/R to Cathode Power Input IOT Element Current Voltage W/R to Cathode Power Input Collector A 36 kv 6.98 kw Collector A 36.9 kv 4.8 kw Collector A 36 kv kw Collector A 36.9 kv kw Collector A 25.2 kv kw Collector A 25.8 kv 16 kw Collector A 18 kv kw Collector A 17 kv kw collector A 0V 0W collector A 0V 0W Total DC Input Power kw Total DC Input Power kw Total Average Output Power 32.5 kw Total Average Output Power 33.5 kw Power Dissipation kw Power Dissipation kw Beam Efficiency 57.8% Beam Efficiency 50.6% Operated on Channel 25. Operated on Channel 38. LSB = -47 db USB = db LSB = -48 db USB = -51 db Idle current for both tubes is 0.55 A at collector 4. No current from other collectors during idle conditions. 04/13/ Page: 6-23

206 Theory of Operation MEDC IOT Collector Currents Verses Output Power Collector 5, 0 V W/R to Cathode Collector 4, +18 kv W/R to Cathode Collector 3, kv W/R to Cathode Collector 2, +36 kv W/R to Cathode Collector 1, +36 kv W/R to Cathode Output Coupling Loop (Loading Control) Drift Tube Output Transmission Line Interstage Coupling Loop (Coupling Control) Bull Nose Primary Resonant Cavity (Surrounds Drift Tube) Drift Tube Secondary Resonant Cavity Figure 6-16 Drift Tube and Cavity Assemblies of a e2v multi-collector IOT 6.2 MEDC IOT Collector Currents Verses Output Power The currents of the various collectors are good indications of the output power with respect to the maximum capabilities of the multi depressed collector IOT. An IOT has three main limitations which help determine its output power, they are as follows. Cathode and Collector Current. This is an indirect limitation due to its effect on efficiency and dissipation of the IOT, and the ability of the cathode to admit electrons. Collector dissipation is the limiting factor for an IOT. It is calculated by subtracting the IOT output power from its input power. Input power is calculated by multiplying the collector to cathode voltage of each collector by its collector current and adding the resultant input powers of each collector, for details see Checking IOT Dissipation and Efficiency, on page Output power is a result of the interaction of the beam voltage, collector current and the beam load impedance Beam Voltage. The maximum beam voltage, modified slightly by the beam load impedance, sets a hard limit of output power. When this limit is approached, the output will be compressed or clipped. Beam voltage with respect to ground for collector 5 is maximum, up to -38 kv. Beam voltage with respect to ground for collector 4 is approximately 50% of the collector 5 beam voltage. Beam voltage with respect to ground for collector 3 is approximately 30% of the collector 5 beam voltage. Beam voltage with respect to ground for collectors 1 and 2 is zero volts. Page: /13/12

207 MEDC IOT Collector Currents Verses Output Power PowerCD Transmitter Theory of Operation 2533s600.fm Figures 6-17 through 6-21 show the primary cavity RF voltage impressed on the maximum collector to cathode dc voltage. The effect of this resultant voltage is felt by the electrons in the vicinity of the lower side of the IOT window. The RF voltage adds to and subtracts from the dc collector to cathode voltage, with the resulting difference voltage being the attractive force for the electrons of the electron bunch. When the cavity voltage is at its maximum negative swing, the resultant voltage is low and low energy spent electrons result. As the RF signal crosses the zero axis of the signal, the resultant voltage approaches that of collectors 1 and 2, and high energy spent electrons result. One would think that the maximum positive swing of the RF would create even higher energy spent electrons, but this is not the case. During the maximum positive RF swing, the lower side of the of the window is almost at the maximum beam supply potential, and this partially cancels the beam voltage pull on the spent electrons located between the IOT window and the collectors. Relative collector currents verses output power is listed below. For digital operation, output power is usually limited by the ability of the adaptive correction to bring the adjacent channel intermods down to and acceptable level. At this operating level, output power, IOT cathode and collector currents, and dissipation will typically be well below their rated IOT data sheet maximum limits If the output power is zero or much lower than the useful IOT level, all of the collector current will flow through collector 4, see Figure As the output power increases, the collector current starts to divide between collectors 3 and 4, with collector 4 current maximum and collector 3 current minimum. This is because the signal peaks are reaching the collector 3 current zone. Current flow through collector 1 and 2 is still zero, see Figure As the output power increases, the collector current starts to divide between collectors 1 through 4, because signal peaks reaching all four collector current zones. Collector 4 current is still maximum and collector 1 current is minimum, see Figure As the output power approaches useful maximum, with minimum peak compression, the currents between collectors 2 and 1 will be close, with the collector 2 current being equal to or slightly more than collector 1, see Figure Excessive peak compression or clipping is indicated when the collector 1 current is significantly greater than the collector 2 current, see Figure Figure 6-22 shows an expanded view of one of the high amplitude, narrow width peaks being clipped. The signal spends a relative short time transitioning through the collectorcurrent zones 4, 3, and 2, but due to the peak clipping, the signal spends much time in the collector 1 current zone. By comparing the time the signal spends in collector current zones 2 and 1, is should be obvious that the dc current drawn by collector 1 will exceed that of collector 2. Refer to Figure Since the average signal spends much time in collector current zones 4 and 3, it should be obvious, due to the narrow width of the peaks traveling in zones 1 and 2, that the dc current of collector 4 will be the greatest with collector 3 current being next, and the currents of collectors 1 and 2 being the least. 04/13/ Page: 6-25

208 Theory of Operation MEDC IOT Collector Currents Verses Output Power Ep max = 68kV Collector 4 current zone. Collector 3 current zone. Collector 2 current zone. Collector 1 current zone. Ep (dc level) = 36kV Ep min = 4kV 0 V Figure VSB Waveform, Low Signal Power Causes all Current to Flow to Collector 4 Ep max = 68kV Collector 4 current zone. Collector 3 current zone. Collector 2 current zone. Collector 1 current zone. Ep (dc level) = 36kV Ep min = 4kV 0 V Figure VSB Waveform, Peaks Reaching Collector 3 Zone, Some Collector 3 Current Flow Ep max = 68kV Collector 4 current zone. Collector 3 current zone. Collector 2 current zone. Collector 1 current zone. Ep (dc level) = 36kV Ep min = 4kV 0 V Figure VSB Waveform, Peaks Reach Collector 1 Zone, Current Flow in collectors 1 through 4 Page: /13/12

209 MEDC IOT Collector Currents Verses Output Power PowerCD Transmitter Theory of Operation Ep max = 68kV 2533s600.fm Collector 4 current zone. Collector 3 current zone. Collector 2 current zone. Collector 1 current zone. Ep (dc level) = 36kV Ep min = 4kV 0 V Figure 6-20 Maximum 8VSB Output, Collector 2 Current Equal To Or Greater Than Collector 1 Ep max = 68kV Collector 4 current zone. Collector 3 current zone. Collector 2 current zone. Collector 1 current zone. Ep (dc level) = 36kV Ep min = 4kV 0 V Figure 6-21 Significant Clipping Of 8VSB, Collector 1 Current Greater Than Collector 2 Current Ep max = 68kV Collector 4 current zone. Collector 4 Current Collector 3 Current Collector 2 Current Collector 1 Current Ep (dc level) = 36kV Collector 3 current zone. Collector 2 current zone. Collector 1 current zone. Ep min = 4kV 0 V Time Expanded Peak Voltage Waveforms In this drawing, the dark lines represent current flow times for collectors 1 through 4. Notice that due to the clipped waveform, the collector 1 current lasts longer than the collector 2 current and therefore has the greater value of the two. Figure 6-22 Expended Clipped Peak Showing Relative Current Flow For Collectors 1 Through 4 04/13/ Page: 6-27

210 Theory of Operation MEDC IOT Collector Currents Verses Output Power IOT RF Output Circuits Refer to Figure 6-16 for e2v multi-collector IOTs. RF current is induced into the primary cavity through the ceramic window that exists between the upper and lower halves of the IOT drift tube. The IOT RF output network (from IOT to Transmission line) is a double tuned over coupled circuit. The transmission line is terminated into a 50 ohm load. The goals of this circuit are to: Efficiently couple the RF energy generated within the IOT to the transmission line. Maintain a flat response across a 6 to 8 MHz channel bandwidth. Match the 50 ohm RF output impedance to the high (4000 to 8000 ohm) IOT beam impedance. The double tuned over coupled output network matches the line impedance to the beam impedance in two equal steps. The purpose of this is to achieve the desired 6 to 8 MHz bandwidth. In a single tuned section, bandwidth is inversely proportional to the impedance matching ratio (of high to low impedance), and in the UHF band the required beam to line impedance matching ratio would not yield a 6 MHz bandwidth in a single matching step. The two impedance matching steps consist of: The primary resonant circuit and the Interstage coupling control. The secondary resonant circuit and the loading control. In a double tuned over coupled network, the primary and secondary cavities are both tuned to the same (center of the channel) frequency. The interstage coupling control sets the bandwidth of the response and the loading control sets the amount of saddle (flatness of response). In reality, the loading control sets the impedance matching ratio from the transmission line to the intermediate impedance (at the junction of the interstage coupling control and the secondary cavity). The secondary cavity tuning makes the intermediate impedance purely resistive (so that it will efficiently transfer the RF energy to the line). Typical intermediate impedance ranges from 400 to 700 ohms. The interstage coupling control actually determines the impedance matching ratio from the intermediate impedance to the beam load impedance. The primary cavity tuning makes the beam load impedance purely resistive (so that it will efficiently transfer the RF energy to the intermediate impedance). A resonant cavity, such as the primary resonant cavity, is similar to a parallel resonant circuit, with the IOT window forming the capacity and the inside surface of the cavity forming the inductance. The secondary cavity is similar, except that the resonating capacity is formed between the bull nose and the semi-circular ball connected to the secondary side of the interstage coupling loop. Two sizes of interstage coupling loops and bull noses are required for coarse tuning across the UHF TV band. Cavity fine tuning is accomplished by varying the inside volume of the cavity. This is accomplished because the front and rear inside walls of the primary and secondary cavities are movable and are linked to the front panel primary and secondary tuning controls. Coupling between primary and secondary cavities and loading between the secondary cavity and the RF output transmission line are adjustable by rotating the respective coupling loops, which are mechanically linked to the coupling and loading adjustments located on the front of the IOT assemblies. Details of IOT tuning can be found in Section 4.6, PowerCD Transmitter IOT Tuning, on page Page: /13/12

211 MEDC IOT Collector Currents Verses Output Power PowerCD Transmitter Theory of Operation HPA Output RF Coupler Samples Three HPA output RF sample directional couplers are included in the RF Breakaway assembly, they are shown in Figure s600.fm Movable breakaway section, attached to the IOT circuit assembly secondary cavity. Customer Sample, Forward Directional Coupler Probe Reflected Directional Coupler Probe, to DC 6 W7 Forward Directional Coupler Probe, to DC 7 IOT Cabinet Right Wall Sample Couplers W2, to IPA FWD Coupler DC 5 In DC 6 In DC 7 In IOT Circuit Assembly Secondary Cavity W6 Rear Wall of IOT Cabinet Coupled Out Coupled Out Coupled Out Outputs to HPA Controller Figure 6-23 HPA Output Couplers (Part of HPA Breakaway Assembly) The directional couplers are factory adjusted to the proper coupling ratios for the transmitter s rated power. Avoid changing the settings of these couplers unless absolutely necessary. Table 6-5 gives the factory settings for a 30 kw (average DTV power). If a coupler output is incorrect, first determine if the level can be corrected by inserting or changing a pad. Adjustment of the coupler should be a last resort and should be done carefully, to ensure the proper coupling ratio is set and that good directivity is obtained. Table 6-5 HPA RF Coupler Coupler Function 30 kw Conditions Front - Top Customer forward power sample -45dB 1 W at output of coupler for 30 kw output. Front Bottom Reflected power -45dB 40 mw output of splitter when reflected power is 1.2 kw (VSWR = 1.5:1). Rear Forward to 2-way splitter SP2-45dB 1 W at output of coupler for 30 kw output. IPA Output Directional Coupler Fwd Forward metering sample -37dB Ref Reflected metering sample -43dB Also included in Table 6-5 are the normal coupling values for the IPA Output directional coupler probes. Uses for the signals are as follows. The forward output is supplied to the detector for the GUI IPA forward power indication and remote metering. The reflected is supplied to the detector for the GUI IPA reflected power indication and remote metering. 04/13/ Page: 6-29

212 Theory of Operation PowerCD Control System 6.3 PowerCD Control System The transmitter uses a distributed architecture control system. This means that each transmitter sub-system is responsible for its own monitoring and protection and simply reports back to the display unit for display on the GUI (graphical user interface) or to the remote interface. The heart of the system is the several micro processors which are used for control, monitoring and protection throughout the transmitter control system. The micro module is used on each of the following driver cabinet controllers: 1. External I/O The external I/O (also referred to as the main controller), provides customer interface connections including parallel remote control, external pump information and serial remote control. This board is responsible for gathering overall system status to report to the user via the remote control interface, display unit (GUI) and the user control panel. The external I/O board is responsible for storing system information that is need to set-up the driver cabinet. This includes system ALC and channel/offset information info. 2. IPA Module Controller, There is one module controller located inside each IPA module. It is responsible for protecting and controlling the IPA module. 3. RFU Controller The RFU controller is located inside the RFU assembly. It is responsible for monitoring system forward and reflected power, RF system reject loads and exciter switching (if there is a main/alternate exciter system). This board also receives the ALC information for each HPA cabinet via CAN and for backup purposes by an analog backup line. Each ALC will control its corresponding HPA output power. The RFU controller is also used to set-up the phasing of each HPA cabinet to allow the system to combine efficiently. This is only done in a multi-tube system. 4. Power Supply Monitor also called Controller and PA Block Controller This board is responsible for control and monitoring of the power supplies and distribution of low voltage power in the driver cabinet. This unit is also responsible for monitoring the cooling system inside the cabinet which includes temperature, glycol coolant flow and leaks. The power supply monitor will report status and analog information to the user interface (GUI) and the main controller. 5. Mode Controller The mode controller uses a different microprocessor, not the micro module used by most controllers on this list. It is responsible for making sure the RF system is in the proper configuration. The mode controller contains what was known as the marshaling interface, which provides a hard wire protection of the RF system. The mode controller also has external remote control functions that allow the user to control the system from a remote site. This board is configurable depending on the RF system being used. This controller will report the RF system status to the user via the display unit and the LEDs that are located on the board. 6. Display Unit This unit functions both as a display driver for the GUI and as a network interface unit (using the ecdi program) to allow the transmitter to be connected to the ethernet for remote control and monitoring. The GUI display is mounted to the front of the display unit. The GUI screens are used to display all transmitter operating status and meter readings. The GUI screens are also used as the transmitter s control panel. 7. Control Panel (Switch Board) The switch board uses a different microprocessor, not the micro module used by most controllers on this list. It is responsible for directing the commands to and from the individual boards and to light the correct LEDs. It is also responsible for detecting if a key is pressed and sending the information to the correct board. Page: /13/12

213 PowerCD Control System PowerCD Transmitter Theory of Operation 2533s600.fm 8. Three other microprocessors are contained in the external cooling monitor and the two exciters. The exciters are connected to the control system by can bus. A microprocessor controlled cooling monitor is associated with each cooling system pump and heat exchanger system. It turns the pump and heat exchanger modules on, performs pump switching, and reports pump/heat exchanger faults and status to the GUI. The micro module is used on each of the following HPA cabinet controllers: 1. HPA Controller The HPA controller monitors all aspects of IOT operation and protection, including the isolated supplies (grid, filament, focus and ION pump). It receives inputs from and sends commands to the DI water cooling system via the external interface board. It also controls on/off functions of the various isolated supplies and controls the beam supply through the step start assembly, initiates a four strike sequence, performs fault reporting (to the GUI), controls fault recovery. 2. Isolated Power Supply The floating power supply, located in each HPA power supply cabinet, looks like a metal suitcase, and is located in the rear (high voltage) compartment of the power supply cabinet. It supplies the IOT filament voltage, grid bias voltage, and ion pump voltage. Since these supplies are referenced to the IOT cathode, they and their metal enclosure float at the cathode potential (-36 to -38kV). 3. External I/O Board This board provides a customer parallel remote control interface and controls, protects, and monitors the DI water cooling system through the cooling control board. It reports status ok and faults as well as commands from the parallel remote control interface to the HPA controller. It also sends status information to the parallel remote control system. 4. GUI ecdi (Display Unit) This unit is the same as the driver display unit. It functions both as a display driver for the GUI and as a network interface unit (using the ecdi program) to allow the transmitter to be connected to the ethernet for remote control and monitoring. The GUI display is mounted to the front of the display unit. The GUI screens are used to display all transmitter operating status and meter readings. The GUI screens are also used as the transmitter s control panel. 5. Control Panel (Switch Board) The switch board is responsible for directing the commands to from the individual boards to light the correct LEDs. It is also responsible for detecting if a key is pressed and sending the information to the correct board. It uses a different microprocessor than the other controllers mentioned in this list The System Bus A serial data bus called a system bus is used to send commands to and receive current status and metering from each HPA power cabinet. The system bus contains the CAN (controller area network) bus plus several parallel control and status lines. The CAN bus allows all subsystems to communicate with each other. Each circuit board and module connected to the CAN bus is considered a node and therefore has a specific address. This allows the display unit to gather information from all parts of the transmitter and display it on the GUI. One big advantage of the CAN bus is that it requires only 3 wires of the system control ribbon cable, eliminating a large amount of discrete wiring which would otherwise be required. 04/13/ Page: 6-31

214 Theory of Operation PowerCD Control System Each HPA interface is identified by its cabinet ID. The HPA cabinet ID is set by programable dip switches on the HPA controller, the HVPS (high voltage power supply) controller, and the External I/O board. Settings for all of the transmitter system programable dip switches can be found in Section , Transmitter System Dip Switch Settings, on page The CAN bus is the primary means of sending commands to the various system controllers and is also used by the various system controllers to send their operating information to the other controllers (as needed) and to the driver and HPA display units. For redundancy, the CAN bus is backed up by parallel hardware control lines that allow the transmitter to stay on the air even if the CAN bus fails, but if it fails, detailed information will not be seen on the GUI. Each sub-assembly protects itself, therefore loss of the CAN bus will not put the transmitter in jeopardy. The other parallel lines act as a life support, which allows the transmitter to be controlled in case of a CAN bus failure. They send operating commands from the control (switch) panels to the various controllers and also send critical status information back to the control panel and, as needed, to the other controllers. The switch panels are mounted on the front of the driver cabinet and on the front of power supply cabinet. The system bus cable (W607) originates at J3 on the customer I/O board, located on the top of the driver cabinet, and is daisy chained to each HPA system power supply cabinet controller board at J8. A list of system bus connector pins is included tn Table 6-6. The control boards and system bus jacks are shown in Figure The system bus is shown as the dark trace. Table 6-6 System Bus Connector Pin Out Pin Number Name Notes 3 CAN Bus High 4 CAN Bus Ground 5 CAN Bus Low 6 CAN Bus Ground 7 Off / On High = on, low = off 9 Restrike High when tx is on, low for 100ms to reset faults. 11 FLT (fault) Off Normal high, latches low for fault. 13 RF Mute Normal high, low while fault is active 15 PS Mute Normally high, low shuts down 32 Vdc PA module PS. 17 AC Low Normally high, low when LVPS AC is low. 19 ALC Backup for CAN bus ALC, range = 0 to Vdc. 21 Standby 23 BG (background) Heat 25 DC Spare Pins 1, 2, 8, 10, 12, 14, 16, 18, 20, 22, 24, 26 are ground. Page: /13/12

215 PowerCD Control System PowerCD Transmitter Theory of Operation HPA 3 System J10 HPA 2 System J10 CAN Bus Only J15 External I/O Board 2533s600.fm J7 Other end of CAN Bus. Terminate externally into 120 ohms. GUI Display Unit J1 CAN Bus only External CAN Bus J16 and J17 via Cust. interface board J29 and J31 J15 Cooling Monitor Exciter A Driver Cabinet J14 External I/O J17 J7 Mode Controller Exciter B J13 J10 Limited System Bus to each IPA System Bus IPA 1 To HPAs via Connector J3 on top of Driver Cabinet System Bus J1 J2 J11 J26 IPA 2 IPA 3 HPA 1 Controller J7 Relay K1 in each HPA controller opens in event of a CAN bus failure. Backplane IPA 4 IPA 5 J10 J38 HPA 1 System Fiber Optic Link PS Monitor also called Controller and PA Block Controller Isolated PS Controller Display Unit GUI Note: The switch board, with its microprocessor is not shown in the HPA 1 through HPA 3 system diagrams. It is connected to the HPA controllers at J34. J1 One end of CAN Bus. Terminate externally into 120 ohms. RFU J30 Note: The switch board, with its microprocessor, is not shown in this diagram. It is connected to the external I/O board and the mode controller board by the local bus, see Section 6.3.3, The Local Bus, on page Figure 6-24 PowerCD Logic Block Diagram 04/13/ Page: 6-33

216 Theory of Operation PowerCD Control System IPA Module Modified System Bus Connections The system bus loops through the IPA module backplane board via connectors J1 and J2, but the system bus is modified before it reaches the IPA modules. The Driver cabinet can accommodate five IPA modules. From left to right, facing the front of the driver cabinet, the modules are numbered 1 through 5. The backplane connectors for modules 1 through 5 respectively are J7, J9, J11, J13, and J15. Table 6-7 gives the pinout for the five IPA module backplane system bus connectors. Table 6-7 IPA Module System Bus Pin Out, Backplane Board J7, J9, J11, J13, J15 Pin Number Name Notes 1 RS232_RxD1 2 RS232_TxD1 3 Fault_Off Normal high, latches low for fault. 4 RF Mute Normal high, low while fault is active 5 On_/Off High = on, low = off 6 Restrike High when tx is on, low for 100ms to reset faults. SW2-6 SW2-7 SW2-8 7 Cabinet ID-2 Cabinet 1 Off Off Off 8 Cabinet ID-1 Cabinet 2 Off Off On 9 Cabinet ID-0 Cabinet 3 Off On Off SW 2 located on power supply monitor, Off = high, On = Low. 10 CAN Low 11 CAN High 12 PS_Mute Normally high, low shuts down 32 Vdc PA module PS Vdc Vdc 15 Module IF Bit 3 (MSB) Hardwired (in backplane) IPA Module ID 16 Module IF Bit 2 Module Module IF Bit 1 Module Module IF Bit 0 (LSB) Module Module Module AC_Low Normally high, low when LVPS AC is low. 20 ALC In Backup for CAN bus ALC, range = 0 to Vdc. 21 Ground 22 TV_ Sync_1 Reserved for future analog operation. 23 Ground Vdc Page: /13/12

217 PowerCD Control System PowerCD Transmitter Theory of Operation In-System Programming or ISP 2533s600.fm The use of the CAN bus for communication between the various micro modules in the transmitter also allows for easy updating of the software used in each transmitter sub-system via a serial port connection to an external computer. This is referred to as in-system programming or ISP. The real benefit of in system programming is that it allows any or all of the transmitter software to be updated without removing or replacing any firmware ICs. Software does not need to be reloaded into the transmitter unless new components are installed or an update is sent from Harris. The transmitter, as shipped from the factory, is preloaded and ready to run The Local Bus The local bus is a 26 conductor ribbon cable which connects the switch board (driver cabinet hardware control panel) to the driver external I/O, the RFU controller, and the mode controller boards. See Table 6-8 and Figure 6-25 for a diagram, description and connector pinout of the local bus. The commands that go from the switch (control) board to the external I/O board are transmitted to the other controllers via the CAN bus. Status information is sent to the external I/O board from the other controllers via the CAN bus and from the external I/O board to the control (switch) panel. Table 6-8 Local Bus Function and Pinout Switch Board Destination Board (connections indicated by x) Function Connector J4 Pin No. Ext I/O RFU Con Mode Con Beam On 1 X X Off 3 X X Power Raise 5 X X Power Lower 7 X X Remote Enable 9 X X Remote Disable 11 X X 7.5 VDC 13, 14, 16 X X CAN H 19 CAN L 20 RS485 B 22 X X RS485 A 23 X X Spare (no connection) 25 +5V Interlock 26 X X X The remainder of the connector pins are grounded. 04/13/ Page: 6-35

218 Theory of Operation PowerCD Control System External I/O RFU Mode Controller J8 J50 J58 Local Bus (26 conductor cable) J4 Switch Board (transmitter hardware control switches in driver cabinet front panel) Figure 6-25 Local Bus, Driver Cabinet Display Unit The display unit is an ecdi system with CAN bus capability and a GUI interface added. ecdi is a transmitter network interface appliance that provides a network connection for control and monitoring of Harris transmitters that have a serial connection port. For the Harris PowerCD digital UHF transmitter, the ecdi has been modified to include a local GUI touchscreen interface in addition to its normal networking capabilities. In the PowerCD transmitter the ecdi is the local transmitter control interface using the attached 12" VGA touchscreen and has been renamed the Display Unit. This means that the ecdi provides both local and remote control for the PowerCD transmitter. A display unit (an ecdi ) is in the driver cabinet for system control and monitoring and one is in each HPA for individual HPA control and monitoring. Page: /13/12

219 PowerCD Control System PowerCD Transmitter Theory of Operation 2533s600.fm Power Supply +5Vdc +12Vdc Advantech Single Board Computer LAN WAN Mini IDE VGA KBRD RS232(a) RS232(b) RS232(c) RS232(d) Interface Board CAN CAN Xmtr, Exciter, Config, Lan RS-232(d) VGA +12Vdc CAN PC/104 RS-232(a,b,c) CAN IDE +12Vdc +5Vdc HDD WAN 12 inch LCD Monitor Hub Figure 6-26 Display Unit Block Diagram Switch Panel (Switch Board, or Control Panel) The switch panel provides a local user interface that is an alternative or backup to using the touchscreen. It provides a means to decode button pressed information and then send the decoded information on to the various controllers for them to determine what needs to be done. The controllers will then send back information that will determine what button/indicator are to be lit, and what color. In event of a CAN bus error, these panels (one on the driver cabinet and one on each HPA system power supply cabinet) become the operating controls at the transmitter. The switch panels are capable of turning the transmitter on and off, but no transmitter information will be given. This is possible because each area of the transmitter system has its own microprocessor control board which is capable of operating and protecting its own area. Each of the control boards only needs to get on/off commands from the switch panel. In the driver, the local control bus provides parallel lines which connect its switch panel to the RFU controller, the mode controller, and the external I/O boards. The system bus provides other parallel lines which pass critical information. A picture of the front of the control panel is shown in Figure 6-27 and a rear view of the panel is shown in Figure /13/ Page: 6-37

220 Theory of Operation PowerCD Control System Figure 6-27 Front View of Control Panel Figure 6-28 Rear View of Control Panel Introduction Due to the complexity of the switch panel, the theory broken up into the following operations: Modes of Operation. Button Presses Button / Indicator Lighting Error Messages and Indications. The following definitions may be useful. MAX 6954: A Maxim LED/Key Matrix Controller. Used to control 128 LEDs and 32 switches. Page: /13/12

221 PowerCD Control System PowerCD Transmitter Theory of Operation Micro-controller: The primary programmable device of the switch panel. It is a Freescale MC9S12DP256 micro-controller. 2533s600.fm Hardwired switches: The hardwired switches are switches that are directly connected to the transmitter s controllers via connector J4 and ultimately, the parallel lines of the system bus. They include the following 8 switches: Off, BG Heat, Stand By, Beam On, Power Raise, Power Lower, Remote Enable, and Remote Disable, see Figure Hot buttons: The lower six buttons on the front of the panel surrounded by a silk screen called STATUS. These buttons indicate if a summery fault has occurred and in what function. Green is normal, orange is warning, and red is fault. The hot buttons includes following: Drive Chain, Power Amp, Output, Power Supply, System, and Performance. By pressing these buttons, the user can open the appropriate screen on the display, see Figure ISP: In System Programming. The process used to update firmware/software on a board without having to change physical components Modes of Operations The switch panel has a dipswitch which allows either of two modes of operations to be selected. Table 6-9 Switch Panel Operating Mode Selection Mode S1 S2 S3 S4 S5 S6 S7 S8 Factory Test Off Off Off Off Off Off Off Off PowerCD On Off Off Off Off Off Off Off In Factory Test mode, the switch panel will provide a means for lamp and switch testing. This is not for customer use since the hardwired switches are still connected to the transmitter s controllers and will work normally. This can produce an unsafe condition in certain situations. In PowerCD mode, the 2UI panel will work normally. For details on what happens in this mode, refer to the following sections on Button Presses and Button/Indicator lighting Button Presses There are 38 buttons on the switch panel. Six of these buttons are hardwired directly to the transmitter s controllers via the 26-pin connector J4. They include Remote Enable, Remote Disable, Power Lower, Power Raise, Beam On and OFF. This is done due to the critical nature of these buttons. The other 32 buttons are programmable. When a hardwired button is pressed, the switch momentarily applies ground to pull the signal line low. The signal line is connected directly to the connector J4 and sent on to the other controllers via a ribbon cable. The controller in charge of that button will acknowledge that it received the hardwired switch signal by sending back a reply with information that will tell the MAX 6954 to blink that particular switch. Then the controller next determines what to do based on the current state of the transmitter. If all is well, it will reply to the switch panel with new information that will now request it to light that button solid. If all is not well, it will most likely turn off the LEDs to that button. 04/13/ Page: 6-39

222 Theory of Operation PowerCD Control System To determine if a programmable switch has been pressed, the MAX 6954 scans the 4x8 matrix of switches. It does this by holding one of the four rows of switches at a level 1, then it looks at the eight columns and stores their states into a switch register for that particular row. After all four rows are scanned, it will repeat the scan to debounce the results. It again looks at the eight columns and compares the new results to the switch register storing the previous scan results for that row. If the compared information is not the same, the new information is then placed into the switch register and the next scan is performed. If they are the same information and it shows one or more of the inputs are at a level 1, it knows that particular switch or switches has been pressed. The results of this are placed into the debounced register for that particular row. This will cause the MAX 6954 to send an interrupt to the micro-controller. The micro-controller will then pull the information from all 4 debounced registers and decode them to determine which switch in that row was pressed. Once this is determined, it blinks the LEDs for that button and then it immediately sends the information to the controller that is responsible for that switch. The controller will then send an acknowledge packet to the switch panel micro controller, which will process it s information to determine the new state of the button. Once it determines the new state of the button, it waits for a status update packet from the switch panel and then sends the new button status. Each button status will include the button number and the state. The switch panel micro controller will act on that information and set the switches accordingly Button / Indicator lighting For the most part, the 2UI front panel does not light any indicators without a status from the controller in charge of that indicator. The only exception to this is when the unit is going through a start up lamp test. To determine the correct lighting state of each button/indicator, the 2UI front panel will send a status update to each of the controllers. The 2UI front panel will send out a status update request to a controller and wait for a reply to the request for 200 ms. After 200 ms it will send a request to the next controller. There are a total of three controllers that the driver front panel will talk to. They are the RFU controller, the mode controller, and the external I/O board. The HPA front panel only talks to the HPA controller. This means that the whole routine is repeated every 600 ms for the driver and 200 ms for the HPA. If a controller replies to the status update, it will reply with a list of data that includes all the id numbers of button/indicators it is in charge of, and their status. Each button/indicator id number is decoded to determine which LEDs are associated with it, then the status of these LEDs are set to one of 6 possible states (solid red, solid green, solid orange, blinking green, blinking orange, or off) and that controller s status is set to being online. If a controller does not respond to three status requests, it s status will be set to being offline, the status indicator for that controller on the back of the front panel will blink red and an error message stating that it s offline will scroll on the LED display in the lower right corner of the front panel. Once an offline controller starts to respond to a status request, it s status will be changed to being online and control of the corresponding status LED will be returned to the controller Button States Refer to Figure The button states of the eight control buttons are as follows. Blinking, for any color, indicates a change of state is in progress. Off button has no color. Page: /13/12

223 PowerCD Control System PowerCD Transmitter Theory of Operation BG Heat, Standby, Power Raise, Power Lower, and Remote Disable buttons light solid orange when on and blinking orange while a change of state is in progress. Beam On and Remote Enable buttons light solid green when on and blinking green while a change of state is in progress. 2533s600.fm The front panel status buttons take the GUI to their fault screens when they are pressed. Their colors are as follows. Green = ok. orange = warning. Red = fault. Refer to Figure The driver switch panel rear view button states are as follows. In the HPA Mode section, the HPA buttons will light green when pressed and the enter light will also light up green if that mode is valid. If an HPA button is pressed and the mode is invalid, neither that button or the enter button will light. The exciter mode buttons light green for auto, green for manual, green if the chosen exciter is ok, and orange if the chosen exciter is faulted. The pump mode buttons light green if the chosen pump is ok, and orange if the chosen pump is faulted Error Messages and Indicators There are nine different messages that may be seen on the LED Display in the lower right corner of the 2UI front panel. POWER CD is displayed during initial startup. This will be shown until the external I/O controller sends information to set the LED display to show the model number of the particular transmitter it s in. The model number will be seen during normal operations. If the front panel is in bootloader mode, the screen will remain blank. If the front panel is in factory test mode, then TEST is displayed on the LED display. The remaining five messages are error messages FP Error This error is displayed when the front panel determines that a hardwired button has been pressed for longer then 30 seconds. This is to alert the operator so that the condition can be corrected immediately. This condition is caused by either a sticking button, or by something leaning against the button. The only exception to this is the power raise and power lower buttons Com Error, Main Controller This error is displayed when the 2UI front panel does not receive a status update from the external I/O controller in the driver cabinet after 3 attempts. The 2UI front panel will then cause the external I/O status indicator on the back panel to blink red. The 2UI front panel will continue to send requests to the external I/O until it starts to reply with status updates. When status updates are again being received, the external I/O status indicator is returned to the control of the external I/O and the model number is shown. The possible causes for this error condition are that the micro-controller on external I/O maybe locked up or busy with a time consuming process such as ISP. 04/13/ Page: 6-41

224 Theory of Operation PowerCD Control System COM ERROR, MODE CONTROLLER This error is displayed when the 2UI front panel does not receive a status update from the Mode Controller in the Driver cabinet after 3 attempts. The 2UI front panel will then start to red blink the Mode Control status indicator on the back panel. The 2UI front panel will continue to send requests to the Mode Controller until it starts to reply with status updates. When status updates are again being received, the Mode Controller status indicator is returned to the control of the Mode Controller and the model number is shown. The possible cause for this error condition is that the micro-controller on Mode Controller maybe locked up COM ERROR, RFU CONTROLLER This error is displayed when the 2UI front panel does not receive a status update from the RFU Controller in the Driver cabinet after 3 attempts. The 2UI front panel will then start to red blink the RFU status indicator on the back panel. The 2UI front panel will continue to send requests to the RFU Controller until it starts to reply with status updates. When status updates are again being received, the RFU status indicator is returned to the control of the RFU Controller and the model number is shown. The possible cause for this error condition is that the micro-controller on RFU Controller maybe locked up COM ERROR, CONTROL SYSTEM This error is displayed when the 2UI front panel does not receive a status update from more then one controller in the Driver cabinet or from the HPA Controller in the Power Supply cabinet after 3 attempts. The 2UI front panel will then start to red blink the status indicators of the controllers it thinks are offline on the back panel. The 2UI front panel will continue to send requests to the controllers until they start to reply with status updates. When status updates are again being received, the status indicators are returned to the control of the controllers and the model number is shown. If there is still one controller that an update is not being received from, the error message will be changed to the appropriate message. The possible cause for this error condition is that the RS485 transceiver may not be operating properly on the 2UI front panel, or that the controllers are offline Power Indicators (DS5 and DS63) There are two power supply LED indicators (DS5 and DS63) on the PC board under the ribbon cable, as shown in Figure 6-28, on page 6-38, to indicate that both +5VDC supplies are functioning properly. If any of these are not lit then the power supply is down. If the power supply is down, check to see that the 0.75A resetable fuses (R11 and R52) are open. If R11 or R52 are open, then disconnect the ribbon cable on J4. Wait a minute or two and reconnect the ribbon cable. If the condition is not cleared, the 2UI front panel will require repair RFU Controller The RFU controller resides in the driver cabinet and provides the ability to control the RF drive and phasing for up to 3 HPAs. This control will be done through an ALC (automatic level control) loop. The RFU controller also monitors the system forward, reflected and reject load powers and has the ability to mute the system or individual IOTs. The primary method of communication is through the CAN bus. Page: /13/12

225 PowerCD Control System PowerCD Transmitter Theory of Operation Critical Life Support Functionality The critical life support functionality occurs when an on board watchdog is triggered as a result of an unresponsive micro module. 2533s600.fm The CPLD will monitor the system bus and mute the individual ALC lines during a system mute. It will also switch from the digital ALC to the analog ALC, so that the system can maintain level control. The CPLD will monitor the individual ALC signals. When any given ALC is below the 200mV threshold hardware on the RFU controller will mute that channel. The CPLD will also monitor a dipswitch that allows for the ALC to be set to automatic or manual gain. The manual gain control will be adjusted through potentiometers. The CPLD will maintain control of exciter switching in life support. If the micro is responsive but the CAN bus is down, exciter switching can still occur through the switch board to the micro. In the event that the micro is unresponsive the CPLD will be able to switch exciters through a local push button. The CPLD will restore the last known exciter state and digital phase upon power up. If the micro is unresponsive the last known mode will be maintained Status Indicators A red LED will indicate a Board Reset. A red LED will indicate if the CPLD is not programmed. A red LED will indicate that the External I/O has Faulted Off the Tx. A red LED will indicate that the External I/O has RF Muted the Tx. There are 8 green LEDs used for debug and development. There are 3 green LEDs to designate if the Tx is operating in N+1 mode. The LEDs indicate which path if any is currently being used as the +1 path. There are 2 green LEDs to indicate which exciter is active, A or B. A red LED will indicate if Manual Gain is active. Green LEDs will indicate the presence of the following control voltages. +15V, +7.5V, -15V, +5V, -5V, +3.3V, +9V Switches A dip switch will be available to select ALC or Manual Gain. A push button will be available to switch between Exciter A and Exciter B. A push button will be provided to reset the board Test Points There are 2 test points for the RS232 Rx and Tx. There are 2 test points for the RS485 Rx and Tx. 04/13/ Page: 6-43

226 Theory of Operation PowerCD Control System There are 2 test points for the CAN Rx and Tx. There are 4 test points for the analog ALC (channels 1 through 3 and N+1). There are 4 test points for the analog (fine) phase (fine phase channels 1 through 3 and N+1). There is a test point for the reference voltage. There are 5 ground test points and also test points for the following control voltages. +15V, +7.5V, -15V, +5V, -5V, +3.3V, +9V External I/O Functionality The external I/O will have dual functionality in the transmitter. The functionality depends on whether the board is located in the driver cabinet or in the cooling cabinet Driver Cabinet Functionality When the external I/O is located in the drive cabinet it will be responsible for communication to the front panel, customer I/O for the driver cabinet, the customer interlock chain, the external pump system and responding to the system bus Cooling Cabinet Functionality When the external I/O is located in the cooling cabinet it will be responsible for the customer I/O to the HPA cabinet and monitoring the signals from the cooling control board through both the CPLD and micro. The HPA system cabinet identification bits are set through dipswitch S1 using switches 7 and 8. An example of the HPA system cabinet ID f dipswitch setting is given Table Table 6-10 Cabinet ID Settings S1-7 S1-8 Cabinet ID Off Off 1 Off On 2 On Off 3 On On Critical Life Support Functionality The critical life support functionality occurs when an on board watchdog is triggered as a result of an unresponsive micro module. The CPLD will monitor and respond to all discrete external customer I/O without the micro present. The CPLD will have control over the system bus, giving it the capability to activate RF mute and fault off when necessary. Page: /13/12

227 PowerCD Control System PowerCD Transmitter Theory of Operation 2533s600.fm Under normal operation, the external I/O will report the system automatic level control (ALC) signal via the CAN bus to all HPA controllers. During a life support condition (assuming that the CAN is dead), the system ALC will be provided to the HPAs via an analog signal from the external I/O. This signal will provide limited resolution of power adjustment. The customer will be capable of raising and lowering power from the front panel or remotely. The last value of ALC from the micro will be captured for life support use. A parallel 8 bit DAC will be used to provide the ALC signal under life support conditions. The raise and lower commands from the front panel will adjust the DAC register value accordingly. A voltage reference will be provided to the DAC, which, if the full dynamic range is applied, will allow millivolts per step. A 16-bit register will be provided to store the transmitter mode of operation during an AC fail condition. The CPLD will write to the register upon receiving an AC low signal from the system control cable, conversely it will read the register contents after a power on reset. The register has a super cap holdup on its logic supply, which will hold the register information for approximately one week after the AC has failed completely Status Indicators A red LED will indicate a board reset. A red LED will indicate if the CPLD is not programmed. A red LED will indicate that the external I/O has faulted off the transmitter. A red LED will indicate that the external I/O has RF muted the transmitter. A red LED will indicate when the external interlock is open. Four greed LEDs indicate which of the four external pump systems is on. Green LEDs will indicate the presence of the following control voltages. +15V, +7.5V, -15V, +5V, +3.3V Switches A push button will be provided to reset the board. Two dip switches will be used to select the HPA system cabinet ID when the external I/O is located in the cooling cabinet Test Points There are 2 test points for the RS232 Rx and Tx. There are 2 test points for the RS485 Rx and Tx. There are 2 test points for the CAN Rx and Tx. There is a test points for the system ALC. There is a test point for the reference voltage. There is a test point for the super-cap voltage. 04/13/ Page: 6-45

228 Theory of Operation PowerCD Control System There are 6 ground test points and also test points for the following control voltages. +15V, +7.5V, -15V, +5V, +3.3V Micro Uses External I/O The external I/O also provides customer interface connections including parallel remote control, external pump information and serial remote control. This board is responsible for gathering overall system status to report to the user via the remote control interface, display unit (GUI) and the user control panel. The external I/O board is responsible for storing system information that is need to set-up the driver cabinet. This includes system ALC and channel/offset information info IPA Module Controller There is one module controller per IPA module and it is responsible for protecting and controlling the IPA module. The modules status is reported directly to the module controller and the external I/O RFU Controller The RFU controller is responsible for monitoring system forward and reflected power, RF system reject loads, station test load and exciter switching (if there is a main/alternate exciter system). This board also receives the ALC information for each HPA cabinet via CAN and for backup purposes and analog backup. Each ALC will control its corresponding HPA output power. The RFU controller will also be used to set-up the phasing of each HPA cabinet to allow the system to combine efficiently. This is only done in a multi-tube system Power Supply Monitor (Controller) The power supply monitor board is responsible for control and monitoring of the power supplies and distribution of low voltage power in the driver cabinet. This unit is also responsible for monitoring the cooling system inside the cabinet, including temperature, flow, and glycol leaks. The power supply monitor will report is status and analog information to the user interface (GUI) and the main controller Micros Mode Controller The mode controller is responsible for making sure the RF system is configured correctly and for RF system status reporting. The mode controller contains what was known as the marshing interface, which provides a hard wire backup protection for the RF system in case of microprocessor or CAN bus failure. The mode controller has external remote control functions that allow the user to control and observe the status of the system from a remote Page: /13/12

229 Automatic Level Control (ALC) System PowerCD Transmitter Theory of Operation site. This board is configured to match the RF system that is used. This controller will report the RF system status to the user via the display unit and the LEDs that are located on the board. 2533s600.fm 6.4 Automatic Level Control (ALC) System The PowerCD automatic level control (ALC) compares an adjustable reference against a power sample taken from the HPA output. This comparison takes place in the HPA controller board. The resulting signal is sent to the radio frequency unit (RFU) where it controls an attenuator, which keeps the output power for that HPA constant. The key to understanding this ALC system lies in understanding the various ALC references. The HPA ALC has two modes of operation, each generating its own ALC reference and each controlling the HPA output power independently from the other. One mode is with the HPA remote disabled and the other is with the remote enabled. The two modes are listed below. A block diagram of the ALC system is provided in Figure HPA ALC In The Remote Disabled Mode Refer to Figure In the remote disable mode the HPA controller generates an ALC reference which is independent of all other ALC references. This reference is controlled by the up and down arrow keys in the HPA GUI transmitter control section (right side) of the screen. It is a digital number which ranges from 0 to 1024, but that number is limited to prevent the HPA output power from exceeding 110%. As this number increases, the HPA output power increases. In the HPA GUI > System > Meters > Control screen, and the driver GUI > System > Meters > HPAs > Control screen this ALC reference number is listed as Local HPA ALC In The Remote Enabled Mode In the remote enabled mode, each HPA controller generates an ALC reference (called Remote) which is independent of its remote disabled ALC reference, but is controlled by the same up and down arrow keys in the HPA GUI transmitter control section (right side) of the screen. This mode of operation uses three reference signals to control the ALC, they are as follows. In the HPA GUI > System > Meters > Control screen, and the driver GUI > System > Meters > HPAs > Control screen, the HPA ALC reference number is listed as Remote, the driver ALC reference number is listed as System (also Analog, this will be explained later), and the modified ALC reference number is listed as Master. The Remote ALC reference is modified by the System ALC reference, which is generated in the driver cabinet main controller. The driver ALC reference is controlled by the up and down arrow keys in the driver GUI transmitter control section (right side) of the screen, when the Tx (transmitter) tab is selected. Both references and the final modified reference (called Master) are digital numbers which ranges from 0 to 1024, but the Remote reference number, and therefore the Master reference number, are limited to prevent the HPA output power from exceeding 110%. As these number increases, the HPA output power increases. The HPA remote enabled mode of the ALC needs further description. Its purpose is to allow the driver cabinet to control the transmitter system power, by controlling the output power of each HPA, and still give each HPA individual control over its own power output. In a system with multiple HPAs, it is important to provide each HPA with a power adjustment (tweak) so that the HPAs will combine properly. 04/13/ Page: 6-47

230 Theory of Operation Automatic Level Control (ALC) System The driver ALC reference goes from the driver cabinet main controller to the HPA controller by two methods. The System ALC reference number is sent over the CAN bus. The Analog ALC reference is a voltage, generated from the System ALC number, it ranges from 0 to volts and is sent via wires in the control bus cable. In the HPA GUI > System > Meters > Control screen, and the driver GUI > System > Meters > HPAs > Control screen the Analog reference voltage (in volts) is displayed in the Analog window. The Analog ALC reference voltage is sent as a backup in case of a can bus failure. Note Pressing the drive disable button (HPA GUI > Power Amp > Service screen) resets both HPA remote and remote disabled ALC pots to zero. When leaving drive disable, the HPA output power will be zero. Therefore, both HPA power adjustments must be reset to 100% power for that HPA ALC Master and Control Signals The Master (modified ALC reference) is the reference which is used to control the HPA output power. If is compared to the HPA output power sample to create the Control signal. In HPA remote disable mode, the Master number is the same as the Local number. In HPA remote enable mode, the Master number is a combination of the HPA Remote reference number and the System reference number. The relationship of the three numbers is shown in the formula below. System number Master number = Remote number 1024 The Control signal is an analog dc voltage which ranges from 0 to volts. This voltage is sent to the RFU, where it is multiplied by three (for a range of 0 to 12.29volts) and applied to the voltage controlled attenuator for that HPA. As the control voltage increases, the gain of the HPA increases, which causes its output power to raise VSWR Foldback Circuit The VSWR foldback circuit is not shown on the block diagram of Figure 6-29 or discussed here because it is less complicated then the rest of the ALC circuit. Page: /13/12

231 Automatic Level Control (ALC) System PowerCD Transmitter Theory of Operation ALC Reference to other system HPAs 2533s600.fm Remote Control Digital Pot. ALC Reference (Via CAN Bus) System ALC Reference Number Range: 0 to D/A Converter Driver Cabinet External I/O Board (Main Controller) Analog (Life Support) ALC Reference Voltage Via Wire Range: 0 to 4.096V A/D Converter Digital Pot. Digital Pot. Limiter Note 1 DAC number range before limiter is 0 to Limiter Note 1 Remote ALC Reference Number Local (Remote Disabled) ALC Reference Number Multiplier Note 1. The DAC number limiter is set by the HPA at the 110% output power level. Control Voltage (Analog) To the RFU Attenuator For This HPA In the RFU the Control voltage (range 0 to volts) is multiplied by 3 (new range 0 to 12.3 volts) before being applied to the attenuator D/A Converter Comparator HPA Output Power DAC Number, Range is 0 to 1024 Master ALC Reference Number A/D Converter Detector HPA Output RF Sample The HPA GUI > Systems > Meters > Control screen gives the ALC system voltages and DAC numbers. On the HPA > Output > Service > Calibrate screen the HPA forward output power level appears in the FWD Power window in kw and as a DAC number. When the ALC is in Range this DAC number should be the same as the master ALC reference number. On the HPA > Service > Service > Configure screen, the nominal forward power entry is used by the computer to determine what the DAC numbers for 100% power and the 110% power limit. If needed, see the System and HPA Automatic Level Control (ALC) Setup, on page 4-33 Figure 6-29 ALC System Block Diagram 04/13/ Page: 6-49

232 Theory of Operation Grid Voltage and Idle Current Adjustment 6.5 Grid Voltage and Idle Current Adjustment There are two IOT grid voltage settings on the HPA GUI > Power Supply > Service screen. They are idle mode voltage and normal mode voltage. Idle mode voltage is active when the beam voltage is applied and drive is prohibited or HPA output power is below 5 kw. Normal mode voltage is active in Beam on mode when the HPA output power if above 5 kw. A simplified block diagram of the grid voltage supply is shown in Figure The idle grid voltage setting must be equal to or more negative than the normal setting. Hardware limitations do not allow it to be set less negative than the normal voltage. When the normal mode grid voltage is adjusted, the idle voltage must be readjusted to reset the idle current to 0.55 A Grid Voltage Normal And Idle Modes In BG Heat mode, the gird voltage can be switched to either idle or normal position and the grid voltage for each mode can be adjusted, but there is no indicator to tell what mode is active. Sometimes it indicates BG Heat. In the Standby and Beam-Drive Prohibit modes, the gird voltage can be switched to either idle or normal position and the grid voltage for each mode can be adjusted, the indicator tells which mode is active. In the Beam-Drive prohibit mode with grid bias in the normal position, ensure that the idle current is below the maximum listed on the data sheet. If the idle current is above maximum in this mode, the HPA will fault after a few seconds. +5Vdc U3, Normal Grid Voltage Adjust E Pot U2, Idle Grid Voltage Adjust E Pot E Pot Out CNTL Range Grid Voltage Range 0 to 5 Vdc 0 to -9.6 Vdc 0 to -250Vdc The idle mode grid voltage will change if the normal mode is adjusted, and it must be equal to or more negative than the normal grid mode voltage. U6, Normal/Idle Grid Voltage Select Switch Inverting Amplifier U9 Control Voltage Input Series Shunt Voltage Regulator Unregulated -340 Vdc Input Grid Voltage Output, 0 to -250 volts Figure 6-30 Grid Bias Circuit Block Diagram Showing E Pot Control Page: /13/12

233 Grid Voltage and Idle Current Adjustment PowerCD Transmitter Theory of Operation Effect of Grid Voltage and Idle Current on Spectrum Response 2533s600.fm Grid voltage is adjusted to set the idle current (zero signal cathode current). The value of idle current sets the linearity of the IOT, which is indicated by the level of adjacent channel shoulders compared to the center channel response. The shoulders are measured +/ MHz from the center of the channel. Refer to Figure When the adjacent channel shoulders are observed on a spectrum analyzer, which is connected prior to the mask filter, their levels should be -30 db with the non linear RTAC circuit bypassed. When non linear RTAC is set to adapt, the shoulders should measure -35 db. The sharp tuned mask filter will lower the shoulders by another 10 db so that the transmitter will easily pass the mask test. It this transmitter is one of the few which has the standard D Mask filter, the pre filter response should measure -32 db or more negative before the mask filter with non linear RTAC bypassed, and -37 db or more negative with the non linear RTAC set to adapt. This is necessary because the standard D Mask filter does not improve the shoulder response, but is effective in improving the adjacent channel intermods beyond the shoulders. The mask test will almost always be passed when the sharp tuned mask filter is used, but it is important to have the pre mask filter shoulders at -35 db or better (more negative) to improve the post filter EVM, digital SNR, and eye pattern. If the shoulders measure less than -35 db with RTAC engaged, the above mentioned digital parameters will degrade due to the excessive in band noise which accompanies the high (less negative) shoulder response. Figure 6-31 Spectrum Of HPA Output, Before High Power Filter, All RTAC Correction Bypassed If the grid bias is reduced (made less negative), the IOT idle current will increase, the IOT will become more linear, and the shoulders response will improve (go more negative). These are good results, but a less desirable effect will be that the IOT will be less efficient and more energy will be used. If the grid bias is increased, the IOT idle current will decrease, the IOT will become less linear, and the shoulders response will degrade (go more positive). This will make the IOT will be more efficient and less energy will be used. The final compromise is to have the transmitter achieve all specifications and operate at the best possible efficiency. 04/13/ Page: 6-51

234 Theory of Operation IOT Idle Current Variation 6.6 IOT Idle Current Variation Idle current (zero signal beam current) in an IOT is controlled by three tube parameters. They are gird bias voltage, beam voltage, and tube operating temperature. For a given grid and beam voltage, the idle current in a cold tube is significantly higher than when the tube has come to full operating temperature, see the graphs in Figure Idle Current Curve A, Higher Grid Bias (Eg, -125V) Curve B, Lower Grid Bias (Eg, -120V) Tube Cold Tube Hot Time (and Temperature) Figure 6-32 Idle Current Changes With Time (IOT Temperature), E b and E g Held Constant For a constant operating temperature and a fixed grid bias voltage, idle current is directly proportional to the beam voltage, see Figure This relationship is shown by the following formula. I b = 5 3 K E b Where: K = A required constant based on the tube parameters. E b = beam voltage. For a given idle current and beam voltage, K can be calculated as follows. K = I b 5 3 E b I b Grid Bias Voltage is held constant. E b Figure 6-33 Idle Current Changes With Eb, Eg and Operating Temperature Held Constant Page: /13/12

235 IOT Idle Current Variation PowerCD Transmitter Theory of Operation An example might be helpful. For a tube at full operating temperature and a beam voltage of 34 kv, the idle current was set at 0.7 A. When operating at 100% power the beam voltage dropped to 32.5 kv. What is the idle current at the new beam voltage? 1 Calculate K: 2533s600.fm I K b = = 5 3 E b = = Calculate the new I b : 5 3 I b = K E b = = = 0.65A Conclusion: 1 If properly set when the IOT was at full operating temperature, the idle current of an IOT will be too high when the tube is cold. 2 If the idle current of an IOT is set when the tube is cold, it will be too low when the tube is at full operating temperature. 3 Assuming full operating temperature, the idle current will be too low at 100% output power because the beam supply voltage sags under full load and the idle current was set under minimum load conditions when the beam supply voltage was higher. A This may reduce the linearity of the IOT because the idle current is below the optimum value. 4 When first turned on, the idle current will be high. When the tube is at full operating temperature, the idle current will decrease as the output power is increased. 04/13/ Page: 6-53

236 Theory of Operation IOT Idle Current Variation Page: /13/12

237 Parts List 2533s701.fm 7 Parts List Replaceable Parts List Index Table 7-1 FORMAT, SYSTEM, PWR30D (Z) Table 7-2 PUMP INTER ASSY - FOR SIGMA PUMP TO POWERCD (J) Table 7-3 PWA, MULTI I/O FOR SIGMA PUMP MODULE W/ POWERCD T (A). 7-4 Table 7-4 FORMAT, XMTR, PWR30D (V) Table 7-5!FORMAT, POWERCD TANK BASE PUMP MODULE (A) Table 7-6 CONTROLLER, DUAL AC, POWER CD PUMP (D) Table 7-7 PA MODULE DIGITAL POWER CD (G) Table 7-8 MODULE, BASIC, RF AMP, UHF BAND (Z) Table 7-9 MK2 UHF BROADBAND PALLET (D) Table 7-10 PWA, PHASE & GAIN (F--). 7-7 Table 7-11 PWA, PS FRONT END (D--). 7-8 Table 7-12 PWA, POWER SUPPLY (F--). 7-8 Table 7-13 PWA, PREDRIVER PALLET (B) Table 7-14 PWA, MODULE CONTROLLER (C) Table 7-15 PWA, 8-WAY COMBINER (B--). 7-9 Table 7-16 KIT, SPARE BOARDS (K) Table 7-17 ASSY, FOCUS SUPPLY, TESTED T (A) Table 7-18 FOCUS SUPPLY (C) Table 7-19 ASSY, GRID SUPPLY, TESTED T (A) Table 7-20 ASSY, GRID SUPPLY (B) Table 7-21 ASSY, FILAMENT SUPPLY, TESTED T (A) Table 7-22 ASSY, FILAMENT SUPPLY (C) Table 7-23 *PWA, SWITCH BOARD, TESTED T (A) Table 7-24 *PWA, ISO SUPPLY MONITOR, TESTED T (A) Table 7-25 *PWA, ISO SUPPLY MONITOR (E) Table 7-26 PWA, SPARK GAP INTERFACE, TESTED T (A) Table 7-27 PWA, SPARK GAP INTERFACE (D-) Table 7-28 PWA, COOLING CONTROL BOARD, TESTED T (A) Table 7-29 PWA, COOLING CONTROL BOARD (E) Table 7-30 *PWA, EXTERNAL I/O, TESTED T (A) Table 7-31 *PWA, EXTERNAL I/O (C) Table 7-32 *PWA, HPA CONTROLLER, TESTED T (A) Table 7-33 *PWA, HPA CONTROLLER (C) Table 7-34 PWA, STEP START CONTROL, TESTED T (A) Table 7-35 PWA, STEP START CONTROL (C-) Table 7-36 PWA, HIGH VOLTAGE METERING, TESTED T (A) Table 7-37 *PWA, HIGH VOLTAGE METERING (H-) Table 7-38 PWA, ION SUPPLY, TESTED T (A) Table 7-39 *PWA, ION SUPPLY (D-) Table 7-40 KIT, SPARE PARTS (F) Table 7-41 KIT, SPARE PARTS, ADVANCED (H) Table 7-42 PWA, ISO SUPPLY AC INTERFACE (B-) Table 7-43 PWA, ISO SUPPLY TRANSIENT INTF (A-) Table 7-44 KIT, SPARE PARTS, BEAM SUPPLY (C) Table 7-45 KIT, SPARE PARTS, NWL STEP START (B) Table 7-46 KIT,SPARES,POLY TANK BASE, 2IN PUMP MODULE (A) Table 7-47 FORMAT, SYSTEM, PWR60D (AA) Table 7-48 FORMAT, XMTR, PWR60D (T) Table PH, 400V, MOV PKG (DELTA) (B) Table 7-50 *PWA, MOV/AC SAMPLE AA, 400VDELTA (C--) Table 7-51 MOV BD, 480 VAC (A) /13/ Page: 7-1

238 Parts List Table 7-52 PWA, MOV/AC SAMPLE, PH (D--) Table 7-53 DRIVER CAB, BASIC, POWER CD (AA) Table 7-54 *ASSY, DISPLAY UNIT W/ GUI P-CD (A) Table 7-55 ASSY, DISPLAY UNIT MINUS GUI POWER-CD (B) Table 7-56 PWA, MODE CONTROLLER (E--) Table 7-57 PWA, CUSTOMER INTERFACE BOARD (D-) Table 7-58 PS CABINET, POWER CD (U) Table 7-59 TOWER, RESISTOR - GND SWITCH (A) Table 7-60 SUPPLY, ISO (E) Table 7-61 ASSY, CONTROL PANEL (115VAC) (G) Table 7-62 IOT CABINET, POWER CD (C) Table 7-63 KIT, EARTH WAND (C) Table 7-64 POWER SUPPLY 480 VAC (S) Table 7-65 *PWA, OVERVOLTAGE PROTECTION UNTESTED (H--) Table 7-66 POWER SUPPLY VAC (L) Table 7-67 PWA, MOV/AC SAMPLE,400 3 PH DE (C--) Table 7-68 FORMAT, SYSTEM, PWR90D (W) Table 7-69 FORMAT, XMTR, PWR90D (T) Table 7-70 DRIVER CAB, BASIC, POWER CD (AA) Table 7-71 PWA, MODE CONTROLLER (E--) Table 7-72 *PWA, PS MONITOR CONTROLLER UNTESTED (A--) Table 7-73 *PWA, PA BLOCK CONTROLLER UNTESTED (J) Table 7-74 *PWA, 376 MICRO MODULE G (A--) 7-40 Table 7-75 COOLING CAB, POWERCD, DOOR FLTR (L) Table 7-76 ASSY, LIQUID LEVEL SWITCH (A) Table 7-77 KIT, POWERCD, RFU, 3 CABINET (F) Table 7-78 KIT, SPARES, 2-1/2 INCH FLANGE PUMP (A) Page: /13/12

239 Parts List 2533s701.fm Table 7-1 FORMAT, SYSTEM, PWR30D (Z) Harris PN Description Qty UM Ref Des B/M NOTE: 0 DWG COOLING FLUID, Dowtherm SR-1, 55GAL 0 DR COOLANT, PROPYLENE GLYCOL BASE 0 DR FLUID COOLER 2 FAN 0 EA KIT,6-1/8 SIGMA RF LINE-MYAT 0 EA KIT,6-1/8 SIGMA RF LINE-DIE 0 EA FLOW MTR, 15GPM, 1 FNPT 0 EA PWR SUPPLY, BEAM, 70KVA, 38KV 0 EA RF SYS, DTV 1 TUBE W/MOT SWTCH 0 EA RF SYS, DTV 1 TUBE W/MOT SWTCH 0 EA RF SYS, DTV 1 TUBE W/MOT SWTCH 0 EA KIT, MIXING VALVE, POWERCD, 1TUBE, 0 EA FAMILY TREE, POWERCD 0 DWG INSTL MTL, WIRE POWERCD,1 TUBE 1 EA PLUMBING KIT, POWERCD, 1 TUBE 1 EA KIT, PLMBNG, REDUNDANT COOLING 0 EA PUMP INTERFACE ASSY - FOR INTERFACING SIGMA PUMP TO POWERCD0 EA DOC PKG, POWERCD 2 EA IB, POWERCD, 1 TUBE SYSTEM 2 EA KIT, SPARES, WATER FILTERS, POWERCD0 EA KIT, SPARES, WATER FILTERS, POWERCD, W/O UV0 EA CALORIMETRY ASSEMBLY 0 EA KIT, INSTALL, 1 TUBE SYSTEM, POWERCD1 EA KIT, EXTERNAL SHUTOFF VALVE, POWERCD0 EA FORMAT, XMTR, PWR30D1 1 EA !FORMAT, POWERCD TANK BASE PUMP MODULE0 EA HEW8482H HEWLETT PACKARD SENSOR PROBE 0 EA HEWEPM-441A POWER METER, RF 0 EA PA MODULE DIGITAL POWER CD 0 EA KIT, SPARE BOARDS 0 EA KIT, SPARE PARTS 0 EA KIT, SPARE PARTS, ADVANCED 0 EA KIT, SPARE PARTS, BEAM SUPPLY 0 EA KIT, SPARE PARTS, NWL STEP START 0 EA KIT,SPARES,POLY TANK BASE, 2IN PUMP MODULE0 EA Table 7-2 PUMP INTER ASSY - FOR SIGMA PUMP TO POWERCD (J) Harris PN Description Qty UM Ref Des CORD, AC, 3C, NEMA/IEC PLUGS 1 EA SPLICE WIRE 22 TO 18 1 EA END STOP, 264 TERM BLOCK 2 EA #TB END PLATE, ORANGE (264) 1 EA #TB JACKSCREW, 4-40 FEMALE HEX 6 EA FUSE, CART 5X20MM 0.5A SLOW 2 EA FL1F1 FL1F XFMR, TOROID, 50VA 24VCT 1 EA FILTER, RFI POWER ENTRY, IEC 1 EA RECP, D, 9C 22-26AWG IDC 2 EA PLUG, 8C 1ROW VERTICAL 2 EA PLUG, 12C 1ROW VERTICAL 3 EA TERM BLK, THRU, 4-POLE, BLUE (264) 4 EA #TB WIRING DIA, PUMP INTERFACE ASSY 0 DWG 04/13/ Page: 7-3

240 Parts List RAIL, CARRIER, EA #TB BRACKET, TRANSFORMER 1 EA COVER 1 EA BOX, PUMP INTERFACE 1 EA CABLE, PUMP INTFC, SIGMA, POWERCD1 EA T PWA, MULTIPURPOSE I/O FOR SIGMA PUMP MODULE W/ POWERCD1 EA Table 7-3 PWA, MULTI I/O FOR SIGMA PUMP MODULE W/ POWERCD T (A) Harris PN Description Qty UM Ref Des PWA, MULTIPURPOSE I/O FOR SIGMA PUMP MODULE W/ POWERCD1 EA Table 7-4 FORMAT, XMTR, PWR30D (V) Harris PN Description Qty UM Ref Des TUBE, E2V ESCIOT5130W 0 EA CIRCUIT ASSY, E2V IMD3000EH 0 EA PUMP, VERTICAL, MULTISTAGE, 50HZ 0 EA SIDEWALLS, PAIR, 2000H X 1200W 1 EA *BREAKAWAY, MSDC IOT 1 EA CIRCULATOR, UHF 0 EA CIRCULATOR, UHF 0 EA CIRCULATOR, UHF 0 EA NAMEPLATE, XMTR EQUIPMENT 1 EA G PWA, CAN ADAPTER 0 EA CABLE PKG, POWERCD, 1 TUBE 1 EA CABLE, 3 TUBLE MARSHALING 1 EA CABLES MONITOR IOT CABINET 1 EA SET (W4 W5) CABLE CHANNEL 1 EA BRACKET EXC RETROFIT 0 EA ND EXCITER BLANK PANEL 0 EA RFU ASSEMBLY 1 EA A PA MODULE DIGITAL POWER CD 1 EA UNIT 1 IPA PH, 400V, MOV PKG (DELTA) 0 EA MOV BD, 480 VAC 0 EA UNIT 4 A12,UNIT 4 A DRIVER CAB, BASIC, POWER CD 1 EA UNIT PS CABINET, POWER CD 1 EA UNIT IOT CABINET, POWER CD 1 EA UNIT COOLING CAB, POWERCD, DOOR FLTR 1 EA UNIT POWER SUPPLY 480 VAC 0 EA UNIT 1 A POWER SUPPLY VAC 0 EA UNIT 1 A OBS, USE FFF EA UNIT 1 A1 UNIT 1 A KIT, 1 MODULE DRIVER 1 EA Table 7-5!FORMAT, POWERCD TANK BASE PUMP MODULE (A) Harris PN Description Qty UM Ref Des PUMP, IMMERSIBLE, CRK8, MULTISTAGE0 EA PUMP, MTR20-6/3, 7.5 HP, 60HZ 0 EA ADAPTER, 2 IN ANSI FLANGE TO 2 MIPT0 EA CONTROLLER, DUAL AC, POWER CD PUMP1 EA PUMP MODULE, TANK BASE, 2 FPT OUTPUT1 EA KIT, ADAPTER, NPT PUMP OUTPUT 2 EA Page: /13/12

241 Parts List 2533s701.fm Table 7-6 CONTROLLER, DUAL AC, POWER CD PUMP (D) Harris PN Description Qty UM Ref Des GASKET, RUBBER 7 FT FUSE, SLOW 2.5A 250V 5X20 4 EA SPIRAL PLASTIC WRAP 1 FT CABLE PUSH MOUNT 11 EA PLATE, END STOP, DIN RAIL MT 2 EA PLATE, END COVER (284, 3-COND) 6 EA *DIODE, RECT 1N EA LABEL, ELECTRICAL HAZARD 2 EA SOCKET RELAY 4PDT DINRAIL 3 EA LATCH, COMPRESSION 1 EA XFMR, PWR CNTL 24V SEC 2 EA CNTOR, MCS, 5.5KW 1 NO 24VAC 2 EA AUX CONTACT, N.O. AB 100-SA01 2 EA RELAY 12VDC 4PDT 2 EA RELAY, 4PDT, 24VAC 1 AMP 1 EA K RELAY, OVERLOAD A 2 EA SWITCH, TGL DP ON OFF ON 1 EA SW, TOGGLE 4PDT 10 AMP 1 EA PLUG, 4C 1ROW VERTICAL 1 EA PLUG, 12C 1ROW VERTICAL 7 EA TERM BLK, 2C MODULAR EA JUMPER, 2P ADJACENT STEP-DOWN 4 EA TERM BLK, 3C MODULAR EA TERM BLK, 2C MODULAR FUSED 4 EA TERM BLK, THRU, 2-POLE, GREY (264) 7 EA TERM BLK, GROUND, 4-POLE, GRN/YEL (264)1 EA LABEL, EARTH WARNING 1 EA MON, PH V 3PH 2 EA SCH, CNTLR, TANK BASED PUMP, PWRCD0 DWG CABLE, GROUND 1 EA SPACER RND THRU M8 X 6 SS 4 EA DIN RAIL, CUT LENGTH 432MM 1 EA CONTROL BOX DOOR 1 EA PLATE, CONTROLLER MOUNTING 1 EA COVER, SAFETY 1 EA STANDOFF, 0.5 HEX X 3.5IN, M8, M4 4 EA COVER, RT SAFETY 1 EA CONTROL BOX ASSY. 1 EA HINGE, SPACER 1 EA HINGE, ENCLOSURE 1 EA CABLE PUMP MODULE 1 EA WI WI, DUAL AC CONTROLLER, POWER CD0 DWG T PWA, MULTIPURPOSE I/O FOR POWERCD TANK BASED CONTROLLER1 EA Table 7-7 PA MODULE DIGITAL POWER CD (G) Harris PN Description Qty UM Ref Des THERMAL INTERFACE, DC-DC CONV 5 EA U3 U4 U5 U6 U CONVERTER, DC/DC 375V/32V 600W 5 EA U3 U4 U5 U6 U LABEL, INSPECTION 1 EA FACEPLATE, PA MODULE 1 EA MODULE, BASIC, RF AMP, UHF BAND 1 EA 04/13/ Page: 7-5

242 Parts List Table 7-8 MODULE, BASIC, RF AMP, UHF BAND (Z) Harris PN Description Qty UM Ref Des BRZ, PH FGR STOCK 4.4 EA FINGERSTOCK, BOTTOM LANCE, CLIP ON0.3 EA GROMMET STRIP, FT TAPE, KAPTON X 1.0W 0 RL MODULE CARTON ATLAS / NEPTUNE 0 EA *THERMAL COMPOUND, 8OZ JAR 0 EA PASTE, PIPE THREAD TEFLON 0 EA TAPE, ELEC 1.75 IN W 0 RL CLAMP RIBBON CABLE S/A 3 EA RECP, 600VAC,THREE LUG W/GND 1 EA WIRE RIBBON SILVER X FT TUBING, SHRINK 1/4 WHITE 0.17 FT #R1 #R THREAD-TAPE, TEFLON 1.00 W 0 RL SCREW, PHIL FHMS M X5 14 EA SCREW, MACH M3-0.5 X 6 4 EA SCREW SEMS M3 X 8 SKT HD SS 77 EA SCREW, MACH M3-0.5 X 6 SEMS 191 EA SCREW, MACH M3-0.5 X 8 SEMS 9 EA SCREW, MACH M3-0.5 X 10 SEMS 28 EA SCREW, MACH M4-0.7 X 8 SEMS 11 EA SCREW, PHMS M4-0.7 X 10 SST SEMS 4 EA SCREW, MACH M4-0.7 X 12 SEMS 24 EA SCREW, SKT BUTTON HD M4X8 S/ST 14 EA SCREW, MACH M3-0.5 X 5 1 EA SCREW, MACH M3-0.5 X 8 1 EA SCREW, MACH M3-0.5 X 12 2 EA #R5 #R SCREW, MACH M3-0.5 X 16 2 EA SCREW, MACH M4-0.7 X 16 1 EA SCREW, FHMS M3-0.5 X 6 37 EA SCREW MACH M3-0.5 X 8 27 EA SCREW MACH M3-0.5 X 10 4 EA SCREW, MACH M5-0.8 X 12 2 EA SCREW SKT HD CAP M3 X 8 77 EA SCREW SKT HD CAP M2.5 X 6 55 EA WASHER, FLAT #4 SST (ANSI NARROW) 19 EA WASHER, FLAT #8 SST (ANSI NARROW) 34 EA WASHER, INT LOCK 1/4 1 EA LOCKWASHER, SPLIT #4 SST (ANSI) 8 EA LOCKWASHER, SPLIT M3 SST (DIN127) 50 EA LOCKWASHER, SPLIT M4 SST (DIN127) 38 EA WASHER, BELLEVILLE ID, STEEL 2 EA #R5 #R WASHER, SHOULDER ID NOM 6 EA ROLL PIN, 2.5MM DIA X 6MM LONG 13 EA RIVET POP.125X EA LUG SHAKE.123 MTG 1 EA CABLE CLAMP, NYLON DIA 1 EA #C CLAMP, FLAT CABLE, 0.5 W 3 EA NIPPLE, 3/8, STAINLESS STEEL 2 EA NIPPLE, BRASS PIPE 3/8 NPT 2 EA DIODE, SCHOTTKY 60V 80AMP 3 EA CR11 CR12 CR PAD, THERMAL INTERFACE 21 EA GASKET, EMI SHIELDING, 1.0MM X 3.0MM18.2 FT Page: /13/12

243 Parts List 2533s701.fm GASKET,EMI,11.8MM X 10.7MM, V 34 IN THERMAL INTERFACE, 12 X 40 MM 3 EA 1/CR11 1/CR12 1/CR STANDOFF NYLON F-F M3 X15 LONG 4 EA STANDOFF, NYLON SNAP-IN 2 EA BUSHING, SPLIT, GUIDE PIN 2 EA HANDLE, PULL, OVAL, BLACK, M5 1 EA CAP 360UF 450V -10/+50% 105C 1 EA C RES, 2.5 OHM 100W 1% TO EA R5 R RECEPTACLE, BLIND-MATE 7/16 1 EA TERMINATION 50 OHM 100W 5% 2 EA R3 R TERMINATION 50 OHM 10W 5% 2 EA R1 R WIRING DIAGRAM MODULE 0 DWG MODULE RIBBON CABLE 1 EA ASSY, 50 CONTACT RIBBON CABLE 1 EA ASSY, 20 CONTACT RIBBON CABLE 1 EA ASSY, 20-CONTACT RIBBON CABLE 1 EA WIRES, DC POWER 1 EA CABLE, FWD POWER SAMPLE 1 EA CABLE, RFL POWER SAMPLE 1 EA CABLE, P&G RF OUTPUT 1 EA JUMPER, DC 2 EA CAPACITOR CABLE 1 EA CABLE, GATE BIAS 1 EA STANDOFF, HEX M4 X 15, M/F 9 EA CABLE, MTA WIRE 1 EA CABLE, RF INPUT 1 EA SCREW, SHOULDER 2 EA COLDPLATE/MANIFOLD ASSY 1 EA PWA, SPLITTLER, PORTS EA A PWA, SPLITTLER, PORTS EA A MECHANICAL KIT ATLAS PA MODULE 1 EA MK2 UHF BROADBAND PALLET 10 EA DRV1 DRV2 PA1 PA2 PA3 PA4 PA5 PA6 PA7 PA PWA, PHASE & GAIN 1 EA A PWA, PS FRONT END 1 EA A PWA, POWER SUPPLY 1 EA A PWA, PREDRIVER PALLET 1 EA A PWA, MODULE CONTROLLER 1 EA A PWA, 8-WAY COMBINER 1 EA A1 Table 7-9 MK2 UHF BROADBAND PALLET (D) Harris PN Description Qty UM Ref Des SCH, MK2 UHF BROADBAND PALLET 0 DWG FET, RF, TINNED 2 EA Q001 Q MK2 UHF BROADBAND PALLET SMT 1 EA Table 7-10 PWA, PHASE & GAIN (F--) Harris PN Description Qty UM Ref Des *THERMAL COMPOUND, 8OZ JAR 0 EA #R EXT SHAKE BRZ 1 EA XSTR, BLF1043 ESD 2 EA Q1 Q <*>IC, MHW EA U PAD, THERMAL INTERFACE 2 EA #Q1 #Q *SOCKET, 9C, 1 ROW, STRAIGHT 1 EA XU2 04/13/ Page: 7-7

244 Parts List PAD, THERMAL INTERFACE 1 EA #U CHOKE, RF, FERRITE BEAD 3 EA RFC17 RFC18 RFC CHOKE WIDE BAND 1 EA RFC JACK RECP, SMB PCB MT VERTICAL 1 EA J *RECP,MALE SMA PC MOUNT RT ANG 1 EA J BARCODE, SN_ITEM_REV 1 EA TERMINATION 50 OHM 10W 5% 1 EA R SCH, PHASE & GAIN BOARD 0 DWG PWA, PHASE & GAIN, SMT 1 EA Table 7-11 PWA, PS FRONT END (D--) Harris PN Description Qty UM Ref Des SCR, 8-32 X 3/4 3 EA E1 E2 E NUT, HEX EA 2#E1 2#E2 2#E WASHER, FLAT #8 BRASS (ANSI REGULAR)9 EA 3#E1 3#E2 3#E WASHER, INT LOCK 8 6 EA 2#E1 2#E2 2#E BRIDGE, FW 3PH 1200V 35AMP 1 EA CR DIODE, 40EPS12 ESD 1 EA CR LED, RED/GRN T1 RTANG 1 EA DS THERMAL INTERFACE, TO EA #CR CHOKE, COMMON MODE 3-PH, PC MT 1 EA L THERMISTOR, 7 OHM +/-15% NOM 1 EA R HDR, 6C VERT 1ROW 1-WALL 1 EA J LUG QC250 MALE PCB VERTICAL 2 EA E9 E BARCODE, SN_ITEM_REV 1 EA SCH, PS FRONT END 0 DWG PWB, PS FRONT END 1 EA Table 7-12 PWA, POWER SUPPLY (F--) Harris PN Description Qty UM Ref Des LUG QC250 MALE PCB RTANG 2 EA E1 E END PLATE, GREY (236) 7 EA J1 J2 J3 J4 J6 J7 J BUS BAR, PCB, 12 PIN, 64 AMP 2 EA X1 X LED, RED BLINKING, T-1-3/4 ESD 1 EA DS FUSE, 30AMP 32VDC (ATM) 12 EA F8 F9 F10 F11 F12 F13 F14 F15 F16 F17 F18 F FUSE, CART 0.25X1.25 5A FAST 7 EA F1 F2 F3 F4 F5 F6 F CLIP, 1/4 DIA FUSE 14 EA 2/F1 2/F2 2/F3 2/F4 2/F5 2/F6 2/F FUSEHOLDER, 0.110W VERTICAL 12 EA 1/F8 1/F9 1/F10 1/F11 1/F12 1/F13 1/F14 1/F15 1/F16 1/F17 1/F18 1/F CAP 3300PF 1500VDC 20% 14 EA C8 C22 C43 C45 C46 C47 C50 C51 C52 C53 C54 C55 C75 C CAP 2.0 UF 600VDC 10% 7 EA C9 C10 C11 C12 C13 C14 C CAP 0.22UF 630VDC 10% 7 EA C1 C2 C3 C4 C5 C6 C RES 20K OHM 3W 5% 3 EA R59 R60 R HDR, 6C RTANG 1ROW FRICTION 1 EA J <*>HDR, 20C 2ROW VERTICAL (SYS 50) 2 EA J12 J <*>HDR, 50C 2ROW VERTICAL (SYS 50) 1 EA J HDR, 12C VERT 1ROW FRICTION 2 EA J8 J TERM BLK, PCB, 1-POLE, GREY (236) 12 EA 1/J2 1/J10 2/J1 2/J3 2/J4 2/J6 2/J BARCODE, SN_ITEM_REV 1 EA ASSY, INSULATING SPACER 14 EA #C8 #C22 #C43 #C45 #C46 #C47 #C50 #C51 #C52 #C53 #C54 #C55 #C75 #C PWA, POWER SUPPLY, SMT 1 EA Page: /13/12

245 Parts List 2533s701.fm Table 7-13 PWA, PREDRIVER PALLET (B) Harris PN Description Qty UM Ref Des *THERMAL COMPOUND, 8OZ JAR 0 EA #R19 #R TERMINATION 50 OHM 10W 5% 2 EA R19 R SCH, PREDRIVER 0 DWG FET, RF, TINNED 1 EA Q PWA, PREDRIVER 1 EA Table 7-14 PWA, MODULE CONTROLLER (C) Harris PN Description Qty UM Ref Des *SEALANT, GLYPTOL, RED 0 QT SCREW 4-40 X.375 BHMS 2 EA 2/J SCREW 6-32 X.25 BHMS 2 EA NUT, HEX EA STANDOFF, HEX 6-32 X 5/16 M/F 2 EA HDR, 10C VERT 2ROW UNSHR 1 EA J <*>HDR, 20C 2ROW VERTICAL (SYS 50) 2 EA J10 J <*>HDR, 50C 2ROW VERTICAL (SYS 50) 1 EA J *HDR (FFC), 24C 2ROW RT ANG 1 EA J *HDR (RIBBON), 20C 2ROW RT ANG 1 EA J RECP, D, 9C VERT PCB PLASTIC 1 EA J RECP, RT ANGLE, MCX 2 EA J4 J BARCODE, SN_ITEM_REV 1 EA SOFTWARE, PA MODULE CONTROLLER 0 DWG SCH, PA MODULE CONTROLLER 0 DWG G *PWA, 376 MICRO MODULE 1 EA *PWA, MODULE CONTROLLER, SMT 1 EA Table 7-15 PWA, 8-WAY COMBINER (B--) Harris PN Description Qty UM Ref Des *THERMAL COMPOUND, 8OZ JAR 0 EA #R1 #R2 #R3 #R4 #R5 #R6 #R7 #R18 #R19 #R20 #R21 #R22 #R23 #R24 #R BARCODE, SN_ITEM_REV 1 EA SCH, COMBINER, UHF 8-WAY 0 DWG PWA, 8-WAY COMBINER, SMT 1 EA TERMINATION 50 OHM 100W 5% 14 EA R1 R2 R3 R4 R5 R6 R18 R19 R20 R21 R22 R23 R24 R TERMINATION 50 OHM 150W 5% 1 EA R7 Table 7-16 KIT, SPARE BOARDS (K) Harris PN Description Qty UM Ref Des T ASSY, FOCUS SUPPLY, TESTED 1 EA T ASSY, GRID SUPPLY, TESTED 1 EA T ASSY, FILAMENT SUPPLY, TESTED 1 EA T MOV BD, 480VAC, TESTED 1 EA T PWA, MODE CONTROLLER, TESTED 1 EA T *PWA, POWER SUPPLY MONITOR CONTROLLER TESTED1 EA T PWA, OVERVOLTAGE PROTECTION TESTED1 EA T PWA, BACKPLANE, TESTED 1 EA T *PWA, SWITCH BOARD, TESTED 1 EA T *PWA, ISO SUPPLY MONITOR, TESTED 1 EA T PWA, SPARK GAP INTERFACE, TESTED 1 EA T PWA, COOLING CONTROL BOARD, TESTED1 EA 04/13/ Page: 7-9

246 Parts List T *PWA, EXTERNAL I/O, TESTED 1 EA T *PWA, HPA CONTROLLER, TESTED 1 EA T PWA, STEP START CONTROL, TESTED 1 EA T PWA, HIGH VOLTAGE METERING, TESTED1 EA T PWA, ION SUPPLY, TESTED 1 EA T PWA, RFU CONTROLLER, TESTED 1 EA T PWA, RFU SWITCH BOARD, TESTED 1 EA T PWA, RFU PA, TESTED 1 EA Table 7-17 ASSY, FOCUS SUPPLY, TESTED T (A) Harris PN Description Qty UM Ref Des B/M NOTE: 0 DWG FOCUS SUPPLY 1 EA Table 7-18 FOCUS SUPPLY (C) Harris PN Description Qty UM Ref Des FLANGE, GREY (262) 1 EA #TB RECT FW BRIDGE 600V 35A ESD 1 EA CR FAN 115V 50/60HZ 1 EA B XFMR, TOROID, 48V 800VA 1 EA T TERM BLK, THRU, 4-POLE, BLUE (262) 2 EA 2#TB CABLE FOCUS SUPPLY 1 EA BRACKET, FAN 1 EA SINK, COOLING FINS 1 EA WING, HEAT SINK 1 EA PLATE, FILAMENT/FOCUS SPLY MTG 1 EA DUCT, AIR 1 EA PLATE, FOCUS SUPPLY MTG 1 EA ASSY, FOCUS SUPPLY 1 EA Table 7-19 ASSY, GRID SUPPLY, TESTED T (A) Harris PN Description Qty UM Ref Des ASSY, GRID SUPPLY 1 EA Table 7-20 ASSY, GRID SUPPLY (B) Harris PN Description Qty UM Ref Des FLANGE, GREY (262) 1 EA #TB XFMR, TOROID, 234V CT 1 EA T TERM BLK, THRU, 4-POLE, BLUE (262) 2 EA 2#TB SINK, COOLING FINS 1 EA WING, HEAT SINK 1 EA PLATE, GRID BIAS SUPPLY MTG 1 EA PWA, GRID BIAS SUPPLY 1 EA Table 7-21 ASSY, FILAMENT SUPPLY, TESTED T (A) Harris PN Description Qty UM Ref Des ASSY, FILAMENT SUPPLY 1 EA Table 7-22 ASSY, FILAMENT SUPPLY (C) Harris PN Description Qty UM Ref Des FLANGE, GREY (262) 1 EA #TB RECT FW BRIDGE 600V 35A ESD 1 EA CR XFMR, TOROID, 48V 800VA 1 EA T2 Page: /13/12

247 Parts List TERM BLK, THRU, 4-POLE, BLUE (262) 2 EA 2#TB SINK, COOLING FINS 1 EA WING, HEAT SINK 1 EA PLATE, FILAMENT/FOCUS SPLY MTG 1 EA ASSY, FILAMENT SUPPLY 1 EA 2533s701.fm Table 7-23 *PWA, SWITCH BOARD, TESTED T (A) Harris PN Description Qty UM Ref Des DISPLAY, 10 CHAR, GRN ESD 1 EA DS CONVERTER, DC/DC 5V.75W ESD 1 EA U HDR, 2C VERT 1ROW UNSHR 2 EA JP2 JP HDR, 10C VERT 2ROW UNSHR 1 EA J *HDR 26C 2ROW VERT TOP LATCH 1 EA J HDR, 6C VERT 2ROW UNSHR 1 EA J JUMPER SHUNT, 2C, 0.1 PITCH 2 EA 1/JP2 1/JP SCH, SWITCH BOARD 0 DWG *S/W, FRONT PANEL SWITCH BOARD 0 DWG #U *PWA, SWITCH BOARD SMT 1 EA Table 7-24 *PWA, ISO SUPPLY MONITOR, TESTED T (A) Harris PN Description Qty UM Ref Des B/M NOTE: 0 DWG *PWA, ISO SUPPLY MONITOR 1 EA Table 7-25 *PWA, ISO SUPPLY MONITOR (E) Harris PN Description Qty UM Ref Des *SEALANT, GLYPTOL, RED 1 QT SCREW 6-32 X.25 BHMS 2 EA NUT, HEX EA STANDOFF, HEX 6-32 X 5/16 M/F 2 EA IC, FIBER OPTIC RCVR ESD 3 EA Z1 Z4 Z IC, FIBER OPTIC XMTR ESD 3 EA Z2 Z3 Z FUSE, CART 5X20MM 0.5A SLOW 1 EA F CLIP, FUSE 5MM DIA FUSE 2 EA 2/F XFMR, 16VCT, 12VA, PC MT 1 EA T HDR, 10C VERT 2ROW UNSHR 1 EA J HDR, 5C VERT 1ROW FRICTION 1 EA J HDR, 10C 2ROW VERTICAL 3 EA J4 J5 J *RECP D RT ANG 9C MET SHELL 1 EA J BARCODE, SN_ITEM_REV 1 EA SCH, ISO SUPPLY MONITOR 0 DWG G *PWA, 376 MICRO MODULE 1 EA *PWA, ISO SUPPLY MONITOR, SMT 1 EA Table 7-26 PWA, SPARK GAP INTERFACE, TESTED T (A) Harris PN Description Qty UM Ref Des B/M NOTE: 0 DWG PWA, SPARK GAP INTERFACE 1 EA Table 7-27 PWA, SPARK GAP INTERFACE (D-) Harris PN Description Qty UM Ref Des CABLE TIE, 5.6 NYLON NATURAL 2 EA DIAC 32V 200UA ESD 1 EA CR6 04/13/ Page: 7-11

248 Parts List DIODE, TVS (BIDIR), SA90CA 1 EA CR RECT, GI V 6A ESD 4 EA CR1 CR2 CR3 CR SCR, 40TPS12A ESD 1 EA Q XFMR, SPARK GAP TRIGGER 1 EA T CAP, 1UF 400V 10% 1 EA C CAP, 0.1UF 400V 10% 1 EA C RES 10 OHM 3W 5% 3 EA R1 R2 R RES 300 OHM 3W 5% 1 EA R RES 1K OHM 3W 5% 1 EA R RES 100K OHM 3W 5% 1 EA R RES 240K OHM 3W 5% 2 EA R6 R BARCODE, SN_ITEM_REV 1 EA SCH, SPARK GAP INTERFACE 0 DWG PWB, SPARK GAP INTERFACE 1 EA TRANSFORMER 1 EA T1 Table 7-28 PWA, COOLING CONTROL BOARD, TESTED T (A) Harris PN Description Qty UM Ref Des B/M NOTE: 0 DWG PWA, COOLING CONTROL BOARD 1 EA Table 7-29 PWA, COOLING CONTROL BOARD (E) Harris PN Description Qty UM Ref Des RES 100 OHM 3W 5% 16 EA R57 R58 R59 R60 R61 R62 R63 R64 R82 R83 R84 R85 R180 R181 R187 R HDR, 9C 1ROW VERTICAL UNSHR 1 EA J HDR, 12C VERT 1ROW FRICTION 2 EA J13 J HDR, 3C 1ROW RT ANGLE 1 EA J HDR, 4C 1ROW RT ANGLE 5 EA J2 J4 J6 J8 J HDR, 6C 1ROW RT ANGLE 2 EA J1 J HDR, 10C 1ROW RT ANGLE 2 EA J5 J HDR, 40C 2ROW VERTICAL 1 EA J SENSOR, AIR PRESSURE, 20 H2O 1 EA U BARCODE, SN_ITEM_REV 1 EA SW/FW COOLING CONTROL BOARD 0 DWG SCH, COOLING CONTROL BOARD 0 DWG PWA, COOLING CONTROL BOARD-SMT 1 EA Table 7-30 *PWA, EXTERNAL I/O, TESTED T (A) Harris PN Description Qty UM Ref Des B/M NOTE: 0 DWG *PWA, EXTERNAL I/O 1 EA Table 7-31 *PWA, EXTERNAL I/O (C) Harris PN Description Qty UM Ref Des *SEALANT, GLYPTOL, RED 0 QT SCREW, PHMS 4-40 X 5/16 BRASS 1 EA XU NUT, HEX EA XU *WASHER, FLAT #4 BRASS (ANSI NARROW)1 EA XU LOCKWASHER, SPLIT #4 PH-BRZ (ANSI) 1 EA XU SCREW 4-40 X.375 BHMS 2 EA 2/J SCREW 6-32 X.25 BHMS 2 EA NUT, HEX EA STANDOFF, HEX 6-32 X 5/16 M/F 2 EA Page: /13/12

249 Parts List 2533s701.fm *IC, 2940 (TO-220) 1 EA U HEAT SINK PA1-1CB 1 EA XU CAP, 1.0F 5.5V GOLD 1 EA C CONVERTER, DC/DC 5V.75W ESD 4 EA U17 U26 U52 U CONVERTER, DC/DC 12V 1.5W ESD 1 EA U RELAY 2PDT 12VDC 2A NON-LATCH 6 EA K1 K2 K3 K4 K5 K HDR, 2C VERT 1ROW UNSHR 3 EA JP1 JP2 JP HDR, 10C VERT 2ROW UNSHR 1 EA J HDR, 9C 1ROW VERTICAL UNSHR 1 EA J HDR, 12C VERT 1ROW FRICTION 1 EA J HDR, 2C 1ROW VERTICAL 1 EA J HDR, 4C 1ROW VERTICAL 3 EA J13 J14 J HDR, 12C 1ROW VERTICAL 8 EA J2 J3 J4 J5 J16 J17 J18 J HDR, 26C 2ROW VERTICAL 2 EA J8 J HDR, 40C 2ROW VERTICAL 1 EA J RECP, D, 9C VERT PCB PLASTIC 1 EA J BARCODE, SN_ITEM_REV 1 EA SCH, EXTERNAL I/O 0 DWG SW/FW, PCD_EXTIO 0 DWG G *PWA, 376 MICRO MODULE 1 EA *PWA, EXTERNAL I/O, SMT 1 EA Table 7-32 *PWA, HPA CONTROLLER, TESTED T (A) Harris PN Description Qty UM Ref Des B/M NOTE: 0 DWG *PWA, HPA CONTROLLER 1 EA Table 7-33 *PWA, HPA CONTROLLER (C) Harris PN Description Qty UM Ref Des *SEALANT, GLYPTOL, RED 0 QT SCREW, PHMS 4-40 X 1/4 BRASS 5 EA 1/CR37 1/CR40 1/CR41 1/CR46 1/U NUT, HEX EA 1/CR37 1/CR40 1/CR41 1/CR46 1/U LOCKWASHER, SPLIT #4 PH-BRZ (ANSI) 5 EA 1/CR37 1/CR40 1/CR41 1/CR46 1/U TERMINAL, SOLDER 5 EA 1/CR37 1/CR40 1/CR41 1/CR46 1/U SCREW 6-32 X.25 BHMS 2 EA NUT, HEX EA SCREWLOCK, M/F 4-40X3/16 2 EA 2/J37 2/J STANDOFF, HEX 6-32 X 5/16 M/F 2 EA IC, FIBER OPTIC XMTR ESD 3 EA Z2 Z5 Z IC, 1085CT-5 (ESD) 1 EA U OPTIC RECEIVER, HFBR-2521 ESD 3 EA Z3 Z4 Z DIODE, SCHOTTKY 32CTQ030 4 EA CR37 CR40 CR41 CR DIODE,SCHOTTKY, 50SQ100 ESD 2 EA CR48 CR FUSE, CART 5X20MM 5A FAST 2 EA 1/F1 1/F FUSE, CART 5X20MM 10A FAST 1 EA 1/F CLIP, FUSE 5MM DIA FUSE 6 EA F1 F2 F *HEATSINK, VERTICAL, TO EA 1/CR37 1/CR40 1/CR41 1/CR46 1/U DISPLAY, ALPHANUMERIC, 1X8 1 EA DS ENCLOSURE 2.25 X 3.25 X EA Z POT, 10K OHM.5W 10% 2 EA R79 R POT 20K OHM.5W 10% 2 EA R194 R CONVERTER, DC/DC 5V.75W ESD 2 EA U24 U HDR, 2C VERT 1ROW UNSHR 2 EA JP1 JP HDR, 10C VERT 2ROW UNSHR 1 EA J39 04/13/ Page: 7-13

250 Parts List HDR, 12C VERT 1ROW FRICTION 1 EA J HDR, 6C VERT 1ROW FRICTION 2 EA J4 J HDR, 9C 1ROW VERTICAL UNSHR 1 EA J HDR, 12C VERT 1ROW FRICTION 1 EA J HDR, 6C VERT 1ROW FRICTION 2 EA J1 J HDR, 10C VERT 1ROW FRICTION 1 EA J HDR, 4C VERT 1ROW FRICTION 1 EA J HDR, 2C VERT 1ROW FRICTION 3 EA J16 J24 J HDR, 8C VERT 1ROW FRICTION 3 EA J10 J31 J HDR, 3C 1ROW RT ANGLE 1 EA J HDR, 10C 2ROW VERTICAL 1 EA J HDR, 20C 2ROW VERTICAL 2 EA J35 J HDR, 26C 2ROW VERTICAL 4 EA J6 J7 J33 J HDR, 4C VERT 1ROW FRICTION 1 EA J JACK, SMA STRAIGHT PCB 4 EA J12 J13 J14 J *RECP D RT ANG 9C MET SHELL 2 EA J37 J JACK, BNC STRAIGHT PCB 1 EA J BARCODE, SN_ITEM_REV 1 EA BATTERY 3V LITHIUM COIN CELL 1 EA 1/BT SCH, HPA CONTROLLER 0 DWG SW OF POWERCD HPA CONTROLLER 0 DWG G *PWA, 376 MICRO MODULE 1 EA PWA, HPA CONTROLLER, SMT 1 EA Table 7-34 PWA, STEP START CONTROL, TESTED T (A) Harris PN Description Qty UM Ref Des B/M NOTE: 0 DWG PWA, STEP START CONTROL 1 EA Table 7-35 PWA, STEP START CONTROL (C-) Harris PN Description Qty UM Ref Des SCREW, PHMS 4-40 X 5/16 BRASS 2 EA 1/U3 1/U NUT, HEX EA 1/U3 1/U *WASHER, FLAT #4 BRASS (ANSI NARROW)2 EA 1/U3 1/U LOCKWASHER, SPLIT #4 PH-BRZ (ANSI) 2 EA 1/U3 1/U XSTR, 2N7000 ESD 4 EA Q1 Q2 Q3 Q *IC, LM340A/LM7805AC (TO-220) 1 EA U IC, LM340/LM7812C (TO-220) 1 EA U *IC, 74HC74 (DIP-14) 1 EA U IC 74HC132 (DIP-14) 1 EA U RECT BRIDGE, 2KBP06 1 EA CR DIODE, TVS (UNIDIR), ICTE-5 6 EA CR7 CR8 CR10 CR11 CR13 CR LED, T1, RED VERTICAL 2 EA DS1 DS RECT MUR V ESD 11 EA CR2 CR3 CR4 CR5 CR6 CR12 CR14 CR16 CR19 CR20 CR DIODE, TVS (UNIDIR), ICTE-12 1 EA CR LED, GRN T1 VERT 2 EA DS3 DS *ZENER 1N4733A 5.1V 5% 1W 2 EA CR1 CR XFMR, PWR 24V 500MA 1 EA T INDUCTOR, 4.70UH 10% (9250) 1 EA L CAP 0.100UF 5% 63V 3 EA C1 C5 C CAP 0.015UF 5% 100V 1 EA C CAP DISC 0.05UF 500V -20/+80% 3 EA C13 C14 C CAP 0.010UF 10% 100V X7R 4 EA C8 C11 C15 C19 Page: /13/12

251 Parts List 2533s701.fm CAP 1.0UF 50V 20% 4 EA C2 C4 C7 C *CAP 100UF 35V 20% (6.3X11) 2 EA C12 C CAP 1UF 100V 20% (5X11) 1 EA C *CAP 3300UF 25V 20% (16X25) 1 EA C RES 3.9 OHM 3W 5% 1 EA R RES 10 OHM 3W 5% 1 EA R RES 10K OHM 3W 5% 1 EA R RES 12.4 OHM 1/2W 1% 2 EA R13 R RES 133 OHM 1/2W 1% 2 EA R22 R RES 332 OHM 1/2W 1% 1 EA R RES 806 OHM 1/2W 1% 1 EA R RES 1K OHM 1/2W 1% 6 EA R2 R4 R6 R7 R9 R RES 10K OHM 1/2W 1% 7 EA R5 R8 R15 R16 R17 R18 R POSISTOR 0.1 AMP 60VDC 8MM DISC 1 EA R POSISTOR 0.5 AMP 60VDC 8MM DISC 1 EA R RELAY 2PDT 12VDC 2A NON-LATCH 2 EA K1 K RELAY, SPDT, 12V, 40A 2 EA K3 K SW, PB MOM SPST-NO TACT (THRU-HOLE)2 EA S1 S TEST POINT, OVAL-LOOP THRU 6 EA TP1 TP2 TP3 TP4 TP5 TP HDR, 5C VERT 1ROW FRICTION 1 EA J HDR, MALE 8C 1ROW RT ANG 1 EA J HDR, 4C 1ROW RT ANGLE 1 EA J HDR, 8C 1ROW RT ANGLE 1 EA J HDR, 10C 1ROW RT ANGLE 1 EA J HDR, 26C 2ROW VERTICAL 1 EA J RECP, BNC, PC MT, RT ANGLE 1 EA J BARCODE, SN_ITEM_REV 1 EA SCH, STEP START CONTROL 0 DWG PWB, STEP START CONTROL 1 EA Table 7-36 PWA, HIGH VOLTAGE METERING, TESTED T (A) Harris PN Description Qty UM Ref Des B/M NOTE: 0 DWG *PWA, HIGH VOLTAGE METERING 1 EA Table 7-37 *PWA, HIGH VOLTAGE METERING (H-) Harris PN Description Qty UM Ref Des SCREW, PHMS 4-40 X 5/16 BRASS 1 EA 1/U SCREW, PHMS, 6-32 X 3/8 2 EA T NUT, HEX EA 1/U *WASHER, FLAT #4 BRASS (ANSI NARROW)1 EA 1/U LOCKWASHER, SPLIT #4 PH-BRZ (ANSI) 1 EA 1/U WASHER FLAT NYLON #6 HOLE 2 EA 2/T IC LT1058C ESD 3 EA U2 U3 U IC, MC7824 ESD 1 EA U RECT BRIDGE, 2KBP06 1 EA CR RECT MUR V ESD 29 EA CR1 CR2 CR3 CR5 CR6 CR7 CR8 CR9 CR10 CR11 CR12 CR13 CR14 CR15 CR16 CR17 CR18 CR19 CR20 CR21 CR22 CR23 CR24 CR25 CR26 CR27 CR28 CR29 CR LED, GRN T1 VERT 3 EA DS1 DS2 DS XFMR, PWR 24V 500MA 1 EA T FIXED IND 100UH, 10% TOLERANCE 1 EA L1 04/13/ Page: 7-15

252 Parts List CAP DISC 0.05UF 500V -20/+80% 1 EA C CAP 0.100UF 10% 100V X7R 6 EA C10 C11 C12 C13 C14 C CAP 0.010UF 10% 100V X7R 5 EA C8 C9 C16 C17 C CAP 1000PF 10% 100V X7R 2 EA C3 C CAP 0.010UF 10% 100V X7R CK05 2 EA C2 C *CAP 100UF 35V 20% (6.3X11) 2 EA C20 C <*>CAP 100UF 63V 20% (10X12.5) 2 EA C1 C CAP 3300UF 50V 20% 1 EA C RES 51 OHM 3W 5% 9 EA R7 R15 R16 R17 R18 R19 R20 R21 R RES 1K OHM 3W 5% 10 EA R10 R11 R12 R13 R14 R23 R24 R25 R26 R RES 2K OHM 3W 5% 7 EA R2 R3 R4 R5 R6 R8 R RES 100 OHM 1/2W 1% 5 EA R30 R32 R40 R41 R RES 1K OHM 1/2W 1% 2 EA R43 R RES 1.62K OHM 1/2W 1% 1 EA R RES 10K OHM 1/2W 1% 10 EA R28 R29 R31 R33 R34 R35 R36 R37 R38 R RES 1MEG OHM 1/2W 1% 5 EA R45 R46 R47 R48 R TEST POINT, OVAL-LOOP THRU 7 EA TP1 TP2 TP3 TP4 TP5 TP6 TP HDR, 5C VERT 1ROW FRICTION 1 EA J HDR, 10C 1ROW RT ANGLE 1 EA J HDR, 12C 1ROW RT ANGLE 2 EA J2 J HDR, 26C 2ROW VERTICAL 1 EA J RECP, BNC, PC MT, RT ANGLE 1 EA J BARCODE, SN_ITEM_REV 1 EA CONVERTER, DC/DC, +/-15V 0.75W 1 EA U SCH, HIGH VOLTAGE METERING 0 DWG PWB, HIGH VOLTAGE METERING 1 EA TRANSFORMER 1 EA T1 Table 7-38 PWA, ION SUPPLY, TESTED T (A) Harris PN Description Qty UM Ref Des B/M NOTE: 0 DWG *PWA, ION SUPPLY 1 EA Table 7-39 *PWA, ION SUPPLY (D-) Harris PN Description Qty UM Ref Des A *TUBING, SHRINKABLE 3/4 0 FT XRV LOCKWASHER, SPLIT #10 SST (ANSI) 2 EA XE1,XE TERMINAL, SCREW 10-32, 30A 2 EA E1 E END PLATE, GREY (236) 1 EA 1/TB XSTR, 2N7000 ESD 2 EA Q1 Q *IC, LM358 (DIP-8) 1 EA U IC TL072ACP ESD 1 EA U IC LM4040AIZ-5.0 ESD 1 EA CR *DIODE, RECT 1N4148/914 1 EA CR RECT BRIDGE, 2KBP06 2 EA CR1 CR SOCKET, DIP, 8 PIN (DL) 2 EA XU1 XU XFMR, 20VCT, 6VA, PC MT 1 EA T CAP, 2200PF 6000V 2 EA C3 C CAP 1.0UF 50V 20% 1 EA C CAP 0.100UF 10% 50V X7R CK05 9 EA C6 C8 C9 C10 C12 C13 C14 C15 C CAP 10UF 100V 20% (6.3X11) 2 EA C7 C *CAP 3300UF 25V 20% (16X25) 2 EA C1 C2 Page: /13/12

253 Parts List 2533s701.fm RES 300 OHM 3W 5% 1 EA R RES 100K OHM 3W 5% 5 EA R14 R15 R16 R17 R RES 1K OHM 1/2W 1% 2 EA R20 R RES 2K OHM 1/2W 1% 1 EA R RES 4.32K OHM 1/2W 1% 1 EA R RES 5.62K OHM 1/2W 1% 1 EA R RES 10K OHM 1/2W 1% 7 EA R6 R7 R8 R9 R11 R19 R RES 15K OHM 1/2W 1% 1 EA R RES 100K OHM 1/2W 1% 1 EA R RES 150K OHM 1/2W 1% 1 EA R RES 1MEG OHM 1/2W 1% 2 EA R5 R TRIMPOT 500K OHM 1/2W 10% 1 EA R MOV, 300WVAC, 165J, 20MM DISC 1 EA RV CONVERTER, DC/DC +12V TO 6KV 1 EA U TEST POINT, OVAL-LOOP THRU 1 EA TP *HDR 10C 2ROW VERT TOP LATCH 1 EA J TERM BLK, PCB, 1-POLE, GREY (236) 2 EA 2/TB BARCODE, SN_ITEM_REV 1 EA SPEC, ION SUPPLY 0 DWG SCH, ION SUPPLY 0 DWG PWB, ION SUPPLY 1 EA Table 7-40 KIT, SPARE PARTS (F) Harris PN Description Qty UM Ref Des CABLE ASSY, FIBER OPTIC 1 EA O-RING, INTER-CANNISTER 2 EA SLEEVE, QUARTZ 1 EA FUSE, CART 5X20MM 4A SLOW 5 EA FUSE, 250A 660VAC 10 EA FUSE, FAST15A 600V 10 EA FUSE, CART 5X20MM 5A FAST 5 EA FUSE, CART 5X20MM 10A FAST 5 EA GASKET, 1-1/4 ANSI FLANGE 2 EA FAN 115V 50/60HZ 1 EA FAN, 6-14VDC, 12V NOMINAL 1 EA FAN, 48VDC 280CFM, 6 DIA 1 EA FAN, 12V 110CFM 119MM SQ 1 EA FAN, 12VDC BRUSHLESS 1 EA SENSOR CONDUCTIVITY OMEGA CDCN 1 EA FILTER,HIGH EFF,STYLE EA FILTER, AIR 430 X 220 X 22.3MM 1 EA XFMR, SPARK GAP TRIGGER 1 EA RES, 6.65K OHM 0.1% 0.25W 1 EA CONTACTOR, 5.5KW, 12A, 3P 1 EA CNTOR, 3P 250A 110/120VAC 1 EA RELAY, OVERLOAD A 1 EA RELAY, OVERLOAD A 1 EA SW, SINGLE POLE,15A,125/250VAC 1 EA CKT BRKR, 80A 3POLE 3PH 480VAC 1 EA CB, 2 POLE, 16 AMP 277/480VAC 1 EA CKT BREAKER, 1A 1P 250VAC 1 EA CKT BREAKER, 3A 1P 250VAC 1 EA CKT BREAKER, 5A 1P 250VAC 1 EA CKT BRKR 2.0 AMPS 1P 480VAC 1 EA 04/13/ Page: 7-17

254 Parts List CKT BRKR 4 AMPS 1P 480VAC 1 EA CKT BRKR 6 AMPS 1P 480VAC 1 EA CKT BRKR 16 AMPS 1P 480VAC 1 EA CKT BRKR 4 AMPS 2P 480VAC 1 EA CKT BRKR 8 AMPS 2P 480VAC 1 EA CKT BRKR 20 AMPS 3P 480VAC 1 EA SENSOR, LIQUID LEVEL, FLOAT 1 EA FLOWMETER, GPM 1 NPT 1 EA FLOW METER, HEDLAND H EA FLOWMETER, GPM 1/2 SAE 1 EA FLOWMETER, GPM 1 SAE 1 EA FLOWMETER, GPM 1 SAE 1 EA SENSOR, CURRENT, 2ADC 1% 1 EA SENSOR, CURRENT, 5ADC 1% 1 EA SEALANT, STAINLESS PIPE 1 EA PSU BRICK, 7.5/15/15VDC 100/75/75W 1 EA PSU BRICK, 48VDC 200W 1 EA SENSOR, DC CURRENT, 100MA 1 EA TEMPERATURE SENSORS [PAIR] 1 EA ASSY, LEAK DETECTOR 1 EA ASSY, LIQUID LEVEL SWITCH 1 EA Table 7-41 KIT, SPARE PARTS, ADVANCED (H) Harris PN Description Qty UM Ref Des BLOWER, REGENERATIVE 2.5 HP 1 EA PUMP, 1.5 HP, VERTICAL, SST 1 EA MTR CONDUCTIVITY OMEGA CDTX-90 1 EA FILTER,HIGH EFF,STYLE EA XFMR, VAC TO 120VAC 1 EA XFMR, TOROID, 234V CT 1 EA XFMR, TOROID, 48V 800VA 1 EA XFMR, ISO, 120V 1.3KVA 1-PH 1 EA XFMR, AUTO 480V 3PH 25KVA 1 EA ATTENUATOR 40DB, 1KW 1 EA UPS 500VA 120AC 50/60HZ 1 EA SWITCH, NETWORK, 5-PORT ESD 1 EA MODULE, MSMCAN104 ESD 1 EA LCD DISPLAY, 12 VGA, COLOR 1 EA ASSY, ROUTER RV082 1 EA *PWA, INTERFACE BOARD 1 EA PWA, ISO SUPPLY AC INTERFACE 1 EA PWA, ISO SUPPLY TRANSIENT INTF 1 EA Table 7-42 PWA, ISO SUPPLY AC INTERFACE (B-) Harris PN Description Qty UM Ref Des CAP DISC 0.05UF 500V -20/+80% 3 EA C1 C2 C RES 10K OHM 3W 5% 1 EA R BARCODE, SN_ITEM_REV 1 EA SCH, ISO SUPPLY AC INTERFACE 0 DWG PWB, ISO SUPPLY AC INTERFACE 1 EA Table 7-43 PWA, ISO SUPPLY TRANSIENT INTF (A-) Harris PN Description Qty UM Ref Des Page: /13/12

255 Parts List 2533s701.fm RECT, GI V 6A ESD 1 EA CR DIODE, TVS (UNIDIR), ICTE-36 3 EA CR2 CR3 CR CAP, DISC 0.001UF 1KV 10% Z5U 4 EA C9 C10 C11 C CAP, DISC 0.01UF 1KV 20% 4 EA C5 C6 C7 C CAP 1UF 100V 20% 3 EA C2 C3 C CAP, 2200PF 6000V 1 EA C BARCODE, SN_ITEM_REV 1 EA SPEC, ISO SUPPLY INTERFACE AND TRANSIENT PROTECTION0 DWG SCH, ISO SUPPLY TRANSIENT INTERFACE0 DWG PWB, ISO SUPPLY TRANSIENT INTF 1 EA Table 7-44 KIT, SPARE PARTS, BEAM SUPPLY (C) Harris PN Description Qty UM Ref Des DOOR GASKET, 15 FT NWL H EA GASKET KIT, NWL EA LIQUID LEVEL GAUGE 1 EA VALVE, PRESSURE RELIEF H EA DRAIN VALVE (NWL REPL) 1 EA BUSHING, 18KV (NWL REPL) 1 EA THERMOMETER 1 EA GASP OIL SAMPLE KIT 1 EA CAP, 0.125UF NWL EA RESISTOR 20 OHM 225 WATT 2 EA RES, 100 OHM 225W NWL H EA LIMIT SWITCH, DPDT (NWL REPL) 1 EA SWITCH, OIL LEVEL (NWL REPL) 1 EA BD, INPUT PRIMARY SNUBBER 1 EA PWA, BLEEDER NWL G31XBCXE 1 EA Table 7-45 KIT, SPARE PARTS, NWL STEP START (B) Harris PN Description Qty UM Ref Des SCR BLOCK, 250A NWL P EA SCR BLOCK, 96A NWL P EA XFMR, CURRENT 200:5 NWL H EA CAP, 5UF NWL H EA RES, 2 OHM 225W NWL EA RES, 2 OHM 225W NWL H EA PWA, SCN SNUBBER NWL D EA PWA, STEP START NWL D EA Table 7-46 KIT,SPARES,POLY TANK BASE, 2IN PUMP MODULE (A) Harris PN Description Qty UM Ref Des HOSE, RUBBER 3/4 RED 8 FT HOSE, RUBBER, 2 ID 1 FT BOOTLACE FERRULE A 6-12 WEIT 12 EA BOOTLACE FERRULE A 4-12 DIN 46228, E-CU GAL. SN 24 EA WASHER, INT LOCK 3/8 1 EA HOSE CLAMP, SST, SAE-36 4 EA HOSE CLAMP, SST, SAE-12 5 EA CARTRIDGE FILTER 10MICRON 1 EA FILTER CARTRIDGE HOLDER, NYLON 1 EA SW,LIQUID LEVEL, 120VAC,0.25A 2 EA TRIDICATOR,0-100PSI, DEG F 1 EA 04/13/ Page: 7-19

256 Parts List WASHER, SNUBBER 1 EA Table 7-47 FORMAT, SYSTEM, PWR60D (AA) Harris PN Description Qty UM Ref Des B/M NOTE: 0 DWG COOLING FLUID, Dowtherm SR-1, 55GAL 0 DR COOLANT, PROPYLENE GLYCOL BASE 0 DR FLUID COOLER 4 FAN 0 EA FLUID COOLER 4-FAN LO-FLOW 0 EA KIT,6-1/8 SIGMA RF LINE-MYAT 0 EA KIT,6-1/8 SIGMA RF LINE-DIE 0 EA FLOW MTR, 15GPM, 1 FNPT 0 EA PWR SUPPLY, BEAM, 70KVA, 38KV 0 EA RF SYS, DTV 2 TUBE W/MOT SWTCH 0 EA RF SYS, DTV 2 TUBE W/MOT SWTCH 0 EA RF SYS, DTV 2 TUBE W/MOT SWTCH 0 EA KIT, MIXING VALVE, POWERCD, 2TUBE, 0 EA FAMILY TREE, POWERCD 0 DWG INSTL MTL, WIRE, POWERCD,2TUBE 1 EA PLUMBING KIT, POWERCD, 2 TUBE 1 EA KIT, PLMBNG, REDUNDANT COOLING 0 EA PUMP INTERFACE ASSY - FOR INTERFACING SIGMA PUMP TO POWERCD0 EA DOC PKG, POWERCD 2 EA IB, POWERCD, 2 TUBE SYSTEM 2 EA KIT, SPARES, WATER FILTERS, POWERCD0 EA KIT, SPARES, WATER FILTERS, POWERCD, W/O UV0 EA CALORIMETRY ASSEMBLY 0 EA KIT, INSTALL, 2 TUBE SYSTEM, POWERCD1 EA KIT, EXTERNAL SHUTOFF VALVE, POWERCD0 EA FORMAT, XMTR, PWR60D2 1 EA !FORMAT, POWERCD TANK BASE PUMP MODULE0 EA HEW8482H HEWLETT PACKARD SENSOR PROBE 0 EA HEWEPM-441A POWER METER, RF 0 EA PA MODULE DIGITAL POWER CD 0 EA KIT, SPARE BOARDS 0 EA KIT, SPARE PARTS 0 EA KIT, SPARE PARTS, ADVANCED 0 EA KIT, SPARE PARTS, BEAM SUPPLY 0 EA KIT, SPARE PARTS, NWL STEP START 0 EA KIT,SPARES,POLY TANK BASE, 2IN PUMP MODULE0 EA Table 7-48 FORMAT, XMTR, PWR60D (T) Harris PN Description Qty UM Ref Des TUBE, E2V ESCIOT5130W 0 EA CIRCUIT ASSY, E2V IMD3000EH 0 EA PUMP, VERTICAL, MULTISTAGE, 50HZ 0 EA SIDEWALLS, PAIR, 2000H X 1200W 1 EA *BREAKAWAY, MSDC IOT 2 EA CIRCULATOR, UHF 0 EA UNIT 2 CIR1 UNIT 5 CIR CIRCULATOR, UHF 0 EA UNIT 2 CIR1 UNIT 5 CIR CIRCULATOR, UHF 0 EA UNIT 2 CIR1 UNIT 5 CIR NAMEPLATE, XMTR EQUIPMENT 1 EA G PWA, CAN ADAPTER 0 EA Page: /13/12

257 Parts List 2533s701.fm CABLE PKG, POWERCD, 2 TUBE 1 EA CABLE, 3 TUBLE MARSHALING 1 EA CABLE CHANNEL 2 EA BRACKET EXC RETROFIT 0 EA ND EXCITER BLANK PANEL 0 EA PA MODULE DIGITAL POWER CD 2 EA UNIT 1 IPA1 UNIT 1 IPA PH, 400V, MOV PKG (DELTA) 0 EA UNIT 4 A12 UNIT 4 A15 UNIT 7 A12 UNIT 7 A MOV BD, 480 VAC 0 EA UNIT 4 A12 UNIT 4 A15 UNIT 7 A12 UNIT 7 A DRIVER CAB, BASIC, POWER CD 1 EA UNIT PS CABINET, POWER CD 2 EA UNIT 4 UNIT IOT CABINET, POWER CD 2 EA UNIT 2 UNIT COOLING CAB, POWERCD, DOOR FLTR 2 EA UNIT 3 UNIT KIT, POWERCD, RFU, 2 CABINET 1 EA POWER SUPPLY 480 VAC 0 EA UNIT 1 A POWER SUPPLY VAC 0 EA UNIT 1 A OBS, USE FFF EA UNIT 1 A1 UNIT 1 A KIT, 2 MODULE DRIVER 1 EA Table PH, 400V, MOV PKG (DELTA) (B) Harris PN Description Qty UM Ref Des MOV, 320WVAC, 460J, 40MM DISC 1 EA RV MOV, 510WVAC, 700J, 40MM DISC 3 EA RV1 RV2 RV CABLES, JUMPERS 3PH DELTA 1 EA *PWA, MOV/AC SAMPLE AA, 400VDELTA1 EA A14 Table 7-50 *PWA, MOV/AC SAMPLE AA, 400VDELTA (C--) Harris PN Description Qty UM Ref Des RIVET 3/16 ALUM.126/.25 8 EA 2XF1 2XF2 2XF3 2XF DIODE, RECT 1N EA CR1 CR2 CR3 CR4 CR LED, RED T1-3/4 VERT 1 EA DS OPTOISO, MOC8050 (DIP-6) 4 EA U1 U2 U3 U FUSE, FAST 600VAC/500VDC 12A 4 EA F1 F2 F3 F CLIP, FUSE 13/32 DIA, SOLDER 8 EA 2XF1 2XF2 2XF3 2XF CAP 0.100UF 5% 63V 3 EA C6 C8 C CAP 1.0UF 50V 20% 8 EA C1 C2 C3 C4 C14 C15 C16 C CAP 10UF 50V 20% (5X11) 3 EA C5 C7 C RES 20K OHM 3W 5% 4 EA R32 R33 R34 R RES, WW 110K OHM 5% 10W AXIAL 4 EA R1 R5 R9 R RES, WW 60K OHM 5% 10W AXIAL 4 EA R2 R6 R10 R RES 1MEG OHM 2W 5% 6 EA R11 R22 R40 R49 R50 R RES 100K OHM 1/2W 1% 8 EA R4 R8 R12 R16 R36 R37 R38 R TRIMPOT 100K OHM 1/2W 10% 3 EA R52 R53 R *HEADER, 20C TWO ROW VERTICAL 1 EA J LUG QC250 MALE PCB VERTICAL 13 EA E1 E4 E5 E8 E9 E10 E11 E14 E15 E16 E19 E20 E BARCODE, SN_ITEM_REV 1 EA SCH, MOV/AC SAMPLE 0 DWG *PWA, MOV/AC SAMPLE AA, SMT 1 EA Table 7-51 MOV BD, 480 VAC (A) Harris PN Description Qty UM Ref Des MOV, 575WVAC, 770J, 40MM DISC 4 EA RV1 RV2 RV3 RV4 04/13/ Page: 7-21

258 Parts List PWA, MOV/AC SAMPLE, PH 1 EA Table 7-52 PWA, MOV/AC SAMPLE, PH (D--) Harris PN Description Qty UM Ref Des RIVET 3/16 ALUM.126/.25 8 EA 2/XF1 2/XF2 2/XF3 2/XF DIODE, RECT 1N EA CR1 CR2 CR3 CR4 CR LED, RED T1-3/4 VERT 1 EA DS OPTOISO, MOC8050 (DIP-6) 4 EA U1 U2 U3 U FUSE, FAST 600VAC/500VDC 12A 4 EA F1 F2 F3 F CLIP, FUSE 13/32 DIA, SOLDER 8 EA 2XF1 2XF2 2XF3 2XF CAP 0.100UF 5% 63V 3 EA C6 C8 C CAP 1UF 100V 20% 3 EA C11 C12 C CAP 1.0UF 50V 20% 8 EA C1 C2 C3 C4 C14 C15 C16 C CAP 10UF 50V 20% (5X11) 3 EA C5 C7 C RES 20K OHM 3W 5% 4 EA R32 R33 R34 R RES, WW 110K OHM 5% 10W AXIAL 4 EA R1 R5 R9 R RES, WW 60K OHM 5% 10W AXIAL 4 EA R2 R6 R10 R RES 15K OHM 3W 1% 12 EA R18 R19 R20 R21 R23 R24 R25 R26 R28 R29 R30 R RES 100K OHM 1/2W 1% 8 EA R4 R8 R12 R16 R36 R37 R38 R RESISTOR, PTC 60V 0.15A 3 EA R17 R22 R *HEADER, 20C TWO ROW VERTICAL 1 EA J LUG QC250 MALE PCB VERTICAL 13 EA E1 E4 E5 E8 E9 E10 E11 E14 E15 E16 E19 E20 E VOLTAGE TRANSDUCER, ESD 3 EA U5 U6 U BARCODE, SN_ITEM_REV 1 EA SCH, MOV/AC SAMPLE 0 DWG PWB, MOV/AC SAMPLE 1 EA Table 7-53 DRIVER CAB, BASIC, POWER CD (AA) Harris PN Description Qty UM Ref Des GROMMET STRIP, FT RUB SILICONE SPONGE 0 RL GLOVES, THERMAL 1 EA POLYURETHANE TUBE, 9MM ID 0.55 ME SCREW, M5 X 16MM, BLK W/WASHER 50 EA SCR, 4 X 1/2 TAPPING 2 EA *HOSE CLAMP, (MINI) SST, SAE-6 1 EA CAGE NUT, M5-0.8, GA. 56 EA HOSE CLAMP, SST, SAE-24 8 EA MOUNT, RIBBON CABLE, 2 6 EA CABLE PUSH MOUNT 10 EA PLUG, WHT HOLE 2 EA END STOP, 264 TERM BLOCK 2 EA END PLATE, ORANGE (264) 1 EA PLATE, END STOP, DIN RAIL MTG 4 EA #TB2 TB PLUG, TAPERED, FITS 1-1/4 NPT 2 EA GROMMET GROOVE DIA 1 EA GROMMET 1-3/4 MTG DIA 1 EA GROMMET GROOVE DIA 5 EA BUMPER 5/8 DIA X 1/4 THK 1 EA FAN GUARD, 120MM WIRE-FORM 3 EA Page: /13/12

259 Parts List 2533s701.fm FAN, 12V 110CFM 119MM SQ 3 EA B1 B2 B HANDLE, PULL, OVAL, BLACK, M5 2 EA HINGE ADJUSTABLE BLACK 2 EA FILTER, AIR 430 X 220 X 22.3MM 1 EA CABINET, 2M X 0.6M X 1.2M 1 EA TOOL, ACTUATION, WAGO 2.5MM 2 EA CKT BRKR 8 AMPS 2P 480VAC 2 EA CB11 CB CKT BRKR 20 AMPS 3P 480VAC 1 EA CB PLUG, MALE 4C 1ROW STRAIGHT 2 EA J1 J JUMPER, 2-POLE, GREY (264) 6 EA PLUG, MALE 10C 1ROW STRAIGHT 1 EA TERM BLK, THRU, 4-POLE, BLUE (264) 10 EA TERM BLK, THRU, 2-POLE, GREY (264) 3 EA TERM BLK, GND, 2-POLE GRN/YEL (283) 12MM1 EA TERM BLK, THRU, 2-POLE GREY (285) 16MM6 EA SPLITTER, 2-WAY-0, BNC 2 EA SP1 SP JACK, BNC 75 OHM BULKHEAD 2 EA A1J13 A1J ADAPTER, SMA-JACK TO SMA-JACK 1 EA ADAPTER, 7/16 JACK TO JACK 2 EA SENSOR, LIQUID LEVEL, FLOAT 1 EA S FLOWMETER, GPM 1 NPT 1 EA U LABEL, DANGER HI VOLTAGE 1 EA NAMEPLATE, DOMED, HARRIS LOGO 1 EA LABEL, GLYCOL WARNING 1 EA NAMEPLATE, DOMED, POWERCD 1 EA PSU BRICK, 7.5/15/15VDC 100/75/75W 2 EA LVPS1 LVPS ACCESSORIES-TORX-TAPPING SCREW BZ5,5X1350 EA SKID, DRIVER, POWER SUPPLY 1 DWG WIRING DIAGRAM DRIVER CABINET 0 DWG LABEL, COMPONENT LOCATING, DRIVER, REAR1 DWG G PWA, CAN ADAPTER 1 EA CABLE, GROUND 1 EA CABLE LVPS AC DISTRIBUTION 1 EA CABLE LVPS DC DISTRIBUTION 1 EA CABLE CONTROLLER 1 EA CABLE CUSTOMER I/O 1 EA LVPS SENSE JUMPER SMALL 2 EA LVPS SENSE JUMPER LARGE 4 EA CABLE CABINET CONTROL PCD 1 EA CABLE CAB AC DIST MODULE PCD 1 EA CABLE BACKPLANE POWER CD 1 EA DIN RAIL, CUT LENGTH 108MM 1 EA DIN RAIL, CUT LENGTH 360MM 1 EA SCREW, SHOULDER 2 EA ALIGNMENT PIN 2 EA STANDOFF, MALE-FEM, 19 MM LONG 6 EA ADAPTER, HOSE 1 EA RAIL, DIN 180MM LG 1 EA BRACKET, SPLITTER MTG 3 EA BRACKET, CAB TO CAB 2 EA STANDOFF, CAB TO CAB 2 EA BRACKET, MANIFOLD SUPPORT 2 EA BRACKET, POSITIONING 1 EA PANEL, BLANK, 1.7 TALL 2 EA 04/13/ Page: 7-23

260 Parts List ANGLE, STIFFENING 1 EA PANEL, I/O 1 EA PANEL, I/O 1 EA PANEL, BLANK, 1U 1 EA BRACKET, SLIDE MTG 4 EA BRACKET, SLIDE MTG 2 EA PANEL, TOP 1 EA PLUMBING, RETURN MANIFOLD 1 EA PLUMBING, SUPPLY MANIFOLD 1 EA GROUND STRAP, DRIVER - COOLING 1 EA SHELF, CAGE 1 EA PANEL, BLANK, PA MODULE, 3 POS 1 EA SIDE, CAGE RIGHT 1 EA MOUNTING BAR, RF CONNECTOR 1 EA DRIP TRAY 1 EA PLATE, MODULE CATCH (5 MOD) 1 EA SIDE, CAGE LEFT 1 EA PANEL, CAGE MIDDLE FRONT 1 EA PANEL, FRONT BLANK 4U 1 EA SUPPORT, CAGE SHELF 5 EA TOP, CAGE 1 EA DEFLECTOR, CAGE AIR 5 EA SUPPORT, RACK FLOOR 3 EA FLOOR, RACK 1 EA MOUNTING PANEL [3 FAN] 1 EA COVER, AIR FILTER 1 EA BRACKET, REMOVABLE FAN 1 EA PAN, DRIP 1 EA CUP, FLOAT DRIP 1 EA BRACKET, C.B. MTG 1 EA BRACKET, C.B STOP 2 EA COVER, LVPS C.B. SAFETY 1 EA TRAY, AIR DEFLECTOR 1 EA PANEL, HOSE DISCONNECT 1 EA BRACE, CAGE TOP 3 EA ROLLER, MODULE ALIGNMENT 10 EA ANGLE, FRONT PANEL SUPPORT 1 EA BRACKET, P.A. MOD C.B. SUPPORT 1 EA GUIDE, MODULE, BLACK PVC 10 EA COVER, CONTROLLER PWA SAFETY 1 EA SPACER, XFMR SHOULDER 1 EA CABLES, RIBBON ATLAS ANALOG 1 EA STRAP, FRONT TO BACK GROUND 1 EA BRACKET, HELIAX SUPPORT 2 EA DIN RAIL, 428 MM LONG 1 EA TEMPERATURE SENSORS [PAIR] 1 EA U2 U SPACER, DUCT SIDE 4 EA COVER, POWER BLOCK 1 EA CONN WC XMTR TO MODULE 1 EA CABLES, RIBBON DRIVER CABINET 1 EA PANEL, UPPER DUCT 2 EA PANEL, DUCT, INNER RIGHT 1 EA CABLE HELIAX W501 1 EA W TRAY, TB MTG 1 EA Page: /13/12

261 Parts List 2533s701.fm COVER, TB 1 EA CHANNEL, TB WIRE ROUTING 1 EA PLATE, GROUND 3 EA PLATE, INTERFACE 1 EA HOSE ASSY, SUPPLY 2 EA SPACER, HINGE 2 EA COVER, I/O 1 EA ARM, CABLE SUPPORT 3 EA PANEL, I/O SILKSCREEN 1 EA DUCT, UPPER SUB ASSY 1 EA DUCT, LOWER SUB ASSY 1 EA SPACER, 0.75 OD ID X EA SPACER, 0.75 OD ID X EA PANEL, DUCT, INNER LEFT 1 EA PANEL, MAIN CIRCUIT BREAKER 1 EA RAIL, TRANSFORMER ASSY 2 EA AIR DEFLECTOR 8 EA PANEL, C.B. ACCESS 1 EA BRACKET EXC RETROFIT 2 EA CABLE DRIVER CONTROL 1 EA CHANNEL, DUCT SIDE 4 EA PANEL, DUCT OUTER 2 EA ASSY, CONTROL PANEL (230VAC) 1 EA A ROUTER CHASSIS, POWER CD 1 EA A *ASSY, DISPLAY UNIT W/ GUI P-CD 1 EA PWA, MODE CONTROLLER 1 EA A *PWA, POWER SUPPLY MONITOR CONTROLLER UNTESTED1 EAA PWA, BACKPLANE 1 EA A PWA, CUSTOMER INTERFACE BOARD 1 EA A *PWA, EXTERNAL I/O 1 EA A6 Table 7-54 *ASSY, DISPLAY UNIT W/ GUI P-CD (A) Harris PN Description Qty UM Ref Des GROMMET, 3/16 MTG DIA 2 EA MOUNTING ARM, ADJ, 6 1 EA #A LCD DISPLAY, 12 VGA, COLOR 1 EA A ASSY, DISPLAY UNIT MINUS GUI POWER-CD1 EA Table 7-55 ASSY, DISPLAY UNIT MINUS GUI POWER-CD (B) Harris PN Description Qty UM Ref Des CORD, AC, 3C, NEMA/IEC PLUG 1 EA CABLE ASSY, SVGA,D15 MALE/MALE 1 EA JACKSCREW, 4-40 FEMALE HEX 3 EA FUSE, CART 5X20MM 4A SLOW 2 EA HANDLE, 1-PULL, BLACK, M4 2 EA *FILTER, RFI POWER LINE ENTRY 1 EA FL LABEL, INSPECTION 1 EA PSU, +5/+12VDC 110W 1 EA PS SWITCH, NETWORK, 5-PORT ESD 1 EA A COMPUTER (SBC), PCM-9375 ESD 1 EA A PC/104 CARD, PCM EA A WIRING DIAGRAM, DISPLAY UNIT 0 DWG G PWA, RJ-45 ETHERNET INTERFACE 1 EA ASSY, 12 VOLT FAN WITH PLUG 1 EA B1 04/13/ Page: 7-25

262 Parts List CABLE, DISPLAY UNIT 1 EA HARD DRIVE ASSEMBLY 1 EA A CHASSIS, DISPLAY UNIT 1 EA FRONT PANEL, DISPLAY UNIT 1 EA COVER, POWER SUPPLY 1 EA BRACKET, HARD DRIVE 1 EA COVER, DISPLAY UNIT 1 EA SPACER 4 EA PLATE, PWB MTG. 1 EA *PWA, INTERFACE BOARD 1 EA A PWA, ADAPTER PCB 1 EA Table 7-56 PWA, MODE CONTROLLER (E--) Harris PN Description Qty UM Ref Des DIODE, SCHOTTKY 32CTQ030 2 EA CR115 CR CONVERTER, DC/DC 5V.75W ESD 1 EA U RELAY 4PDT 12VDC 2A NON-LATCH 7 EA K17 K18 K19 K20 K21 K22 K HDR, 2C VERT 1ROW UNSHR 15 EA JP1 JP2 JP3 JP4 JP5 JP6 JP7 JP8 JP9 JP10 JP11 JP12 JP13 JP14 JP HDR, 6C VERT 2ROW UNSHR 5 EA J54 J55 J65 J76 J HDR, 12C VERT 1ROW FRICTION 1 EA J <*>HDR, 50C 2ROW VERTICAL (SYS 50) 2 EA J71 J HDR, 2C 1ROW VERTICAL 3 EA J73 J80 J HDR, 3C 1ROW VERTICAL 4 EA J57 J61 J66 J HDR, 4C 1ROW VERTICAL 7 EA J53 J56 J60 J68 J72 J78 J HDR, 6C 1ROW VERTICAL 5 EA J51 J59 J62 J69 J HDR, 8C 1ROW VERTICAL 16 EA J37 J38 J39 J40 J41 J42 J43 J44 J45 J46 J47 J48 J49 J50 J67 J HDR, 12C 1ROW VERTICAL 32 EA J1 J2 J3 J4 J5 J6 J7 J8 J9 J10 J18 J19 J20 J21 J22 J23 J24 J25 J26 J27 J28 J29 J30 J31 J32 J33 J34 J35 J63 J64 J74 J HDR, 26C 2ROW VERTICAL 2 EA J17 J JUMPER SHUNT, 2C, 0.1 PITCH 17 EA #J55 #J65 #J76 #J83 #JP1 #JP2 #JP3 #JP4 #JP5 #JP6 #JP7 #JP8 #JP11 #JP12 #JP13 #JP14 #JP RECP, D STRT 9C PCB 1 EA J PLUG, 2C 1ROW VERTICAL 3 EA #J73 #J80 #J PLUG, 3C 1ROW VERTICAL 4 EA #J57 #J61 #J66 #J PLUG, 4C 1ROW VERTICAL 7 EA #J53 #J56 #J60 #J68 #J72 #J78 #J PLUG, 6C 1ROW VERTICAL 5 EA #J51 #J59 #J62 #J69 #J PLUG, 8C 1ROW VERTICAL 5 EA #J39 #J40 #J47 #J67 #J PLUG, 12C 1ROW VERTICAL 24 EA #J1 #J3 #J5 #J7 #J8 #J10 #J19 #J20 #J22 #J23 #J25 #J26 #J28 #J29 #J30 #J31 #J32 #J33 #J34 #J35 #J63 #J64 #J74 #J BARCODE, SN_ITEM_REV 1 EA SCH, MODE CONTROLLER 0 DWG SW, MODECONTROLLER SOURCE CODE0 DWG PWA, MODE CONTROLLER SMT 1 EA Table 7-57 PWA, CUSTOMER INTERFACE BOARD (D-) Harris PN Description Qty UM Ref Des B/M NOTE: 2 DWG J8 J <*>HDR, 50C 2ROW VERTICAL (SYS 50) 2 EA J1 J10 Page: /13/12

263 Parts List 2533s701.fm HDR, 12C 1ROW VERTICAL 30 EA J2 J3 J4 J5 J6 J7 J11 J12 J13 J14 J15 J16 J17 J18 J19 J20 J21 J22 J23 J24 J25 J26 J27 J28 J29 J30 J31 J32 J33 J BARCODE, SN_ITEM_REV 1 EA SCH, CUSTOMER INTERFACE BOARD 0 DWG PWB, CUSTOMER INTERFACE BOARD 1 EA Table 7-58 PS CABINET, POWER CD (U) Harris PN Description Qty UM Ref Des GASKET, RUBBER 1.5 FT FILTER,AIR X 15.0 X EA CABLE ASSY, FIBER OPTIC 6 EA W7 W8 W9 W10 W12 W SCREW M5 X 16MM, BLK W/WASHER 30 EA BOLT, SHLDR, M X 54.4LG 1 EA CAGE NUT, M5-0.8, GA. 16 EA CABLE CLAMP, 1/2 ID STEEL 6 EA MOUNT, RIBBON CABLE, 2 14 EA CABLE PUSH MOUNT 35 EA FLANGE, GREY (262) 1 EA SLIDES, DRAWER 1 PR PLATE, END STOP, DIN RAIL MTG 14 EA END PLATE, GREY (283, 2-POLE) 1 EA LED REPL. LAMP, WHT, SOCKETED 2 EA LM1 LM LAMP HOLDER, SINGLE, 12V, 25W 2 EA CORE, EMI SUPPRESSION, 0.5 ID 1 EA FAN, 48VDC 280CFM, 6 DIA 3 EA B1 B2 B *KEYLOCK SET, POWERCD 1 EA LATCH, FLUSH, LIFT & TURN 2 EA XFMR, VAC TO 120VAC 1 EA T XFMR, ISO, 120V 1.3KVA 1-PH 1 EA T ATTEN, SMA, 3DB, 2W, 50 OHM 1 EA R ATTEN, SMA, 5DB, 2W, 50 OHM 2 EA R7 R SPARK GAP, 3-ELECTRODE 1 EA SG CNTOR, 3P 250A 110/120VAC 1 EA K SW, DPDT 15A 125/250 VAC 2 EA S2 S CB, 3 POLE, 20 AMP 277/480VAC 1 EA CB CB, 2 POLE, 16 AMP 277/480VAC 1 EA CB CIRCUIT BREAKER, 2A 1P 277V 2 EA CB3 CB CIRCUIT BREAKER, 1A 1P 277V 1 EA CB CIRCUIT BREAKER, 2.5A 1P 277V 1 EA CB CIRCUIT BREAKER, 4A 1P 277V 1 EA CB CIRCUIT BREAKER, 4.5A 1P 277V 1 EA CB PLUG, MALE 10C 1ROW STRAIGHT 1 EA J TERM BLK, THRU, 4-POLE, BLUE (262) 1 EA TERM BLOCK,3C MODULAR EA JUMPER, ADJACENT 2-POLE (283:283) 12MM4 EA PWR DIST BLK, 310AMP 1P 1X1 1 EA TB PWR DIST BLK, 310AMP 3P 1X2 2 EA TB1 TB JUMPER, 2-POLE ADJACENT EA TERM BLK, THRU, 2-POLE GREY (283) 12MM8 EA SENSOR, CURRENT, 2ADC 1% 5 EA U2 U3 U4 U6 U5B SENSOR, CURRENT, 5ADC 1% 1 EA U5A 04/13/ Page: 7-27

264 Parts List PSU BRICK, 7.5/15/15VDC 100/75/75W 2 EA LVPS1 LVPS PSU BRICK, 48VDC 200W 2 EA LVPS2 LVPS CTRLR, STEP START 3-PH 480V 1 EA A SENSOR, DC CURRENT, 100MA 1 EA U ACCESSORIES-TORX-TAPPING SCREW BZ5,5X1370 EA GROUNDING PLATE 3 EA SKID, DRIVER, POWER SUPPLY 1 DWG WIRING DIAGRAM, PWR CD PWR SUP 0 DWG CABLE PS SENSOR 1 EA CABLE TOWER 1 EA LVPS SENSE JUMPER SMALL 2 EA LVPS SENSE JUMPER LARGE 4 EA SWITCH STANDOFF 7 EA STDOFF, 0.38 X LG X M4 4 EA DAMPER 1 EA ROD, SENSOR GND 6 EA LABEL, COMP LOC, FRONT TOP, PS 1 EA LABEL, COMP LOC, FRONT, BOT,PS 1 EA LABEL, COMP LOCATION, REAR, PS 1 EA DIN RAIL, CUT LENGTH 72MM 1 EA DIN RAIL, CUT LENGTH 180MM 1 EA DIN RAIL, CUT LENGTH 468MM 1 EA BRACKET, LOCK MTG. 2 EA VERTICLE STOP 1 EA BRACKET, LOCK MTG 1 EA SUPPORT SECTION 1 EA ANGLE, BRACE SUPPORT 2 EA BRACE 3 EA WINDOW, REAR DOOR 1 EA BRACKET, MICRO-SWITCH MTG 1 EA BRACKET, SLIDE MTG 2 EA ANGLE, UPPER SUPPORT 2 EA ANGLE, SHELF SUPPORT (L) 1 EA ANGLE, SHELF SUPPORT (R) 1 EA CHANNEL, SUPPORT W/PIVOT HOL 1 EA CHANNEL, SUPPORT 1 EA PLATE, HOMING 1 EA POST, PIVOT 1 EA PAD, PIVOT 1 EA SHIM, FILTER FRAME 2 EA SHIM, FILTER FRAME 1 EA BRKT, SENSOR GND 6 EA BRKT, LOCK MTG 1 EA PLATE, SUPPLY AIR 1 EA PLATE, SUPPLY AIR 1 EA PLATE, SUPPLY AIR 1 EA ANGLE, DOOR LOCK 1 EA PANEL, VICOR MOUNTING 2 EA ANGLE, FRONT CLOSEOUT 1 EA PANEL, MOV MOUNTING 1 EA PANEL, AC ACCESS 1 EA FRAME, FILTER 1 EA ANGLE, LOCK 2 EA BRKT, LED LAMP 1 EA Page: /13/12

265 Parts List 2533s701.fm BOX, MICROSWITCH 1 EA ANGLE, DOOR LOCK 1 EA PANEL, TRIM 1 EA BRKT, SPARK GAP 1 EA SWITCH, 30 AMP MOD W/KEYLOCK 1 EA SWITCH, 200 AMP MOD W/ KEYLOCK 1 EA EARTH SWITCH ASSEMBLY 1 EA TOWERS SUPPORT PLATE 1 EA PLATE, LOCK 1 EA BASE, CABINET 1 EA PANEL, LEFT SIDE 1 EA PANEL, RIGHT SIDE 1 EA SHELF, FRONT 1 EA PANEL, FRONT DIVIDER 1 EA PANEL, REAR DIVIDER 1 EA CHASSIS, 480V MOUNTING 1 EA STRAP, PS CAB GND 1 EA STRAP, PS CAB GND 1 EA STRAP, PS CAB GND 1 EA TOP, CABINET 1 EA SHELF, REAR 1 EA CABINET, MODIFIED RITTAL 1 EA PANEL, FRONT ACCESS 1 EA PANEL, FAN DIVIDER 1 EA PANEL, FAN MOUNTING 1 EA GUARD, FAN 1 EA TRIM, FRONT ACCESS 1 EA ANGLE, FRONT ACCESS 1 EA HINGE, FRONT ACCESS 1 EA PANEL, FRONT ACCESS 1 EA SUPPORT, RACK FLOOR 2 EA RIBBON CABLES, POWER SUPPLY 1 EA PLATE, EXHAUST AIR 1 EA AIR DEFLECTOR 1 EA DUCT, LOWER 1 EA DUCT, UPPER 1 EA CLOSE-OUT PLATE 1 EA BRACKET, CIRCUIT BREAKER PANEL 2 EA COVER, CIRCUIT BREAKER 1 EA SCREEN, REAR DOOR 1 EA BUSBAR 1 EA #CB3-CB COVER, HIGH VOLTAGE METERING 1 EA CABLE PWR SUPPLY AC DIST. 1 EA CABLE PWR SUPPLY LVPS 1 EA CABLE, HPA CONTROL 1 EA CABLE STEP START CONTROL 1 EA TOWER, RESISTOR - GND SWITCH 4 EA A2 A3 A4 A SUPPLY, ISO 1 EA A FOCUS SUPPLY 1 EA A ASSY, CONTROL PANEL (115VAC) 1 EA A *ASSY, DISPLAY UNIT W/ GUI P-CD 1 EA A PWA, SPARK GAP INTERFACE 1 EA *PWA, HPA CONTROLLER 1 EA A PWA, STEP START CONTROL 1 EA A10 04/13/ Page: 7-29

266 Parts List *PWA, HIGH VOLTAGE METERING 1 EA Table 7-59 TOWER, RESISTOR - GND SWITCH (A) Harris PN Description Qty UM Ref Des SCREW, SHCS, M6 X 40MM LG 2 EA LUG RING # AWG RED 2 EA CONTACT, SPRING 1 EA FLANGE, GREY (262) 1 EA CLIP, FUSE 0.250DIA 4 EA RES 22K OHM 3W 5% 2 EA R3 R RES, 50 MEG 48KV 19W 0.25% 2 EA R1 R TERM BLK, THRU, 4-POLE, BLUE (262) 1 EA MTG, CONTACT 1 EA DISC, RESISTOR TOWER 1 EA ANGLE BRACKET 1 EA ISOLATION BLOCK 1 EA BRACKET, ANGLE 2 EA PILLAR, EARTHING 4 EA Table 7-60 SUPPLY, ISO (E) Harris PN Description Qty UM Ref Des LUG QC FEM AWG YEL 4 EA #T CLAMP, FLAT CABLE 1 IN. 2 EA CABLE PUSH MOUNT 11 EA END STOP, 264 TERM BLOCK 2 EA #TB END PLATE, ORANGE (264) 1 EA #TB CORE, EMI SUPRESSION, ID 1 EA GROMMET GROOVE DIA 1 EA FAN 115V 50/60HZ 1 EA B CATCH DRAW 1 EA CKT BREAKER, 1A 1P 250VAC 2 EA CB1 CB CKT BREAKER, 3A 1P 250VAC 1 EA CB CKT BREAKER, 5A 1P 250VAC 1 EA CB JUMPER, 2-POLE, GREY (264) 2 EA #TB TERM BLK, THRU, 4-POLE, BLUE (264) 5 EA 5#TB POST, BINDING, BLK, GOLD FLASH 3 EA 1#A6 2#A POST, BINDING, RED, GOLD FLASH 3 EA 1#A6 2#A POST, BINDING, STD NYLON, RED 3 EA 3#A WIRING DIAGRAM ISO SUPPLY 0 DWG CARRIER RAIL, EA #TB STANDOFF, M4 X 1.00 LG HEX 6 EA 6#A BRACKET, THERMAL BREAKER MTG 1 EA BRACKET, FAN 1 EA POST, HOMING 2 EA PAD, TEFLON 3 EA TAB, LEAD-IN 2 EA DUCT, AIR 1 EA HINGE, ENCLOSURE 1 EA BOX, TRANSIENT INTERFACE 1 EA BOX, AC INTERFACE 1 EA ENCLOSURE, AL BOX MOD (L) 1 EA ENCLOSURE, AL BOX MOD (R) 1 EA LABEL, FOCUS SUPPLY 1 EA CABLE ISO SUPPLY 1 EA Page: /13/12

267 Parts List 2533s701.fm ASSY, GRID SUPPLY 1 EA A ASSY, FILAMENT SUPPLY 1 EA A *PWA, ISO SUPPLY MONITOR 1 EA A PWA, ISO SUPPLY AC INTERFACE 1 EA A PWA, ISO SUPPLY TRANSIENT INTF 1 EA A *PWA, ION SUPPLY 1 EA Table 7-61 ASSY, CONTROL PANEL (115VAC) (G) Harris PN Description Qty UM Ref Des STANDOFF, HEX M3 X 16, M/F 4 EA GROMMET, 3/16 MTG DIA 2 EA HANDLE, 1-PULL, BLACK, M4 2 EA HINGE, 120 DEG, SELF CLOSING 2 EA ELASTOMER, CONTROL BUTTONS, FRONT1 EA UPS 500VA 120AC 50/60HZ 1 EA WINDOW, FRT PNL 1 EA BRACKET, DOOR STOP MTG 2 EA BLOCK, HINGE MTG 2 EA BLOCK, DOOR MTG 2 EA PANEL, PWA COVER, REAR 1 EA CHASSIS, CONTROL/UPS UNIT 1 EA MTG BRACKET, UPS 2 EA FRONT PANEL, CONTROL 1 EA *PWA, SWITCH BOARD 1 EA Table 7-62 IOT CABINET, POWER CD (C) Harris PN Description Qty UM Ref Des CABLE PUSH MOUNT 8 EA CLIP, FUSE A 250V 2 EA #EARTH WAND CABINET, 2M X 0.8M X 0.8M 1 EA SW, SINGLE POLE,15A,125/250VAC 1 EA S DIRECTIONAL COUPLER 10DB BNC 3 EA DC5 DC6 DC ADAPTER, 7/16 JACK TO JACK 1 EA ACCESSORIES-TORX-TAPPING SCREW BZ5,5X1380 EA DIRECTIONAL COUPLER, 1000W 1 EA DC GROUNDING PLATE 1 EA SKID, IOT 1 DWG WIRING DIAGRAM IOT CABINET 0 DWG LABEL, COMPONENT LOCATION, IOT 1 EA BLOCK, MTG 1 EA BRACKET, BREAKAWAY 2 EA BRACKET, SPLITTERS 1 EA BRACE, IOT CABINET 1 EA PLATE, CLOSE-OUT 1 EA PLATE, EXHAUST AIR 1 EA BRACKET, COOLING HOSE 1 EA PLATE, EARTH WAND 1 EA SPACER, CABINET 4 EA TOP, CABINET 1 EA PANEL, LEFT SIDE 1 EA PANEL, RIGHT SIDE 1 EA BRACKET, SUPPORT 1 EA #BREAKAWAY PANEL, REAR 1 EA 04/13/ Page: 7-31

268 Parts List CABLES, COAX IOT 1 EA KIT, EARTH WAND 1 EA Table 7-63 KIT, EARTH WAND (C) Harris PN Description Qty UM Ref Des ASSY INSTR, EARTH WAND KIT 0 DWG HOOK, GROUNDING 1 EA ROD, GROUNDING 1 EA A *BUS WIRE, 10AWG, STRANDED TINNED CU6.3 FT PLASTIC TUBE 4AWG CLEAR 6.2 FT LUG RING 1/4 8AWG N-INSUL 2 EA LOCKWASHER, SPLIT 1/4 PH-BRZ (ANSI) 1 EA WASHER, INT LOCK 1/4 1 EA WASHER, FLAT 1/4 BRASS (ANSI REGULAR)1 EA NUT, HEX 1/ EA *SEALANT, GLYPTOL, RED 0 QT Table 7-64 POWER SUPPLY 480 VAC (S) Harris PN Description Qty UM Ref Des SCREW, M4 X.7 X 16 4 EA PLATE, END STOP, DIN RAIL MTG 6 EA BOLT, SHOULDER AXLE 4 EA END PLATE, GREY (283, 2-POLE) 1 EA TB HANDLE, PULL, OVAL, BLACK, M5 2 EA CASTER, WHEEL ONLY 4 EA XFMR, AUTO 480V 3PH 25KVA 1 EA T MOV, 575WVAC, 770J, 40MM DISC 4 EA CIRCUIT BREAKER, 40A 3POLE 480V 1 EA CB TERM BLOCK,3C MODULAR EA JUMPER, STEP-DOWN 2-POLE (283:281) 9MM3 EA TERM BLK, THRU, 2-POLE GREY (283) 12MM6 EA TERM BLK, THRU, 2-POLE GREY (285) 16MM9 EA JUMPER, ADJACENT 2-POLE (285:285) 16MM3 EA CABLES, JUMPERS 3PH DELTA 1 EA XFMER CABLE, POWERCD 1 EA DIN RAIL, CUT LENGTH 108MM 1 EA DIN RAIL, CUT LENGTH 144MM 1 EA DIN RAIL, CUT LENGTH 324MM 1 EA BRACKET, SLED MTG 1 EA SPACER, NYLON 6.35 DIA X 9MMLG 2 EA CHASSIS ASSY 208V TRANSFORMER 1 EA COVER, MOV SAFETY 1 EA SUPPORT, SHIELD 1 EA SHIELD, SAFETY OVP BD 1 EA PANEL, MOV BD MTG 1 EA INSULATOR, PS 8 EA CHASSIS, PS 1 EA BRKT, MOV BD MTG 1 EA TRAY, OVP BD MTG 1 EA STANDOFF, MALE-FEMALE, M4 2 EA PWA, MOV/AC SAMPLE, PH 1 EA A *PWA, OVERVOLTAGE PROTECTION UNTESTED1 EAA2 Page: /13/12

269 Parts List 2533s701.fm Table 7-65 *PWA, OVERVOLTAGE PROTECTION UNTESTED (H--) Harris PN Description Qty UM Ref Des B/M NOTE: 2 DWG C11 R A *TUBING, SHRINKABLE 3/ FT END PLATE, GREY (236) 1 EA XTB DIODE, RECT 1N EA CR DIODE, 40EPS12 ESD 3 EA CR13 CR14 CR THYRISTOR, CS45-16IO1 3 EA Q1 Q2 Q OPTOISO, MOC8050 (DIP-6) 1 EA U *ZENER 1N4755A 43V 5% 1W 3 EA CR10 CR11 CR *ZENER 1N5383B 150V 5% 5W 9 EA CR1 CR2 CR3 CR4 CR5 CR6 CR7 CR8 CR FUSE, FAST15A 600V 3 EA F1 F2 F FUSE CLIP, 13/32, 30 AMP, PCB MT 6 EA 2/XF1 2/XF2 2/XF CAP, 0.22UF 275V CLASS X2 3 EA C1 C2 C CAP 0.100UF 10% 100V X7R 3 EA C4 C5 C CAP 1.0UF 50V 20% 2 EA C7 C CAP 2200PF 10% 100V X7R CK05 3 EA C8 C9 C RES 100 OHM 3W 5% 3 EA R13 R14 R RES 30K OHM 3W 5% 6 EA R1 R2 R6 R7 R10 R RES 51K OHM 3W 5% 1 EA R RES 1K OHM 1/2W 1% 3 EA R17 R18 R RES 100K OHM 1/2W 1% 5 EA R3 R4 R5 R8 R MOV, 175WVAC, 135J, 20MM DISC 9 EA RV1 RV2 RV3 RV4 RV5 RV6 RV7 RV8 RV HDR, 6C VERT 1ROW 1-WALL 1 EA J LUG QC250 MALE PCB VERTICAL 3 EA E1 E2 E TERM BLK, PCB, 1-POLE, GREY (236) 2 EA 2/TB BARCODE, SN_ITEM_REV 1 EA SCH, OVERVOLTAGE PROTECTION 0 DWG PWB, OVERVOLTAGE PROTECTION 1 EA Table 7-66 POWER SUPPLY VAC (L) Harris PN Description Qty UM Ref Des SCREW, M4 X.7 X 16 4 EA PLATE, END STOP, DIN RAIL MTG 4 EA BOLT, SHOULDER AXLE 4 EA HANDLE, PULL, OVAL, BLACK, M5 2 EA CASTER, WHEEL ONLY 4 EA XFMR, AUTO 400 3PH 38KVA 1 EA T MOV, 320WVAC, 460J, 40MM DISC 1 EA MOV, 510WVAC, 700J, 40MM DISC 3 EA CIRCUIT BREAKER, 40A 3POLE 480V 1 EA CB TERM BLOCK,3C MODULAR EA JUMPER, STEP-DOWN 2-POLE (283:281) 9MM3 EA TERM BLK, THRU, 2-POLE GREY (283) 12MM6 EA TERM BLK, THRU, 2-POLE GREY (285) 16MM15 EA JUMPER, ADJACENT 2-POLE (285:285) 16MM3 EA CABLES, JUMPERS 3PH DELTA 1 EA XFMER CABLE, POWERCD 1 EA DIN RAIL, CUT LENGTH 108MM 1 EA DIN RAIL, CUT LENGTH 144MM 1 EA DIN RAIL, CUT LENGTH 324MM 1 EA BRACKET, SLED MTG 1 EA 04/13/ Page: 7-33

270 Parts List SPACER, NYLON 6.35 DIA X 9MMLG 2 EA COVER, MOV SAFETY 1 EA SUPPORT, SHIELD 1 EA SHIELD, SAFETY OVP BD 1 EA PANEL, MOV BD MTG 1 EA INSULATOR, PS 8 EA CHASSIS, PS 1 EA BRKT, MOV BD MTG 1 EA TRAY, OVP BD MTG 1 EA STANDOFF, MALE-FEMALE, M4 2 EA PWA, MOV/AC SAMPLE,400 3 PH DE 1 EA A *PWA, OVERVOLTAGE PROTECTION UNTESTED1 EAA2 Table 7-67 PWA, MOV/AC SAMPLE,400 3 PH DE (C--) Harris PN Description Qty UM Ref Des RIVET 3/16 ALUM.126/.25 8 EA 2XF1 2XF2 2XF3 2XF DIODE, RECT 1N EA CR1 CR2 CR3 CR4 CR LED, RED T1-3/4 VERT 1 EA DS OPTOISO, MOC8050 (DIP-6) 4 EA U1 U2 U3 U FUSE, FAST 600VAC/500VDC 12A 4 EA F1 F2 F3 F CLIP, FUSE 13/32 DIA, SOLDER 8 EA 2XF1 2XF2 2XF3 2XF CAP 0.100UF 5% 63V 3 EA C6 C8 C CAP 1UF 100V 20% 3 EA C11 C12 C CAP 1.0UF 50V 20% 8 EA C1 C2 C3 C4 C14 C15 C16 C CAP 10UF 50V 20% (5X11) 3 EA C5 C7 C RES 20K OHM 3W 5% 4 EA R32 R33 R34 R RES, WW 110K OHM 5% 10W AXIAL 4 EA R1 R5 R9 R RES, WW 60K OHM 5% 10W AXIAL 4 EA R2 R6 R10 R RES 15K OHM 3W 1% 12 EA R18 R19 R20 R21 R23 R24 R25 R26 R28 R29 R30 R RES 100K OHM 1/2W 1% 8 EA R4 R8 R12 R16 R36 R37 R38 R RESISTOR, PTC 60V 0.15A 3 EA R17 R22 R *HEADER, 20C TWO ROW VERTICAL 1 EA J LUG QC250 MALE PCB VERTICAL 13 EA E1 E4 E5 E8 E9 E10 E11 E14 E15 E16 E19 E20 E VOLTAGE TRANSDUCER, ESD 3 EA U5 U6 U BARCODE, SN_ITEM_REV 1 EA SCH, MOV/AC SAMPLE 0 DWG PWB, MOV/AC SAMPLE 1 EA Table 7-68 FORMAT, SYSTEM, PWR90D (W) Harris PN Description Qty UM Ref Des B/M NOTE: 0 DWG COOLING FLUID, Dowtherm SR-1, 55GAL 0 DR COOLANT, PROPYLENE GLYCOL BASE 0 DR FLUID COOLER 3-FAN HI-FLOW 0 EA KIT,6-1/8 SIGMA RF LINE-MYAT 0 EA KIT,6-1/8 SIGMA RF LINE-DIE 0 EA FLOW MTR, 15GPM, 1 FNPT 0 EA FLOW MTR, 30GPM, 1 FNPT 0 EA PWR SUPPLY, BEAM, 70KVA, 38KV 0 EA RF SYS, DTV 3 TUBE W/MOT SWTCH 0 EA RF SYS, DTV 3 TUBE W/MOT SWTCH 0 EA RF SYS, DTV 3 TUBE W/MOT SWTCH 0 EA Page: /13/12

271 Parts List 2533s701.fm FAMILY TREE, POWERCD 0 DWG INSTL MTL, WIRE POWERCD,3TUBE 1 EA PLUMBING KIT, POWERCD, 3 TUBE 1 EA KIT, HT EX CROSSOVER, POWERCD 0 EA PUMP INTERFACE ASSY - FOR INTERFACING SIGMA PUMP TO POWERCD0 EA DOC PKG, POWERCD 2 EA IB, POWERCD, 3 TUBE SYSTEM 2 EA KIT, SPARES, WATER FILTERS, POWERCD0 EA KIT, SPARES, WATER FILTERS, POWERCD, W/O UV0 EA CALORIMETRY ASSEMBLY 0 EA KIT, INSTALL, 3 TUBE SYSTEM, POWERCD1 EA KIT, EXTERNAL SHUTOFF VALVE, POWERCD0 EA FORMAT, XMTR, PWR90D3 1 EA FORMAT, POWER CD TANK BASE PUMP MODULE FOR 3 TUBE0 EA HEW8482H HEWLETT PACKARD SENSOR PROBE 0 EA HEWEPM-441A POWER METER, RF 0 EA PA MODULE DIGITAL POWER CD 0 EA KIT, SPARE BOARDS 0 EA KIT, SPARE PARTS 0 EA KIT, SPARE PARTS, ADVANCED 0 EA KIT, SPARE PARTS, BEAM SUPPLY 0 EA KIT, SPARE PARTS, NWL STEP START 0 EA KIT, SPARES, 2-1/2 INCH FLANGE PUMP 0 EA Table 7-69 FORMAT, XMTR, PWR90D (T) Harris PN Description Qty UM Ref Des TUBE, E2V ESCIOT5130W 0 EA CIRCUIT ASSY, E2V IMD3000EH 0 EA PUMP, VERTICAL, MULTISTAGE, 50HZ 0 EA SIDEWALLS, PAIR, 2000H X 1200W 1 EA *BREAKAWAY, MSDC IOT 3 EA CIRCULATOR, UHF 0 EA UNIT 2 CIR1 UNIT 5 CIR1 UNIT 8 CIR CIRCULATOR, UHF 0 EA UNIT 2 CIR1 UNIT 5 CIR1 UNIT 8 CIR CIRCULATOR, UHF 0 EA UNIT 2 CIR1 UNIT 5 CIR1 UNIT 8 CIR NAMEPLATE, XMTR EQUIPMENT 1 EA G PWA, CAN ADAPTER 0 EA CABLE PKG, POWERCD, 3 TUBE 1 EA CABLE, 3 TUBLE MARSHALING 1 EA CABLE CHANNEL 3 EA BRACKET EXC RETROFIT 0 EA ND EXCITER BLANK PANEL 0 EA PA MODULE DIGITAL POWER CD 3 EA UNIT 1 IPA1 UNIT 1 IPA2 UNIT 1 IPA PH, 400V, MOV PKG (DELTA) 0 EA UNIT 10 A12 UNIT 10 A15 UNIT 4 A12 UNIT 4 A15 UNIT 7 A12 UNIT 7 A MOV BD, 480 VAC 0 EA UNIT 10 A12 UNIT 10 A15 UNIT 4 A12 UNIT 4 A15 UNIT 7 A12 UNIT 7 A DRIVER CAB, BASIC, POWER CD 1 EA UNIT PS CABINET, POWER CD 3 EA UNIT 4 UNIT 7 UNIT IOT CABINET, POWER CD 3 EA UNIT 2 UNIT 5 UNIT COOLING CAB, POWERCD, DOOR FLTR 3 EA UNIT 3 UNIT 6 UNIT KIT, POWERCD, RFU, 3 CABINET 1 EA POWER SUPPLY 480 VAC 0 EA UNIT 1 A POWER SUPPLY VAC 0 EA UNIT 1 A OBS, USE FFF EA UNIT 1 A1 UNIT 1 A2 04/13/ Page: 7-35

272 Parts List KIT, 3 MODULE DRIVER 1 EA Table 7-70 DRIVER CAB, BASIC, POWER CD (AA) Harris PN Description Qty UM Ref Des GROMMET STRIP, FT RUB SILICONE SPONGE 0 RL GLOVES, THERMAL 1 EA POLYURETHANE TUBE, 9MM ID 0.55 ME SCREW, M5 X 16MM, BLK W/WASHER 50 EA SCR, 4 X 1/2 TAPPING 2 EA *HOSE CLAMP, (MINI) SST, SAE-6 1 EA CAGE NUT, M5-0.8, GA. 56 EA HOSE CLAMP, SST, SAE-24 8 EA MOUNT, RIBBON CABLE, 2 6 EA CABLE PUSH MOUNT 10 EA PLUG, WHT HOLE 2 EA END STOP, 264 TERM BLOCK 2 EA END PLATE, ORANGE (264) 1 EA PLATE, END STOP, DIN RAIL MTG 4 EA #TB2,TB PLUG, TAPERED, FITS 1-1/4 NPT 2 EA GROMMET GROOVE DIA 1 EA GROMMET 1-3/4 MTG DIA 1 EA GROMMET GROOVE DIA 5 EA BUMPER 5/8 DIA X 1/4 THK 1 EA FAN GUARD, 120MM WIRE-FORM 3 EA FAN, 12V 110CFM 119MM SQ 3 EA B1 B2 B HANDLE, PULL, OVAL, BLACK, M5 2 EA HINGE ADJUSTABLE BLACK 2 EA FILTER, AIR 430 X 220 X 22.3MM 1 EA CABINET, 2M X 0.6M X 1.2M 1 EA TOOL, ACTUATION, WAGO 2.5MM 2 EA CKT BRKR 8 AMPS 2P 480VAC 2 EA CB11 CB CKT BRKR 20 AMPS 3P 480VAC 1 EA CB PLUG, MALE 4C 1ROW STRAIGHT 2 EA J1 J JUMPER, 2-POLE, GREY (264) 6 EA PLUG, MALE 10C 1ROW STRAIGHT 1 EA TERM BLK, THRU, 4-POLE, BLUE (264) 10 EA TERM BLK, THRU, 2-POLE, GREY (264) 3 EA TERM BLK, GND, 2-POLE GRN/YEL (283) 12MM1 EA TERM BLK, THRU, 2-POLE GREY (285) 16MM6 EA SPLITTER, 2-WAY-0, BNC 2 EA SP1 SP JACK, BNC 75 OHM BULKHEAD 2 EA A1J13 A1J ADAPTER, SMA-JACK TO SMA-JACK 1 EA ADAPTER, 7/16 JACK TO JACK 2 EA SENSOR, LIQUID LEVEL, FLOAT 1 EA S FLOWMETER, GPM 1 NPT 1 EA U LABEL, DANGER HI VOLTAGE 1 EA NAMEPLATE, DOMED, HARRIS LOGO 1 EA LABEL, GLYCOL WARNING 1 EA NAMEPLATE, DOMED, POWERCD 1 EA PSU BRICK, 7.5/15/15VDC 100/75/75W 2 EA LVPS1 LVPS ACCESSORIES-TORX-TAPPING SCREW BZ5,5X1350 EA SKID, DRIVER, POWER SUPPLY 1 DWG WIRING DIAGRAM DRIVER CABINET 0 DWG Page: /13/12

273 Parts List 2533s701.fm LABEL, COMPONENT LOCATING, DRIVER, REAR1 DWG G PWA, CAN ADAPTER 1 EA CABLE, GROUND 1 EA CABLE LVPS AC DISTRIBUTION 1 EA CABLE LVPS DC DISTRIBUTION 1 EA CABLE CONTROLLER 1 EA CABLE CUSTOMER I/O 1 EA LVPS SENSE JUMPER SMALL 2 EA LVPS SENSE JUMPER LARGE 4 EA CABLE CABINET CONTROL PCD 1 EA CABLE CAB AC DIST MODULE PCD 1 EA CABLE BACKPLANE POWER CD 1 EA DIN RAIL, CUT LENGTH 108MM 1 EA DIN RAIL, CUT LENGTH 360MM 1 EA SCREW, SHOULDER 2 EA ALIGNMENT PIN 2 EA STANDOFF, MALE-FEM, 19 MM LONG 6 EA ADAPTER, HOSE 1 EA RAIL, DIN 180MM LG 1 EA BRACKET, SPLITTER MTG 3 EA BRACKET, CAB TO CAB 2 EA STANDOFF, CAB TO CAB 2 EA BRACKET, MANIFOLD SUPPORT 2 EA BRACKET, POSITIONING 1 EA PANEL, BLANK, 1.7 TALL 2 EA ANGLE, STIFFENING 1 EA PANEL, I/O 1 EA PANEL, I/O 1 EA PANEL, BLANK, 1U 1 EA BRACKET, SLIDE MTG 4 EA BRACKET, SLIDE MTG 2 EA PANEL, TOP 1 EA PLUMBING, RETURN MANIFOLD 1 EA PLUMBING, SUPPLY MANIFOLD 1 EA GROUND STRAP, DRIVER - COOLING 1 EA SHELF, CAGE 1 EA PANEL, BLANK, PA MODULE, 3 POS 1 EA SIDE, CAGE RIGHT 1 EA MOUNTING BAR, RF CONNECTOR 1 EA DRIP TRAY 1 EA PLATE, MODULE CATCH (5 MOD) 1 EA SIDE, CAGE LEFT 1 EA PANEL, CAGE MIDDLE FRONT 1 EA PANEL, FRONT BLANK 4U 1 EA SUPPORT, CAGE SHELF 5 EA TOP, CAGE 1 EA DEFLECTOR, CAGE AIR 5 EA SUPPORT, RACK FLOOR 3 EA FLOOR, RACK 1 EA MOUNTING PANEL [3 FAN] 1 EA COVER, AIR FILTER 1 EA BRACKET, REMOVABLE FAN 1 EA PAN, DRIP 1 EA CUP, FLOAT DRIP 1 EA 04/13/ Page: 7-37

274 Parts List BRACKET, C.B. MTG 1 EA BRACKET, C.B STOP 2 EA COVER, LVPS C.B. SAFETY 1 EA TRAY, AIR DEFLECTOR 1 EA PANEL, HOSE DISCONNECT 1 EA BRACE, CAGE TOP 3 EA ROLLER, MODULE ALIGNMENT 10 EA ANGLE, FRONT PANEL SUPPORT 1 EA BRACKET, P.A. MOD C.B. SUPPORT 1 EA GUIDE, MODULE, BLACK PVC 10 EA COVER, CONTROLLER PWA SAFETY 1 EA SPACER, XFMR SHOULDER 1 EA CABLES, RIBBON ATLAS ANALOG 1 EA STRAP, FRONT TO BACK GROUND 1 EA BRACKET, HELIAX SUPPORT 2 EA DIN RAIL, 428 MM LONG 1 EA TEMPERATURE SENSORS [PAIR] 1 EA U2,U SPACER, DUCT SIDE 4 EA COVER, POWER BLOCK 1 EA CONN WC XMTR TO MODULE 1 EA CABLES, RIBBON DRIVER CABINET 1 EA PANEL, UPPER DUCT 2 EA PANEL, DUCT, INNER RIGHT 1 EA CABLE HELIAX W501 1 EA W TRAY, TB MTG 1 EA COVER, TB 1 EA CHANNEL, TB WIRE ROUTING 1 EA PLATE, GROUND 3 EA PLATE, INTERFACE 1 EA HOSE ASSY, SUPPLY 2 EA SPACER, HINGE 2 EA COVER, I/O 1 EA ARM, CABLE SUPPORT 3 EA PANEL, I/O SILKSCREEN 1 EA DUCT, UPPER SUB ASSY 1 EA DUCT, LOWER SUB ASSY 1 EA SPACER, 0.75 OD ID X EA SPACER, 0.75 OD ID X EA PANEL, DUCT, INNER LEFT 1 EA PANEL, MAIN CIRCUIT BREAKER 1 EA RAIL, TRANSFORMER ASSY 2 EA AIR DEFLECTOR 8 EA PANEL, C.B. ACCESS 1 EA BRACKET EXC RETROFIT 2 EA CABLE DRIVER CONTROL 1 EA CHANNEL, DUCT SIDE 4 EA PANEL, DUCT OUTER 2 EA ASSY, CONTROL PANEL (230VAC) 1 EA A ROUTER CHASSIS, POWER CD 1 EA A *ASSY, DISPLAY UNIT W/ GUI P-CD 1 EA PWA, MODE CONTROLLER 1 EA A *PWA, POWER SUPPLY MONITOR CONTROLLER UNTESTED1 EAA PWA, BACKPLANE 1 EA A PWA, CUSTOMER INTERFACE BOARD 1 EA A5 Page: /13/12

275 Parts List *PWA, EXTERNAL I/O 1 EA A6 2533s701.fm Table 7-71 PWA, MODE CONTROLLER (E--) Harris PN Description Qty UM Ref Des DIODE, SCHOTTKY 32CTQ030 2 EA CR115 CR CONVERTER, DC/DC 5V.75W ESD 1 EA U RELAY 4PDT 12VDC 2A NON-LATCH 7 EA K17 K18 K19 K20 K21 K22 K HDR, 2C VERT 1ROW UNSHR 15 EA JP1 JP2 JP3 JP4 JP5 JP6 JP7 JP8 JP9 JP10 JP11 JP12 JP13 JP14 JP HDR, 6C VERT 2ROW UNSHR 5 EA J54 J55 J65 J76 J HDR, 12C VERT 1ROW FRICTION 1 EA J <*>HDR, 50C 2ROW VERTICAL (SYS 50) 2 EA J71 J HDR, 2C 1ROW VERTICAL 3 EA J73 J80 J HDR, 3C 1ROW VERTICAL 4 EA J57 J61 J66 J HDR, 4C 1ROW VERTICAL 7 EA J53 J56 J60 J68 J72 J78 J HDR, 6C 1ROW VERTICAL 5 EA J51 J59 J62 J69 J HDR, 8C 1ROW VERTICAL 16 EA J37 J38 J39 J40 J41 J42 J43 J44 J45 J46 J47 J48 J49 J50 J67 J HDR, 12C 1ROW VERTICAL 32 EA J1 J2 J3 J4 J5 J6 J7 J8 J9 J10 J18 J19 J20 J21 J22 J23 J24 J25 J26 J27 J28 J29 J30 J31 J32 J33 J34 J35 J63 J64 J74 J HDR, 26C 2ROW VERTICAL 2 EA J17 J JUMPER SHUNT 2C, 0.1 PITCH 17 EA #J55 #J65 #J76 #J83 #JP1 #JP2 #JP3 #JP4 #JP5 #JP6 #JP7 #JP8 #JP11 #JP12 #JP13 #JP14 #JP RECP, D STRT 9C PCB 1 EA J PLUG, 2C 1ROW VERTICAL 3 EA #J73 #J80 #J PLUG, 3C 1ROW VERTICAL 4 EA #J57 #J61 #J66 #J PLUG, 4C 1ROW VERTICAL 7 EA #J53 #J56 #J60 #J68 #J72 #J78 #J PLUG, 6C 1ROW VERTICAL 5 EA #J51 #J59 #J62 #J69 #J PLUG, 8C 1ROW VERTICAL 5 EA #J39 #J40 #J47 #J67 #J PLUG, 12C 1ROW VERTICAL 24 EA #J1 #J3 #J5 #J7 #J8 #J10 #J19 #J20 #J22 #J23 #J25 #J26 #J28 #J29 #J30 #J31 #J32 #J33 #J34 #J35 #J63 #J64 #J74 #J BARCODE, SN_ITEM_REV 1 EA SCH, MODE CONTROLLER 0 DWG SW, MODECONTROLLER SOURCE CODE0 DWG PWA, MODE CONTROLLER SMT 1 EA Table 7-72 *PWA, PS MONITOR CONTROLLER UNTESTED (A--) Harris PN Description Qty UM Ref Des BARCODE, SN_ITEM_REV 1 EA SW POWERCD POWER SUPPLY MONITOR CONTROLLER0 DWG *PWA, PA BLOCK CONTROLLER UNTESTED1 EAA7 Table 7-73 *PWA, PA BLOCK CONTROLLER UNTESTED (J) Harris PN Description Qty UM Ref Des *THERMAL COMPOUND, 8OZ JAR 0 EA *SEALANT, GLYPTOL, RED 0 QT SCREW 4-40 X.375 BHMS 6 EA 2/J10 2/J12 2/J SCREW 6-32 X.25 BHMS 2 EA 376 MOD NUT, HEX EA 376 MOD STANDOFF, HEX 6-32 X 5/16 M/F 2 EA 376 MOD DIODE, SCHOTTKY 32CTQ030 4 EA CR1 CR10 CR14 CR FUSE, CART 5X20MM 5A FAST 2 EA F2 F3 04/13/ Page: 7-39

276 Parts List FUSE, CART 5X20MM 10A FAST 1 EA F CLIP, FUSE 5MM DIA FUSE 6 EA 2/F1 2/F2 2/F HEATSINK VERTICAL, TO EA XCR1 XCR10 XCR14 XCR RES 2 OHM 5% 8W 3 EA R363 R393 R *HEADER, 20C TWO ROW VERTICAL 2 EA J14 J *HEADER, 26C TWO ROW VERTICAL 2 EA J11 J HDR, 2C VERT 1ROW UNSHR 4 EA JP1 JP2 JP3 JP HDR, 10C VERT 2ROW UNSHR 1 EA J HDR, 12C VERT 1ROW FRICTION 1 EA J HDR, 6C VERT 1ROW FRICTION 4 EA J4 J5 J16 J HDR, 9C 1ROW VERTICAL UNSHR 1 EA J HDR, 12C VERT 1ROW FRICTION 2 EA J8 J HDR, 6C VERT 1ROW FRICTION 2 EA J6 J HDR, 10C VERT 1ROW FRICTION 1 EA J JUMPER SHUNT, 2C, 0.1 PITCH 1 EA JP RECP, D, 9C VERT PCB PLASTIC 2 EA J10 J RECP, D, 15C VERT PCB PLASTIC 1 EA J BARCODE, SN_ITEM_REV 1 EA SOFTWARE, PA BLOCK CONTROLLER 0 DWG G *PWA, 376 MICRO MODULE 1 EA PWA, PA BLOCK CONTROLLER, SMT 1 EA Table 7-74 *PWA, 376 MICRO MODULE G (A--) Harris PN Description Qty UM Ref Des N-MOSFET, 2N EA Q1 Q2 Q IC, MAX705/ADM705 (SOIC-08) 1. EA U IC, CY7C109B/ EA U5 U IC LM4040CIM3-4.1 ESD 1. EA CR IC NC7ST04 ESD 1. EA U *DIODE, SCHOTTKY MBR EA CR LED, RED 0805 DIFFUSED ESD 1. EA DS LED, GREEN 0805 DIFFUSED ESD 1. EA DS *IC, MC68376 PROG/ESD 1. EA U EEPROM (SPI), 25LC040A ESD 1. EA U FLASH, 29F800 (TSOP-48) 1. EA U XTAL, MHZ 1. EA Y IND CHIP 1UH 10% 3. EA L1 L2 L *CAP 27PF 0805 C0G 100V 5% 2. EA C25 C *CAP 0.1UF 1206 X7R 50V 10% 22. EA C4 C5 C6 C7 C8 C9 C10 C11 C13 C14 C16 C17 C18 C19 C20 C21 C22 C23 C24 C29 C27 C CAP, 10UF 10V 10% SMT EA C1 C2 C3 C12 C RES NTWK 10K OHM 5% BUSS 5. EA R13 R14 R17 R25 R RES 22.1 OHM 1% 1/8W EA R1 R2 R3 R6 R7 R8 R15 R16 R19 R20 R RES 68.1 OHM 1% 1/8W EA R RES 100 OHM 1% 1/8W EA R RES 200 OHM 1% 1/8W EA R RES 1K OHM 1% 1/8W EA R4 R9 R12 R18 R RES 1.5K OHM 1% 1/8W EA R RES 1.62K OHM 1% 1/8W EA R RES 10K OHM 1% 1/8W EA R RES 20K OHM 1% 1/8W EA R RES 1M OHM 1% 1/8W EA R27 Page: /13/12

277 Parts List 2533s701.fm SW, PB MOM SPST-NO TACT (SMT) 1. EA S PLUG, 80C 2 ROW VERTICAL 2. EA J1 J BARCODE, SN_ITEM_REV 1 EA SPEC, 376 MICRO MODULE 0 DWG SCH, 376 MICR0 MODULE 0 DWG G *PWB, 376 MICRO MODULE 1. EA Table 7-75 COOLING CAB, POWERCD, DOOR FLTR (L) Harris PN Description Qty UM Ref Des B/M NOTE: 0 DWG HOSE, GEN PURPOSE, EPDM, 1.25 ID, RED3 FT GASKET, EMI 3/16 MAX COMP 3.33 ME FILTER, CAVITY AIR CA EA LUBRICANT PASTE GN 0 EA *COMPOUND #4 0.5 EA * PIPE SEALANT PST LOCTITE EA * SEALANT, ADHESIVE 0 EA A TUBING POLYETHYLENE OD 10.5 FT THREAD-TAPE, TEFLON 0.50 W 0 RL TUBING NYLON 3MM OD 8 FT SCREW, HHMS M X 30 (SST) 4 EA SCREW, HHMS M X 60 (SST) 4 EA NUT, STD HEX M (SST) 8 EA WASHER, FLAT M12 SST (DIN125) 16 EA WASHER, INT LOCK 1/2 4 EA LOCKWASHER, SPLIT M12 SST (DIN127) 8 EA CABLE CLAMP, NYLON DIA 6 EA BUSHING TEFLON 2 EA HOSE CLAMP, SST, SAE-12 1 EA HOSE CLAMP, SST, SAE-24 4 EA CABLE TIE MOUNT, 4-WAY 2 EA CABLE TIE, PUSH MOUNT SNAP IN 8 EA HOSE CAP, 3/4 HOSE THD. 1 EA PLATE, END STOP, DIN RAIL MTG 4 EA ELBOW CU 90DEG 2.000C X 2.000FTG 1 EA BOILER DRAIN VALVE 1 EA COUPLING, 1 INCH FXF 2 EA BUSHING, 1 X 1/8, NPT, SST 1 EA PLUG, TAPERED, FITS 1-1/4 NPT 2 EA ADAPTER, 1 NPT-M X FLARE 1 EA NIPPLE, 1 IN X CLOSE BRASS 1 EA HOSE BARB, 1.25H X 1.00MPT 4 EA CLIP, FUSE A 250V 2 EA GROMMET GROOVE DIA 2 EA #B1 #B GROMMET GROOVE DIA 1 EA ELL, 2 INCH, RUBBER BOOT 1 EA ASSEMBLY, HOSE, 33 INCH 1 EA ASSEMBLY, HOSE, 22.5 INCH 1 EA ISOLATION MOUNT 4 EA BLOWER, REGENERATIVE 2.5 HP 1 EA PUMP, 1.5 HP, VERTICAL, SST 1 EA HEAT EXCHANGER, PLATE, COPPER 1 EA MTR CONDUCTIVITY OMEGA CDTX-90 1 EA U SENSOR CONDUCTIVITY OMEGA CDCN 1 EA U10 04/13/ Page: 7-41

278 Parts List CABINET, 2M X 0.8M X 0.6M 0 EA CABINET, POWER CD COOLING 1 EA THERMISTOR, IMMERSION, 10K 1 EA CONTACTOR, 5.5KW, 12A, 3P 2 EA K1 K RELAY, OVERLOAD A 2 EA #K1 #K SWITCH, DISCONNECT 480VAC 3P 1 EA S PLUG, MALE 4C 1ROW STRAIGHT 9 EA J1 J2 J3 J4 J5 J6 J7 J8 J KIT, METER MNTG OMEGA FP90UM 1 EA LABEL, DANGER HI VOLTAGE 1 EA SEALANT, STAINLESS PIPE 1 EA ATTENUATOR 40DB, 1KW 1 EA R ACCESSORIES-TORX-TAPPING SCREW BZ5,5X1380 EA GROUNDING PLATE 3 EA SKID, COOLING CABINET 0 DWG WIRING DIA. PWR CD COOLING CAB 0 DWG ASSY INSTR, HOSE COOLING BOARD AIR INTERFACE0 DWG LABEL, COMP LOC, COOLING CAB 1 EA DIN RAIL, CUT LENGTH 108MM 1 EA DIN RAIL, CUT LENGTH 180MM 1 EA CLAMP, PLUMBING 5 EA BRACKET, OMEGA 1 EA COLD PLATE, ATTENUATOR 1 EA CLAMP, COLD PLATE 1 EA STRAP, INTERCONNECT GND 3 EA BLOCK, CLAMP 1 EA BRACKET, FILTER LOOP 1 EA BRACKET, BREAKER/DISCONNECT 1 EA BRACKET, CPVC 1 EA CLAMP, CPVC 1 EA BUSHING, GROUND 1 EA SPACER, CABINET 4 EA BRACKET, HEAT EXCHANGER 1 EA STRAP, HEAT EXCHANGER 2 EA BRACKET, PLUMBING 3 EA ASSY, GLYCOL SUPPLY PIPE 1 EA ASSY, GLYCOL RETURN PIPE 1 EA SUPPLY MANIFOLD, DI WATER 1 EA ASSY, PUMP INLET PIPE 1 EA ASSY, COOLANT RETURN MANIFOLD 1 EA ASSEMBLY, PUMP OUTPUT FLANGE 1 EA ASSY, MODIFIED FLOW METER 1 EA BASE, CABINET 1 EA PANEL, LEFT SIDE 1 EA TOP, CABINET 1 EA SHELF, TANK 1 EA SUPPORT, BASE 1 EA ENCLOSURE, FILTER 1 EA STRAP, GROUND 1 EA PANEL, I/O 1 EA CHASSIS, PUMP MTG 1 EA STRAP, GROUND, TO IOT 1 EA STRAP, GROUND, TO PS 1 EA CHASSIS, BREAKER/CONTACTOR 1 EA COVER, BREAKER/CONTACTOR 1 EA Page: /13/12

279 Parts List 2533s701.fm GUARD, SPLASH 2 EA PAN, DRIP 1 EA STRAP, GROUND 1 EA PANEL, FRONT 1 EA PANEL, RIGHT SIDE 1 EA DUCT, HIGH ALTITUDE 1 EA CHASSIS, CAVITY AIR BLOWER 1 EA VENTURI 1 EA RING, CLAMP 1 EA SEAL, TEFLON 1 EA ASSEMBLY, FILTER GRILLE 1 EA ASSEMBLY, CAVITY AIR OUT 1 EA ANGLE 2 EA GASKET, 1-1/4 FLANGE 2 EA BKT, FLOW METER MOUNTING 1 EA BKT, PUMP ADAPTER 1 EA CABLE, COOLING CABINET CONTROL 1 EA CABLE, COOLING CAB AC 1 EA ASSY, LEAK DETECTOR 1 EA ASSY, LIQUID LEVEL SWITCH 1 EA WI WI, POWER CD COOLING CABINET 0 DWG ASSY, DI TANK 1 EA ASSY, DI WATER RETURN 1 EA FILTER SYSTEM-CHEMICAL 1 EA KIT, EARTH WAND 1 EA PWA, COOLING CONTROL BOARD 1 EA A *PWA, EXTERNAL I/O 1 EA A1 Table 7-76 ASSY, LIQUID LEVEL SWITCH (A) Harris PN Description Qty UM Ref Des NUT, HEX FINISH 5/8-11 SST 1 EA WASHER, RUBBER 1 EA SWITCH LIQ LEVEL GEMS LS EA FITTING, LEVEL SWITCH 2 EA SHIELD, LIQUID LEVEL SWITCH 1 EA Table 7-77 KIT, POWERCD, RFU, 3 CABINET (F) Harris PN Description Qty UM Ref Des B/M NOTE: 0 DWG RIVET, DRIVE FASTENER ID 8 EA LINE STRETCHER 8 TRAVEL 2 EA SLIDER BUSHING, TROMBONE TRAY 2 EA BRACKET, BOTTOM & TOP 2 EA SHELF, TROMBONE TRAY 4 EA TRAY, TROMBONE MOUNTING 2 EA SIDE PANEL, TROMBONE RACK 2 EA ASSY, 3 CABINET RFU ASSEMBLY 1 EA A4 Table 7-78 KIT, SPARES, 2-1/2 INCH FLANGE PUMP (A) Harris PN Description Qty UM Ref Des BOOTLACE FERRULE A 6-12 WEIT 6 EA BOOTLACE FERRULE A 4-12 DIN 46228, E-CU GAL. SN 26 EA GASKET KIT, PIPE FLANGE 2-1/2 2 EA 04/13/ Page: 7-43

280 Parts List CARTRIDGE FILTER 10MICRON 1 EA FILTER CARTRIDGE HOLDER, NYLON 1 EA ASSEMBLY, LONG FLOAT TUBE 1 EA TUBE, GAUGE 1 EA ASSEMBLY, SIGHT GAUGE FLOAT 1 EA Page: /13/12

281 Suggested Cutting And Soldering Procedure PowerCD Transmitter Cutting and Soldering Transmission Line Appendix A Cutting and Soldering Transmission Line A.1 Suggested Cutting And Soldering Procedure 2533apa.fm The purpose for this procedure is to provide guidelines for field cutting and soldering of RF transmission line used to interconnect the transmitter to the RF system. Try to cut and flange the longest pieces first. Complete one run at a time in order to avoid accumulated errors. (i.e.: Cut, solder, and hang line from antenna port of Bandpass filter to patch panel. Then cut, solder, and hang line from the Amplifier output to the input port of the Bandpass filter.) Listed in Table A-1 are some tools and materials that have proven effective for RF Feed Line Construction. Table A-1 Tools and Materials Needed For RF Feed Line Construction Welding Torch Set Hacksaw and Extra Blades Oxygen and Acetylene Tanks Plumb Bob Welder s Mask or Goggles Chalk Line Power Band Saw (can be rented) and Extra Blades Wrenches Silver Solder 1/16 inch diameter, 30%-45%, Hard Stay-Silv #45, Aladdin #45, Crowbar HARRIS part number Paste flux (Engelhard Ultra-Flux 1 lb jar) HARRIS part number Rope Stay Clean Flux, 16oz bottle (HARRIS part number ) Saw Horses or Cutting Table Muriatic Acid (quart) Come-along or Chain-Fall Hoist Baking Soda (two 1-pound boxes) Ladders Three plastic 5-gallon buckets or containers with open tops Garden Hose Scotch Brite 25-Ft Tape Measure Steel Wool Files Emery Cloth (roll type like plumber uses) Rubber Hammer Carpenters Square Claw Hammer Level Gloves Hole Saw, 1-7/8 inches, for installing directional couplers Safety Glasses NOTE: All-thread rod, hangers, angle iron or channel will be needed to support transmission line, dummy load, etc. A.2 Line Cutting and Flange Soldering Procedure 1. Determine the flange-face to flange-face length of the transmission line run needed. If the run includes an elbow, see Figure A-1 to determine the elbow length. 2. If both ends of the line are unflanged, subtract twice the cutback dimension of the flange. This dimension varies with flange manufacturer. See Figure A-2. If one end of the line is already flanged, subtract the cutback dimension of the flange. 3. Using one of the suggested methods for cutting the line given in Section A.3 on page A-3, cut the outer conductor to the length just calculated. 4. If holes in the outer conductor are needed for directional couplers, tuning paddles, etc. they should be added now with the holes properly deburred. Instructions for constructing a fine matcher are given in Section on page /13/ Page: A-1

282 Cutting and Soldering Transmission Line Line Cutting and Flange Soldering Procedure 5. Using the suggested techniques for installing the flanges given in Section A.4 on page A-6, solder a flange to each end of the outer conductor. 6. Measure the flange-face to flange-face dimension after soldering to confirm the proper length and to determine the initial length of the inner conductor. 7. Determine the length of the inner conductor by using the flange-face to flange-face dimension of the outer conductor and subtracting the dimension of the anchor connector (bullet) shown in Figure A-3. The inner conductor should be shortened an additional 1/16 inch to allow for expansion. This dimension determines the proper cutback of the inner conductor for both ends of the line at the same time. do not double this dimension when subtracting from the outer conductor length. 8. Cut the inner conductor and debur the cut edges. 9. Ensure the inside of the outer conductor is clean; then insert the inner conductor. The line is ready to install. Measure center of elbow to flange. Figure A-1 Measurements When Elbows Are Used See Section Below Cut Length Outer Conductor Flange to Flange Length Mating Surface Groove For O-ring Flange Silver Solder Ring (some suppliers may not provide this grove) Outer Conductor Teflon Portion of Bullet Cut Back For Each Flange Note: The cutback will vary for different transmission line manufacturers. Figure A-2 Outer Conductor Measurements Page: A /13/12

283 Cutting The Transmission Line PowerCD Transmitter Cutting and Soldering Transmission Line 2533apa.fm Cutback for inner conductor. The amount of cutback vary for different transmission line manufacturers. Figure A-3 Measurement for Cutback of Inner Conductor A.3 Cutting The Transmission Line A square smooth cut is required. Several methods, listed below, may be used with the choice depending on tools and labor available. 1. Method 1. A hand hack saw and cast iron cutting guide are a good combination for making a cut with a minimum of tools for one or two pieces, but can be very labor intensive for putting up an entire system. See Figure A Method 2. Hand Band Saw. These popular saws can be rented or purchased. See Figure A Method 3. Swing Arm Band Saw. This is a good way to go if one can be rented or borrowed. Many pipe fitters and electrical contractors own them. If the saw has an automatic feed, cut slowly. It is critical that the support saw horses be made level with the saw. Test cuts should first be made using scrap pipe or a wood 4x4 to verify that the blade is not creeping and the saw is in alignment. See Figure A-6. Caution Do not over tighten the vise used with these saws. it will be difficult to put the flange on an out of round pipe. 4. Method 4. Tubing Cutter. This is generally not recommended. Many cuts end up with crimped ends due to dull cutters or trying to cut too fast. Use with caution. Avoid if possible unless someone is available that has had a lot of experience using a tubing cutter on this type of installation. See Figure A Method 5. Cut Off Saw. These saws are similar to radial arm saws. It is rare to find one big enough to cut 6-1/8 line. The set up is similar to the swing arm band saw. See Figure A-6. 04/13/ Page: A-3

284 Cutting and Soldering Transmission Line Cutting The Transmission Line Figure A-4 Guide For Use With Hand Hack Saw Start Cut Stop Cut On the first pass score the cut. Do not Turn Line Approximately 45 Degrees let the blade go below the surface. Correct Depth Cut Too Deep Finish cut on second pass. Keeping the blade from falling too far below the surface keeps the cut smooth Figure A-5 Cutting With a Hand Band Saw Page: A /13/12

285 Cutting The Transmission Line PowerCD Transmitter Cutting and Soldering Transmission Line 2533apa.fm Figure A-6 Swing Arm Band Saw Cutting Tips Figure A-7 Use Of Tubing Cutter Results In Crimped Cut (Exaggerated) 04/13/ Page: A-5

286 Cutting and Soldering Transmission Line Soldering Flanges A.4 Soldering Flanges Transmission line flanges that are supplied with the optional transmission line kit are the silver solder type. Although the attachment of this type of flange may require more care and skill than the soft solder type, it has been found that the silver soldered flange provides much greater reliability. The services of a steam fitter or plumber may be helpful if personnel are not available that are experienced with silver soldering. A.4.1 Soldering Procedure 1. The line should be free of burrs. The outer corner may be beveled slightly to make assembly of flange easier. See Figure A Emery cloth should be used to clean the outside of the line where it will meet the flange. Also clean the inner surface of the flange with emery cloth. 3. Insert the solder ring into the groove on the flange. If solder rings are not included with the flange, they can be made from inch diameter silver solder wire (30-45% silver). 4. Apply a thin coat of flux to the line and to the flange. 5. Slide the flange onto the end of the outer conductor. Warning Skin burn hazard. Temperature of the heated line in the following steps is quite high and precautions must be taken to avoid contact with exposed skin. 6. Stand the line on end (vertical) for soldering (flange to be soldered pointing down). Ensure that the flange remains square with the outer conductor. 7. Using a #3 or #4 torch tip, heat the entire circumference of the line and flange. Keep the torch moving and heat 2 or 3 inches of the line/flange at a time. Aim the torch at the copper just above the crack between the flange and the line. This will minimize the need for fill solder. If the brass flange is heated more than the copper line, the flange will expand and create an unnecessary gap to fill with solder. Use caution. There is a fine line between melting the solder and melting the brass flange or burning a hole in the copper. The solder will pull up into the joint from the solder ring by capillary action. Once it starts to flow, do not stop until the entire circumference of the joint has solder appearing in it. If the solder from the internal solder ring does not wick up and become visible at the joint after a few minutes, a small amount of solder can be applied to the joint to enhance the heat transfer. See Figure A-9. Page: A /13/12

287 Cleaning The Soldered Joint PowerCD Transmitter Cutting and Soldering Transmission Line 2533apa.fm Figure A-8 Bevel Cut End and Remove Burs Figure A-9 Torch Aiming Location A.5 Cleaning The Soldered Joint Vigorous scrubbing with a wire brush and steel wool will remove torch black with good results. In addition, cleaning with an acid solution can make this job easier. The procedure is as follows: Warning Muriatic acid used in the following procedure is hazardous. Use eye and skin protection when handling or mixing. keep an extra box of baking soda handy for first aid or to neutralize spills. perform the procedures outdoors if possible. If the work must be done indoors, work only in well ventilated area. Warning In the following mixing procedure, always put water in the container first and then add acid to the water. Adding water to a container of acid may result in a violent & dangerous reaction. 04/13/ Page: A-7

288 Cutting and Soldering Transmission Line Cleaning The Soldered Joint 1. Prepare three plastic 5 gallon buckets as follows: A. Bucket #1 - Water B. Bucket #2 - One quart muriatic acid in four gallons of water (See Warnings Above) C. Bucket #3 - One pound baking soda in five gallons of water 2. After soldering is finished, dip the end of the line in the water to cool. 3. Set the cooled end of the line into the acid-water mixture for 5-10 minutes. This will loosen the film and brighten the silver. 4. Immerse the end of the line into the soda solution. This will stop the action of the acid. 5. Use a Scotch Bright pad or steel wool to scrub off the remaining torch black. 6. If the flux scale is particularly stubborn repeat the process. 7. When finished, rinse thoroughly when done with water and dry the line before assembling. A.5.1 Alternate Cleaning Method The following is an alternate procedure to clean the soldered transmission line. The following materials are needed. Water and Hose Small Paint Brush Rubber Gloves Scotch Brite Pad or BBQ Grill Cleaning Pad With Handle Naval Jelly (or equivalent rust remover). Warning Naval jelly contains phosphoric acid and can be dangerous if it comes in contact with skin or eyes or if it is swallowed. Read and follow the precautions and emergency procedures on the naval jelly container before using. 1. After soldering the flange, dip the end of the line into water or spray it with a hose until it is cool. 2. Using a small paint brush, apply a coating of Naval Jelly to the torch black and flux scale on the outside and inside of the line. Let the Naval Jelly set from 10 to 20 minutes. 3. Scrub the line with Scotch Brite or the BBQ Grill pad to loosen the torch black and flux scale. 4. Flush with water until the Naval Jelly residue is gone. 5. Repeat the process until all the torch black and flux scale is removed. The first application of the Naval Jelly will remove the torch black and some of the flux scale. Normally, if vigorous scrubbing is done, repeating the process a second time will completely clean the line. Page: A /13/12

289 Introduction Appendix B Lightning Protection Recommendation PowerCD Transmitter Lightning Protection Recommendation B.1 Introduction 2533apb.fm What can be done with a 2 million volt pulse pushing 220,000 amps of current into your transmitting plant? Like the 500 pound gorilla it does what ever it wants to. There is not much that can be done to protect against a major direct lightning strike. This is called a significant impulse lightning stroke. It usually lasts less than 100 microseconds and is most destructive to electronic equipment because it contains huge amounts of high frequency energy. Here are some examples of this damage: Melted ball and horn gaps. Ground straps burned loose. H.V. rectifier stacks shorted. Massive arc marks in the output circuit of AM transmitters. Ball lightning traveling into building on outer conductor of transmission line. Figure B-1 is a map of the United States that shows the number of lightning days expected in any year, with Colorado, New Mexico, and Florida leading the list. Figure B-2 shows the incidents to tall structures. A triggered event is one that happens because the tower was present. Without the tower the strike would not have occurred. Figure B-1 Map Showing Lightning Days Per Year 04/13/ Page: B-1

290 Lightning Protection Recommendation Environmental Hazards 40 All Triggered Events 30 Number Per Year Collected Events Structure Height In Feet Figure B-2 Lightning Incidents to Tall Structures B.2 Environmental Hazards There are devices and procedures that do offer protection from lessor environmental hazards than lightning. Some of these anomalies are listed and defined: 1. Over voltage/under voltage (brownout). Where the lines voltage differs from the nominal RMS for longer than one cycle. Remedy - Automatic voltage regulators, preferably individual regulators on each phase. This can only be accomplished when the power feed line is delta or 4/wire wye connected, See Figure B Single phasing. This is where one leg of the three phase service is open. Remedy - Protection afforded by a loss of phase detector. Without protection power transformers and 3 phase motors over heat. 3. Radio frequency interference (RFI). This is something we must design into all transmitters, however, equipment may be purchased that is susceptible, is not protected, and may develop problems. Remedy - RFI filters on the ac lines and control lines are sometimes effective. Sometimes the entire device must be enclosed in an RF free space. 4. Electromagnetic pulse (EMP). This is a interfering signal pulse that enters the system by magnetic coupling (transformer). Generally caused by lightning. Lightning from cloud to cloud produces horizontally polarized waves while lightning from cloud to earth produce vertically polarized waves. The waves couple into the power lines and transmission lines causing large induced voltage that destroy high voltage rectifier stacks and output circuit faults. High frequency energy is coupled back into the transmitter causing VSWR overloads, See Figures B-4 and B-5. Page: B /13/12

291 Environmental Hazards PowerCD Transmitter Lightning Protection Recommendation 2533apb.fm Remedy - Ball or horn gaps at the base of the antenna prevent the voltage from exceeding some high potential. Transient suppressor devices on the input power lines remove excessive voltage spikes. Buried power and transmission lines will reduce the amount of coupled energy to a great extent. This does not totally eliminate the problem because there are currents traveling in the earth, which prefer to travel on the metal conductors, when lightning strikes close to the station. 5. Surge. A rapid increase in voltage on the power lines usually caused by lightning. The duration is less than 1/2 cycle and can be very destructive. Remedy - Transient protectors are very effective in preventing damage to the equipment when properly designed and installed, See Figure B-6. Table B-1 Significant Lightning Stroke Characteristics Charge Range 2 to 200 coulombs Peak Currents 2,000 to 400,000 Amperes Rise Time to 90% 300 Nanoseconds to 10 Microseconds Duration to 50% 100 Microseconds to 10 Milliseconds Potential Energy at 99% 1010 Joules* * Only a small portion is manifested in a surge, usually less than 10,000 Joules. Figure B-3 Regulators for Delta and 4-Wire WYE systems 04/13/ Page: B-3

292 Lightning Protection Recommendation Environmental Hazards Figure B-4 EM Flux Field 2400 A 2000 B Voltage KV 1600 C Time in usec A = 1/2 mile from station B = 1 mile from station C = 2 miles from station. Figure B-5 Sample Surge Voltage as a Function of Distance From Stroke to Line Page: B /13/12

293 What Can Be Done? PowerCD Transmitter Lightning Protection Recommendation 2533apb.fm Figure B-6 Surge Protectors and Ferrite Chokes B.3 What Can Be Done? Installation of the transmitter building, antenna tuning unit if applicable, and antenna should be done so that the risk of destruction due to lightning is minimal and the efficiency of the over all system is maximized. To do this, separate ground systems should be installed for the building and antenna. This forces all of the RF return currents to flow in the transmission line shield. The coax can be buried below the antenna ground plane to still further reduce the RF current coupled to it. In medium and short wave installations the antenna ground plane is very important as it is of the radiating element. RF current leaving the antenna must return via the ground path (ground wave). For this reason the antenna coupling unit must be close to the base of the tower and securely connected to the ground plane. Figure B-7 shows the basic elements of a properly designed antenna system. Good ground plane. Ball gap on tower. Series inductor in tower feeder. Antenna coupling unit connected to antenna ground. The circuit is equivalent to the normal Tee used by Harris. Underground coax. Guy wire length broken by insulators and grounded at the bottom end. The transmitter building must be given extra protection to insure reliable equipment operation. A low impedance safety ground system must be installed using 3 inch wide copper strap hard soldered at all joints and connected to multiple ground rods located at the 04/13/ Page: B-5

294 Lightning Protection Recommendation AC Service Protection perimeter of the building. The ground rods should be wet to make good connection to the earth water table. All equipment cabinets within the building must be connected to the ground straps for safety reasons. Figure B-7 Basic Elements of a Properly Designed Antenna System B.4 AC Service Protection All incoming ac lines should have a choke connected in series to limit the high frequency surges on the lines followed by a surge protector. The surge protector must be connected to the building ground system by short direct connections, see Figure B-6. A surge protector is a solid state device that has a high impedance until the voltage across it reaches its rated clamping voltage, at which time its impedance suddenly decreases. The protector will then conduct hundreds to thousands of amperes to ground. All protectors are rated for maximum voltage and maximum surge energy. If the surge energy exceeds rating of the device it will normally short and for this reason must be fused so it will disconnect itself from the line being protected. When this happens all protection is lost so some warning system must be used to tell the operators that a new protector should be installed. Speed is essential to protect equipment from current surges with rates of rise exceeding 10,000 amps per microsecond and pulses that last no longer than 100 microseconds. Very short, low inductance ground straps are required to pass surges of this type. The surge protectors must be selected for the line to ground voltage and the maximum energy to be diverted. Bigger is always better in this case. There are several manufacturers of surge protectors: Lightning Elimination Associates., Inc. Current Technology Control Concept MCG Electronics, Inc. EFI Corp. General Electric All of these vendors provide parts and systems to protect broadcast transmitters. Page: B /13/12

295 Conclusion PowerCD Transmitter Lightning Protection Recommendation All audio and control lines should be protected the same as described for ac lines with components sized accordingly. 2533apb.fm B.5 Conclusion All coaxial lines should have the shield connected to the system ground at the point of entrance and in addition have a ferrite choke around it located between the entrance point and the equipment rack. This will provide a high impedance for current flowing in the shield but does not affect the signal currents. The 1% chance of a major lightning strike probably can not be protected against but the other 99% can be controlled and damage prevented. Install surge protection on all incoming and outgoing lines at the wall of the building connected to a well designed ground system. Properly install the antenna ground system with spark gap adjusted correctly and maintained. With this done you can sleep peacefully at night if your bed isn t under the feed line. 04/13/ Page: B-7

296 Lightning Protection Recommendation Conclusion Page: B /13/12

297 Surge and Lightning Protection PowerCD Transmitter Grounding Considerations, Surge & Lightning Protection Appendix C Grounding Considerations, Surge & Lightning Protection C.1 Surge and Lightning Protection 2533apc.fm A lightning storm can cause transients in excess of 2kV to appear on power or field signal lines. The duration of these transients varies from a few hundred nanoseconds to a few microseconds. Power distribution system transient protectors can efficiently protect the transmitter from transients of this magnitude. Transients are shunted to ground through the protection devices and do not appear on the output. To protect the transmitter from high transients on field cables, electronic surge protectors are recommended. All lightning protection is defensive in nature, that is, reacting to a lightning strike that has already occurred; therefore, its effectiveness is limited. Nothing can provide total immunity from damage in the case of a direct lightning strike. However, surge protectors installed immediately after the main power disconnect switch in the power distribution panel will afford some protection from electrical surges induced in the power lines. Surge protection devices are designed to operate and recover automatically. When operated within specifications, a surge protector does not require testing, adjustment, or replacement. All parts are permanently enclosed to provide maximum safety and flexibility of installation. To assure the safety of equipment and personnel, primary power line transformers must be protected by lightning arrestors at the service entrance to the building. This will reduce the possibility that excessive voltage and current due to lightning will seek some low impedance path to ground such as the building metallic structure or an equipment cabinet. The most effective type of power line lightning protection is the one in which a spark gap is connected to each primary, secondary, and the case of the power line transformer. Each spark gap is then independently connected to earth ground. In cases where driven ground rods are used for building ground, the primary and secondary neutrals must be separated by a spark gap. If two separate ground rods are used, the rods must be at least 20 feet apart. All connections between lightning arrestors, line connections, and ground must be made as short and straight as possible, with no sharp bends. C.2 System Grounding Signals employed in transmitter control systems are on the order of a few microseconds in duration, which translates to frequencies in the megahertz region. They are therefore radio-frequency signals, and may be at levels less than 500 microvolts, making them susceptible to noise appearing on ground wires or adjacent wiring. Thus, all ground wiring must be low in impedance as well as low in resistance, without splices, and as direct as possible. Four basic grounds are required: 1. AC ground 2. DC ground 3. Earth ground 4. RF ground 04/13/ Page: C-1

298 Grounding Considerations, Surge & Lightning Protection System Grounding C.2.1 Ground Wires Ground wires should be at least as large as specified by the local electrical code. These leads must be low impedance direct runs, as short as possible without splices. In addition, ground conductors should be insulated to prevent intermittent or unwanted grounding points. Connection to the earth ground connection must be made with copper clamps which have been chemically treated to resist corrosion. Care must be taken to prevent inadvertent grounding of system cabinets by any means other than the ground wire. Cabinets must be mounted on a support insulated from ground. C.2.2 AC Ground The suggested grounding method consists of two separately structured ground wires which are physically separated from each other but terminate at earth ground. The green ground wire from the AC power input must connect to the power panel and the ground straps of the equipment cabinets. The primary electrostatic shield of the isolation transformer, if used, connects to the AC neutral wire (white) so that in the event of a transformer primary fault, fault current is returned directly to the AC source rather than through a common ground system. The AC neutral is connected to earth ground at the service entry. Use of separate grounds prevents cross-coupling of power and signal currents as a result of any impedance that may be common to the separate systems. It is especially important in low-level systems that noise-producing and noise-sensitive circuits be isolated from each other; separating the grounding paths is one step. Noise Grounding Plate. Where excessive high-frequency noise on the AC ground is a problem, a metal plate having an area of at least 10 square feet embedded in concrete and connected to the AC ground will assist in noise suppression. The connection to AC ground should be shorter than 5 feet, as direct as possible, and without splices. Local wiring codes will dictate the minimum wire size to be used. Peripheral Equipment Grounds. All peripherals are supplied with a separate grounding wire or strap. All branch circuit receptacles must permit connection to this ground. This service ground must be connected through the branch circuit to a common grounding electrode by the shortest and most direct path possible. This is a safety ground connection, not a neutral. Often, circuit common in test equipment is connected to power ground and chassis. In these cases, isolated AC power must be provided from a separate isolation transformer to avoid a ground loop. C.2.3 DC Ground DC grounds in the transmitter are connected to a ground bus, which in turn is routed to a common cabinet ground and then connected to an earth ground. The use of separate ground busses is a suggested method of isolation used to prevent cross-coupling of signals. These ground buses are then routed to the cabinet ground and to earth ground. Page: C /13/12

299 System Grounding PowerCD Transmitter Grounding Considerations, Surge & Lightning Protection C.2.4 Earth Ground The transmitter must be connected to earth ground. The connection must have an impedance of 5 ohms or less. For example, a one-inch metal rod driven 20 feet into moist earth will have a resistance of approximately 20 ohms, and a large ground counterpoise buried in moist earth will exhibit a resistance on the order of 1 to 5 ohms. 2533apc.fm The resistance of an electrode to ground is a function of soil resistivity, soil chemistry and moisture content. Typical resistivity of unprepared soil can vary from approximately 500 ohms to 50kohms per square centimeter. The resistance of the earth ground should be periodically measured to ensure that the resistance remains within installation requirements. C.2.5 RF Ground Electrical and electronic equipment must be effectively grounded, and shielded to achieve reliable equipment operation. The facility ground system forms a direct path of low impedance of approximately 10 ohms between earth and various power and communications equipment. This effectively minimizes voltage differentials on the ground plane to below levels which will produce noise or interference to communication circuits. The basic earth electrode subsystem consist of driven ground rods uniformly spaced around the facility, interconnected with 2 or 4 inch copper strap. The strap and rods should be placed approximately 40 inches (1 meter) outside the roof drip line of the structure, and the strap buried at least 20 inches (0.5 meters). The ground rods should be copper-clad steel, a minimum of eight feet (2.5 meters) in length and spaced apart not more than twice the rod length. Brazing or welding should be used for permanent connections between these items. Where a resistance of 10 ohms cannot be obtained with the above configuration, alternate methods must be considered. Ideally, the best building ground plane is an equipotential ground system. Such a plane exists in a building with a concrete floor if a ground grid, connected to the facility ground system at multiple points, is embedded in the floor. The plane may be either a solid sheet or wire mesh. A mesh will act electrically as a solid sheet as long as the mesh openings are less than 1/8 wavelength at the highest frequencies of concern. When it is not feasible to install a fine mesh, copper-clad steel meshes and wires are available. Each crossover point must be brazed to ensure good electrical continuity. Equipotential planes for existing facilities may be installed at or near the ceiling above the equipment. Each individual piece of equipment must be bonded to its rack or cabinet, or have its case or chassis bonded to the nearest point of the equipotential plane. Racks and cabinets should also be grounded to the equipotential plane with a copper strap. RF transmission line from the antenna must be grounded at the entry point to the building with 2 or 4 inch copper strap. Wire braid or fine-stranded wire must not be used. All building main metallic structural members such as columns, wall frames, roof trusses, and other metal structures must be made electrically continuous and grounded to the facility ground system at multiple points. Rebar, cross over points, and vertical runs should also be made electrically continuous and grounded. Conduit and power cable shields that enter the building must be bonded at each end to the facility ground system at each termination. 04/13/ Page: C-3

300 Grounding Considerations, Surge & Lightning Protection System Grounding Page: C /13/12

301 Equipment Purpose PowerCD Transmitter External Heat Exchanger System Appendix D External Heat Exchanger System 2533apd.fm This Appendix contains the information necessary to install, operate, maintain and service the External Cooling System. The PowerCD cooling system is divided into the external cooling system and the internal or pure water cooling system for the IOT. The pure water cooling system is covered by Appendix D+1. The pure water cooling system is internal to each HPA. In normal operation the only significant heat dissipated by the transmitter is from the pure water cooling system via the plate heat exchanger in the cooling system to the external cooling system. The external cooling system includes the test and reject loads. The test load is used to dissipate transmitter power when the antenna is not used and the reject loads dissipate unbalance power when multiple HPA s are in operation. The parts listing for the External Cooling System (Fluid Cooler, Pump Module and Kit of Interconnecting Piping, Flow Control Valves and Flow Monitoring Devices) will be found in Section 7 of the manual. D.1 Equipment Purpose The heat exchanger system transfers the heat generated by each tube and from each water cooled test and reject RF Loads to the atmosphere outside the building. D.2 General Description See Figure D-1. The external cooling system consists of a one stage heat transfer cooling system to cool the tube and RF Loads. The External Cooling System circulates water directly in contact with the plate heat exchanger in the cooling cabinet; absorbing heat from the HPA. See Appendix Q for details of the coolant which may be used in the External Cooling System. Figure D-1 Block Diagram Heat Exchanger System 04/13/ Page: D-1

302 External Heat Exchanger System General Description D.2.1 Major Hardware The major pieces of hardware that make up the external cooling system are: Fluid Cooler (liquid to air heat exchanger) Pump Module Kit of Interconnecting Piping, Flow Control Valves and Flow Monitoring Devices D.2.2 Equipment Characteristics D Electrical Requirements Table D-1 lists the electrical requirements of the External Cooling System. Table D-1 Cooling System Electrical Characteristics All modules 480 Vac at 60 Hz 380 Vac at 50 Hz Transcool CD 1 Pump module (for 1 tube transmitter) 6.2 amps, 4 HP pump Transcool CD 2 Pump module (for 2 tube transmitter) 7 amps, 5.5 HP pump Transcool CD 3 Pump module (for 3 tube transmitter) 14 amps,10 HP pump 2 fan fluid cooler 2 kva 0.8 power factor 3 fan fluid cooler 3 kva 0.8 power factor 4 fan fluid cooler 4 kva 0.8 power factor D Mechanical/Environmental Characteristics Table D-2 lists the physical/environmental characteristics of the major parts of the heat exchanger system. Note Specifications are subject to change without notice. Page: D /13/12

303 General Description PowerCD Transmitter External Heat Exchanger System 2533apd.fm Table D-2 Cooling System Physical/Environmental Characteristics Mechanical: Transcool Pump Module Dimensions (H x W x D) 69.9 x 29.1 x 45.9 (176 cm x 74 cm x 117 cm) Weight (no coolant) 163 lbs (74kg) Glycol coolant tank Normal tank operating level is 46 gallons (182 liters) Note: The tank holds 68 gallons total and should be filled to 70% capacity. Tank empty level is 9 gallons. Tank low level is 24 gallons. Tank overfull warning occurs at 53 gallons. Output pressure range, Transcool CD1 50 psi at 50 gpm flow rate with SV407F306 pump Transcool pump module Transcool CD2 61 psi at 70 gpm flow rate with SV1602F406 pump Transcool CD3 63 psi at 120 gpm flow rate with SV3302-2N756 pump Mechanical: Sigma Pump Module Dimensions (H x W x D) x 36.0 x 55.0 (166 cm x 91 cm x 140 cm) Weight (no coolant) 800 lbs (363 kg) Glycol coolant tank 30 gallons (114 liters) Output pressure range PSIG Environmental: Pump Module Ambient temperature 113 F (45 C), see Note 1. Maximum temperature is 113 F (45 C) up to 1640 ft (500 m). Derate linearly to 77 F (25 C) at 6360 ft (1938 m). Ambient humidity range 0-95% relative humidity Altitude Sea level to 6562 ft (2000 m) Mechanical: Fluid Cooler Modules 2 Fan Unit - dimensions (H x W x D) 43.1 x 92 x 44 (110 cm x 234 cm x 110 cm) 2 Fan Unit - Weight 685 lbs (311 kg) 3 Fan Unit - dimensions (H x W x D) 43.1 x 132 x 44 (110 cm x 335 cm x 110 cm) 3 Fan Unit - Weight 946 lbs (430 kg) 4 Fan Unit - dimensions (H x W x D) 43.1 x 172 x 44 (110 cm x 437 cm x 110 cm) 4 Fan Unit - Weight 1340 lbs (609 kg) Environmental: Fluid Cooler Modules Ambient temperature 115 F (+46 C) at sea level, see Note 1 Derate maximum temperature is 3.6 F per 1000 ft (2 C per 305 m). Ambient humidity range 0-95% relative humidity Altitude Sea level to 6562 ft (2000 m) Note 1. Minimum ambient temperature is 32 F (0 C) if system is filled with water. For Glycol/water mixture, see Glycol manufacturers specifications to determine freezing point of the mixture. D.2.3 Recommended Coolants D During Checkout and Flushing Distilled or reverse osmosis purified water is used during initial checkout of the system and for flushing and cleaning the external liquid cooling loop. 04/13/ Page: D-3

304 External Heat Exchanger System Installation Caution If freezing conditions exist during the checkout and flushing procedures, the flushing procedure and subsequent fill with the final glycol/water must be finished before still water is allowed to remain in the fluid cooler. If the procedure cannot be finished, care must be taken to prevent the water from freezing in the outside fluid cooler. If water remains in the cooler long enough to freeze, the unit will be damaged. Pump a mixture of glycol/water into the cooler to prevent damage. Caution Do not use automotive grade anti-freeze as a substitution for the recommended ethylene or propylene based glycol. It does not contain the proper inhibitors for this application and will lead to eventual damage of the system. Since the water used to mix with the glycol will affect the corrosivity of the mixture, the water used should be de-ionized water with chloride and sulfate concentrations less than 100 ppm of each substance. Table D-3 contains a list of recommended glycol based coolants. Caution should be advised concerning the use of Propylene glycol for extreme cold conditions. Propylene Glycol solutions will gel at temperatures higher than Ethylene glycol solutions. This can result in higher pump current draw and very low flow rates until the Propylene glycol solution reaches a warmer temperature Table D-3 Recommended Coolants Description Dow SR1, ethylene glycol base, 55 gallon drum concentrated solution Dowfrost HD, propylene glycol base, 55 gallon drum concentrated solution Part Numbers D.3 Installation This section contains information for installing the External Cooling System and performing preoperational checks. D.3.1 Unpacking Carefully unpack the External Cooling System components and perform a visual inspection to determine that no apparent damage was incurred during shipment. Retain the shipping materials until it has been determined that the unit is not damaged. The contents of the shipment should be as indicated on the packing list. If the contents are incomplete or if the unit is damaged electrically or mechanically, notify the carrier and Harris Corporation, Broadcast Transmission Division. Page: D /13/12

305 Installation PowerCD Transmitter External Heat Exchanger System D.3.2 Plumbing Layout Drawings 2533apd.fm Individual systems vary greatly dependent upon equipment type, power output and building layout. Only general installation recommendations will be presented. Look for the appropriate water plumbing layout drawings in the system specific installation drawing set shipped with the transmitter: If a typical system layout is not utilized, a consulting engineering firm should be contracted to analyze flow losses to insure the flow rates can be maintained Plumbing Flow, One Tube Plumbing Flow, Two Tubes Plumbing Flow, Three Tubes. D.3.3 Pump Module Location The pump module is installed inside the building and should be near the fluid cooler (which is located outside the building. It should be located in a manner which will provide access to all sides for ease of maintenance. A minimum of 36 inches clearance must be provided on all sides of the module for maintenance access. D.3.4 Externally Mounted Fluid Cooler The system cooling coil assembly should be located outside the building on a level concrete pad and securely fastened with anchor bolts. The cooler should be oriented so that plumbing connections to the cooler minimize plumbing elbows and complex plumbing assemblies. In addition, the cooler should be oriented so access to the fans and fan motors can be accomplished. Refer to the appropriate manufacturer s guidelines in the back of this manual. Caution The 2 fan fluid cooler s weight is 685 lbs. The 3 fan fluid cooler s weight is 946 lbs. The 4 fan fluid cooler weighs 1150 lbs. Ensure the proper equipment is available to safely install the unit. Refer to the appropriate manufacturer s guidelines. Extreme care should be exercised during the following steps to avoid equipment damage or personnel injury. 1 Lift the unit into a horizontal position using manufacturer s recommended lifting points. 2 Install the leg channels and brace angles. 3 Carefully place assembled unit onto concrete pad. 4 Fasten unit to the concrete pad. D.3.5 Ice/Sun Shield The fluid cooler must be protected from large pieces of falling ice. A non-air restricting structure, installed well above the cooler, that breaks up large pieces of ice before they reach the cooler is needed. Often a 2x8 or 2x10 wood planks installed vertically and spaced several inches apart have been used as an effective ice shield. 04/13/ Page: D-5

306 External Heat Exchanger System Startup Checkout and Operation If the cooler will be exposed to strong sunlight in hot weather, the efficiency of the fluid cooler may be adversely affected. In this case, a sun shield that reduces the full effect of the sun should be considered. The ice shield covering, described above, can reduce the full effect of the sun and yet allow free movement of exhaust air from the fluid cooler. D.3.6 Pipe Sizing and Routing If a typical system layout is not used, the typical plumbing layout should still be consulted for pipe size information, connection details, techniques at the amplifier cabinets, RF Loads, pump module and outside fluid cooler. A custom plumbing installation must not unduly restrict flow rates or change the design of the cooling system. Locate the plumbing so that access to transmitter system components is not restricted. Note Pipes must be sized no smaller than shown on the typical plumbing layout. Their routing should minimize turns and long runs. Note If additional amplifier cabinets are to be added to the system in the future, consider these plans when sizing and laying out the cooling system. Doing so now may slightly increase the installation cost, but will greatly lower the cost of conversion later. D.3.7 Plumbing System Installation The plumbing lines must be type L hard drawn copper with soft silver soldered joints (96.5% Tin, 3.5% Silver; Aladdin #450 silver solder or equivalent). An adequate amount of soft silver solder (Harris part ) is supplied with the plumbing kit. Good silver brazed joints are acceptable but not required. A poorly done brazed joint is much harder to repair than a soft silver solder joint. D.3.8 Reserve Coolant Supply A sufficient reserve supply of coolant should be kept on hand to refill the entire system in the event of a major leak. D.3.9 Clean-Up Plan A plan for containment and spill clean-up acceptable to local environmental regulations should be considered. D.4 Startup Checkout and Operation This section contains information pertaining to identification, location and function of the controls and indicators on the Heat Exchanger system. shows component location. D.4.1 Controls and Indicators Refer to the Transcool pump module technical manual. Page: D /13/12

307 Startup Checkout and Operation PowerCD Transmitter External Heat Exchanger System D.4.2 Pump Rotation Check pumps for correct direction of rotation. The pump casing is marked with an arrow indicating correct direction of rotation. 2533apd.fm Caution Pump must not be operated more than 5 seconds dry to check rotation. Warning Disconnect primary power at source before interchanging wires. If rotation direction is incorrect, interchange any two of the three phase input wires at TB1-1, 2 and 3 and recheck rotation. D Fan Rotation The fans on the cooling coil should blow upwards. If a fan motor is rotating in the wrong direction, reverse two of the phase wires at the input to the Cooling Unit. D.4.3 Start Up Procedure Caution Under no condition should the pumps be operated dry or with suction lines partially closed. Pumps may be operated only briefly (less than 3 minutes) with discharge closed. Impellers, seals and bearings will be damaged if pumps are operated improperly. D.4.4 Flushing The Cooling System Before the initial transmitter operation and for periodic maintenance (approximately every two years) the cooling system needs to be flushed and filled with fresh coolant. Cooling system capacities are given in Table D-4. For systems which are excessively dirty, flush using a mixture of 4 cups of a non-sudsing detergent (such as Cascade) in 2 gallons of water. Strain mixture into tank through a fine filter. Fill tank with distilled or reverse osmosis purified water. Operate pumps for 30 minutes, drain the system and reflush with distilled or reverse osmosis purified water. For initial cooling system flush or clean out of an existing system, follow the procedure below using distilled or reverse osmosis purified water. 1 Open pumps A and B service valves on suction and discharge sides. 2 For the initial flush, or for a flush with detergent to clean a dirty system, bypass the coolant around the IPAs, cooling cabinet heat exchanger, and loads until the contamination is removed. 3 Fill the system with distilled or reverse osmosis purified water. Pump module tank capacity is 50 gallons (189 liters). Capacity will vary with individual system size and layout. 04/13/ Page: D-7

308 External Heat Exchanger System Startup Checkout and Operation Note The system cannot be filled to capacity at this time. Water must be added as pipes and equipment fill up at initial pump turn on. The reservoir tank is equipped with a level switch which will shut the pump off if a low water level occurs. 4 Open all flow control valves in the transmitter system. 5 Vent air from each pump casing by removing seal flushing fitting at top of pump casing. Replace fitting after air vents. Warning Ensure primary power is off before jumper is installed in Step 6A. 6 To operate the pumps independent of the transmitter operating state, follow sub step A for the Sigma (Harris built) pump module and sub step B for the Transcool pump module. A. For the Sigma (Harris built) install a jumper wire across terminals 1 to 10 of TB2 to allow pump turn on independent of transmitter. 1. Switch S1 (labeled local control switch and located under the handle) controls the operation of the pumps. Center is off, left operates pump A, and right operates pump B. B. For the Transcool pump module two 3-position switches control the operation of the two pumps. S1 controls pump A and S2 controls pump B. 1. Each switch has three positions which are manual, off, and automatic. 2. To operate pump A, S2 must be off and S1 (the pump A switch) is on manual to start the pump and on off to stop the pump. 3. To operate pump B, S1 must be off and S2 (the pump B switch) is on manual to start the pump and on off to stop the pump. 4. For normal operation, where pumps are controlled by the transmitter, both switches are in the automatic position. 7 Set both pumps to the off position. 8 Turn on primary power. 9 For initial startup of a new installation, jog each pump on to verify direction of rotation. If the direction of both pumps is wrong, power down the unit and swap any two phases at the safety disconnect switch on the pump module. If correct proceed to Step Allow pump A to operate for approximately 5 seconds. The pressure gauge should rise to 50 to 70 psi. If pressure does not rise, shut off pump and vent air from pump casing by removing seal flushing fitting at top of pump casing. Replace fitting after the air vents. 11 Repeat Step 10 for pump B. Page: D /13/12

309 Startup Checkout and Operation PowerCD Transmitter External Heat Exchanger System 2533apd.fm 12 Air must be vented from the rest of the system, since the supply and return lines are often mounted at the higher elevation than the pump module. If the lines are allowed to fill and push the air out without the venting process, hydraulic action (hammering noises) will occur as the system fills. This can damage the system. The venting procedure is given below. A. locate the vent valves or plugs. They are located at the highest places in the system. B. Have one man open a vent (start with the supply line vents) while another man turns on one of the pumps. When water runs out the vent, turn the pump off and close the vent valve or replace the vent plug. C. If multiple vents exist, repeat this process until all of the air is purged from the system. 13 For initial startup of a new installation, turn one of the pumps on and adjust the various flow control valves to their normal flow rates. The pressure at the pump module should be within the 50 to 70 psi range. A. Refer to the overall transmitter cooling flow diagrams listed below. They are located in the system specific installation drawing set: PWR30P PWR60P PWR90P Caution Pumps used in this system will deliver to the point where a motor overload occurs. In no case should the flow required from a single pump be allowed to exceed the total flow requirement stated in the appropriate coolant flow diagram. 14 Allow the water to circulate 30 minutes with the pump operating. Run each pump for half of the time. 15 Shut off the pumps. Drain water from the system and clean any strainers installed in the system. A. Open the air bleed vents at the system high places to facilitate system draining. B. Drain valves should have been installed in the low parts of the system to facilitate system draining. 16 Repeat flushes (following steps 3 to 15, skipping steps 9 and 13) until cooling fluid appears to be clean. 17 Remove the bypasses around the IPAs, cooling cabinet heat exchanger, and loads and restore the normal coolant path through them. 18 Normalize the pump controls. Warning Ensure primary power is off before jumper is installed in Step 18A. A. For the Sigma (Harris built) pump modules, remove the jumper wire across terminals 1 to 10 of TB2 and turn on the pump module primary power. 04/13/ Page: D-9

310 External Heat Exchanger System Theory of Operation B. For the Transcool pump modules, set switches S1 and S2 to the automatic position. 19 Refill the system with a 50/50 glycol/water mixture. Warning Ensure primary power is off before jumper is removed in Step Shut off primary power and remove jumper wire installed in step 6 21 Turn on primary power. Set pump switch (S1) to OFF. The heat exchanger system is now operational. Table D-4 External Cooling Systems Capacities System Type Coolant Capacities 1 tube 60 gallons (227 liters) 2 tube 80 gallons (303 liters) 3 tube 100 gallons (379 liters) Note: Total cooling system capacity is variable, it depends on exact cooling system dimensions, pipe sizes, number of pump modules and number of heat exchanger modules, all of which can change from one installation to the next. D.5 Theory of Operation Temperature control of the transmitter is accomplished by pumping a water/glycol fluid through a closed loop, from the pump(s) through the HPA cabinets, driver cabinet, and the RF Load(s), where the fluid absorbs heat. The coolant is then directed to the External Fluid Cooler and back to the pump(s). D.5.1 External Fluid Cooler The fluid cooler is a weatherproof unit designed to be mounted outdoors. The fluid cooler supplied with the transmitter has been chosen to provide sufficient transmitter cooling under worst case ambient and heat load conditions. The number of fans and size of heat exchangers is a function of the size of the transmitter. The unit is equipped with finned coils through which the hot coolant passes. The finned coils transfer heat from the hot coolant to the air. Fans mounted above the coils draw cool air from the bottom of the cooler, through the coils, and is exhausted from the top of the cooler. The fans, driven directly from the motor shafts, are cycled on as a function of the liquid temperature leaving the cooler. Two temperature sensors, attached to the coil outlet header, operate thermostats that energize the fan contactors when the coolant temperature reaches preset limits. Because the fans operate strictly as a function of exiting fluid temperature, the fans may not run at all during cold weather. As the ambient temperature rises, half or all of the fans will be switched on by the thermostats. Page: D /13/12

311 Maintenance PowerCD Transmitter External Heat Exchanger System If the temperature of the outlet coolant is less than 95 o F, no fans are running. When the temperature reaches 95 o F half the fans activate. Should the outlet coolant temperature rise above 115 o F the remaining fans will activate. 2533apd.fm D.6 Maintenance The following information is intended to provide guidelines in establishing a regular maintenance program that will minimize downtime. Preventative maintenance should be performed as shown in Table D-5. Table D-5 Cooling System Maintenance Schedule Check Frequency Results/Notes Clean RF Load(s) particle filters At first 30 hours then semi-annually. Note any unusual contents Check pump pressure Weekly Approximately 90 PSI. Compare with previous readings. Check plumbing system and Weekly Repair leaks immediately tubes for leaks Check level in coolant reservoir Weekly Compare with previous levels. Check fluid cooler fan operation. Monthly Check for unusual noises. Make sure fans are tight on motor shafts Check pumps Monthly Listen for unusual noises. Look for leaks around pump shaft. Check alternate pump operation Monthly Check for correct pressure range, quiet operation, and leaks. Clean dirt from fluid cooler coils and fans. Semi-annually Use air conditioner cleaning solution and high pressure water hose. Check condition of glycol solution Lubricate glycol pumps (do not over lubricate) Annually Annually Use hydrometer to check freezing point. Check clarity of solution and be aware of increased granular particles in filters. This could be an indication of glycol breakdown. Check PH of the solution, it should be between 8 and 9. Check the manufactures literature for lubrication type and instructions D.7 Troubleshooting Troubleshooting is separated into pump troubleshooting, see Table D-6 and fan and thermal troubleshooting, see Table D-7. Refer by symptom to the applicable table and follow the corrective action indicated. Prior to starting a troubleshooting procedure check all switches, power connections, connecting cables and power fuses. 04/13/ Page: D-11

312 External Heat Exchanger System Fluid Cooler Parts Lists Table D-6 Pump Troubleshooting Trouble Symptom Probable Cause Corrective Action Pressure erratic, Clogged suction line. Clean suction line. Sounds like pumping Closed discharge valve Open discharge valve gravel (cavitation) Pump discharge check valve stuck closed Replace check valve. System flow to high, pressure to low Add fluid, adjust system valves for correct flow, check for leaks System filter screens clogged Clean screens. Pump Leaks Seal broken or worn Replace seal Casing gasket broken Replace gasket Pump rotor locked Bearings frozen Replace pump, motor, or bearings. Foreign object lodged in impeller casing. Disassemble pump, remove object and replace damaged parts. Pump shuts off Extremely low coolant level. Add coolant (use correct mixture). Incorrect heaters in pump contactors. Replace with correct heaters. Motor overload (flow too high) Adjust control valves for correct flow. Blown fuse Replace fuse Pressure too low Worn impeller or casing rings. Replace impeller or casing rings. Flow rate too high. Adjust control valves for correct flow. Table D-7 Fan and Thermal Troubleshooting Trouble Symptom Probable Cause Corrective Action Excessive vibration or Damaged fan Replace fan noise. Loose or broken motor mount Tighten, repair, or replace mount. Motor rain shield loose or damaged Tighten or replace. Fan safety guards loose or damaged Tighten, repair, or replace guards Fan won t run Blown fuse Replace fuse One or more input phases low or missing. Check indicator on phase loss monitor. Check power line voltage Fan won t run when Motor overload Check for free rotation coolant is hot, or fan shuts off too soon. Thermostat set wrong or is defective. Check thermostat Thermostat is sensing air temperature not coolant temperature. Insure sensor is tightly pressed against pipe using straps or thermally insulated tape. Coolant overheats Fluid cooler fins dirty Clean coils with industrial air conditioner cleaner and high pressure water spray. Air flow blocked by foreign matter in fan cooler assembly Fluid cooler fans not operating. Clean fan cooler assembly and correct blockage. See symptoms 2 or 3 in this table. D.8 Fluid Cooler Parts Lists Electrical parts for 50 and 60 Hz - 2, 3, or 4 fan fluid coolers are listed in Table D-8. Page: D /13/12

313 Fluid Cooler Parts Lists PowerCD Transmitter External Heat Exchanger System 2533apd.fm Table D-8 Fluid Cooler Electrical Parts List For 2, 3, or 4 Fan Units Harris P/N Description Quantity Ref. Symbol Contactor 50 Hz 2 FA1, FA Contactor 60 Hz 2 FA1, FA Fan Motor 50 Hz 2 or 3 or 4 N/A Fan Motor 60 Hz 2 or 3 or 4 N/A Control Transformer 50 Hz 1 T Control Transformer 60 Hz 1 T Fan Blade 2 or 3 or 4 N/A Fan guard 2 or 3 or 4 N/A Thermostat +55 F to +175 F 2 AQ1, AQ2 No Harris P. N. Fuse, Slow Blow, 15 Amp 3 FB1, Liebert Part Number: E-2410 Note: Parts not labeled for 50 or 60 Hz operation can be used for either. 04/13/ Page: D-13

314 External Heat Exchanger System Fluid Cooler Parts Lists Page: D /13/12

315 Pure Water Loop Component Descriptions PowerCD Transmitter Internal Pure Water System Setup and Maintenance Appendix E Internal Pure Water System Setup and Maintenance This section covers installation, setup and maintenance of the pure water loop in the PowerCD transmitter cooling cabinet. 2533ape.fm E.1 Pure Water Loop Component Descriptions The cooling cabinet is the part of the HPA assembly. It supplies and controls pure water coolant and cavity cooling air to the IOT. There is an identical cooling cabinet for each HPA assembly. Heat from the pure water coolant loop is transferred to the glycol/water external coolant system described in the previous section. Metering sensors for the cooling equipment are multiplexed in the cooling control board. Purification of the pure water coolant is done in the cooling cabinet. A driver reject load is also mounted in the cooling cabinet where it transfers RF energy to the glycol coolant. E.1.1 Supply Loop The supply loop starts at the tank and includes an isolation valve, strainer, drain tee, pump, plate heat exchanger, supply manifold, supply, pressure sensor, and supply temperature sensor. E.1.2 Return Loop The return loop receives DI coolant from the collector loop, anode loop, and purification loop. In addition to these three inputs, it has a drain tee, a conductivity sensor, isolation valve, and tank return connection. E.1.3 Purification Loop The cooling cabinet purification loop consists of a throttling valve on the supply manifold, a flow meter, UV sterilizer, an ion-exchange demineralizer, a filter, and return valve to the coolant return manifold. E.1.4 Collector Cooling Loop The collector cooling loop begins at the coolant supply manifold and consists of a globe valve, a flex hose to the IOT, a quick supply disconnect with automatic valve, a similar return quick disconnect with automatic valve, a bulkhead feed through fitting, coolant temperature sensor, a return shutoff valve, a turbine flow meter, and a union for connection by the return loop. E.1.5 Anode Cooling Loop The anode cooling loop is nearly identical to the collector cooling loop above except that the piping is smaller for the lesser flow in the anode cooling loop. 04/13/ Page: E-1

316 Internal Pure Water System Setup and Maintenance Cooling Cabinet Prestart Checklist E.1.6 Glycol External Cooling Loop The glycol external cooling loop consists of a coolant inlet at the top of the cooling cabinet, a glycol inlet temperature sensor, a flex hose to the heat exchanger, the plate heat exchanger cool side, a flex hose to the glycol flow meter, a drain valve, and return to the top of the cooling cabinet. The glycol-water pumps and liquid-to-air heat exchangers are covered by another section. E.2 Cooling Cabinet Prestart Checklist Complete this procedure checklist before closing the 480 VAC power isolation switch S1. Do this procedure whenever the pure water system has been drained or the coolant hose connectors have been disconnected from the IOT. 1 Check that there is a minimum of 6 inches of water in the deionized water tank. Check for coolant leaks around the tank fittings. 2 Check that the drain plug in the PVC return manifold in front of the pump is in place. 3 Check that both of the drain plugs are installed in the pump. There may be one on each side of the pump, depending on the pump configuration. 4 Check that the pump internal recirculation valve is closed. This is the center screw on the drain plug on the front lower side of the pump. This may be used to drain the pump, but must be closed when the pump is operating. 5 Open the PVC ball valve in the pump supply line below the tank, and the PVC ball valve in the return line at the front corner of the cabinet just below the tank shelf. 6 Open both vent plugs on the top of the pump housing and vent as much air as possible from the pump housing. Close these plugs when water flows from them. 7 Open all three return valves in the rear cabinet. These are stainless steel ball valves with yellow handles. 8 Check that the collector supply valve on the front (IOT) side of the cooling cabinet is fully open, and that collector hoses are connected to the IOT. The anode supply throttling valve will be adjusted after the coolant is running in HPA standby mode. 9 To purge air from the purification cartridges, open each of the two vent valve levers on the top of the cartridges until water comes out. 10 Check for leaks. 11 Close the 480 VAC power isolation switch S1 in the right front of the cabinet. 12 Briefly start the cooling cabinet pump and observe the pump motor fan for correct rotation (counter-clockwise looking at the top of the motor). E.3 Cooling Cabinet Pure Water Loop Service The ion-exchange cartridge, the coolant filter, or the UV sterilizer bulb may be changed while the HPA is operating at nominal power. These items are located on the rear door of the HPA cooling cabinet. To do this or to do any other service to the purification loop, do the following: Note that in the following instructions refer to front, back, right, and left as seen from the front of the transmitter lineup, so when you look in the back door of the cooling cabinet the right side of the cabinet is on your left. The plate heat exchanger, for example, is on the left side of the cabinet, although it is to your right as you are looking into the back door of the cooling cabinet. Page: E /13/12

317 Cooling Cabinet Pure Water Loop Service PowerCD Transmitter Internal Pure Water System Setup and Maintenance 2533ape.fm 1 Close the purification supply valve. It is the one with the red knob and is located under the tank. 2 Close the yellow handled purification return ball valve at the front of the cabinet. A These valves must be closed in the stated order to avoid excessive pressure on the purification loop components. The HPA may be operated for 12 to 24 hours without the purification loop if the coolant resistivity is initially 5 megohms or better. 3 Insert the drain plugs in the purification loop sink. These are 6 mm screws with nylon washers. 4 If the ion-exchange cartridge is to be changed, follow Steps A through F listed below. A Open the vent valve briefly to relieve the pressure on the cartridge holder. B Release the thumb lock and turn the blue cartridge canister handle to the left. 1 The handle, cartridge, and canister will lower, and a about a cup of coolant will spill into the sink. C Regrease the GSX28 large head seal O-ring with silicon grease. D Discard the cartridge and replace it with a new cartridge. E Carefully mate the canister, O-ring, and cartridge to the head with the blue handle out of the way, observing the seating of the O-ring into the head. F Hold the canister in place and secure it to the head with the blue handle. 1 Use care with the thumb lock of the blue head handle. It can be broken. 5 If the filter element is to be changed, perform Step 4, except on the filter cartridge in the half height canister instead of the ion-exchange cartridge. 6 Follow the procedure below to vent the air from the two canisters. This step is necessary to avoid large air bubbles in the coolant tank, they could be pumped to the IOT. A Hold the vent valves open on the canister heads and carefully crack the red handled purification supply valve below the tank. 1 Air will vent and water can be seen filling the canisters. B Close the purification supply valve when water flows from the vent valves 1 If replacing both canisters, release the vent valve on the first canister when water flows from it and wait for the second canister to fill before closing the purification supply valve. 2 Do not allow the canisters to become pressurized by releasing the last canister vent valve before closing the purification supply valve. C Open the yellow handled purification return valve on the front of the cabinet. D Carefully open the purification supply valve below the tank until the flow meter reads gpm. 04/13/ Page: E-3

318 Internal Pure Water System Setup and Maintenance Cooling Cabinet Pure Water Loop Service Page: E /13/12

319 Review of Heterodyne Action PowerCD Transmitter Linear RF Amplifiers Appendix F Linear RF Amplifiers A linear amplifier must be used to amplify NTSC television (visual or common mode) signals, digital television (DTV), digital video broadcasting (DVB), audio, or any time two or more signals (even FM or PM signals) must be amplified in a common amplifier with minimum distortion, minimum crosstalk, and minimum intermodulation products). 2533apf.fm Intermodulation products are commonly referred to as intermods. A linear amplifier increases the power of a signal, but does not change its waveform or frequency content; therefore, its output has minimum harmonics or intermodulation products. It is useful when amplifying audio, AM signals, F.1 Review of Heterodyne Action Linear RF amplifiers are required in digital television transmitters to limit the adjacent channel spurious intermodulation products. The process of producing intermods through heterodyne action is similar any time multiple RF signals are amplified in a common amplifier, so an example of common mode analog television will be used here. Heterodyne action occurs when two signals are simultaneously passed through a nonlinear device. The output contains four frequencies; they are the two original frequencies, the sum of the originals, and the difference between the two originals. Heterodyne action is known by other names, such as mixing, beating, intermodulation, modulating, demodulating, alias products (in the digital world) and various other names. Heterodyne action will occur when two (or more) signals simultaneously pass through an amplifier that is not perfectly linear. If either or both signals are modulated, the modulation of either or both will appear on the output signals, this is referred to as crosstalk. Often, this type of first-order intermodulation (commonly referred to as intermod) is less harmful because its products are distanced from the operating frequencies by the sum and difference of the two input frequencies, and therefore are easier to filter out. F.1.1 Multiple-Order Intermodulation Products Heterodyne action is also possible between one signal and harmonics of the another, or between harmonics of both signals. This particular type of intermodulation can cause problems because its products fall close to or within the frequency spectrum of the original signals. Third-order intermodulation occurs when the second harmonic of one signal heterodynes with the fundamental frequency of another signal. An example may be useful: Consider the intermodulation products between visual and aural carriers of a multiplexed NTSC signal on channel 38. F 1 = MHz (the visual carrier), F 2 = MHz (the aural carrier). Two third-order intermodulation difference products occur, they are: F A = 2F 1 - F 2 = = MHz (4.5 MHz below visual carrier), F B = 2F 2 - F 1 = = MHz (4.5 MHz above aural carrier), where F A and F B are the third-order intermodulation difference products. The third-order intermodulation sum products are also present in the output, but are not discussed here since their frequencies are far removed from that of the carriers and therefore are easily removed. 04/13/ Page: F-1

320 Linear RF Amplifiers Review of Heterodyne Action Other multiple order intermodulation products can occur, such as the third harmonic of one frequency with the second harmonic of the other, and the fourth harmonic of one frequency and the third harmonic of the other. Examples of this are shown below: F C = 3F 1-2F 2 = = MHz (9 MHZ below visual carrier), F D = 3F 2-2F 1 = = MHz (9 MHz above aural carrier), F E = 4F 1-3F 2 = = MHz (13.5 MHz below visual carrier), F F = 4F 2-3F 1 = = MHz (13.5 MHz above aural carrier), where FC through FF are other intermod difference products, see Figure F-1. Other NTSC TV intermod products include the 920 khz beat between the color sub carrier and the aural carrier. This product heterodynes with the visual carrier and is found 920 KHz above and below the visual carrier. Also, amplifier nonlinearity causes regeneration of the portion of the NTSC lower sideband removed by the vestigial sideband filter within the visual exciter. A new DTV 560 khz beat product is created when the N+1 NTSC/DTV combination is amplified in a common RF amplifier with less than perfect linearity. It is the result of a beat between the NTSC aural carrier and the DTV signal pilot. As with the 920 khz beat, it is also found 560 khz above and below the visual carrier. F Intermodulation Product Levels The levels of the various intermod products depend on the degree of nonlinearity of the amplifiers. When viewed on a spectrum analyzer, the two original signals and their intermod products resemble the teeth of a comb; see Figure F-1. The amplitude of the intermod products can often be reduced by slightly tweaking the RF PA bias (idle current) for minimum intermod products as viewed on the spectrum analyzer. F 1 and F 2 are the original frequencies, F A through F F are the intermod products. Spacing between displayed frequencies are same as that of F 1 and F 2. F E = MHz F C = MHz F A = MHz F 1 = MHz F 2 = 619,75 MHz F B = MHz F D = MHz F F = MHz Figure F-1 Spectrum Analyzer Display Showing Intermodulation Products F.1.2 Modulation Crosstalk Modulation crosstalk is defined as the condition where the modulation of one carrier appears on the other carrier. This occurs when more than one modulated signal is simultaneously amplified in an amplifier that is not perfectly linear. It can also be caused by insufficient amplifier bandwidth or excessive amplifier group (envelope) delay. Page: F /13/12

321 Classes of Operation PowerCD Transmitter Linear RF Amplifiers F.2 Classes of Operation Four classes of operation are commonly used for RF amplifiers, they are class A, AB, B, and C. A brief review of class AB operation is presented here. 2533apf.fm F.2.1 A single ended class A amplifier is linear for all signals. Push pull class AB amplifiers must be used to amplify baseband audio signals, but a single ended class AB amplifier is considered linear for RF signals. Class AB Refer to Figure F-2. The conduction angle of class AB is greater than 180 degrees and less than 360 degrees. More than one half, but less than a complete input cycle is reproduced in the output. This amplifier is biased in the lower part of the transfer curve, usually in the nonlinear portion. A class AB amplifier will draw some idle current, and therefore will dissipate some power under no signal conditions. This amplifier has low efficiency when amplifying low signal levels, but its efficiency approaches that of class B when it is operated near to or at full output power. This class of amplification is preferred when high power RF is required from a linear amplifier. If the amplifier transfer curve is perfectly linear, as shown on the left side of Figure F-2, class AB will produce more nonlinearity (distortion) than class B, but due to the normal amount of nonlinearity near cutoff, as shown on the right side of Figure F-2, the class AB amplifier linearity increases. F Class AB Bias The class AB bias is set by adjusting the bias for a predetermined amount of idle current. The effect of this adjustment can be seen on the right hand drawing of Figure F-2. The linear portion of the transfer curve is extrapolated to the cutoff point. This point is where the bias is set. The effective result is good linearity over one half cycle. Under real world conditions, the bias is set for the correct predetermined idle current, and can be tweaked slightly for the lowest distortion or lowest amount of intermodulation products. After the bias is tweaked for best operation, the new value of idle current should be measured to be sure it is within the allowable range, and recorded for future reference. Since the dc output current of class AB changes with the output power and is relatively low at idle, the class A automatic feedback regulator system cannot be used. This can cause a problem because the amplifier bias requirements also changes with temperature and, in some cases, with amplifier device aging. Temperature dependent bias variations can be controlled by sensing the amplifier device temperature with another solid state device, often a diode, which is mounted close to or in contact with the amplifying device. The temperature sensing device provides feedback to the bias regulator, which changes the bias to eliminate temperature drift. The temperature sensing device is carefully chosen to match its thermal characteristic to those of the amplifying device. Class AB amplifier idle current should be checked periodically as part of preventive maintenance, when an amplifying device is changed, or when distortion or intermodulation measurements suggest that the amplifier is becoming less linear. 04/13/ Page: F-3

322 Linear RF Amplifiers Classes of Operation Instantaneous Output Current Transfer Curve Instantaneous Output Current Transfer Curve Output Waveform Idle Current Output Waveform Input Waveform Instantaneous Input Level Extrapolated Transfer Curve Idle Current Instantaneous Input Level Input Waveform Bias Level Class AB, Linear Transfer Curve If the transfer curve is perfectly linear, the output is more distorted. Bias Level Class AB, Nonlinear Transfer Curve If transfer curve has typical nonlinearity near cutoff, class AB operation increases the output linearity. Figure F-2 Class AB Amplifier Transfer Curves Page: F /13/12

323 S-SERIES LOW FLOW METER INSTRUCTIONS SeaMetrics S-Series Low Flow Meter Instructions PowerCD Transmitter Vendor Data Appendix G Vendor Data 2533apg.fm G.1 SeaMetrics S-Series Low Flow Meter Instructions S-SERIES LOW FLOW METER INSTRUCTIONS SPX SPT The Leader in Flow Meter Value 04/13/ Page: G-1

324 Vendor Data SeaMetrics S-Series Low Flow Meter Instructions GENERAL INFORMATION These versatile impeller flowmeters are available in 3/8", 1/2, 3/4, and 1" nominal pipe sizes with female NPT threads (SAE optional). They employ jewel bearings to allow for very low minimum flow rates and superior life. With a body material of polypropylene, the SPX is an economical choice for metering water or low corrosion fluids. The lens cover is available in a choice of materials: acrylic for visual flow indication of low-corrosive fluids; polypropylene when more corrosion resistance is needed. The standard rotor assembly is Kynar with tungsten carbide shaft (ceramic shaft optional). The O-ring is EPDM. The pulse output of these meters is compatible with many different types of controls, including a full range of SeaMetrics rate displays and controls. The SeaMetrics FT420 provides flow rate and total flow indication, with 4-20 ma ouput capability. The FT415 is a battery-operated rate & total display. For metering pump pacing or interfacing with lowspeed counters, the PD10 pulse divider is recommended. The AO55 may be used for blind 4-20mA transmission. The SPT offers greater chemical resistance with a Teflon body and cover, Teflon-coated Viton O-ring, and standard Kynar/ceramic rotor assembly (carbide shaft optional). FEATURES Thread-in Sensor, Field Replaceable, 6-24 Vdc pulse 18 Sensor Cable Removable Lens Assembly Standard Acrylic Top (SPX) Hex Screws Female NPT Ports (SAE optional) (Internal) Jewel bearings Kynar/Carbide or Kynar/Ceramic Rotor Assembly EPDM (SPX) or Teflon-coated Viton (SPT) O-ring SPX shown SPECIFICATIONS Connection Ports Sensor Cable Materials Body Rotor Shaft O-Ring Bearings Cover Maximum Temperature Maximum Pressure Accuracy Power Outputs Page 2 SPX 3/8, 1/2, 3/4, 1, Female NPT thread (SAE optional) 18 feet standard (maximum cable run 2000 ft.) Polypropylene PVDF (Kynar) Nickel tungsten carbide (zirconia ceramic optional) EPDM (Kalrez or Teflon-coated Viton optional) Ruby ring and ball Acrylic (Polypro optional) 160 F (70 C) 150 PSI (10 bar) +1% of full scale 5-24 Vdc, 2 ma min Current sinking pulse, 6-24 Vdc SPT 3/8, 1/2, 3/4, 1, Female NPT thread (SAE optional) 18 feet standard (maximum cable run 2000 ft.) TFE Teflon PVDF (Kynar) Zirconia ceramic Teflon-coated Viton (EPDM or Kalrez optional) Ruby ring and ball TFE Teflon 160 F (70 C) 150 PSI (10 bar) +1% of full scale 5-24 Vdc, 2 ma min Current sinking pulse, 6-24 Vdc Page: G /13/12

325 SeaMetrics S-Series Low Flow Meter Instructions PowerCD Transmitter Vendor Data INSTALLATION and CONNECTIONS 2533apg.fm INSTALLATION Piping Requirements. Standard fittings are female NPT. If the piping connected to the meter is metallic, care should be taken not to overtighten. Straight pipe of at least five diameters upstream of the meter is recommended. Vertical, horizontal, or inverted (lens down) installations are all acceptable. K-Factor. The meter is factory calibrated. The K-factor is found on the label on the meter body and must be input into the control/display for accurate reading. K-FACTOR ON LABEL Warning: This meter has low-friction bearings. Do not at any time test operation of the meter with compressed air. Doing so will subject it to rotational speeds many times those for which it was designed, and will certainly damage the rotor, shaft, and/or bearings. CONNECTIONS Connecting to Non-SeaMetrics Control Devices. It is often desirable to connect an SPX/SPT flow sensor to a PLC or industrial computer board, and the sensors are well suited for this. Typically it can be connected directly, or with a single resistor added. The pickup sensors are current sinking (NPN) GMR devices that require 5-24 Volts DC and 2 ma current. They can connect directly to a PLC or computer board (See Fig. 1) if: 1. The sensor power supply on the PLC is 5-24 Vdc (24 Vdc is typical). 2. The sensor power supply can provide at least 2 ma (100 ma is typical). 3. The sensor input on the PLC can accept a current sinking device. 4. The PLC frequency response > flow meter output frequency. If the PLC input only accepts current sourcing devices, a pull-up resistor must be added (See Fig. 2). Typically, on a 24 Vdc input a 2.2 K Ohm resistor will be effective. Figure 2 Input Designed for Current Sourcing (PNP) Devices 2.2K Ohm Pull-up Resistor NPN Device Red White Black +DC Voltage Signal Ground PNP Device Figure 1 Input Designed for Current Sinking (NPN) Devices Red +DC Voltage Since the three-wire pickup sensors are solid state, they do not exhibit switch bounce and can be used at relatively high frequencies. NPN Device White Black Signal Ground NPN Device If the PLC is equipped with a 4-20 ma analog input module, it is necessary to order the S- Series flow sensor with some form of 4-20 ma transmitter. Two options are the AO55 blind transmitter and the FT420 indicating transmitter. Follow the connection diagrams for these products to connect to the analog input. Page 3 04/13/ Page: G-3

326 Vendor Data SeaMetrics S-Series Low Flow Meter Instructions MAINTENANCE and REPAIR REPAIR Rotor Replacement. There is only one moving part to this meter. The bearings are made of ruby, which rarely wears out or needs replacement unless they have been physically damaged by severe shock. The shaft is integrally molded into the rotor, and shaft and rotor are replaced as one part. (You may wish to replace the bearings, using the bearing removal tool, while the meter is disassembled for rotor replacement). To replace the rotor, disconnect the meter and remove the four screws that hold the cover in place. Lift the cover and remove the rotor (see parts diagram below). When putting in the new rotor, be sure that the ends of the shaft are in both bearings before tightening the cover. The rotor can be easily dropped into the bottom bearing. Starting the shaft into the upper bearing requires a bit of care. It is easier if the rotor is spinning, which can be done by lightly blowing into a port. When the upper bearing plate drops into place, hold it down and check for free spinning (by blowing lightly) before replacing the cover. Check that the O-ring is in its seat on the bearing plate before replacing the cover. Replace the cover, insert the four cap screws and tighten. Sensor Replacement. The sensor ordinarily does not need replacement unless it is electrically damaged. If replacement is necessary, unthread the sensor by hand. Thread the replacement sensor in and tighten by hand. Reconnect the sensor according to the diagram below. (BLACK) Power (-) (WHITE) Signal (RED) Power (+) 6-24 Vdc SPX/SPT PARTS LISTING SPX SPT 1 Body Flow Direction Label Bearing Assembly (2 required) Bearing Removal Tool (not shown) Rotor with Shaft Kynar/ceramic (2 magnet) Kynar/carbide (2 magnet) Kynar/ceramic (6 magnet, high res) Kynar/cabide (6 magnet, high res) O-Ring EPDM Teflon-coated Viton Cover Before 5/05 After 5/05 Before 5/05 After 5/05 Polypro Acrylic TFE Teflon Cover Screws (4 required) Hexscrew Screw (use with hexnut 07705) Hexnut (use with screw 07685) Sensor Standard Micropower Page 4 SeaMetrics Incorporated nd Avenue South Kent, Washington USA (P) (F) LT B 8/16/06 Page: G /13/12