Instruction Manual 6X Series, Liquid-Cooled Transmitter Axcera, LLC 103 Freedom Drive, P.O. Box 525 Lawrence, PA 15055-0525 USA PHONE: 1-724-873-8100 • FAX 1-724-873-8105 www.axcera.com • info@axcera.
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6X Series Liquid-Cooled Transmitter Table of Contents Table of Contents Instruction Manual, Rev.
6X Series Liquid-Cooled Transmitter Chapter 1, Introduction CHAPTER 1 ........................................................................................................ 3 1.1 1.2 1.3 1.4 1.5 1.6 Manual Overview ..........................................................................................3 Assembly Designators ...................................................................................3 Safety .......................................................................................
6X Series Liquid-Cooled Transmitter 4.3.2 4.3.1 4.3.2 4.3.3 4.3.4 4.3.5 4.3.6 4.3.7 4.3.8 Chapter 1, Introduction Front Panel Smart Button Board (1310349).................................................4 (A2) Phase/Gain Board (1312011) .............................................................4 (A8) Interface Board (1312562) ................................................................6 (A5) 4 Way Splitter Board, Top (1312033) ..................................................
X Series Liquid-Cooled Transmitter Chapter 1, Introduction Chapter 1 Introduction 1.1 Manual Overview This instruction manual is divided into five chapters and supporting appendices. Chapter 1, Introduction, contains information on safety, material return procedures, and warranties. Chapter 2, System Description, contains the system and assembly descriptions. Chapter 3, Installation and Set Up Procedures, describes the installation procedure, set up procedure and the operation of the transmitter.
6X Series Liquid-Cooled Transmitter Chapter 1, Introduction familiarize yourself with the operation and servicing procedures before working on the product. Hazardous Accessibility – Axcera has made attempts to provide appropriate connectors, wiring and shields to minimize hazardous accessibility. Circuit Breakers and Wiring – All circuit breakers and wire are UL and CE certified and are rated for maximum operating conditions.
6X Series Liquid-Cooled Transmitter Chapter 1, Introduction Before calling Axcera, please be prepared to supply the Axcera technician with answers to the following questions. This will save time and help insure the most direct resolution to the problem. 1. 2. 3. 4. What are the Customers’ Name and call letters? What are the model number and type of transmitter? Is the transmitter digital or analog? How long has the transmitter been on the air? (Approximately, when was the transmitter installed?) 5.
6X Series Liquid-Cooled Transmitter Chapter 1, Introduction Axcera's operating instructions. This warranty shall not apply to tubes, fuses, batteries, or bulbs.
6X Series Liquid-Cooled Transmitter Chapter 1, Introduction WARNING!!! HIGH VOLTAGE DO NOT ATTEMPT TO REPAIR OR TROUBLESHOOT THIS EQUIPMENT UNLESS YOU ARE FAMILIAR WITH ITS OPERATION AND EXPERIENCED IN SERVICING HIGH VOLTAGE EQUIPMENT. LETHAL VOLTAGES ARE PRESENT WHEN POWER IS APPLIED TO THIS SYSTEM. IF POSSIBLE, TURN OFF POWER BEFORE MAKING ADJUSTMENTS TO THE SYSTEM.
6X Series Liquid-Cooled Transmitter Chapter 1, Introduction EMERGENCY FIRST AID INSTRUCTIONS Personnel engaged in the installation, operation, or maintenance of this equipment are urged to become familiar with the following rules both in theory and practice. It is the duty of all operating personnel to be prepared to give adequate Emergency First Aid and thereby prevent avoidable loss of life. RESCUE BREATHING 1. Find out if the person is breathing. You must find out if the person has stopped breathing.
6X Series Liquid-Cooled Transmitter Chapter 1, Introduction dBm, dBw, dBmV, dBµ µV, & VOLTAGE EXPRESSED IN WATTS 50 Ohm System WATTS 1,000,000,000,000 100,000,000,000 10,000,000,000 1,000,000,000 100,000,000 10,000,000 1,000,000 100,000 10,000 1,000 100 50 20 10 1 0.1 0.01 0.001 0.0001 0.00001 0.000001 0.0000001 0.00000001 0.000000001 0.0000000001 0.00000000001 0.
6X Series Liquid-Cooled Transmitter Chapter 1, Introduction USEFUL CONVERSION FACTORS To Convert From To Multiply By mile (US statute) kilometer (km) inch (in) millimeter (mm) inch (in) centimeter (cm) inch (in) meter (m) foot (ft) meter (m) yard (yd) meter (m) mile per hour (mph) kilometer per hour(km/hr) mile per hour (mph) meter per second (m/s) pound (lb) kilogram (kg) gallon (gal) liter U.S. liquid (One U.S. gallon equals 0.
6X Series Liquid-Cooled Transmitter Chapter 1, Introduction ABBREVIATIONS/ACRONYMS AC Alternating Current FCC Federal Communications Commission AFC Automatic Frequency Control FEC Forward Error Correction AGC Automatic Gain Control FM Frequency modulation ALC Automatic Level Control FPGA Field Programmable Gate Array AM Amplitude modulation HXB High Power Transmitter, B-line ASI Asynchronous Digital Interface Hz Hertz ATSC Advanced Television Systems Committee (Digital) ICPM Incid
6X Series Liquid-Cooled Transmitter Chapter 2, System Description Chapter 2 System Description The 6X Series Liquid-Cooled Transmitter is made up of a frequency agile exciter and a multi tray power amplifier system. The 6X Series is a state-of-the-art liquid cooled transmitter which uses our frequency agile exciter and the latest LDMOS devices for broadband operation across the entire UHF band. The power amplifier system operates at the highest power density available, reducing floor space requirements.
6X Series Liquid-Cooled Transmitter Chapter 2, System Description compensate for errors in the SMPTE-310M input sample rate, ensuring the best possible signal generation. Non-volatile operation is achieved through flash-RAM (random access memory), which instantaneously stores all digital settings for the entire exciter-modulator system.
6X Series Liquid-Cooled Transmitter Chapter 2, System Description All ATSC Axciters are field upgradeable to new operating modes, such as ATSC M/H Mobile DTV, DTx slave, Watermark, or other yet to be adopted ATSC enhancements. A dual exciter system is an option for the 6X transmitter. 2.
6X Series Liquid-Cooled Transmitter Chapter 2, System Description 2.3: Power Amplifiers The Axcera 6X Series transmitter is comprised of highly reliable broadband amplifier modules operating in a parallel configuration. Each module uses the latest LDMOS transistors, providing very efficient and linear operation and the highest power density available today. For convenience, each amplifier module operates independently, allowing easy removal and replacement while the transmitter is on the air.
6X Series Liquid-Cooled Transmitter Chapter 2, System Description stress on system components, maximizing component life. The control and pump rack is typically mounted indoors, but is also available in an outdoor version, if required. 3) Fan and Heat Exchanger System – The heat exchanger is a very compact, highefficiency unit, manufactured by Gunter USA.
6X Series Liquid-Cooled Transmitter Chapter 2, System Description The GUI also contains operation and help screens for the transmitter. Any touch area on the screen that can affect the on-air operation of the transmitter is colored RED, no matter what the function. You can touch anything, anywhere on the touch screen without worry of its effect on the transmitter EXCEPT those that are Red.
6X Series Liquid-Cooled Transmitter Chapter 3, Installation, Set Up and Problem Identification Procedures Chapter 3 Installation and Setup Procedures As part of the installation of the 6X transmitter, it will be necessary to plan for mechanical, electrical, and plumbing issues.
6X Series Liquid-Cooled Transmitter Chapter 3, Installation, Set Up and Problem Identification Procedures 3.1: Unpacking and Installation of the Cabinets Locate the driver/amplifier cabinet, which contains the Axciter, exciter/driver, amplifier, controller and power supply trays, the pump cabinet assembly and the heat exchanger. Remove the driver/amplifier cabinet, the pump cabinet assembly, the heat exchanger and any installation material from the crates and boxes.
6X Series Liquid-Cooled Transmitter Chapter 3, Installation, Set Up and Problem Identification Procedures Water Input Water Output Water Input Water Output Water Input Water Output Block Diagram 6X Water System Pump Rack Instruction Manual, Rev.
6X Series Liquid-Cooled Transmitter Chapter 3, Installation, Set Up and Problem Identification Procedures 6X Typical Cooling System Block Diagram 3.2.1: Ethylene Glycol/Distilled Water Cooling System 3.2.1.1: Initial Filling the Water Cooled System A positive displacement pull must be used to fill and charge the coolant system. During the filling process, check for leaks through-out the system. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Check and tighten all fittings.
6X Series Liquid-Cooled Transmitter Chapter 3, Installation, Set Up and Problem Identification Procedures 6X Typical Electrical System 3.3: Main AC Connections The Electrician should install the Main AC and the control & monitoring conduit for the transmitter site to meet all NEC regulations and also according to the electrical system transmitter site drawing. Use conduit, in the size needed for running the wires, as called out on the Electrical drawing for your site and as required by NEC regulations.
6X Series Liquid-Cooled Transmitter Chapter 3, Installation, Set Up and Problem Identification Procedures 3.5: Initial Turn-On Procedures After the cabinets and the transmission lines have been connected, the system should first be swept and fine matched through to the Station Load. Then the system should be turned on using the following procedure. During the initial turn-on procedure the system should be tested into a system test load and not the antenna.
6X Series Liquid-Cooled Transmitter Chapter 3, Installation, Set Up and Problem Identification Procedures Axciter to the upconverter. Proper setting of these parameters is system dependent, and other systems manuals should be referenced for information on their setting. 3.6.2: Transmitter Set Up Procedures 3.6.2.1: Initial Test Set Up This Exciter Digital transmitter was aligned at the factory and should not require additional adjustments to achieve normal operation.
6X Series Liquid-Cooled Transmitter Chapter 3, Installation, Set Up and Problem Identification Procedures Switch Position 6 must be switched ON (0) which allows the user to modify the AGC 1 and AGC 2 gain through the Axciter Modulator. On the Axciter Upconverter Screen, set AGC 1 to 1.5 Volts, by selecting 4 on the key board entry. This will cause a detail screen to appear prompting you to enter a number value.
6X Series Liquid-Cooled Transmitter Chapter 3, Installation, Set Up and Problem Identification Procedures 10 dBm & 0 dBm no adjustment is needed. If it is not, adjust the “Downconverter Gain”, then view the RMS value until it is within the –10 dBm to 0 dBm range. This completes the set up and adjustment of the transmitter using the Axciter Modulator. If a problem occurred during set up, contact Axcera field service at 1-724-873-8100. 3.7: Problem Identification 3.7.
6X Series Liquid-Cooled Transmitter Chapter 3, Installation, Set Up and Problem Identification Procedures Coolant System Schematic 3.8: 6X PLC pump rack control software 3.8.
6X Series Liquid-Cooled Transmitter Chapter 3, Installation, Set Up and Problem Identification Procedures Monitor pressure sensors Display all pressure sensor readings Monitor pressure sensors to issue alarms (see Warning / Alarm table) Monitor request to start from transmitter controller Must be normally high signal (Low means shut down or lost cable to pump rack) Control Heat Exchanger High signal from contactor overload relay Low signal from fan motor temperature switch Instruction Manual, Rev.
6X Series Liquid-Cooled Transmitter Chapter 3, Installation, Set Up and Problem Identification Procedures This page has intentionally been left blank. Instruction Manual, Rev.
6X Series Liquid-Cooled Transmitter Chapter 4, Circuit Descriptions Chapter 4 Circuit Descriptions 4.1 Exciter, Upconverter, Driver Tray Boards 4.1.1 Frequency Agile Upconverter Board (1309695) The board takes a 44 MHz or 36 MHz IF signal and converts it to a TV channel in the range of 54-860 MHz. The 44 MHz or 36 MHz IF input signal, (≈-8dBm level), is connected to J6 on the board. The IF first passes through a frequency response precorrector, consisting of R145, C188, R 146 and C189.
6X Series Liquid-Cooled Transmitter Chapter 4, Circuit Descriptions A 1 GHz LO1 signal, typically -15 dBm, which is generated externally on the Frequency Agile Upconverter Board is connected to the downconverter board at J12. The 1 GHz LO is amplified by U9 and applied to a high pass filter, amplified by J10 and connected to a low pass filter. The filters are designed to eliminate any other interfering signals that might be coupled into the 1 GHz LO.
6X Series Liquid-Cooled Transmitter Chapter 4, Circuit Descriptions 4.2 Power Controller/AC Distribution Assembly, Boards 4.2.1 Button Board (1311306) The Button Board provides the front panel accessed push button switch which is illuminated by multicolored LEDs. The switch lit Blue indicates normal operation. When lit Red, indicates a malfunction has occurred.
6X Series Liquid-Cooled Transmitter Chapter 4, Circuit Descriptions programming port which is initially used to program the U7 microcontroller and is not used by the customer. J10 is the programming port which is initially used to program the U9 microcontroller and is not used by the customer. The fan power supply that uses the T1 transformer takes the +42 VDC input and produces the +12 VDC output, which connects to the (A20) F1 Fan through Jack J1-2 & 1.
6X Series Liquid-Cooled Transmitter Chapter 4, Circuit Descriptions the event of a fault. The switch can be controlled by three separate sources, the overdrive protection circuitry, the reflected power protection circuitry, and the Rabbit microcontroller that is controlling and monitoring the amplifier tray. The overdrive protection and reflected power protection circuitry are extremely fast, and will remove the RF drive in a few hundred nanoseconds.
6X Series Liquid-Cooled Transmitter Chapter 4, Circuit Descriptions 4.3.4 (A8) Interface Board (1312562) The RF output of the phase/gain board connects to the SMB connector J1 on the interface board. The RF is fed though solder track to J4 the output pad on the board. A wire jumper is soldered from the J4 pad to the J1 input pad, (≈.6Watts ATSC), on the driver pallet assembly. A wire jumper is soldered from the J3 pad to the J3 Data pad on the driver pallet assembly.
6X Series Liquid-Cooled Transmitter Chapter 4, Circuit Descriptions to amplifier pallet 5, J10 to amplifier pallet 6, J11 to amplifier pallet 7, and J12 to amplifier pallet 8. J15 is the programming port which is initially used to program the U4 microcontroller and is not used by the customer.
6X Series Liquid-Cooled Transmitter Chapter 4, Circuit Descriptions R33 and the output Balun assemblies to the drains of Q1 and Q2. The +42 VDC is also connected through the 12V Zener diode CR1 to the regulator IC U4 that supplies +3.3 VDC, which is used by the U2, U6 and U7 ICs on the pallet. 4.3.
6X Series Liquid-Cooled Transmitter Chapter 4, Circuit Descriptions and combines them into a single output (≈750Watts) at J2 on the board which is cabled to one input of the Power Combiner. The microcontroller, U5 takes the parameter sample inputs and supplies a serial data output that is buffered by U4 before it is wired to the Serial Data Line connections at J11-2 and J15-2. The Serial Data Line connects to the system controller for the transmitter.
6X Series Liquid-Cooled Transmitter Instruction Manual, Rev.
6X Series Liquid-Cooled Transmitter Chapter 5, Maintenance Chapter 5: Maintenance 5.1: Maintenance The 6X Series Transmitter is designed with components that require little periodic maintenance except for the routine cleaning of the filters and the fans in the amplifier cabinets and trays.
6X Series Liquid-Cooled Transmitter Chapter 5, Maintenance Output Valves Input Valves Figure 5-2: Input and Output Valves Let the water run for approximately 3 seconds. This should clean the strainer. Repeat for the strainer in the other line. Periodically, the strainers should be removed and cleaned. This is accomplished by first isolating the desired pump and strainer by turning off the input and output valves to the pump. See Figure 5-2. Place a bucket under the drain and open the drain valve.
6X Series Liquid-Cooled Transmitter Chapter 5, Maintenance NOTE: Dowtherm SR-1 in the undiluted state should not be stored outside during the summer, because it begins to decompose at temperatures above 100°° F. In addition, undiluted SR-1 will freeze at a few degrees under 32°° F, but it will recover. 5.1.2.
X Instruction Manual, Rev. 0 5-4 X X Visual check of all Fans, Blowers and Pumps in the system for normal operation and any signs of wear or overheating Verify proper operation of all Interlock and Ready Status Switches X X X X Visual check of Power Amplifiers condition, including voltage cable forms, resistors and capacitors and miscellaneous hardware Visual check of sub-systems power supplies Inspection of Heat Exchangers Fans and Lubrication.
Instruction Manual, Rev.
Appendix A 6X Drawings
6X Series Liquid-Cooled Transmitter Appendix A, Drawing List 6X Series Liquid-Cooled Transmitter 6X Series Transmitter System Block Diagram ........................................ 1312362 6X Series Transmitter System Block Diagram Water Cooling System........ 1311561 6X Series Transmitter System Rack Interconnect ................................... 1311569 6X Series Transmitter System Rack Interconnect ................................... 1313729 6X Series Transmitter Typical Racking Plan.................
6X Series Liquid-Cooled Transmitter Appendix A, Drawing List System Controller Tray, 6X Block Diagram ................................................................................. 1312829 Interconnect .................................................................................... 1313638 System Controller Button Board Schematic.......................................................................................... 1312056 Power Controller/AC Distribution Assembly, 6X Block Diagram .............
6X Series Liquid-Cooled Transmitter Appendix A, Drawing List Power Supply Assembly, 6X Pioneer Magnetics Information Pump Rack Assembly, 6X Grainger Pump Information Block Diagram Electrical Water Cooling System...................................... 1312836 Instruction Manual, Rev.
6X Series Liquid-Cooled Transmitter Appendix A, Drawing List Appendix B Transmitter Specifications Instruction Manual, Rev.
6X SERIES Liquid-Cooled Solid State ATSC Transmitter With over twenty five years of experience in the design and manufacture of solid state transmitters, Axcera continues to provide the latest technology, enabling our customers to focus on the future. Axcera’s 6X Series liquid-cooled solid state transmitters are available in power levels up to 40 kW ATSC.
6X SERIES DIGITAL Liquid-Cooled Solid State ATSC Transmitter Performance Frequency Range General 1 470 to 862 MHz Standard ATSC Frequency Stability w/GPS 0.2 ppm (max 30 day variation) 0.001 ppm Operational Temperature Range Indoor Outdoor Regulation of RF Output Power 3% Out of Band Emissions Compliant with FCC Mask Signal to Noise (SNR) 30dB or better (typical), 27dB min. Data Interface Input Rate Input Interface Cable Equalization Impedance Level 19.
