Axcera Innovator HX Series User manual

Instruction Manual
InnovatorTM HX Series
Digital UHF
Solid State
Transmitter
Volume 2
UHF Amplifier Cabinet
AXCERA , LLC
103 FREEDOM DRIVE •P.O. BOX 525 •LAWRENCE, PA 15055-0525 USA
[phone] •FAX [phone]
www.axcera.com •[email protected]

Innovator® HX Series, Digital, Table of Contents
UHF Transmitter
Volume 2, Rev. 0 iJuly 7, 2008
TABLE OF CONTENTS
CHAPTER 1 INTRODUCTION
SECTION PAGE
1.1 Manual Overview...................................................................................1-1
1.2 Safety..................................................................................................1-1
1.3 Assembly Designators............................................................................1-2
1.4 Material Return Procedure ......................................................................1-2
1.5 Limited One-Year Warranty for Axcera Products........................................1-3
CHAPTER 2 UHF AMPLIFIER CABINET
2.1 Cabinet Overview ..................................................................................2-1
2.2 Description of the UHF Amplifier Cabinet..................................................2-2
2.2.1 5 kW Amplifier Cabinet with 8 Amplifier Assemblies ........................2-2
2.2.2 3.7 kW Amplifier Cabinet with 6 Amplifier Assemblies......................2-2
2.2.3 2.5 kW Amplifier Cabinet with 4 Amplifier Assemblies......................2-3
2.2.4 1.8 kW Amplifier Cabinet with 3 Amplifier Assemblies......................2-3
2.3 Description of the UHF Amplifier Tray ......................................................2-5
2.3.1 Description of the 8 Way Combiner Assembly (5 kW).......................2-6
2.3.1.1 Description of the 6 Way Combiner Assembly (3.7 kW)...........2-7
2.3.1.2 Description of the 4 Way Combiner Assembly (2.5 kW)...........2-7
2.3.1.3 Description of the 3 Way Combiner Assembly (1.8 kW)...........2-8
2.3.2 Removal of an Amplifier Assembly .................................................2-8
2.3.3 Amplifier Cabinet Power Supply Assemblies.....................................2-9
2.3.4 Control and Monitoring .................................................................2-9
2.3.5 Cabinet Cooling............................................................................2-9
2.4 Cabinet Controller Assembly.................................................................2-11
2.4.1 Controller Connections to the Transmitter’s System Controller ........2-12
2.4.2 Controller Connections to the Amplifier Cabinet Components ..........2-12
2.4.2.1 Power Amplifiers ...............................................................2-12
2.4.2.2 High Power Supply Controllers............................................2-13
2.4.2.3 Low Power Supply and AC Line Monitoring...........................2-13
2.4.2.4 Air Temperature and Amplifier Temperature Monitoring.........2-14
2.4.2.5 RF Power Monitoring..........................................................2-14
2.4.2.6 Reject Load Monitoring ......................................................2-15
2.4.3 Cabinet Controller Settings..........................................................2-15
2.4.4 Cooling Blower Control................................................................2-15
2.4.5 Cabinet Controller Problem Resolution Guide.................................2-16
2.5 Functional Description of Amplifier Cabinet.............................................2-18
2.5.1 Signal Path................................................................................2-18
2.5.2 Test Signal Evaluation.................................................................2-18
2.5.3 Regulation of Transmitter Output Power .......................................2-18
2.5.4 Fault Protection Circuitry.............................................................2-18
2.5.5 Capture of Operating Values in the Amplifiers................................2-19
2.5.6 Amplifier Cabinet Connections .....................................................2-19
2.6 Service...............................................................................................2-20
2.6.1 Safety Information .....................................................................2-20
2.6.1.1 Labeling of Dangerous Substances......................................2-20
2.6.2 Test point Evaluation ..................................................................2-20
2.6.3 Display of Operating Values.........................................................2-20
2.7 Exchange of an Amplifier Module...........................................................2-21

Innovator® HX Series, Digital, Table of Contents
UHF Transmitter
Volume 2, Rev. 0 ii July 7, 2008
TABLE OF CONTENTS (continued)
CHAPTER 3 UHF AMPLIFIER ASSEMBLY & CABINET ASSEMBLIES
CIRCUIT DESCRIPTIONS
SECTION PAGE
3.1 Amplifier Overview ................................................................................3-1
3.2 Design of the UHF Amplifier....................................................................3-2
3.2.1 Capture of Test Values in the UHF Amplifier ....................................3-5
3.2.2 Functional Description of the Boards in the Amplifier Assembly .........3-6
3.2.2.1 40W UHF Module Assembly..................................................3-6
3.2.2.2 UHF Module Assembly .........................................................3-6
3.2.2.3 Coupler Board.....................................................................3-6
3.2.2.4 4 Way Splitter Board ...........................................................3-7
3.2.2.5 UHF Dual Stage Pallets ........................................................3-7
3.2.2.6 4 Way Combiner Board........................................................3-7
3.2.2.7 FET Switch/Metering Board ..................................................3-8
3.2.2.7.1 Operating voltages for the Amplifier Boards.................3-8
3.2.2.8 Amplifier Control Board........................................................3-8
3.2.2.8.1 Schematic Page 1 .....................................................3-9
3.2.2.8.2 Schematic Page 2 .....................................................3-9
3.2.2.8.3 Schematic Page 3 ...................................................3-10
3.2.2.8.4 Schematic Page 4 ...................................................3-10
3.2.2.8.5 Schematic Page 5 ...................................................3-10
3.3 Troubleshooting and Repair of the Amplifier ...........................................3-11
3.3.1 Safety Information .....................................................................3-11
3.3.2 Troubleshooting .........................................................................3-11
3.3.2.1 Front Panel LEDs...............................................................3-11
3.3.2.2 Polling Fault Indications .....................................................3-11
3.4 Exchanging Amplifiers..........................................................................3-11
3.4.1 Exchange of a Module.................................................................3-12
3.4.2 Mounting a New Module..............................................................3-12
3.4.3 Final Steps ................................................................................3-12
3.4.4 External Connections to Amplifier Assembly ..................................3-12
3.5 Power Supply Assembly .......................................................................3-13
3.5.1 Overview of the +32V Power Supply Unit......................................3-13
3.5.2 Description of SCR Controllers .....................................................3-14
3.5.3 Description of the Step Down Transformers ..................................3-14
3.5.4 Description of the Linear Power Supply Assemblies ........................3-14
3.6 Full Amplifier Cabinet Controller Board...................................................3-16
3.6.1 Page 1 of Schematic 1307524 .....................................................3-16
3.6.2 Page 2 of Schematic 1307524 .....................................................3-16
3.6.3 Page 3 of Schematic 1307524 .....................................................3-17
3.6.4 Page 4 of Schematic 1307524 .....................................................3-17
3.6.5 Page 5 of Schematic 1307524 .....................................................3-17
3.7 Half Amplifier Cabinet Controller Board..................................................3-19
3.7.1 Page 1 of Schematic 1307841 .....................................................3-19
3.7.2 Page 2 of Schematic 1307841 .....................................................3-19
3.7.3 Page 3 of Schematic 1307841 .....................................................3-20
3.7.4 Page 4 of Schematic 1307841 .....................................................3-20
3.7.5 Page 5 of Schematic 1307841 .....................................................3-20
3.8 Temperature Sensor Board...................................................................3-21
3.9 Reflected Metering Board .....................................................................3-21

Innovator® HX Series, Digital, Table of Contents
UHF Transmitter
Volume 2, Rev. 0 iii July 7, 2008
TABLE OF CONTENTS (continued)
SECTION PAGE
3.10 Serial Loop-Thru Board......................................................................3-21
3.11 Load Regulator Assembly ...................................................................3-21
3.11.1 Load Regulator Board ...............................................................3-22
APPENDICES
APPENDIX A RF AMPLIFIER CABINET ASSEMBLY, HX SERIES
DRAWINGS AND PARTS LISTS
APPENDIX B UHF AMPLIFIER ASSEMBLY, HX SERIES
DRAWINGS AND PARTS LISTS
APPENDIX C +32 VDC POWER SUPPLY ASSEMBLIES, TOP AND BOTTOM
DRAWINGS AND PARTS LISTS

Innovator® HX Series, Digital, Table of Contents
UHF Transmitter
Volume 2, Rev. 0 iv July 7, 2008
LIST OF FIGURES
FIGURE PAGE
1-1Typical Brady Marker Identification Drawing......................................1-2
2-1Typical UHF Amplifier Cabinet (Front View) .......................................2-1
2-2Block Diagram Typical UHF Amplifier Cabinet 8 Way (5 kW)................2-1
2-3Block Diagram Typical UHF Amplifier Cabinet 4 Way (2.5 kW).............2-4
2-4Components in the Amplifier Cabinet................................................2-4
2-5Block Diagram Typical UHF Amplifier Tray Assembly ..........................2-5
2-6Block Diagram Typical 8 Way UHF Combiner Assembly.......................2-6
2-7Block Diagram Typical 4 Way UHF Combiner Assembly.......................2-8
2-8Air Flow in the Amplifier Cabinet ....................................................2-10
2-9A Full Cabinet Controller Assembly....................................................2-10
2-9B Half Cabinet Controller Assembly ...................................................2-10
2-10 Amplifier Cabinet Connections .......................................................2-19
2-11 Labeling of Toxic Substances in Drawings .......................................2-20
2-12 Location and Assignment of the Circuit Breakers and LEDs ...............2-21
2-13 Amplifier Tray Lock Location..........................................................2-22
3-1UHF Amplifier Assembly..................................................................3-1
3-2Remaining Power after Failure of Amplifier Modules............................3-2
3-3Location of the Assemblies in the UHF Amplifier.................................3-3
3-4Block Diagram of the UHF Amplifier..................................................3-4
3-5Interconnect Typical UHF Amplifier Assembly ....................................3-5
3-6AC Wiring Harness UHF Amplifier Cabinet........................................3-13
3-7Interconnect Linear Power Supply #1, Top......................................3-14
3-8Interconnect Linear Power Supply #2, Bottom.................................3-15
3-9Control Interconnect Cabinet Full Controller System.........................3-15
3-10 Control Interconnect Cabinet Half Controller System........................3-18

Innovator® HX Series, Digital, Table of Contents
UHF Transmitter
Volume 2, Rev. 0 vJuly 7, 2008
LIST OF TABLES
TABLE PAGE
2-1Serial Cable Pin Out......................................................................2-12
2-2Cabinet Controller DIP Switch Settings ...........................................2-14
2-3Cabinet Controller Assembly Problem Resolution Guide ....................2-16
2-4Amplifier Cabinet Connections .......................................................2-20
3-1Assemblies in the UHF Amplifier.......................................................3-2
3-2Module OK LED Red and Blinking Interpretation.................................3-5
3-3Module OK LED Red and Blinking Interpretation.................................3-9
3-4Module OK LED Red and Blinking Interpretation...............................3-11
3-5RF Connectors on the Front Panel ..................................................3-12
3-6Operating Voltage Connection (Rear Panel).....................................3-12
3-7Configuration of SW2 on Full Amplifier Cabinet Control Board............3-17
3-8Configuration of SW2 on Half Amplifier Cabinet Control Board...........3-21

InnovatorHX Series Digital Chapter 1, Introduction
UHF Transmitter
Volume 2, Rev. 0 1-1
Chapter 1
Introduction
The InnovatorTM HX Series UHF digital
solid-state transmitter is comprised of
two cabinet types: An exciter/control
cabinet and a UHF amplifier cabinet.
Every InnovatorTM HX includes one or
more of each cabinet type, dependent
upon the power configuration ordered.
This volume, Volume 2, of the manual
describes the UHF amplifier cabinet
portion of the transmitter. The system
and the exciter/control assemblies are
covered in Volume 1.
1.1: Manual Overview
Volume 2, of the Innovator HX Series
Digital UHF Transmitter Instruction
Manual, is divided into three chapters
and supporting appendices. Chapter 1,
Introduction, contains information on
safety, return procedures, and
warranties. Chapter 2, Amplifier
Cabinet, describes the UHF amplifier
cabinet. Chapter 3, UHF Amplifier Tray
Assembly and Cabinet Assemblies Circuit
Descriptions, contains a detailed
discussion of the UHF amplifier module
and power supply assemblies that are
contained in the cabinet. Appendix A
contains the RF amplifier cabinet
assembly drawings and parts lists.
Appendix B contains the UHF amplifier
assembly drawings and parts lists.
Appendix C contains the top and bottom
+32VDC power supply assemblies
drawings and parts lists.
1.2: Safety
The HX Series UHF transmitters
manufactured by Axcera are designed to
be easy to use and repair while providing
protection from electrical and mechanical
hazards. Listed throughout the manual
are notes, cautions, and warnings
concerning possible safety hazards that
may be encountered while operating or
servicing the transmitter. It is important
that users review these warnings and
become familiar with the operation and
servicing procedures before working on
the transmitter.
Read All Instructions –It is important
that any user of this equipment read
and understand all of the operating and
safety instructions, especially the safety
information in this chapter, before
operating the Transmitter.
Retain Manuals –The manuals for the
transmitter should be retained at the
transmitter site for future reference. We
provide two sets of manuals for this
purpose; one set can be left at the office
while one set can be kept at the site.
Heed all Notes, Warnings, and
Cautions –All of the notes, warnings,
and cautions listed in this safety section
and throughout the manual must be
followed.
Follow Instructions –All of the
operating and use instructions for the
transmitter should be followed.
Cleaning –Unplug or otherwise
disconnect all power from the equipment
before cleaning. Do not use liquid or
aerosol cleaners. Use a damp cloth for
cleaning.
Servicing –Do not attempt to service
this product until becoming familiar with
the equipment. If in doubt, refer all
servicing questions to qualified Axcera
service personnel.
Replacement Parts–When
replacement parts are needed, be sure
that the parts have the same functional
and performance characteristics as the
original part. Unauthorized substitutions
may result in fire, electric shock, or other
hazards. Please contact the Axcera
Technical Service Department with any
questions regarding service or
replacement parts.

InnovatorHX Series Digital Chapter 1, Introduction
UHF Transmitter
Volume 2, Rev. 0 1-2
1.3: Assembly Designators
Axcera has assigned assembly numbers,
Ax designations such as A1, where
x=1,2,3…etc, to all assemblies, modules,
and boards in the system. These
designations are referenced in the text of
this manual and shown on the block
diagrams and interconnect drawings
provided in the appendices. The Block
Diagrams, Interconnects, Schematics,
Assembly Drawings and Parts Lists are
arranged in increasing numerical order in
the appendices. Section titles in the text
for assembly or module descriptions or
alignment procedures contain the
associated part number(s) and the
relevant appendix that contains the
drawings for that item.
The cables that connect between the
boards within a tray or assembly and
that connect between the trays, racks
and cabinets are labeled using Brady
markers.
Figure 1-1 is an example of a Brady
marked cable. There may be as few as
two or as many as four Markers on any
one cable. These Brady markers are
read starting farthest from the
connector. If there are four Brady
Markers, this marker is the transmitter
number such as transmitter 1 or
Transmitter 2. The next or the farthest
Brady Marker is the rack or cabinet
number on an interconnect cable or the
board number within a tray. The next
number on an interconnect cable is the
Tray location or number. The Brady
marker closest to the connector is the
Jack or Connector number on an
interconnect cable or the jack or
connector number on the board within a
tray.
Figure 1-1: Brady Marker Identification
Drawing
1.4: Material Return Procedure
To insure the efficient handling of
equipment or components that have been
returned for repair, Axcera requests that
each returned item be accompanied by a
Return Material Authorization Number
(RMA#).
An RMA# can be obtained from any
Axcera Service Engineer by contacting
the Axcera Technical Service Department
at 1-724-873-8100 or by fax at 1-724-
873-8105. This procedure applies to all
items sent to the Technical Service
Department regardless of whether the
item was originally manufactured by
Axcera.
When equipment is sent to the field on
loan, an RMA# is included with the unit.
The RMA# is intended to be used when
the unit is returned to Axcera. In
addition, all shipping material should be
retained for the return of the unit to
Axcera.
Replacement assemblies are also sent
with an RMA# to allow for the proper
routing of the exchanged hardware.
Failure to close out this type of RMA# will
normally result in the customer being
invoiced for the value of the loaner item
or the exchange assembly.
When shipping an item to Axcera, please
include the RMA# on the packing list and
on the Axcera-provided shipping
container. The packing slip should also
include contact information and a brief
description of why the unit is being
returned.
Please forward all RMA items to:
Axcera
Customer Service Department
103 Freedom Drive
P.O. Box 525
Lawrence, PA 15055-0525 USA

InnovatorHX Series Digital Chapter 1, Introduction
UHF Transmitter
Volume 2, Rev. 0 1-3
For more information concerning this
procedure, call the Axcera Technical
Service Department.
Service can also be contacted through e-
mail at [email protected] and on the
Web at www.axcera.com.
1.5: Limited One-Year Warranty for
Axcera Products
Axcera warrants each new product that
it has manufactured and sold against
defects in material and workmanship
under normal use and service for a
period of one (1) year from the date of
shipment from Axcera's plant, when
operated in accordance with Axcera's
operating instructions. This warranty
shall not apply to tubes, fuses,
batteries, or bulbs.
Warranties are valid only when and if
(a) Axcera receives prompt written
notice of breach within the period of
warranty, (b) the defective product is
properly packed and returned by the
buyer (transportation and insurance
prepaid), and (c) Axcera determines, in
its sole judgment, that the product is
defective and not subject to any misuse,
neglect, improper installation,
negligence, accident, or (unless
authorized in writing by Axcera) repair
or alteration.
Axcera's exclusive liability for any
personal and/or property damage
(including direct, consequential, or
incidental) caused by the breach of any
or all warranties, shall be limited to the
following: (a) repairing or replacing (in
Axcera's sole discretion) any defective
parts free of charge (F.O.B. Axcera’s
plant) and/or (b) crediting (in Axcera's
sole discretion) all or a portion of the
purchase price to the buyer.
Equipment furnished by Axcera, but not
bearing its trade name, shall bear no
warranties other than the special hours-
of-use or other warranties extended by
or enforceable against the manufacturer
at the time of delivery to the buyer.
NO WARRANTIES, WHETHER
STATUTORY, EXPRESSED, OR
IMPLIED, AND NO WARRANTIES OF
MERCHANTABILITY, FITNESS FOR
ANY PARTICULAR PURPOSE, OR
FREEDOM FROM INFRINGEMENT,
OR THE LIKE, OTHER THAN AS
SPECIFIED IN PATENT LIABILITY
ARTICLES, AND IN THIS ARTICLE,
SHALL APPLY TO THE EQUIPMENT
FURNISHED HEREUNDER.

InnovatorHX Series Digital Chapter 1, Introduction
UHF Transmitter
Volume 2, Rev. 0 1-4
FWARNING!!!
×HIGH VOLTAGE Ø
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.
«RADIO FREQUENCY RADIATION HAZARD «
MICROWAVE, RF AMPLIFIERS AND TUBES GENERATE HAZARDOUS RF
RADIATION THAT CAN CAUSE SEVERE INJURY INCLUDING CATARACTS,
WHICH CAN RESULT IN BLINDNESS. SOME CARDIAC PACEMAKERS MAY BE
AFFECTED BY THE RF ENERGY EMITTED BY RF AND MICROWAVE
AMPLIFIERS. NEVER OPERATE THE TRANSMITTER SYSTEM WITHOUT A
PROPERLY MATCHED RF ENERGY ABSORBING LOAD ATTACHED. KEEP
PERSONNEL AWAY FROM OPEN WAVEGUIDES AND ANTENNAS. NEVER
LOOK INTO AN OPEN WAVEGUIDE OR ANTENNA. MONITOR ALL PARTS OF
THE RF SYSTEM FOR RADIATION LEAKAGE AT REGULAR INTERVALS.