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.

InnovatorHX Series Digital Chapter 1, Introduction
UHF Transmitter
Volume 2, Rev. 0 1-5
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. If you
think he is not breathing, place
him flat on his back. Put your ear
close to his mouth and look at his
chest. If he is breathing you can
feel the air on your cheek. You
can see his chest move up and
down. If you do not feel the air
or see the chest move, he is not
breathing.
2. If he is not breathing, open
the airway by tilting his head
backwards.
Lift up his neck with one hand
and push down on his forehead
with the other. This opens the
airway. Sometimes doing this will
let the person breathe again by
himself.
3. If he is still not breathing,
begin rescue breathing.
-Keep his head tilted backward.
Pinch nose shut.
-Put your mouth tightly over his
mouth.
-Blow into his mouth once every
five seconds
-DO NOT STOP rescue breathing
until help arrives.
LOOSEN CLOTHING -KEEP
WARM
Do this when the victim is
breathing by himself or help is
available. Keep him as quiet as
possible and from becoming
chilled. Otherwise treat him for
shock.
BURNS
SKIN REDDENED: Apply ice cold water to burned
area to prevent burn from going deeper into skin
tissue. Cover area with a clean sheet or cloth to
keep away air. Consult a physician.
SKIN BLISTERED OR FLESH CHARRED: Apply
ice cold water to burned area to prevent burn from
going deeper into skin tissue.
Cover area with clean sheet or cloth to keep away
air. Treat victim for shock and take to hospital.
EXTENSIVE BURN -SKIN BROKEN: Cover area
with clean sheet or cloth to keep away air. Treat
victim for shock and take to hospital.

InnovatorHX Series Digital Chapter 2, Amplifier Cabinet
UHF Transmitter
Volume 2, Rev. 0 2-1
Chapter 2
Amplifier Cabinet
2.1: Cabinet Overview
The fully populated amplifier cabinets
used in Innovator HX Transmitters
contain eight UHF amplifiers connected
in parallel (Figure 2-1). The number of
amplifiers varies according to the
needed output power for the
transmitter. The amplifiers operate,
without the need for tuning or
alignment, on the UHF channel
designated.
All equipment in the cabinet is fully
solid-state and designed for high-
operational reliability and a service-
friendly layout. The cabinet is cooled by
external air cooling equipment. The
cooling air is ducted into and out of the
top of the cabinet.
Figure 2-1: Typical 8 Way UHF Amplifier Cabinet (Front View)
Figure 2-2: Block Diagram of the typical UHF Amplifier Cabinet 8 Way (5kW)
POWER SUPPLY #1
CIRCUIT BREAKER
POWER SUPPLY #2
CIRCUIT BREAKER
(A19) UHF AMPLIFIER #3
(Not present in 2.5kW)
(A20) UHF AMPLIFIER #4
(Not present in 2.5kW)
(A17) UHF AMPLIFIER #1
(Not present i
n 2.5kW)
(A18) UHF AMPLIFIER #2
(Not present in 2.5kW)
(A23) UHF AMPLIFIER #7
(A24) UHF AMPLIFIER #8
(A21) UHF AMPLIFIER #5
(A22) UHF AMPLIFIER #6
±12VDC POWER SUPPLY
RESET BREAKERS

InnovatorHX Series Digital Chapter 2, Amplifier Cabinet
UHF Transmitter
Volume 2, Rev. 0 2-2
2.2: Description of the UHF Amplifier
Cabinet
The features of the amplifier cabinet
include: 1) Amplifiers that are 100%
transistors. 2) High redundancy due to
the parallel connection of power
transistors. 3) A mean junction
temperatures less than 120°C. 4)
Multiple fault protection circuitry in each
amplifier. 5) A power supply for
Amplifiers 1 thru 3 (3.7kW) and 4
(5kW). 6) A separate power supply for
Amplifiers 6 thru 8 (1.8kW) and 5
(2.5kW & 5kW). 7) Amplifiers that
operate over the selected band of UHF
frequencies without the need for
alignment. 8) The important operating
parameters are displayed in the
transmitter touch screen control unit. 9)
There are multiple test points in the
signal path. 10) It has air cooling, with
the input and output air connections on
the top of the amplifier cabinet.
The amplifier assemblies in each
amplifier cabinet (see Figure 2-3) are
slide-in units, inserted from the front.
In a 5kW cabinet, two 4 way splitters
are installed, one in the top and one in
the bottom half of the cabinet. In a 2.5
kW cabinet, just the bottom 4 way
splitter is present. These splitters
distribute the RF input to each of the
amplifiers. In a 3.7kW cabinet, 3 way
splitters are installed in the top and
bottom half of the cabinet. In a 1.8 kW
cabinet, just the bottom 3 way splitter is
present. These distribute the RF input
to each of the amplifiers. A 3, 4, 6 or 8
way combiner is installed in the middle
of the cabinet. The lower part of the
cabinet accommodates a power
distribution panel that contains two 480
VAC 30 Amp 3 Phase or 208 VAC 50
Amp 3 Phase circuit breakers for 3.7 & 5
kW or one circuit breaker for 1.8 & 2.5
kW. The left breaker, if present,
distributes the main AC voltage to the
top power supply and the right circuit
breaker controls the bottom power
supply. The top power supply provides
the +32 VDC to the top three or four
amplifier assemblies. The bottom power
supply provides the +32 VDC to the
bottom three or four amplifier
assemblies
There is also either one or two 1 Amp
reset circuit breakers, mounted on the
power distribution panel that protect the
AC voltage to the switching power
supply, located in the bottom and top
power supply. If one breaker is present,
it connects to the bottom power supply,
for 1.8 & 2.5 kW. If 2 one Amp reset
breakers are present, the second one
amp breaker connects to the top power
supply for 3.7 & 5 kW. The switching
supply provides the ±12 VDC to the top
and bottom amplifier assemblies.
2.2.1: 5 kW Amplifier Cabinet with 8
Amplifier Assemblies
Refer to Figure 2-2. The DTV RF signal
from the exciter/control cabinet is
connected through RG-55 cable through
an opening in the roof in the UHF
amplifier cabinet. The RF (+26 dBm,
400 mW) from the output of the exciter
control cabinet connects to the SMA “S”
input on (A14) a 2 way splitter with each
of the two outputs connecting to a 4
way splitter panel (A15 top & A16
bottom). The four outputs of the (A15-
A1) Top 4 way splitter are at the “N”
connectors X1-X4.
The outputs (+15.3 dBm, 34 mW)
connect to the (A17) UHF amplifier #1,
(A18) UHF amplifier #2, (A19) UHF
amplifier #3 and (A20) UHF amplifier
#4. Each amplifier tray has a gain of
approximately +40.5dB. The four
outputs of the (A16-A1) Bottom 4 way
splitter, at “N” connectors X1-X4,
connect to the (A21) UHF amplifier #5,
(A22) UHF amplifier #6, (A23) UHF
amplifier #7, and (A24) UHF amplifier
#8. The eight outputs of the amplifier
modules at 7/16” connectors (+58.3
dBm, 675W) are cabled to the (A24) 8
way combiner. The output of the
combiner connects to the (A26) RF
coupler. The output of the cabinet is

InnovatorHX Series Digital Chapter 2, Amplifier Cabinet
UHF Transmitter
Volume 2, Rev. 0 2-3
approximately (+67.2 dBm, 5.2kW) at
the 3-1/8” output connector of the (A26)
RF Coupler Assembly.
2.2.2: 3.7 kW Amplifier Cabinet with
6 Amplifier Assemblies
The DTV RF signal from the
exciter/control cabinet is connected
through RG-55 cable through an opening
in the roof in the UHF amplifier cabinet.
The RF (+27 dBm, 500 mW) from the
output of the exciter control cabinet
connects to the SMA “S” input on (A14)
a 2 way splitter with each of the two
outputs connecting to a 3 way splitter
panel (A15 top & A16 bottom). The
three outputs of the (A15) Top 3 way
splitter are at the “N” connectors X1-X3.
The outputs (+18 dBm, 63 mW) connect
to the (A17) UHF amplifier #1, (A18)
UHF amplifier #2 and (A19) UHF
amplifier #3. The three outputs of the
(A16) Bottom 3 way splitter, at “N”
connectors X2-X4, connect to the (A22)
UHF amplifier #6, (A23) UHF amplifier
#7, and (A24) UHF amplifier #8. Each
amplifier tray has a gain of
approximately +40.5dB. The six
outputs of the amplifier modules at
7/16” connectors (+58.5 dBm, 700W)
are cabled to the (A24) 6 way combiner.
The output of the combiner connects to
the (A26) RF coupler. The output of the
cabinet is approximately (+65.7 dBm,
3.7 kW) at the 3-1/8” output connector
of the (A26) RF Coupler Assembly.
2.2.3: 2.5 kW Amplifier Cabinet with
4 Amplifier Assemblies
Refer to Figure 2-3. The DTV RF signal
from the exciter/control cabinet is
connected through RG-55 cable through
an opening in the roof in the UHF
amplifier cabinet. The RF (+26 dBm,
400 mW) from the output of the exciter
control cabinet connects to the 4 way
splitter panel (A16) mounted at the
bottom of the cabinet. The four outputs
of the (A16-A1) 4 way splitter, at “N”
connectors X1-X4, connect to the (A21)
UHF amplifier #5, (A22) UHF amplifier
#6, (A23) UHF amplifier #7, and (A24)
UHF amplifier #8. Each amplifier tray
has a gain of approximately +40.5dB.
The four outputs of the amplifier
modules at 7/16” connectors (+58.5
dBm, 700W) are cabled to the (A25) 4
way combiner assembly. The combiner
produces a single output that connects
to the (A26) RF Coupler Assembly. The
RF output for the cabinet, approximately
+64.1 dBm, 2570 Watts, is at the 3-1/8”
output connector of the RF Coupler
Assembly.
2.2.4: 1.8 kW Amplifier Cabinet with
3 Amplifier Assemblies
The DTV RF signal from the
exciter/control cabinet is connected
through RG-55 cable through an opening
in the roof in the UHF amplifier cabinet.
The RF (+27 dBm, 500 mW) from the
output of the exciter control cabinet
connects to the 3 way splitter panel
(A16) mounted at the bottom of the
cabinet. The three outputs of the (A16)
3 way splitter, at “N” connectors X2-X4,
connect to the (A22) UHF amplifier #6,
(A23) UHF amplifier #7, and (A24) UHF
amplifier #8. Each amplifier tray has a
gain of approximately +40.5dB. The
three outputs of the amplifier modules
at 7/16” connectors (+58.5 dBm, 700W)
are cabled to the (A25) 3 way combiner
assembly. The combiner produces a
single output that connects to the (A26)
RF Coupler Assembly. The RF output for
the cabinet, approximately +62.6 dBm,
1800 Watts, is at the 3-1/8” output
connector of the RF Coupler Assembly.

InnovatorHX Series Digital Chapter 2, Amplifier Cabinet
UHF Transmitter
Volume 2, Rev. 0 2-4
Figure 2-3: Block Diagram of the typical UHF Amplifier Cabinet 4 Way (2.5kW)
Figure 2-4: Components in the Amplifier Cabinet
Components in the Amplifier Cabinet
8 UHF Amplifier Trays (5kW)
6 UHF Amplifier Tray (3.7kW)
2 Power Supply Assemblies (3.7 &
5kW)
4 UHF Amplifier Trays (2.5kW)
3 UHF Amplifier Trays (1.8kW)
1 Power Supply Assembly (1.8 &
2.5kW)
One Circuit Breaker Assembly
One 3, 4, 6 or 8 Way Combiner
Assembly
Splitter 1 : 4 (5kW)
Splitter 1 : 3 (3.7kW)
Splitter 1 : 4 (2.5kW & 5kW)
Splitter 1 : 3 (1.8kW & 3.7kW)
Circuit Breaker for Top
12VDC Power Supply (3.7kW &
5kW) Assembly
UHF Amplifier Trays (A17,
A18, A19 & A20) (5kW)
(A20) not used in 3.7kW
UHF Amplifier Trays
(A21, A22, A23 & A24)
(2.5kW & 5kW)
(A21) not used in 1.8 & 2.7kW
Combiner 8 : 1 (5kW)
Combiner 6 : 1 (3.7kW)
Combiner 4 : 1 (2.5kW)
Combiner 3 : 1 (1.8kW)
Circuit Breaker for Top
+32VDC Power Supply (3.7kW & 5kW)
Circuit Breaker for Bottom +32VDC
Power Supply (1.8, 2.5 3.7 & 5kW)
Circuit Breaker for Bottom
12VDC Power Supply (1.8, 2.5 &
5kW) Assembly

InnovatorHX Series Digital Chapter 2, Amplifier Cabinet
UHF Transmitter
Volume 2, Rev. 0 2-5
Figure 2-5: Block Diagram Typical UHF Amplifier Tray Assembly
2.3: Description of the UHF Amplifier
Tray
There are eight of these trays in an 8
way Amplifier Cabinet Assembly for
5kW, six in a 6 way Amplifier Cabinet
Assembly for 3.7 kW, four in a 4 way
Amplifier Cabinet Assembly for 2.5 kW,
or three in a 3 way Amplifier Cabinet
Assembly for 1.8 kW. The Amplifier
Tray has an approximate gain of +40.5
dB.
The RF input (+18 dBm) at the “N”
connector J1 on each UHF amplifier
assembly is fed to the RF input
connections on (A1) the 40 Watt UHF
Module Assembly, which is a predriver
assembly with ≈9 dB gain. The output
(+27 dBm) is cabled to the RF input
connections on (A3) a UHF Module Pallet
Assembly (1300116) with ≈13 dB gain.
The UHF Module Pallet Assembly
contains a RF Module Pallet w/o
transistors (1152336). The output (+40
dBm) is fed to J9 on (A12) a Coupler
Board (1306639) that supplies a driver
forward power sample out of J3-5 to the
FET switch/metering board at J1-1. The
sample is not used on the FET
switch/metering board; it is just fed
through to J15-1 that is wired to J3-13
on the (A14) amplifier control board
(1308540 or 1306830) where it is used
in the amplifier protection circuitry.
The output of the coupler board at J8
(+40 dBm) is fed to J1 on (A4) the 4
Way Splitter Board (1306371) where it
is split. Each output of the splitter (+34
dBm) is cabled to the RF Input jack of
one of the four (A5-A8), UHF dual stage
pallet boards, (1307602, CH: 14-20, or
1306689, CH: 21-34 & 41-69), or
1307690, CH: 35-40). Each pallet board
has ≈+21 dB of gain. The outputs of
each amplifier board (+55 dBm) are
combined on (A13) the 4 way combiner
assembly, (1306396, CH: 14-34, or
1308853, CH: 35-40, or 1306890, CH:
41-69).
The RF output jack J2, of the 4 way
combiner assembly (+58.6 dBm), is Bus
wire jumpered to J4 on the (A12)
Coupler Board (1306639) that supplies a
RF sample out at J1. Also, the Coupler
Board provides a final amp forward
metering sample at J3-1 and a final amp
reflected metering sample at J3-2. The
samples are connected to (A17) the FET
switch/metering board (1306497) at J1-
6 and J1-7. The samples are not used
on the FET switch/metering board, they
are just fed through to J15-2 and J15-14

InnovatorHX Series Digital Chapter 2, Amplifier Cabinet
UHF Transmitter
Volume 2, Rev. 0 2-6
that are wired to J3-12 and J3-25 on the
amplifier control board where they are
used in the amplifier protection circuitry.
The RF output of the coupler board is at
J2 that is Bus wire connected to J2 the
7/16” connector RF Output Jack of the
amplifier assembly. Typical output level
is +58.5 dBm.
2.3.1: Description of the 8 Way
Combiner Assembly (5 kW Amplifier
Cabinet)
The RF outputs of the eight amplifiers
are combined by means of an 8:1
combiner assembly w/circulators that is
mounted in the middle of the cabinet.
The 8 way combiner is made up of two
identical 4 way combiners and a two
way combiner. Refer to Figure 2-5.
The eight RF inputs, +58.3 dBm in level,
each connect to a separate circulator.
The circulators protect the amplifiers in
the event of high VSWR generated by
the output circuits. A reflected sample
from the circulator is fed through a 30dB
attenuator to one of the two Reflected
Metering Boards (A80 & A81). The A80
Reflected Metering Board has the top
four amplifier assemblies connected to it
and the A81 Reflected Metering Board
has the bottom four amplifier assemblies
connected to it. If one or more of the
reflected samples exceeds 10%, the
affected Reflected Metering Board will
shut down the associated power supply
therefore removing the voltages to the
four amplifier assemblies that it
supplies. The power supply can only be
reset by switching the transmitter to
standby then operate after repair of the
cause for the high VSWR. Each 4 Way
combiner has three dummy loads, two
600W and a 1200W, which dissipate any
power due to an imbalance or mismatch
during the combining of the amplifiers.
The outputs of the 4 way combiners,
each +64.1 dBm, connect to the (A3)
Two Way Combiner. The 2 Way
combiner has a 2500W load connected
to it. The output of the 2 Way
Combiner, which is the output of the 8
Way Combiner Assembly is at the
3 1/8” RF output jack, typically
˜+67 dBm.
Figure 2-6: Block Diagram Typical 8 Way UHF Combiner Assembly w/Circulators

InnovatorHX Series Digital Chapter 2, Amplifier Cabinet
UHF Transmitter
Volume 2, Rev. 0 2-7
2.3.1.1: Description of the 6 Way
Combiner Assembly (3.7 kW
Amplifier Cabinet)
The RF outputs of the six amplifiers are
combined by means of an 6:1 combiner
assembly w/circulators that is mounted
in the middle of the cabinet. The 6 way
combiner is made up of two identical 3
way combiners and a two way combiner.
The six RF inputs, +58.5 dBm in level,
each connect to a separate circulator.
The circulators protect the amplifiers in
the event of high VSWR generated by
the output circuits. A reflected sample
from the circulator is fed through a 30dB
attenuator to one of the two Reflected
Metering Boards (A80 & A81). The A80
Reflected Metering Board has the top
three amplifier assemblies connected to
it and the A81 Reflected Metering Board
has the bottom three amplifier
assemblies connected to it. If one or
more of the reflected samples exceeds
10%, the affected Reflected Metering
Board will shut down the associated
power supply therefore removing the
voltages to the four amplifier assemblies
that it supplies. The power supply can
only be reset by switching the
transmitter to standby then operate
after repair of the cause for the high
VSWR. Each 3 Way combiner has two
600W dummy loads, which dissipate any
power due to an imbalance or mismatch
during the combining of the amplifiers.
The outputs of the 3 way combiners,
each +64.1 dBm, connect to the (A5)
Two Way Combiner. The 2 Way
combiner has a 2500W load connected
to it. The output of the 2 Way
Combiner, which is the output of the 6
Way Combiner Assembly is at the
3 1/8” RF output jack, typically
˜+65.7 dBm.
2.3.1.2: Description of the 4 Way
Combiner Assembly (2.5 kW
Amplifier Cabinet)
The RF outputs of the four amplifiers are
combined by means of a 4:1 combiner
assembly that is mounted in the middle
of the cabinet. Refer to Figure 2-7.
The four RF inputs, +58.5 dBm Digital in
level, each connect to a separate
circulator. The circulators protect the
amplifiers in the event of high VSWR
generated by the output circuits. A
reflected sample from the circulator is
fed through a 30dB attenuator to the
Reflected Metering Board #2 (A81). If
one or more of the reflected samples
exceeds 10%, the Reflected Metering
Board will shut down the +32 VDC
power supply therefore removing the
voltages to the four amplifier assemblies
that it supplies. The power supply can
only be reset by switching the
transmitter to standby then operate
after repair of the cause for the high
VSWR. The 4 Way combiner has three
dummy loads, two 600W and a 1200W,
which dissipate any power due to an
imbalance or mismatch during the
combining of the amplifiers. The output
of the 4 Way Combiner Assembly is at
the 1 5/8” RF output jack, typically
˜+64.1 dBm Digital.

InnovatorHX Series Digital Chapter 2, Amplifier Cabinet
UHF Transmitter
Volume 2, Rev. 0 2-8
Figure 2-7: Block Diagram Typical 4 Way UHF Combiner Assembly w/Circulators
2.3.1.3: Description of the 3 Way
Combiner Assembly (1.8 kW
Amplifier Cabinet)
The RF outputs of the three amplifiers
are combined by means of a 3:1
combiner assembly that is mounted in
the middle of the cabinet.
The three RF inputs, +58.5 dBm Digital
in level, each connect to a separate
circulator. The circulators protect the
amplifiers in the event of high VSWR
generated by the output circuits. A
reflected sample from the circulator is
fed through a 30dB attenuator to the
Reflected Metering Board #2 (A81). If
one or more of the reflected samples
exceeds 10%, the Reflected Metering
Board will shut down the +32 VDC
power supply therefore removing the
voltages to the three amplifier
assemblies that it supplies. The power
supply can only be reset by switching
the transmitter to standby then operate
after repair of the cause for the high
VSWR. The 3 Way combiner has two
600W dummy loads, which dissipate any
power due to an imbalance or mismatch
during the combining of the amplifiers.
The output of the 3 Way Combiner
Assembly is at the 1 5/8” RF output
jack, typically ˜+62.6 dBm Digital.
2.3.2: Removal of an Amplifier
Assembly
The amplifiers are of broadband design
and cover the frequency for the desired
UHF channel without the need for
alignment or adjustment.
For reasons of safety, amplifier modules
MUST be in standby (RF disabled)
before any connections are removed. If
the amplifier control board is loaded
with software version 2.4 or higher, an
Axcera Amplifier disable plug (1308219)
can be used to place an individual
module in standby. If your amplifier
module has a front panel disable switch,
this switch can be used to disable the
amplifier. Regardless of the version of
code, any power amplifier may safely be
removed by disabling its power supply.
The power supply, either the top power
supply #1 for the top four Amplifier
assemblies, or the bottom power supply
#2 for the bottom three Amplifier
assemblies, may be isolated from main
AC power by switching off the
appropriate front panel circuit breaker.
This is accomplished by tripping the
respective breaker located on the circuit
breaker assembly panel, at the bottom
of the amplifier cabinet.

InnovatorHX Series Digital Chapter 2, Amplifier Cabinet
UHF Transmitter
Volume 2, Rev. 0 2-9
To remove a disabled amplifier
assembly, first remove the input cable
connected to the top connector then the
output cable connected to the bottom
connector on the front panel of the
assembly. They must be removed in
this sequence to prevent damage to the
amplifier assemblies. Then loosen the
two fixing screws, one located at the
top, middle and one at the bottom,
middle of the assembly. The amplifier
can then be pulled from the cabinet. To
replace the assembly, insert the
assembly into the slots and replace the
two fixing screws. Then connect the RF
output cable first and the RF input cable
last, they must be replaced in this
sequence to prevent damage to the
amplifier assemblies.
The paralleling network of the amplifier
cabinet with its load balancing resistors
is designed so that operation continues
at reduced power when one or more
amplifiers are removed or failed.
All RF cables from the outputs of the
first splitter up to the output of the
output combiner assembly are phase
matched (in phase) to the particular
frequency and their lengths must again
be determined when a change in
operating frequency is made. All
amplifier cabinets of a transmitter, from
cabinet input to cabinet output, are also
aligned to the same phase with equal
length cables.
2.3.3: Amplifier Cabinet Power
Supply Assemblies
The voltages to the UHF Amplifier Trays
are supplied by two +32 VDC power
supply assemblies. One supply, the top
power supply #1, provides the +32 VDC
to the three or four UHF amplifier
assemblies mounted at the top of the
cabinet (3.7 or 5kW). The other supply,
the bottom power supply #2, provides
the +32 VDC to the three or four UHF
amplifier assemblies mounted at the
bottom of the cabinet (1.8 kW, 2.5 kW,
3.7 kW, & 5 kW).
The AC input voltages to the power
supplies are controlled through two 480
VAC 30 Amp 3 Phase or two 208 VAC 50
Amp 3 Phase circuit breakers located on
the AC distribution panel mounted at the
bottom of the cabinet (3.7 & 5 kW).
There is only one 480 VAC or 208 VAC
circuit breaker in a 1.8 & 2.5 kW
amplifier cabinet.
2.3.4: Control and Monitoring
Each amplifier has multiple-fault
protection circuitry that prevents
damage to or destruction of the power
transistors during critical operating
conditions, such as high reflected power,
overtemperature, overcurrent, or
overvoltage. Furthermore, the operating
voltages and currents of the amplifiers
are monitored in the power supply units
as well as the mains voltage. All
important amplifier operating
parameters, such as drain currents, RF
power, and heat sink temperatures, are
connected to the control unit.
2.3.5: Cabinet Cooling
The amplifier cabinet is exclusively air
cooled as shown in Figure 2-8. The
cooling system is exemplified by low
airflow requirements, low noise levels,
and high efficiency. With an inlet air
temperature of +25° C, the junction
temperatures of the RF power
transistors remain under 120°C,
resulting in a high amplifier service life.
A major fraction of the heat is dissipated
by the amplifiers and their power
supplies. This heat is carried away by an
external cooling system. Connections
are available on the top of the amplifier
cabinet for the intake and exhaust of the
air. The amplifiers are equipped with
highly efficient finned heat sinks, which
radiate, into the vertically flowing air
stream, the heat generated by the
power transistors. By utilizing special
construction techniques in the cabinet,
as well as employing conservatively
dimensioned ducting, a uniform
distribution of cooling air over the