Nautel NX100 User manual

NX100 - Passighat
Main-Standby Transmitter
System
All India Radio (AIR)
APPENDIX C
ANTENNA TUNING UNIT
Issue 0.2 .................................. 09 October 2014
Nautel Limited
10089 Peggy's Cove Road,
Hackett's Cove, NS, Canada B3Z 3J4
T.877 6 nautel (628835) or +1.902.823.2233
F.+1.902.823.3183 [e-mail]
U.S. customers please contact:
Nautel Inc.
201 Target Industrial Circle, Bangor ME 04401
T.877 6 nautel (628835) or +1.207.947.8200
F.+1.207.947.3693 [e-mail]
e-mail: [email protected]
www.nautel.com
© Copyright 2014 NAUTEL. All rights reserved.

Page 1
INSTALLATION INSTRUCTIONS
FOR RF EQUIPMENT TO BE INSTALLED
IN TUNING HUT AT THE
1062 KHZ STATION
AIR SITE PROJECT
PASSIGHAT
Kintronic Laboratories, Inc.
Bristol, TN

Page 2
Table of Contents:
Table of Contents:............................................................................................................... 2
Tools and Materials Required:............................................................................................ 3
General Instructions............................................................................................................3
Inventory and Staging of Parts.................................................................................... 4
Building Measurements.............................................................................................. 4
Overview of Installation Steps............................................................................................ 6
Detailed Installation Procedure........................................................................................... 7
A. Floor Layout Panels.................................................................................................. 7
B. Critical Overview of Component Installation........................................................... 8
C. Installation of Floor-Mounted RF components.......................................................... 9
D. Installation of Copper Pipe Bus-Work.................................................................... 10
E. Installation of Vacuum Capacitors.......................................................................... 11
F. Installation of Auxiliary Equipment........................................................................ 12

Page 3
Tools and Materials Required:
(Not supplied by KTL):
1. Duct Tape or similar adhesive tape, for securing the floor layout panels
2. Masonry drill bits, suitable for drilling in concrete (¼” or metric equivalent and
recommended)
3. Vacuum cleaner for cleaning out drilled holes in concrete.
4. ¼” Hardware anchors suitable for use with concrete or similar, as appropriate for
the actual construction material used to construct the Tuning Houses.
5. “English” –sized Allen wrench set
6. “English” –sized wrench set
7. Hammer
8. Drill capable of drilling concrete
9. Tin Snips
10. Screw Driver Set
11. Flux
12. Silver Solder
13. Crescent Wrenches
14. Oxygen and Acetylene Torch Set
(Supplied by KTL):
15. Hardboard Floor Layout Panels
16. Drawings used for component layout, measurements, and assembly of parts –
included in this installation manual.
a. RF Schematic KTL Dwg A-6230-PAS
b. Component Layout KTL Dwg A-6246-PAS
c. Floor Panel Layout KTL Dwg C-4258-PAS
17. RF Components as specified in RF Schematic.

Page 4
General Instructions
These instructions are to be used in conjunction with the final drawing package for the
ATU Network supplied by Kintronic Labs (KTL) for installation at the tower base.
Before beginning the actual installation process, it is recommended that these instructions
be read through in their entirety, and also that the drawings referred to in the instructions
are reviewed in connection with the specific steps in which these drawings are
referenced.
Inventory and Staging of Parts
Next, to prepare for the installation process, it is important to insure that all of the parts
and components are accounted for, and ready to be used when needed. An appropriate
location (such as the Transmitter Building) should be used as a staging area.
Using the RF Schematic and the Component Layout Drawing, a complete inventory
should be made of the components and checked against the drawings for completeness.
These include:
- coils mounted on component panels
- component panels for capacitors
- capacitors in boxes (NOTE: keep all capacitors in their respective protective
boxes until it is time to install them per the instructions)
- Arc Gap Assemblies
- Grounding Switch Assemblies
- Meters and meter toroids (keep meters in boxes until installation)
- Hardware, and other misc. parts
Make a complete inventory of all of the interconnecting bus-work pipe sections, each of
which has been wrapped and labeled individually. Keep the pipe sections in their
protective wrap until it is time to install in the system.
Building Measurements
These instructions have been written with the underlying assumption that the building
size correctly matches the dimensions indicated on the KTL drawing set, that the walls
are plumb and vertical, that the wall-to-wall and wall-to-floor interfaces are square, and
that all mounting surfaces are flat and even.
Since these dimensions are critical for the successful installation of the equipment, the
following measurements should be made before bringing any parts or equipment into the
ATU building. NOTE: If any discrepancies are discovered, KTL should be
contacted immediately, in order to determine the impact they have on the
installation process, and whether corrective action or changes will be advised.

Page 5
Measure all dimensions of the building interior, and compare to the dimensions as
indicated on the relevant drawings. In particular, measure the interior width of the
building at both the front end and at the rear end of the building, and also measure the
interior depth of the building on both right and left sides of the building.
Take note of the locations of the openings in the wall for the RF input (which will
connect to the transmission line from the Transmitter Building) and the RF output (which
provides the interface to the Tower. Measure the size of each opening, and make
measurements needed to determine its exact location, and compare these measurements
to the KTL layout drawings.
Note: If floor dimensions deviate from those indicated on the KTL Component
Layout Drawing by more than 2.5 cm (1 inch) for either the length or the width,
please contact KTL or designated representative to discuss the best means of
compensating for the discrepancy during the assembly and installation process.

Page 6
Overview of Installation Steps
Before presenting the detailed installation steps, the present section presents an
overview of the basic approach that will be taken in the installation of the RF
equipment into the ATU building.
The basic steps to be taken are as follows:
1. Inventory the components and parts needed for the assembly, and carefully
measure the interior of the building to verify dimensions. (These steps are
covered above in “General Instructions.”)
2. Place the Hardboard Floor Layout Panels onto the floor.
3. Drill the mounting holes into floor using Floor Layout Panels as a template.
4. Remove the Floor Layout Panels one at a time, and mark onto the concrete floor
the identification, orientation and position of each floor-mounted component
appearing on each Floor Layout Panel, as each panel is removed.
5. Become familiar with the pictures showing the factory mock-up of the ATU and
review these pictures against the RF schematic and the Component Layout
drawing.
6. Starting with the reference corner of the building, place component panels on the
floor.
7. Verify correct placement by temporarily installing associated bus-work pipe
between components.
8. Remove any interconnecting pipe that was temporarily connected to components,
and then remove the floor-mounted components that were used in the previous
step.
9. Install the Safety Screen wall, and secure with hardware.
10. Install the Floor-mounted component panels, and secure with hardware.
11. Install the interconnecting bus-work pipe sections for the floor-mounted
components.
12. Install the capacitors onto their component panels.
13. Check out entire RF system as assembled and compare to the RF schematic and
relevant KTL drawings.
14. Install the auxiliary components and equipment (meters, grounding switches, arc
gaps, etc.)

Page 7
Detailed Installation Procedure
A. Floor Layout Panels
1. Refer to the ATU floor layout drawing. This drawing provides an overall
dimensional view of the major structural elements of the ATU building, without
the RF components. This drawing also shows the placement of the input and
output panels relative to the rest of the building.
2. Locate the 4’ x 8’ x 1/8” Hardboard panels that will be used as a layout pattern for
the floor of the ATU RF components. Referring to the ATU floor layout drawing,
the panels should be placed tightly together leaving no spaces between the panels.
The proper placement of the components has been marked on the panels, and
these markings can also be used as a guide to ensure that the panels are correctly
placed. Duct tape or similar adhesive tape may be used to secure the Hardboard
panels into place, once they have been all correctly placed.
Note the location in the drawing for the “Reference Corner”, and the locations of
the RF input and the RF output for the ATU building. Also refer to the photos of
the factory mockup of the system for which the components have been removed
from the floor, leaving only the Hardboard template.
3. After the Hardboard layout pattern is fully assembled and secured, pre-drill all the
marked hole locations for each panel with a 5/16” nominal drill bit through
Hardboard material and copper if necessary. Make sure the holes are drilled
vertical to the floor and are drilled completely through the Hardboard, and then
using 1/4” masonry drill bit (or nearest size that corresponds to the concrete
anchor bolt sizes that will be used.), drill anchor holes in the concrete floor using
Hardboard template. The holes must be drilled to the appropriate depth dictated
by the concrete anchors being used to secure the panels to the concrete floor.
4. When all of the marked hole locations have been pre-drilled, remove the
Hardboard sheets one at a time. As each Hardboard sheet is removed, mark each
component number on the floor for the placement of each component.
5. Make sure all of the mounting holes have been drilled to the correct depth for all
mounting holes in the floor. When all the holes have been drilled, clean out the
debris from the holes with a vacuum cleaner. Then, install the hardware anchors
into the holes in the concrete for each component panel. To ensure that all of the
holes have been included, do this for only one component panel at a time.

Page 8
B. Critical Overview of Component Installation
1. This is an important overview section, which will make it easier to identify each
RF component in the system, and also ensure that each component will be located
in its proper position and orientation. While going through this overview section,
refer to the RF schematic and Component Layout Drawing.
2. The Component Layout Drawing shows the correct placement of all the RF
components.
3. The set of factory photos of the ATU network mockup provide numerous
examples of the components mounted on their respective component panels, as
well as the identifying labels that are used on all components and all relevant
drawings. An example photo noting typical ATU components is given below
(Note the photo is not for this particular system, but is a representative factory
photo).
Figure 1: Component Panel details
Each insulator and all
associated hardware must
be securely mounted to
the component panel.
Capacitor mounted
on its component
panel
Coil mounted on its
component panel
Example of
component panel
Identifying label for the component. This
label (e.g., “L106” for this example) is used
to identify each component on the RF
schematic, on the component panel, and on
the la
y
out drawin
g
.

Page 9
4. While using the factory mockup photos as a guide, trace through the RF
schematic for the ATU system, starting at the RF input, and working through to
the RF output. As the components are identified in the RF schematic, the
corresponding location of the component should be identified in the component
layout drawing, and also observed in the corresponding photo(s).
5. During the actual installation of the components, which is covered in the
following sections, the factory mockup photos should be referred to as needed for
clarification.
D. Installation of Floor-Mounted RF components
1. Refer again to the ATU floor layout drawing, showing the correct placement of all
the RF components.
2. Make sure all of the mounting holes were drilled to the correct depth for
anchoring the floor-mounted components, and that all the holes have been cleared
of debris using the vacuum cleaner.
3. When all the holes have been drilled and vacuumed, install the hardware anchors
into the holes in the concrete for each component panel. To ensure that all of the
holes have been included, do this for only one component panel at a time.
4. Find all the floor-mounted component panels, as labeled on the drawing. Make
sure all insulators and hardware are securely mounted on each component panel.
Install each component panel as shown in the ATU floor layout drawing. Make
sure each component is oriented in the correct direction (refer to photos as
needed).
5. Note: Do not install any of the capacitors yet. Only install the component
panels at this time. The capacitors will be mounted on these panels in a later
step.
6. The correct orientation for each component may be determined by carefully
examining the photographs from the factory mockup of the ATU. The final
verification of the correct position and orientation will be made when the
interconnecting copper pipe sections are installed. In order for the copper pipe
sections to mate properly with the components, the components must be
positioned and oriented correctly.

Page 10
E. Installation of Copper Pipe Bus-Work
1. Locate the copper pipe for the RF components. Each piece of copper pipe is
labeled on the outside of the protective wrapping to show which components are
to be connected with that particular piece of pipe. When you remove the
protective wrapping you will see that each end of the pipe has also been marked
so as to indicate the component that it connects to on that end of the pipe.
2. Install the pipe sections for the interconnections between each component,
ensuring the label on the copper pipe (hand marked in ink) and the component
numbers (engraved tag on panel) match correctly. Make sure all the connections
are tight.
3. Many of the pipe sections are connected together through the use of “splitters.”
The splitters are used to allow for small length adjustments. Each splitter will
allow for an adjustment of up to ~ 1 cm. If a greater adjustment than this is
required, it is possible that adjustments in positioning might be required
somewhere else in the system. A splitter is illustrated below.
Figure 3: Example of bus work splitter
4. After all of the pipe sections have been secured, go through the system and make
sure that all the splitter connections have been tightened.
Where splitters are
used to connect
pipes together, both
pipes are labeled
with matching
letters. In this
example, “D”.

Page 11
F. Installation of Vacuum Capacitors
1. Reserve the actual installation of the capacitors themselves until it is absolutely
necessary. This will help prevent damage to the capacitors. The vacuum
capacitors used throughout this system are both fragile and expensive. They
should be handled carefully to prevent damaging them.
2. First install the variable capacitors. Note that variable capacitors must be
installed with the knob oriented in the proper direction. Most variable vacuum
capacitors will be packed with the mounting plate factory installed on the end of
the capacitor that has the adjustment knob. For the few that may not, note that one
of the two mounting plates or brackets will have a large clearance hole in the
center. The end of the capacitor with the adjustment knob must mount on this
plate so that the knob passes down through this clearance hole. Refer carefully to
the factory mockup photos to ensure that the variable capacitors are being
oriented properly.
3. After the variable capacitors have been installed, locate any fixed capacitors in the
system and install them on their appropriate locations. Install each capacitor in its
proper location by matching the component labels and referring to the factory
mockup photos.
4. For each of the capacitors, make sure that all of the hardware has been tightened.
5. Refer to the RF schematic. After all of the capacitors have been installed, use the
RF schematic to trace through the entire RF network, to ensure that all the
interconnections correctly match the schematic. Make sure that all hardware has
been tightened properly.

Page 12
G. Installation of Auxiliary Equipment
1. Locate the remote meters for the input and output RF current.
2. Each meter has been calibrated together with its toroid and cable as a matched set.
Use the serial numbers to match each meter with the correct transformer.
3. For each meter/toroid combination, temporarily route the cable that connects them
to make sure that the cable routing allows a proper connection on each end
without causing stretching or strain of the cable. When a suitable routing has
been determined, the cable can then be routed and secured properly. Note that the
cable must remain tight against the copper wall/floor or in grounded conduit for
protection.
4. Mount the meters in the correct hole marked by the labels on the front of the
safety screen wall.
5. The factory mockup photos will show the locations of the meters.
6. A typical example photo showing the meters mounted is below. This shows the
meters as seen from inside the RF compartment. The meters are to be read and
operated from the safe side of the safety screen wall.
Figure 4: Rear view of meters
This completes the ATU network installation.
Refer questions to Kintronic Labs, Inc. Engineering Dept.
Close-up of back of
RF current meters
from the inside of
safety screen wall

Page 13

Page 14

DWG NO:
REV:
REF DWG:
DATE:
DRAWN:
SCALE:
APPROVED:DESIGNED:
KINTRONIC LABORATORIES INC.
BLUFF CITY, TN.
JOB NO:
COPYRIGHT KINTRONIC LABORATORIES INC.

KINTRONIC LABORATORIES INC.
BLUFF CITY, TN.
JOB NO:
DWG NO:
REV:
REF DWG:
DATE:
DRAWN:
SCALE:
APPROVED:DESIGNED:
COPYRIGHT KINTRONIC LABORATORIES INC.