Nautel NX300 User manual

NX300 Transmitter
Installation Manual
Document:NHB-NX300-INS-3.0
Issue: 3.0 2012-11-01
Status: Standard

Nautel Limited
10089 Peggy’s Cove Road
Hackett’s Cove, NS Canada B3Z 3J4
Phone: [phone] or
Toll Free: +1.877.6NAUTEL (6628835) (Canada & USA only)
Fax: [phone]
Nautel Inc.
201 Target Industrial Circle
Bangor, Maine USA 04401
Phone: [phone]
Fax: [phone]
Customer Service (24 hour support)
+1.877.628.8353 (Canada & USA only)
+1.902.823.5100 (International)
Email: [email protected]
Web: www.nautel.com
The comparisons and other information provided in this document
have been prepared in good faith based on publicly available
information. The reader is encouraged to consult the respective
manufacturer's most recent published data for verification.
© Copyright 2012 NAUTEL. All rights reserved.

NX300 Installation Manual Table of contents
Page v
Contents
Release control record vii
Preparing for installation 1-1
Unpacking and positioning 2-1
Completing cabinet assembly 3-1
Connecting transformer taps/load wiring 4-1
Connecting the station reference ground 5-1
Connecting ac power 6-1
Adjusting the spark gap 7-1
Installing audio inputs 8-1
Planning complete? 8-1
Routing cables 8-1
Setting Exgine audio parameters 8-4
Installing control/monitor wiring 9-1
PLanning complete? 9-1
Routing cables 9-1
Commissioning tasks 10-1
Pre-commissioning tasks 10-1
Commissioning 10-2

NX300 Installation Manual Table of contents
Page vi Issue 3.0 2012-11-01
Going on-air 10-4
Parts and tools 11-1
Contacting Nautel 11-1
Parts supplied by Nautel 11-1
Parts not supplied by Nautel 11-2
Parts ordering 11-2
Module replacement program 11-2
Tools for installation 11-3
Pre-installation / Installation assistance 12-1
Pre-installation consulting 12-1
Installation and commissioning service 12-1
Online documentation 12-3
On-site support 12-3
Training 12-3
Standard warranty 12-4
Extended warranties 12-7
List of terms 13-1

NX300 Installation Manual
Issue 3.0 2012-11-01 Page vii
Release control record
Issue Date Reason
3.0 2012-11-01 Release 3 of product (NARA54B)

NX300 Installation Manual
Page viii Issue 3.0 2012-11-01

NX300 Installation Manual Preparing for installation
Issue 3.0 2012-11-01 Page 1-1
Section 1: Preparing for installation
Before installing your NX300 transmitter, perform the following steps:
1. Ensure that you have performed the pre-installation tasks described in the
NX300 Pre-installation Manual.
2. Make sure that you received all the components. (Check your packing list.)
3. Inspect all crates and packages for damage.
4. Report any damage immediately to your Nautel sales representative and the carrier.
5. Move the crates as close as possible to the transmitter’s planned location.
6. Unpack the crates in accordance with the instructions provided on the outside of the crates.
• For each crate, remove the panel labelled open this side. The panel is attached using
Philips head screws.
• Remove any visible packing material, including braces, from the crate's interior.
7. Review any assembly notes or instructions contained inside the transmitter crates. (For sites
requiring custom configurations, the instructions provided with the transmitter replace the
instructions provided here.)
8. Assemble your parts and tools.
For a list of required tools, see “Parts and tools” on page 11-1.
9. When you are ready to install the NX300 transmitter, follow the steps shown in Figure 1.1
on page 1-2.
TIP When you have completed a task or step, put a check mark beside the step
number.
CAUTION:
FAILURE TO COMPLY WITH RECOMMENDATIONS MAY VOID YOUR MANUFACTURER’S
WARRANTY. FOR MORE INFORMATION, REVIEW YOUR WARRANTY DOCUMENTS.

NX300 Installation Manual Preparing for installation
Page 1-2 Issue 3.0 2012-11-01
Figure 1.1: Flowchart - Installing the transmitter
Unpacking and positioning - see page 2-1
Connecting the station reference ground - see page 5-1
Connecting transformer taps/load wiring - see page 4-1
Installing control/monitor wiring - see page 9-1
Commissioning tasks - see page 10-1
Perform operational tasks:
“Commissioning”, “Modulation checks” and “Going on-air”, beginning on page 10-2
Connecting ac power - see page 6-1
Installing audio inputs - see page 8-1
Adjusting the spark gap - see page 7-1
Completing cabinet assembly - see page 3-1

NX300 Installation Manual Unpacking and positioning
Issue 3.0 2012-11-01 Page 2-1
Section 2: Unpacking and positioning
To install an NX300 transmitter, perform the following tasks:
1. Lift and slide the transmitter cabinets off the base of their crates. The NX300 contains four
main crates - a control cabinet, a middle cabinet, an output cabinet and a transformer
cabinet. Crated and uncrated cabinet weights are shown in Table 2.1. An additional crate,
which contains the ac safety interlock switch, may be provided.
Table 2.1: NX300 Cabinet Weights
2. Using necessary mechanical assistance (forklift, etc), position the four cabinets in their final
location, with their mating surfaces in close proximity. See Figure 2.1 on page 2-2 for cabinet
layout. Cabinets are labelled to assist in their positioning.
3. During assembly, remove any packing materials, loose wires or connectors that are
sandwiched between cabinet mating surfaces.
WARNING:
Do not move the transformer cabinet unless sufficient manpower or
mechanical assistance is available to move it into position without
damaging the cabinet or causing injury to personnel.
Note:
The position of the transformer cabinet can be determined by the user. The
cabinet’s location should accommodate input wiring from the ac power source (or
ac power disconnect switch), output wiring to each of the transmitter cabinets, as
well as a cable carrying system to support the output wiring..
Cabinet Crated Weight
kg (lbs) Uncrated Weight kg (lbs)
Control Cabinet 670 (1477) 567 (1250)
Middle and Output Cabinets 670 (1477) 567 (1250)
Transformer Cabinet TBA (TBA) 1579 (3481)
Ac Power Disconnect Switch TBA (TBA) 372 (820)

NX300 Installation Manual Unpacking and positioning
Page 2-2 Issue 3.0 2012-11-01
Figure 2.1: NX300 Cabinet Layout
4. Verify that the ac power cable from the ac power disconnect switch reaches the entry point
in the power transformer cabinet.
5. Verify that the RF feed cable reaches the RF output connector on the top of the output
cabinet.
6. Install the antenna ground switch on top of the transmitter cabinet as follows:
• Locate the antenna ground switch (Nautel Part # 213-8320-05) that was packed with the
ancillary crate for shipping.
• Open the front door of the output cabinet and unlock and open the filter door to gain
access to the inside of the transmitter cabinet.
• Remove any protective wrapping from the antenna ground switch and position it on top
of the output cabinet cabinet, noting proper orientation and that the aluminum rod
protruding from the bottom of the antenna ground switch must pass through a clearance
hole in the transmitter cabinet (see Figure 2.2 on page 2-4).
100 kW
Control
Cabinet
RACK 1
100 kW
Middle
Cabinet
RACK 2
100 kW
Output
Cabinet
RACK 3
Transformer
Cabinet
T1
(position is
user-defined)
Cable Tray System
(shown with overhead supports)

NX300 Installation Manual Unpacking and positioning
Issue 3.0 2012-11-01 Page 2-3
• See Figure 2.2 on page 2-4. Temporarily remove the right-hand side cover (as viewed
from the front) from the antenna ground switch, to allow access to the securing
hardware. Using the hardware provided with the transmitter, secure the antenna ground
switch to the top of the cabinet using 12 sets of M10 hardware (dome head bolt, split
washer, flat washer, nut and acorn nut). Secure the aluminum rod to the output plate
using an M10 button-head cap-screw, split washer and flat washer. Ensure hardware is
tight. Re-install the antenna ground switch’s side cover.
• Close and lock the filter panel. Close the front door of the transmitter. Continue with
transmitter installation.
7. Locate the cable tray parts kit that was provided to support the cables that will connect ac
power between the ac power disconnect switch and the primary for the power transformer,
and also between the secondary of the power transformer and the transmitter cabinets.
These parts may have been provided by Nautel (Cable Tray Parts List # 207-8385-**) or
purchased from an alternate vendor. Install the cable tray system according to your
transmitter system dimensions. If the cable tray kit was purchased from Nautel, refer to
Section 5 - Electrical Requirements of the NX300 Pre-installation Manual for standard
drawings and parts lists or to the provided system manual for custom drawings and parts lists
- to aid in the installation.

NX300 Installation Manual Unpacking and positioning
Page 2-4 Issue 3.0 2012-11-01
Figure 2.2: Installing Antenna Ground Switch
Four sets of M4 hardware
UPPER SIDE OF 12 DOME-HEAD
CARRIAGE BOLTS. INSTALL FLAT
WASHER, SPLIT WASHER & NUT
AND TIGHTEN IN PLACE. INSTALL
M10 ACORN OVER REMAINING
END OF EACH BOLT AND TIGHTEN.

NX300 Installation Manual Completing cabinet assembly
Issue 3.0 2012-11-01 Page 3-1
Section 3: Completing cabinet assembly
To complete the assembly of the NX300 transmitter’s cabinets, perform the following tasks:
1. Remove the side panel (see Figure 3.4 on page 3-10) from each of the control cabinet and
output cabinet by removing the three M5 screws at the top of the panel and lifting the panel
upward, then pullign upward. Retain hardware for reassembly later in this section.
2. Position the front and top edges of the control cabinet (Rack 1), middle cabinet (Rack 2) and
output cabinet (Rack 3) so that they are flush with a straight line representing the front and
top of the transmitter. Make sure the sides of adjacent cabinets are touching each other.
3. Open the front door of the control cabinet and lock it in the open position using the door
stop near the top of the cabinet. Open the remaining front and rear doors. Door stops on the
rear doors are located at the bottom of the cabinet.
4. Loosely bolt the cabinets together using eight sets of M8 hardware [long bolts, split washers
and flat washers], two between each cabinet interface in the front and two between each
cabinet interface in the back (Figure 3.5 on page 3-11). Do not tighten hardware at this time.
If you cannot install all eight sets of cabinet interfacing hardware, try levelling the cabinets in
Step 5 and then install the remaining hardware.
5. Using a 5 mm hex key (located in the ancillary kit), level the cabinets by adjusting the levelers
in each cabinet’s bottom corner (see Figure 3.1 on page 3-2). Ensure the front and rear faces
of all three cabinets are flush and the tops (front and back) are level.
Note:
The assembly instructions in this section help to achieve basic cabinet assembly,
and are mostly limited to exterior mechanical connections. All assembly items and
hardware that is not already in the transmitter is located in the transmitter’s
ancillary crate.
Do not allow any loose or dropped hardware to remain inside the transmitter.
CAUTION:
Before adjusting the levelers in Step 5, make sure that the cabinets are in their
final position. Moving the cabinets after the levelers have been adjusted may
damage the levelers.

NX300 Installation Manual Completing cabinet assembly
Page 3-2 Issue 3.0 2012-11-01
Figure 3.1: Cabinet Leveler Detail
6. Open the filter door behind each cabinet’s front door by unlocking the door and removing
its M5 screws. Retain hardware.
7. See Figure 3.2 on page 3-3 and Figure 3.5 on page 3-11. Locate two “Long Vertical Cabinet
Joiners” (Nautel Part # 207-8270), one “Horizontal Cabinet Joiner” (Nautel Part #
207-8270-01), two “Side Cabinet Joiners” (Nautel Part # 207-8270-02) and one “Connector
Pipe” (Nautel Part # 194-6298-02), which are packed inside the filter compartment of each
cabinet.
8. Install the joiners between the control cabinet and the middle cabinet, and between the
middle cabinet and the output cabinet. Install the short joiners from the back of the cabinets,
taking care not to damage the upper and lower teflon support plates. Install the vertical and
horizontal joiners from the inside of the filter compartment. Secure each joiner using M6
hardware - starting at one end and moving toward the other end while making sure the joiner
is properly seated.
Note:
It may be necessary to move the individual cabinets slightly to allow cabinet joiner
installation. Any hardware dropped into the cabinets during installation must be
located and removed.
CABINET
LEVELER
(located in each
corner of each
cabinet)

NX300 Installation Manual Completing cabinet assembly
Issue 3.0 2012-11-01 Page 3-3
Figure 3.2: Cabinet Joiner Channel Detail
VERTICAL
CHANNEL
JOINERS
HORIZONTAL
CHANNEL
JOINER
UPPER TEFLON
SUPPORT
PLATE
LOWER TEFLON
SUPPORT
PLATE
SHORT
VERTICAL
CHANNEL
JOINERS

NX300 Installation Manual Completing cabinet assembly
Page 3-4 Issue 3.0 2012-11-01
9. Locate two “Top Joiner Plates” 207-8274-01. Attach each plate between the top of the
two cabinet interfacing junctions (see Figure 3.5 on page 3-11) using 16 M5 screws.
10. Tighten the cabinet bonding hardware installed in Step 4.
11. Install the connector pipe (194-6298-02) (see Figure 3.5 on page 3-11 and Figure 3.6 on page
3-12) between cabinets 2 and 3. Torque securing nuts to 60 in-lb (6.8 N-m).
12. See Figure 3.6 on page 3-12. In the control cabinet (Rack 1), unwrap the copper straps from
inductors RK1-L7 and RK1-L8. Reattach the straps to the aluminum plate in the middle
cabinet (Rack 2) using supplied hardware. Ensure proper hardware orientation as shown in
Figure 3.6 on page 3-12. Torque the strap hardware to 292 in-lb (32.7 N-m). Arrange or
form the straps so that they do not touch inductors RK1-L7 or RK1-L8 or come within
0.5 inches (1.25 cm) of any ground potential point.
13. Locate and unpack all the “NX300 Internal Assembly” items (see Figure 3.5 on page 3-11)
from the ancillary crate.
14. Remove the two cover plates (Nautel Part # 207-8162) from the side of the control and
output cabinets (four plates total). Retain all securing hardware. It is not necessary to remove
the center cover plate.
15. Refer to the “NX300 Internal Assembly” diagram in Figure 3.5 on page 3-11, noting all parts
are identified with a Nautel Part # (e.g., 207-xxxx). The combiner covers are already installed,
and shown for reference only.
• Locate and unpack a Nautel Part # 207-8251-02 “Copper Tube”. From the Output
Cabinet side, carefully insert the “Copper Tube” (flat brass end first) into the upper, left
opening behind the removed side cover plate and slide in approximately 2 ft (0.6 m),
leaving at least six inches of the copper tube’s L-shaped brass end outside of the cabinet.
Ensure that combiner transformer windings are not damaged.
• Locate and unpack a Nautel Part # 207-8251-03 “Copper Tube”. Align its L-shaped
brass end with the other copper tube and use the “Combiner Tube Jig” (Nautel Part #
207-9566) to hold the copper tubes in place while securing them together using two M8
captive screws. Remove the jig.
• Carefully slide the joined copper tube section in and guide the end through the large hole
in the “Teflon Plate” between the output cabinet and middle cabinet, leaving at least six
inches of the second copper tube’s L-shaped brass end outside of the cabinet.

NX300 Installation Manual Completing cabinet assembly
Issue 3.0 2012-11-01 Page 3-5
• Locate and unpack a Nautel Part # 207-8251-01 “Copper Tube”. Align its L-shaped
brass end with the other copper tube and again use the “Combiner Tube Jig” to hold
the copper tubes in place while securing them together using two M8 captive screws.
Remove the jig.
• Carefully slide the full-length copper tube assembly in and guide the end through the
large holes in the “Teflon Plates” between the cabinets until it reaches the opposite end
of the control cabinet. Secure the end of the copper tube assembly to the copper angle
using an M12 bolt, Belleville washer and flat washer, torqued to 275 in-lbs (31 N-m).
16. Repeat Step 15 for the lower copper tube assembly, noting the Nautel Part # identification.
17. Locate and unpack current probes A67 (Nautel Part # 207-6213-02) and A71(Nautel Part #
207-6213-03) in the ancillary crate.
18. Install current probe A71 at the output cabinet end of the “upper” copper tube installed in
Step 15 (see Figure 3.5 on page 3-11), using three sets of M8 hardware on the side and an
M12 bolt, Belleville washer and flat washer on the end. Torque the M12 bolt to 275 in-lbs
(31 N-m).
19. Install current probe A67 at the output cabinet end of the “lower” copper tube installed in
Step 16 (see Figure 3.5 on page 3-11), using three sets of M8 hardware on the side and an
M12 bolt, Belleville washer and flat washer on the end. Torque the M12 bolt to 275 in-lbs
(31 N-m).
20. Re-install the four side cover plates removed in Step 14.
21. Locate four combiner splice plates (Nautel Part # 207-8140-09), packed in the transmitter.
22. Install the combiner splice plates, as shown in Figure 3.5 on page 3-11, between the existing
combiner covers in each cabinet. Install two plates between the upper and lower combiner
covers in cabinets 1 and 2. Install two plates between the upper and lower combiner covers
in cabinets 2 and 3. Secure each plate using M8 hardware already in the combiner covers.

NX300 Installation Manual Completing cabinet assembly
Page 3-6 Issue 3.0 2012-11-01
23. Locate and install the directional coupler (3A68, Nautel Part # NAFP107A) on top of the
output cabinet (Rack 3) using the hardware provided. Locate the directional coupler’s mating
connectors (9-pin D-sub P27 and Rogowski current probe BNC P1) that are tyrapped inside
the output cabinet. Remove shipping tyraps and route these cables through the clearance
hole adjacent the directional coupler. Mate D-sub connector P27 to A1J3. Mate BNC
connector P1 to A1J4.
24. See Figure 3.3 on page 3-9. Locate the RF drive cables terminated by RJ45 connectors RK2-
W64P1 and RK3-W64P1, noting they are tyrapped in the front of each of the middle cabinet
(Rack 2) and output cabinet (Rack 3), in each cabinet’s bottom, left-hand corner. Cut
securing tyraps and neatly route RK2-W64P1 and RK3-W64P1 into the control cabinet
(Rack 1) to the control/exciter panel (RK1-A11). Route both connectors to the control/
interface PWB (RK1-A11A1). Connect RK2-W64P1 to J14C and connect RK3-W64P1 to
J14E.
25. See Figure 3.3 on page 3-9. Locate the PDM drive cables terminated by RJ45 connectors
RK2-W62P1 and RK3-W63P1, tyrapped in the front of each of the middle cabinet (Rack 2)
and output cabinet (Rack 3), in each cabinet’s bottom, left-hand corner. Cut securing tyraps
and neatly route RK2-W62P1 and RK3-W63P1 into the control cabinet (Rack 1). Route
both connectors to the control/interface PWB (RK1-A11A1). Connect RK2-W62P1 to
J15B and connect RK3-W63P1 to J15C.
26. See Figure 3.3 on page 3-9. Locate 25-pin D-sub connectors RK1-P32 and RK2-P33 that are
tyrapped in the front of control cabinet Rack 1 (bottom, right-hand corner) and middle
cabinet Rack 2 (bottom, left-hand corner). Cut securing tyraps, route RK1-P32 to RK2-P33
and mate them together.
27. See Figure 3.3 on page 3-9. Locate 25-pin D-sub connectors RK2-P32 and RK3-P33 that are
tyrapped in the front of middle cabinet Rack 2 (bottom, right-hand corner) and output
cabinet Rack 3 (bottom, left-hand corner). Cut securing tyraps, route RK2-P32 to RK3-P33
and mate them together.
28. See Figure 3.3 on page 3-9. Locate 9-pin D-sub connector RK1-P27 that is tyrapped in the
front of control cabinet Rack 1, in the upper, right-hand corner. Cut securing tyraps. Route
RK1-P27 through middle cabinet Rack 2, into output cabinet Rack 3 and up through a top
clearance hole in rack 3. Connect RK1-P27 to A1J3 of the output cabinet’s directional
coupler (RK3-A68).
29. See Figure 3.3 on page 3-9. Locate BNC connector P35 that is tyrapped in the back of
middle cabinet Rack 2, near a side clearance hole adjacent control cabinet Rack 1. Cut
securing tyraps and neatly route RK2-P35 into control cabinet Rack 1. Locate BNC
connector P24 that is tyrapped in control cabinet Rack 1. Connect RK2-P35 to RK1-P24.