XR6/XR3 Transmitter Installation Manual Document: XR6/XR3-INST Issue: 3.
Nautel Limited 10089 Peggy’s Cove Road Hackett’s Cove, NS Canada B3Z 3J4 Phone: +1.902.823.3900 or Toll Free: +1.877.6NAUTEL (6628835) (Canada & USA only) Fax: +1.902.823.3183 Nautel Inc. 201 Target Industrial Circle Bangor, Maine USA 04401 Phone: +1.207.947.8200 Fax: +1.207.947.3693 Customer Service (24 hour support) +1.877.628.8353 (Canada & USA only) +1.902.823.5100 (International) Email: support@nautel.com Web: www.nautel.
XR6/XR3 Installation Manual Table of contents Contents About this manual vii About safety ix Safety precautions xi Preparing for installation 1-1 Installing the power transformer 2-1 Unpacking and positioning 3-1 Connecting the station reference ground 4-1 Connecting ac power 5-1 Installing the RF connector 6-1 Adjusting the spark gap 7-1 Audio and IBOC inputs 8-1 Audio configuration 8-2 Control and monitoring 9-1 Controls 9-1 Alarm definitions 9-1 Remote control circuits and
XR6/XR3 Installation Manual LAN interface (NxLink) Other considerations 9-13 10-1 External RF drive source 10-1 External 10 MHz frequency reference 10-2 Commissioning tasks 11-1 Pre-commissioning tasks 11-1 Commissioning 11-3 Going on-air 11-7 Parts and tools 12-1 Contacting Nautel 12-1 Parts supplied by Nautel 12-1 Parts not supplied by Nautel 12-2 Parts ordering 12-2 Module replacement program 12-2 Tools for installation 12-3 Pre-installation / Installation assistance 13-1
XR6/XR3 Installation Manual About this manual This manual provides information about installing an XR6/XR3 transmitter. This manual is intended for use by qualified, trained installers. Technical support Nautel offers technical support to customers over the Internet and by telephone. Nautel’s customer support team will answer your questions and work with you to identify and resolve problems. For technical support, call the Customer Support Team at 902-823-3900 or - in U.S.A.
XR6/XR3 Installation Manual XR6/XR3 Operating and Maintenance Manual, XR6/XR3-OPS-MAINT. The Operating and Maintenance Manual provides instructions for operating, maintaining and troubleshooting an XR6/XR3 transmitter. It also provides reference information needed when performing diagnostic procedures. XR6/XR3 Troubleshooting Manual, XR6/XR3-TROUBLE. The Troubleshooting Manual provides detailed technical information about the XR6/XR3 transmitter, including electrical schematics and mechanical drawings.
XR6/XR3 Installation Manual About safety All Nautel transmitters are designed to meet the requirements of EN60215, Safety Requirements for Radio Transmitters. The philosophy of EN60215 is that the removal of any cover or panel that can only be opened using a tool is a maintenance activity, and that any person performing a maintenance activity is expected to be trained for that activity.
XR6/XR3 Installation Manual Lightning hazards Before opening the transmitter and touching internal parts, remove and solidly ground the antenna connection. WARNING: It is not enough to ground the antenna terminal with the antenna still connected. Even a small impedance in the ground strap will result in lethal voltages during a lightning strike. RF hazards A serious RF hazard and very high voltages exist in the vicinity of the antenna and its networks during normal operations.
XR6/XR3 Installation Manual Safety precautions This section provides very important information about protecting the safety of personnel and equipment: • Personal safety - see page xi • Site safety - see page xii • Equipment safety - see page xiv Personal safety Training The training of any personnel who will have physical access to the site or the transmitter is very important.
XR6/XR3 Installation Manual Voltage awareness Ensure that all personnel that are able to access areas with high voltage circuits or high field strengths are aware of the hazards associated with high voltage.
XR6/XR3 Installation Manual Marking hazards Place warning signs close to any hazardous areas or systems (e.g., the feedline or the antenna system). Make the signs large enough that they cannot be missed. Provide signage in all languages used in the region. These signs are intended not only for authorized personnel, but also for emergency responders or accidental trespassers.
XR6/XR3 Installation Manual Safety interlocks The transmitter contains an electrical interlock, which is an external circuit that turns off the RF output if any of its switches are opened. Ac disconnect switch Safe operation of the transmitter requires an ac disconnect switch. Lock the ac disconnect switch in the disconnected (open) position during the installation process. Equipment safety Electrostatic protection The transmitter’s systems are very rugged and resistant to damage.
XR6/XR3 Installation Manual Earthquake protection If the transmitter site is in a region that experiences any noticeable earthquake activity, take steps to prevent the transmitter from shifting or rocking during an earthquake. Even during minor earthquakes, rocking or movement of the transmitter is likely to damage the feedline connection, and could even cause a catastrophic failure of the ac power feed into the transmitter.
XR6/XR3 Installation Manual Page xvi Issue 3.
XR6/XR3 Installation Manual Preparing for installation Section 1: Preparing for installation Before installing your XR6/XR3 transmitter, perform the following steps: 1. Ensure that you have performed the pre-installation tasks described in the XR6/XR3 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.
XR6/XR3 Installation Manual Preparing for installation Figure 1.
XR6/XR3 Installation Manual Installing the power transformer Section 2: Installing the power transformer 1. Before placing the transformer into the transmitter, set the line voltage tap selections. Based on your nominal line to line (or line to neutral for some single-phase ac power sources) voltage, select the appropriate tap position identified on the labels mounted on the terminal board end of the transformer. One label identifies the tap number and the line-to-line (or line-to-neutral) voltage.
XR6/XR3 Installation Manual Installing the power transformer Figure 2.2: Single-phase XR6 power transformer line voltage tap layout LOAD 2 LOAD 1 LINE 1 LINE 2 4 3 2 1 Page 2-2 Issue 3.
XR6/XR3 Installation Manual Installing the power transformer Table 2.1: Three-phase primary winding tap nominal voltages (rms, phase-to-phase) Voltage (V ac) Tap 198 6 Voltage (V ac) Tap 342 6 or 208 5 361 5 218 4 380 4 229 3 399 3 239 2 418 2 250 1 437 1 Table 2.
XR6/XR3 Installation Manual Installing the power transformer 3. Remove the back plate at the bottom/back of the transmitter cabinet by removing four mounting screws (see Figure 2.4 on page 2-5). 4. For single-phase transmitters only: Remove the four choke shims at the bottom of the tray supporting the three chokes. The shims are secured using M5 hardware (see Figure 2.3). Discard shims and hardware or retain for future shipping of the transmitter.. 5.
XR6/XR3 Installation Manual Installing the power transformer Figure 2.3: XR6/XR3 1-phase choke shim removal Shims Qty 4 T2 TB1 Figure 2.4: XR6/XR3 3-phase power transformer installation Load 1-3 connections Line 1-3 connections Transformer ground Station reference ground Issue 3.
XR6/XR3 Installation Manual Installing the power transformer Figure 2.5: XR6/XR3 1-phase power transformer installation Line 1, 2 and Load 1, 2 connections Transformer ground Back plate Station reference ground 9. Slide the transformer into its final position in the cabinet. Ensure that the anchor holes in the base of transformer line up with the anchor holes in the bottom of the transmitter. 10.
XR6/XR3 Installation Manual Unpacking and positioning Section 3: Unpacking and positioning To install an XR6/XR3 transmitter, perform the following tasks: 1. Lift and slide the transmitter cabinet off the base of its crate. 2. If necessary, remove the power modules from the transmitter. Without the power transformer, and with one power module installed, the XR6/XR3 transmitter weighs about 145 kg (319 lbs).* * For XR6/XR3 transmitters, a second RF power module is optional.
XR6/XR3 Installation Manual Unpacking and positioning Figure 3.1: RF Power Module Top Mounting Screw Holes Rear Panel Cutout Bottom Mounting Screw Connector Page 3-2 Issue 3.
XR6/XR3 Installation Manual Unpacking and positioning 3. Move the transmitter cabinet to its assigned position. 4. Verify that the ac power cable conduit from the ac disconnect switch reaches the entry point in the cabinet. 5. Verify that the RF feed cable reaches the RF output connector on the cabinet. Figure 3.2: XR6/XR3 Transmitter – Rear View 2 Packing Bolts (1 per module) Safety Ground Stud Assembly Connection Issue 3.
XR6/XR3 Installation Manual Page 3-4 Unpacking and positioning Issue 3.
XR6/XR3 Installation Manual Connecting the station reference ground Section 4: Connecting the station reference ground To connect the station reference ground, perform the following steps: 1. Locate the safety ground stud assembly. It has been set back in its final location at the bottom left rear of the transmitter.. 2. Remove the two nuts holding it to the phenolic bar. 3. Re-assemble as shown in Figure 4.1.
XR6/XR3 Installation Manual Connecting the station reference ground Figure 4.1: Safety Ground Stud Assembly Detail 7 3 1 5 4 2 INTERIOR EXTERIOR 8 6 1) M10 BRASS STUD 2) M10 NUT 3) 4) 5) 6) M10 FLAT WASHER M10 SPLIT WASHER EXTERIOR REFERENCE GROUND CONDUCTOR CABINET FRAME 7) TRANSFORMER GROUND WIRE 8) CABINET GROUND WIRE Page 4-2 Issue 3.
XR6/XR3 Installation Manual Connecting ac power Section 5: Connecting ac power To connect ac power to the transmitter, perform the following steps: 1. Run the ac power cable from the ac disconnect switch to the transmitter, passing all the conductors, as a group, through a ferrite toroid (provided in the ancillary kit). The preferred entry point is the top of the transmitter. Internal conduit is provided to guide the cable to the power supply space at the bottom of the transmitter (see Figure 5.1).
XR6/XR3 Installation Manual Connecting ac power 2. Connect the ac power ground to the station reference ground. 3. Verify that the station reference ground and the transformer ground terminal are connected to the safety ground stud assembly on the rear of the transmitter, (see Figure 2.2 on page 2-3 and Step 3 - Step 4, page 4-1). 4. Verify that the ac power conductors are connected to the power transformer as shown in Section 2, “Installing the power transformer” on page 2-1. 5.
XR6/XR3 Installation Manual Installing the RF connector Section 6: Installing the RF connector The XR6/XR3 comes with one of several types of RF output connectors. All types are illustrated in this section. Preparation WARNING: THE AC VOLTAGES PRESENT IN THE TRANSMITTER CAN BE FATAL. EXERCISE EXTREME CAUTION. 1. Make sure that the ac power is turned off at the ac service entrance. 2.
XR6/XR3 Installation Manual Installing the RF connector Figure 6.1: XR6/XR3 Exciter Panel Assembly (NAE93 – A2) A2A6 Remote Interface PWB A2A2 RF Synthesizer PWB ‘A’ A2A1 A2A1 Exciter Exciter Interface Interface PWBPWB A2A4 RF Synthesizer PWB ‘B’ A2A3 Interphase PDM Driver PWB ‘A’ A2A5 Interphase PDM Driver PWB ‘B’ A2 Exciter Panel assembly mounting screws (11) Page 6-2 Issue 3.
XR6/XR3 Installation Manual Installing the RF connector 7/8 EIA Output Connection 1. Locate and unpack the output connector kit. 2. Attach the brass connector cup from the kit to the output strap using the M5 x 16 mm long hex head bolt, split washer and flat washer supplied, such that the cup is pointing towards the large hole in the top (Figure 6.2). 3.
XR6/XR3 Installation Manual Installing the RF connector 1-5/8 EIA Output Connection 1. Locate and unpack the output connector kit. 2. Attach the brass connector cup from the kit to the output strap using the 5/16 x 1 inch long socket head cap screw, split washer and flat washer supplied, such that the cup is pointing towards the large hole in the top (Figure 6.3). 3.
XR6/XR3 Installation Manual Installing the RF connector Stud Output Connector 1. Unpack the stud connector assembly. Remove the M6 nut, split washer and one flat washer off the longer leg of the brass stud in the stud plate (Figure 6.4). 2. Position the stud plate on top of the transmitter over the large hole above the output strap. 3. Slide the brass stud through the hole in the output strap and re-attach the M6 nut, split washer and flat washer. 4.
XR6/XR3 Installation Manual Page 6-6 Installing the RF connector Issue 3.
XR6/XR3 Installation Manual Adjusting the spark gap Section 7: Adjusting the spark gap The XR6/XR3’s RF output filter contains a spark gap that must be adjusted - based on frequency and site altitude - to provide protection against excessive voltage (i.e., lightning) on the RF output. If the altitude of the transmitter site is known prior to transmitter delivery, then the spark gap is adjusted at Nautel. If this is the case, it may only be necessary to verify the spark gap setting.
XR6/XR3 Installation Manual Adjusting the spark gap Figure 7.1: RF Output Spark Gap Location Spark Gap E1 Page 7-2 Issue 3.
XR6/XR3 Installation Manual Adjusting the spark gap Table 7.1: Spark Gap Setting versus Altitude Frequency (kHz) Spark Gap (in.) @ 0 ft. Altitude 530 0.050 (XR3) 0.079 (XR6) 535 0.049 (XR3) 0.078 (XR6) 540 0.049 (XR3) 0.077 (XR6) 545 0.048 (XR3) 0.077 (XR6) 550 0.048 (XR3) 0.076 (XR6) 555 0.047 (XR3) 0.075 (XR6) 560 0.047 (XR3) 0.074 (XR6) 565 0.046 (XR3) 0.074 (XR6) 570 0.046 (XR3) 0.073 (XR6) 575 0.046 (XR3) 0.072 (XR6) 580 0.045 (XR3) 0.072 (XR6) 585 0.045 (XR3) 0.
XR6/XR3 Installation Manual Adjusting the spark gap Table 7.1: Spark Gap Setting versus Altitude (continued) Frequency (kHz) Spark Gap (in.) @ 0 ft. Altitude 680 0.076 (XR3) 0.122 (XR6) 685 0.076 (XR3) 0.121 (XR6) 690 0.075 (XR3) 0.120 (XR6) 695 0.075 (XR3) 0.119 (XR6) 700 0.074 (XR3) 0.118 (XR6) 705 0.073 (XR3) 0.117 (XR6) 710 0.073 (XR3) 0.116 (XR6) 715 0.072 (XR3) 0.115 (XR6) 720 0.071 (XR3) 0.114 (XR6) 725 0.071 (XR3) 0.113 (XR6) 730 0.070 (XR3) 0.112 (XR6) 735 0.070 (XR3) 0.
XR6/XR3 Installation Manual Adjusting the spark gap Table 7.1: Spark Gap Setting versus Altitude (continued) Frequency (kHz) Spark Gap (in.) @ 0 ft. Altitude 830 0.061 (XR3) 0.096 (XR6) 835 0.060 (XR3) 0.096 (XR6) 840 0.060 (XR3) 0.095 (XR6) 845 0.059 (XR3) 0.095 (XR6) 850 0.059 (XR3) 0.094 (XR6) 855 0.059 (XR3) 0.093 (XR6) 860 0.058 (XR3) 0.093 (XR6) 865 0.058 (XR3) 0.092 (XR6) 870 0.057 (XR3) 0.091 (XR6) 875 0.057 (XR3) 0.091 (XR6) 880 0.057 (XR3) 0.090 (XR6) 885 0.056 (XR3) 0.
XR6/XR3 Installation Manual Adjusting the spark gap Table 7.1: Spark Gap Setting versus Altitude (continued) Frequency (kHz) Spark Gap (in.) @ 0 ft. Altitude 980 0.050 (XR3) 0.080 (XR6) 985 0.050 (XR3) 0.080 (XR6) 990 0.050 (XR3) 0.079 (XR6) 995 0.050 (XR3) 0.079 (XR6) 1000 0.049 (XR3) 0.078 (XR6) 1005 0.049 (XR3) 0.078 (XR6) 1010 0.049 (XR3) 0.078 (XR6) 1015 0.049 (XR3) 0.077 (XR6) 1020 0.048 (XR3) 0.077 (XR6) 1025 0.048 (XR3) 0.076 (XR6) 1030 0.048 (XR3) 0.076 (XR6) 1035 0.
XR6/XR3 Installation Manual Adjusting the spark gap Table 7.1: Spark Gap Setting versus Altitude (continued) Frequency (kHz) Spark Gap (in.) @ 0 ft. Altitude 1130 0.043 (XR3) 0.069 (XR6) 1135 0.043 (XR3) 0.069 (XR6) 1140 0.043 (XR3) 0.068 (XR6) 1145 0.043 (XR3) 0.068 (XR6) 1150 0.043 (XR3) 0.068 (XR6) 1155 0.042 (XR3) 0.068 (XR6) 1160 0.042 (XR3) 0.067 (XR6) 1165 0.042 (XR3) 0.067 (XR6) 1170 0.042 (XR3) 0.067 (XR6) 1175 0.042 (XR3) 0.066 (XR6) 1180 0.042 (XR3) 0.066 (XR6) 1185 0.
XR6/XR3 Installation Manual Adjusting the spark gap Table 7.1: Spark Gap Setting versus Altitude (continued) Frequency (kHz) Spark Gap (in.) @ 0 ft. Altitude 1280 0.082 (XR3) 0.131 (XR6) 1285 0.082 (XR3) 0.131 (XR6) 1290 0.082 (XR3) 0.130 (XR6) 1295 0.081 (XR3) 0.130 (XR6) 1300 0.081 (XR3) 0.129 (XR6) 1305 0.080 (XR3) 0.128 (XR6) 1310 0.080 (XR3) 0.128 (XR6) 1315 0.080 (XR3) 0.127 (XR6) 1320 0.079 (XR3) 0.126 (XR6) 1325 0.079 (XR3) 0.126 (XR6) 1330 0.079 (XR3) 0.125 (XR6) 1335 0.
XR6/XR3 Installation Manual Adjusting the spark gap Table 7.1: Spark Gap Setting versus Altitude (continued) Frequency (kHz) Spark Gap (in.) @ 0 ft. Altitude 1430 0.072 (XR3) 0.115 (XR6) 1435 0.072 (XR3) 0.114 (XR6) 1440 0.071 (XR3) 0.114 (XR6) 1445 0.071 (XR3) 0.113 (XR6) 1450 0.071 (XR3) 0.113 (XR6) 1455 0.071 (XR3) 0.112 (XR6) 1460 0.070 (XR3) 0.112 (XR6) 1465 0.070 (XR3) 0.112 (XR6) 1470 0.070 (XR3) 0.111 (XR6) 1475 0.069 (XR3) 0.111 (XR6) 1480 0.069 (XR3) 0.110 (XR6) 1485 0.
XR6/XR3 Installation Manual Adjusting the spark gap Table 7.1: Spark Gap Setting versus Altitude (continued) Frequency (kHz) Spark Gap (in.) @ 0 ft. Altitude 1580 0.064 (XR3) 0.102 (XR6) 1585 0.064 (XR3) 0.102 (XR6) 1590 0.064 (XR3) 0.101 (XR6) 1595 0.063 (XR3) 0.101 (XR6) 1600 0.063 (XR3) 0.101 (XR6) 1605 0.063 (XR3) 0.100 (XR6) 1610 0.063 (XR3) 0.100 (XR6) 1615 0.063 (XR3) 0.099 (XR6) 1620 0.062 (XR3) 0.099 (XR6) 1625 0.062 (XR3) 0.099 (XR6) 1630 0.062 (XR3) 0.098 (XR6) 1635 0.
XR6/XR3 Installation Manual Adjusting the spark gap Table 7.2: Altitude Scale Factor Altitude (ft) Spark Gap (in.) Spark Gap Scale Factor (multiply gap by...) 0 1.00 1,000 1.05 2,000 1.10 3,000 1.15 (XR3), 1.16 (XR6) 4,000 1.21 (XR3), 1.22 (XR6) 5,000 1.28 (XR3), 1.29 (XR6) 6,000 1.35 (XR3), 1.36 (XR6) 7,000 1.43 (XR3), 1.45 (XR6) 8,000 1.52 (XR3), 1.54(XR6) 9,000 1.62 (XR3), 1.65 (XR6) 10,000 1.73 (XR3), 1.77 (XR6) Issue 3.
XR6/XR3 Installation Manual Page 7-12 Adjusting the spark gap Issue 3.
XR6/XR3 Installation Manual Audio and IBOC inputs Section 8: Audio and IBOC inputs This section describes requirements associated with audio feeds to the XR6/XR3 transmitter. This section includes the following topics: • Analog audio • IBOC input • Audio configuration - see page 8-2 Analog audio Modulating audio must be applied from an external source. The RF drive source configuration determines the audio requirements.
XR6/XR3 Installation Manual Audio and IBOC inputs Audio configuration 1. To configure an analog installation, go to “Analog Configuration” below. 2. To configure an IBOC installation, choose which exciter you will configure for analog operation (A or B), and which you will configure for IBOC operation, then go to “IBOC Configuration” on page 8-3. Figure 8.
XR6/XR3 Installation Manual Audio and IBOC inputs Routing Analog Installation Cables 1. Route audio cables through the cable entry hole in the transmitter’s top panel. See Figure 8.3 on page 8-6. 2. Route the cables through the ferrite toroid, provided in the ancillary kit, then toward the remote interface PWB, behind the GUI panel (see Figure 6.3 on page 6-4). Figure 8.2: RF Drive Buffer PWB Details – IBOC Configuration Connections for an analog installation 1.
XR6/XR3 Installation Manual • Audio and IBOC inputs If you provide a backup analog program stream to an exciter configured as analog in an IBOC installation, the system can automatically switch to the backup analog exciter and audio program stream. Refer to the XR6/XR3 Operating and Maintenance Manual for information about setting up exciter changeover. Configuring Exciter A for IBOC See Figure 8.1 on page 8-2 and Figure 8.2 on page 8-3. 1.
XR6/XR3 Installation Manual Audio and IBOC inputs 2. On the remote interface PWB, connect a jumper from J3-23, and a jumper from J3-25 to ground (TB2-4) permanently (or through the remote system). This will enable the IBOC inputs on Exciter A and B. A connecter shell and solder pins for J3 are provided in the ancillary kit. 3. On the RF drive buffer PWB, set E3 to Low to select low sensitivity by shorting pins 2 and 3. 4. On the RF drive buffer PWB, set E1 and E2 to Ext, by shorting pins 2 and 3.
XR6/XR3 Installation Manual Audio and IBOC inputs Figure 8.3: Location of cable entry hole (top view of XR6/XR3 transmitter) Front AUDIO CABLE ENTRY AC IN Rear Page 8-6 Issue 3.
XR6/XR3 Installation Manual Control and monitoring Section 9: Control and monitoring This section describes control and monitoring of the XR6/XR3 transmitter.
XR6/XR3 Installation Manual Control and monitoring LVPS fault The +24 V, +15 V, -15 V and +5 V power supplies are monitored. A fault will be reported if the voltage varies by more than ± 10%. • One or more of these faults will result in only one LVPS Fault message on the Status screen, though each one would be logged separately in the Event Log. High B+ voltage A fault is reported when the B+ voltage goes above 380 V. No other action will be performed automatically.
XR6/XR3 Installation Manual Control and monitoring Output network faults High DC current This alarm is triggered when the dc current goes above approximately 41 A (XR6) or 21 A (XR3). High RF current This alarm is triggered when the RF current exceeds the factory-set alarm threshold. High VSWR shutback This alarm is triggered when the reflected power exceeds the factory-set alarm threshold approximately 480 W (XR3) or 960 W (XR6).
XR6/XR3 Installation Manual Control and monitoring RF driver fault This fault indicates a problem with the RF drive on the current exciter. If the exciter transfer function is set to auto, then the microcontroller will attempt a changeover to the other exciter. If it cannot, or if the exciter transfer function is set to manual, then this fault will cause a shutback. PDM drive fault This fault indicates that the PDM drive has stopped functioning.
XR6/XR3 Installation Manual Control and monitoring Mod. protection This fault is reported from the remote interface PWB. The fault indicates that excessive low frequency modulation has triggered the transmitter’s protection circuit. Softstart faults Softstart active The softstart relays are initially open for 1.6 seconds when the transmitter is first powered on. The software should close the relays after 1.6 seconds and clear this alarm.
XR6/XR3 Installation Manual Control and monitoring The backup battery should be replaced while ac power is ON. If the ac power faults, without adequate backup battery power, then the log files will be lost. CAUTION: Do not wait for an extended period to replace the batteries. The control/monitor PWB’s microcontroller may not retain its settings if ac power is turned off when the backup battery voltage is too low. Page 9-6 Issue 3.
XR6/XR3 Installation Manual Control and monitoring Remote control circuits and alarms You can control the active (A/B) exciter, the on/off status of the RF power stage, the preset RF power level, the power level adjustment, and system alarm reset remotely. The remote interface PWB contains a selection circuit that lets you select internal (single ended input) or external (differential input) input for all controlled functions.
XR6/XR3 Installation Manual Control and monitoring Option 2 - Differential Input (External V dc). When you use an external dc voltage (24 V to 30 V) as the current source for a control function's opto coupler, configure the control function's external switching circuit and the remote interface PWB’s selection circuit for a differential input. The SINGLE/DIFF 3-pin header (E19) must have its 2-socket shunt post connected between pins 1 and 2 to configure the circuit. Figure 9.
XR6/XR3 Installation Manual Control and monitoring • TB2-6 (-): PDM INHB terminal. Continuous active signal inhibits the PDM by causing a shutback. This also works when the remote/local status is set to local. • TB1-1 and TB1-2: EXT INTLK terminals. A short circuit between the pins for normal operating status, an open between these pins causes a shutback. This also works when the remote/ local status is set to local. • TB1-4 (-): RF OFF terminal. Same as pressing the RF Off button on the front panel.
XR6/XR3 Installation Manual Control and monitoring • TB1-14 (-): EXCITER A terminal. Causes a changeover to select exciter A as the main exciter. Setting is saved in current preset. Provide an active pulse to select this exciter. • TB1-16 (-): EXCITER B terminal. Causes a changeover to select exciter B as the main exciter. Setting is saved in current preset. Provide an active pulse to select this exciter. • TB1-10 (-): POWER INCREASE terminal. Increases the power level of the current preset.
XR6/XR3 Installation Manual Control and monitoring • J3-13: Pwr Mod Fail. One or more power modules has a fault. • J3-12: Low B+. See “Low B+ voltage” on page 9-2. • J3-11: High VSWR. See “High VSWR shutback” on page 9-3. • J3-17: Cutback. See “Cutback level (1-8)” on page 9-4. • J3-16: Shutback. Indicates that a shutback is currently active. • J3-3: RF On Status. Indicates that the RF On LED is active, showing the operator’s request for RF power. • J3-(5,6,7,8,9,10): Preset (1-6) Status.
XR6/XR3 Installation Manual Control and monitoring Remote performance monitoring The transmitter provides outputs that let you monitor RF performance. They include dc voltages that represent the forward power level, the reflected power level, the B+ voltage and the dc current. In addition, a true RF sample of the RF output voltage waveform is available for external monitoring. These outputs are provided on the remote interface PWB.
XR6/XR3 Installation Manual Control and monitoring RF monitor sample. A true sample of the RF output voltage waveform is available through the J8 BNC connector (RF MONITOR) on the remote interface PWB. The RF monitor output is intended to be applied to a station modulation monitor with a 50 Ω input impedance. It may also be monitored by an oscilloscope during maintenance procedures. The RF monitor output can be set to provide 1.0 V rms or 5.
XR6/XR3 Installation Manual Page 9-14 Control and monitoring Issue 3.
XR6/XR3 Installation Manual Other considerations Section 10: Other considerations This section describes other considerations regarding the XR6/XR3 transmitter. • External RF drive source • External 10 MHz frequency reference - see page 10-2 External RF drive source You can apply an externally generated RF drive (carrier frequency only) to the remote interface board’s digital EXT RF IN BNC connector (J6). This replaces the internal carrier frequency oscillator for one or both exciters (A/B).
XR6/XR3 Installation Manual Other considerations Installing an external RF drive source 1. If the RF drive for one or both exciters is to be applied from an external source, connect its wiring as follows: – Route RF drive coaxial cable through a cable entry hole in the cabinet and through the ferrite toroid, to the vicinity of the remote interface PWB. – Cut the RF drive coaxial cable to length, terminate it with a coaxial BNC connector and connect it to the remote interface PWB’s EXT RF connector (J6).
XR6/XR3 Installation Manual Commissioning tasks Section 11: Commissioning tasks WARNING: Before applying ac power and turning on the transmitter, you must customize some circuits to the station's power source and operating requirements. Do not perform this pre-commissioning unless you are a station engineer or a competent electronics technician. The transmitter contains solid-state devices that may be damaged if subjected to excessive heat or high-voltage transients.
XR6/XR3 Installation Manual Commissioning tasks Exciter RF drive board 5. The default is INTERNAL RF DRIVE. See Section 8, “Audio and IBOC inputs” on page 8-1 and Section 10, “Other considerations” on page 10-1 for information on using an external RF drive source. Internal/external RF drive source 6. RF synthesizer PWBs can use their integral RF oscillator, or an external RF generator, as their RF drive source. Verify that the transmitter is configured to use the desired RF drive source.
XR6/XR3 Installation Manual Commissioning tasks Commissioning Turning on the transmitter 1. Terminate the transmitter's RF output into a precision, 50 Ω, resistive dummy load that is able to dissipate the RF power being applied to it: 6 kW carrier, 9 kW total required (XR6) or 3 kW carrier, 4.5 kW total required (XR3). 2. Verify that all panels are installed, and ensure that their attaching hardware is firmly tightened.
XR6/XR3 Installation Manual Commissioning tasks 11. Set the active preset’s power output to zero by pressing Increase and Decrease simultaneously. 12. Press RF ON. 13. Check the output of the 48 V and 62 V power supplies. 14. Ensure that the fans are running – listen for the sound of the fans. 15. Check for alarms on the status screen. 16. With an oscilloscope, verify the RF drive frequency and duty cycle on the RF drive buffer PWB (NAPE77) test output J5, located on the bottom, front of the transmitter.
XR6/XR3 Installation Manual Commissioning tasks Modulation checks Verify that the RF output is appropriately modulated when audio is applied: 23. Connect an appropriate modulation monitor to the remote interface PWB’s RF MONITOR connector (J8). The modulation monitor should have an impedance of 50 Ω. to obtain accurate readings. 24. Verify that forward power is selected for display on the RF KILOWATTS meter. 25.
XR6/XR3 Installation Manual Commissioning tasks 33. Disconnect the audio signal generator from TB2-1(+) and TB2-3(-) on the remote interface PWB. Page 11-6 Issue 3.
XR6/XR3 Installation Manual Commissioning tasks Going on-air WARNING: If a jumper is placed between interlock inputs TB1-1/TB1-2 on the remote interface pwb, safety features controlled by the external interlocks will be disabled. A fail safe method of alerting personnel to this fact should be implemented. Voltages which are dangerous to life will be present on the RF output stages and the antenna system if the transmitter is turned on.
XR6/XR3 Installation Manual Page 11-8 Commissioning tasks Issue 3.
XR6/XR3 Installation Manual Parts and tools Section 12: Parts and tools This section describes parts associated with the XR6/XR3 transmitter, and tools needed during installation and routine operation.
XR6/XR3 Installation Manual Parts and tools Documentation See “XR6/XR3 transmitter manuals” on page vii. Parts not supplied by Nautel Some parts and materials required to complete installation are not supplied by Nautel. The parts you need vary with the installation requirements. The list of parts you normally provide yourself during installation include: • A suitable 50 Ω RF output coaxial cable, terminated by the proper connector, complete with center male connector at the transmitter end.
XR6/XR3 Installation Manual Parts and tools Tools for installation The tools you need during transmitter installation include the following: • Digital voltmeter • Philips screwdrivers, sizes #1 and #2 • Pliers • Wire cutters • Slot screwdriver, 5 mm (3/16 inch) • Metric and Imperial socket set up to 24 mm (15/16 inch) • Metric and Imperial wrench set up to 25 mm (1 inch) • Feeler gauge (to measure spark gap) Issue 3.
XR6/XR3 Installation Manual Page 12-4 Parts and tools Issue 3.
XR6/XR3 Installation Manual Pre-installation / Installation assistance Section 13: Pre-installation / Installation assistance Nautel provides a number of support options to help you during pre-installation planning and preparation: • Pre-installation consulting • Installation and commissioning service • Online documentation - see page 13-3 • On-site support - see page 13-3 • Training - see page 13-3 • Standard warranty - see page 13-4 • Extended warranties - see page 13-7 Pre-installation co
XR6/XR3 Installation Manual Pre-installation / Installation assistance • Ac power wiring for the transmitter has been installed and connected at the breaker panel or the building’s service entrance. If local electrical codes allow Nautel personnel to connect the transmitter to the ac supply, using the customer's cable, that task is included in this service. Otherwise, the customer must ensure that an approved electrician is present for this task.
XR6/XR3 Installation Manual Pre-installation / Installation assistance These tests ensure that the transmitter is operating normally in compliance with its specifications. The service representative also provides a demonstration and a short explanation of the operation of the transmitter. Finally, the customer signs an Acceptance of Installation Certificate that provides feedback to Nautel regarding the commissioning service.
XR6/XR3 Installation Manual Pre-installation / Installation assistance All training courses at the Nautel Training Centre combine classroom and hands-on laboratory work to ensure a balanced learning experience. Nautel training courses feature: • Limited class sizes to ensure maximum student participation and access to equipment • Emphasis on need-to-know, day-to-day knowledge • Labs that focus on the tasks most often performed at the transmitter site.
XR6/XR3 Installation Manual Pre-installation / Installation assistance 6. Nautel will not assume responsibility for any charges incurred by other than Nautel employees. 7. Nautel shall have the privilege of investigating whether failures have been caused by factors beyond its control. 8. Nautel shall in no event be liable for any consequential damages arising from the use of this equipment. 9. When requesting a warranty repair/replacement, please provide complete and accurate information.
XR6/XR3 Installation Manual Pre-installation / Installation assistance +1.902.823.5100 (International) Email: support@nautel.com Web: www.nautel.com Module exchange service In order to provide Nautel customers with a fast and efficient service in the event of a problem, Nautel operates a factory rebuilt, module exchange service which takes full advantage of the high degree of module redundancy in Nautel equipment.
XR6/XR3 Installation Manual Pre-installation / Installation assistance • Serial number of part/assembly • *Complete reference designation of part/assembly • *Nautel's part number of part/assembly • *OEM's part number of part/assembly • Number of hours in use • Nature of defect • *Return shipping address Extended warranties Nautel's standard 13-month warranty provides excellent coverage and satisfies most customers’ needs.
XR6/XR3 Installation Manual Pre-installation / Installation assistance One-year Extended Warranty Plans add an additional year (12 months) of coverage after the end of the customer’s standard 13-month warranty. The two-year plan adds an additional two years (24 months). Only repairs done at Nautel's facilities or by Nautel authorized personnel will be covered by the Extended Warranty Plans.
XR6/XR3 Installation Manual List of terms Section 14: List of terms This section defines some of the terms that are used in Nautel documentation. AES-EBU. Audio Engineering Society/European Broadcasting Union (AES/EBU) is the name of a digital audio transfer standard. The AES/EBU digital interface is usually implemented using 3-pin XLR connectors (the same type connector used in professional microphones). One cable carries both left- and right-channel audio data to the receiving device. AMC.
XR6/XR3 Installation Manual List of terms Preset. A setting that controls power level, active exciter, and power scheduler status on a time-ofday and date basis. Exciters can be configured on a preset for a specific operating mode (for example, Exciter A - conventional AM, and Exciter B - IBOC). The XR6/XR3 allows you to pre-program up to six presets. Shutback.
XR6/XR3 Installation Manual Index Numerics 10 MHz Reference Input BNC connector, 10-2 A active exciter 9-7 active exciter, 9-1 adjustment, RF power, 9-1, 9-7 ancillary kit, 12-1 assistance, onsite, 13-3 assistance, technical, 13-1 audio IBOC, 8-1 requirements, 8-1 B binders, documentation, 13-3 C carrier frequency oscillator, 10-1 carrier frequency, 10-1, 10-2 CDROM documentation, 13-3 coaxial cable, 12-2 conduit, 12-2 consulting assistance, 13-1 control and monitor wiring, 12-2 D digital PHASE COMPONE
XR6/XR3 Installation Manual oscilloscope, 9-13 output voltage waveform, 9-12 P parts ordering 12-2 parts, 12-1 planning assistance, 13-1 preset power level 9-13 preset RF power level, 9-1, 9-7 pricing, support, 13-3 tools, 12-1 transformer taps, 2-1 transients, in remote control wiring, 9-7 typical program content, 9-8, 9-9 W waveform, RF input voltage, 9-12 website 12-2 R reference frequency, 10-2 reflected power level, 9-12 refurbished modules 12-2 replacement parts 12-2 reset, system alarm, 9-1, 9-7,
XR6/XR3 Installation Manual Document: XR6/XR3-INST Issue: 3.0 2009-07-15 Nautel Limited 10089 Peggy’s Cove Road Hackett’s Cove, NS Canada B3Z 3J4 Phone: +1.902.823.3900 or Toll Free: +1.877.6NAUTEL (6628835) (Canada & USA only) Fax: +1.902.823.3183 Nautel Inc. 201 Target Industrial Circle Bangor, Maine USA 04401 Phone: +1.207.947.8200 Fax: +1.207.947.3693 Customer Service (24 hour support) +1.877.628.8353 (Canada & USA only) +1.902.823.5100 (International) Email: support@nautel.com Web: www.nautel.
