XL12 Technical Instruction Manual

e-mail: [email protected]: www.nautel.com

Nautel Maine Inc. Nautel Limited201 Target Industrial Circle, Hacketts Cove, RR #1 Tantallon,Bangor, Maine USA 04401 Nova Scotia Canada B0J 3J0Phone: (207) 947-8200 Phone: (902) 823-3900Fax: (207) 947-3693 Fax: (902) 823-3183

ISO 9002 REGISTERED ISO 9001 REGISTERED

Copyright 2002 NAUTEL. All rights reserved

TECHNICAL INSTRUCTIONS

XL12AM BROACAST TRANSMITTER

12 000 WATT(SIX PRESET POWER LEVELS)

Original Issue...................01 January 2002

12 000 WATT AM BROADCAST TRANSMITTERXL12

Effective Pages (Page 1)15 January 2002

LIST OF EFFECTIVE PAGES

The list of effective pages lists the status of all pages in this manual. Original pages are identified by a zero in theChange No. column. Pages subsequently changed are identified by the date of the change number. On a changedpage, the text affected by the latest change is indicated by a vertical bar in the margin opposite the changedmaterial.

Original...............................................01 January 2002

Total number of printed sides in this manual is 251 as listed below:

CHANGE CHANGEPAGE No. DATE PAGE No. DATE

Title 0 01 January 2002Title (Rear) - BlankEffective (1) 0 01 January 2002Effective (2) 0 01 January 2002Effective (3) 0 01 January 2002Effective (4) - BlankSafety (1) 0 01 January 2002Safety (2) 0 01 January 2002Safety (3) 0 01 January 2002Safety (4) - BlankWarranty (1) 0 01 January 2002Warranty (2) 0 01 January 2002Contents (1) 0 01 January 2002Contents (2) 0 01 January 2002Contents (3) 0 01 January 2002Contents (4) 0 01 January 2002Contents (5) 0 01 January 2002Contents (6) 0 01 January 2002Contents (7) 0 01 January 2002Contents (8) 0 01 January 2002Contents (9) 0 01 January 2002Contents (10) 0 01 January 2002Contents (11) 0 01 January 2002Contents (12) 0 01 January 2002Contents (13) 0 01 January 2002Contents (14) - Blank

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5-14 0 01 January 20025-15 0 01 January 20025-16 0 01 January 20026-1 0 01 January 20026-2 0 01 January 20026-3 0 01 January 20026-4 0 01 January 20026-5 0 01 January 20026-6 0 01 January 20026-7 0 01 January 20026-8 0 01 January 20026-9 0 01 January 20026-10 0 01 January 20026-11 0 01 January 20026-12 0 01 January 20026-13 0 01 January 20026-14 - Blank7-1 0 01 January 20027-2 0 01 January 20027-3 0 01 January 20027-4 0 01 January 20027-5 0 01 January 20027-6 0 01 January 20027-7 0 01 January 20027-8 0 01 January 20027-9 0 01 January 20027-10 0 01 January 20027-11 0 01 January 20027-12 0 01 January 20027-13 0 01 January 20027-14 0 01 January 20028-1 0 01 January 20028-2 0 01 January 20028-3 0 01 January 20028-4 0 01 January 20028-5 0 01 January 20028-6 0 01 January 20028-7 0 01 January 20028-8 0 01 January 20028-9 0 01 January 20028-10 0 01 January 20028-11 0 01 January 20028-12 0 01 January 20028-13 0 01 January 20028-14 0 01 January 20028-15 0 01 January 20028-16 0 01 January 2002



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12 000 WATT FM BROADCAST TRANSMITTERXL12

Safety (Page 1)01 January 2002

ARTIFICIAL RESPIRATION (MOUTH-TO-MOUTH)

(a) START MOUTH-TO-MOUTH BREATHING IMMEDIATELY.SECONDS COUNT. Do not wait to loosen clothing, warmthe casualty, or apply stimulants.

(b) ASSESS RESPONSIVENESS OF CASUALTY. Do not jarcasualty or cause further physical injury (Figure 1)

(c) IF POSSIBLE, SEND A BYSTANDER TO GET MEDICALHELP. Do not leave casualty unattended (Figure 2)

(d) CHECK CAROTID PULSE (Figure 3)

(e) LAY CASUALTY ON HIS/HER BACK and place anyavailable jacket or blanket under his/her shoulders.

(f) TILT THE HEAD BACK AND LIFT THE CHIN to open theairway (Figure 4)

(g) PINCH CASUALTYS NOSE AND EXHALE TWO SLOWBREATHS INTO CASUALTY (Figure 5)

(h) REMOVE YOUR MOUTH and check for breathing (Figure6)

(i) CONTINUE GIVING ONE BREATH EVERY FIVESECONDS without interruption. If any air is retained in thestomach after exhalation by casualty, press gently onstomach to expel air.

(j) IF CHEST DOES NOT RISE CHECK for obstruction incasualtys mouth: clear foreign material using your finger,tissues, etc. Use chin lift and recommence mouth-to-mouthbreathing.

(k) WHILE MOUTH-TO-MOUTH BREATHING IS CONTINUEDhave someone else:

(a) Loosen casualtys clothing.(b) Keep the casualty warm.

(l) DONT GIVE UP. Continue without interruption until thecasualty is revived, or until a doctor pronounces thecasualty dead. Four hours or more may be required.

(m) DO NOT PROVIDE ANYTHING ORALLY while victim isunconscious.

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2

3

4

5

6



GENERAL RULES FOR TREATMENT FOR BURNS, BLEEDING, AND SHOCK

1. After casualty has revived, treat for injuries and shock.

2. Reassure casualty.

3. Try to make him comfortable.

4. Keep him reasonably warm but do not apply heat.

5. If thirsty, liquids may be given but no alcohol (no liquids should be given in cases of severe burns).

6. Treat burns or wounds. Infection danger in treating burns or wounds is very great so ensure hands areclean and do not handle affected areas more than necessary.

7. Do not apply salves, grease, etc. to burns.

8. Do not remove burned clothing which adheres to the skin or break blisters.

9. Cover the burn with a dry sterile dressing, piece of sheeting, etc.

10. Bandage lightly over blisters where care must be taken to cover and not to break.

11. If severe bleeding of wound, elevate affected area, except in the case of a fracture.

12. Expose wound and apply pressure.

13. Apply dressing, pad and bandage.

14. For burns and bleeding, immobilize injured part using splints if necessary and keep patient in restfulposition during removal to hospital or expert medical attention.

15. In all cases, send for medical aid immediately.



ELECTRIC SHOCK - RESCUE METHODS

Electricity can damage the body in a number of ways. It may interfere with the proper functioning of the nervoussystem and the heart action, it can subject the body to extreme heat and can cause severe muscular contractions. The path that the current of electricity takes through the body is important. Currents which pass from hand to handor from hand to foot may pass directly through the heart and upset its normal functioning. This threat to life isrelated to the amount of current or amperage that will flow through a victim's body. Very little current (as little as10 milliamps) can result in severe shock or death.

Speed in the application of first aid measures is absolutely essential in cases of electrical injury. As soon as thevictim is freed safely from the source of the electrical current, if breathing has stopped, artificial respiration shouldbe commenced immediately. If the carotid pulse cannot be felt, external cardiac massage should be commencedsimultaneously. Resuscitation should be continued until the patient is breathing on his own or until medical aidarrives. Survival rates can be quite high if cardio-pulmonary resuscitation is started within 3 to 4 minutes of theinjury being received.

ACT AT ONCE - DELAY OR INDECISION MAY BE FATAL

1. Turn OFF the electrical source.

2. Commence artificial respiration immediately.

3. Treat for burns, bleeding and shock.

REMOVING A CASUALTY FROM ELECTRICAL CONTACT

LOW VOLTAGE - 0 to 240 volts (household use)

Switch off the current, if possible and time permits. If the switch cannot be located immediately and the supply isthrough a flexible cord or cable, the current may be shut off by removing the plug or even breaking the cable orwrenching free. Never attempt to shut off current by cutting cord with a knife or scissors.

If the current cannot be shut off, the greatest care is necessary in removing the casualty. Household rubber gloves,rubber or plastic hose (if there is no water in them), a dry unpainted stick or a clean dry rope can be used to freevictim.

HIGH VOLTAGE - 240 volts and up (industrial machines and power lines)

Do not touch any person or equipment in contact with a wire.

Use a dry unpainted pole , clean dry rope, dry rubber or plastic water hose to separate the casualty from thecontact.

Keep as far away as possible.

Do not touch the casualty until he is free.


Warranty (Page 1)01 January 2002

WARRANTY

Nautel Limited/Nautel Maine Incorporated, hereinafter referred to as Nautel, guarantees all mechanical andelectrical parts of the equipment for a period of thirteen months from date of shipment.

1. A "Part Failure" shall be deemed to have occurred when the part has become defective, or does not havethe characteristics required for the specified equipment performance:

(a) When the equipment is operated within the design parameters, and

(b) When the equipment is installed and adjusted according to Nautel's prescribed procedures as stated inthe instruction manual.

2. Nautel shall provide replacements for all "Parts" at no cost to the Customer when they become defectiveduring the warranty period, and upon the return of the defective part.

3. In the event that a "Part" fails during the warranty period and causes damage to a sub-assembly that cannotbe readily repaired in the field, the entire sub-assembly so damaged may be returned to Nautel for repair. The repairs will be made without charge to the Customer.

4. Where warranty replacements or repair are provided under items 2 or 3, Nautel will pay that part of theshipping costs incurred in returning the part/assembly to the Customer.

5. Warranty replacement parts and repair, which are provided under items 2 or 3, shall be guaranteed for aperiod of ninety days from date of shipment or until the end of the original warranty period, whicheveroccurs later.

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 itscontrol.

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. Observe the instructions regarding 'Equipment Being Returned to Nautel' on page two of this warranty andprovide the information requested.

10. When ordering spare/replacement parts; please provide complete and accurate information. Refer to theparts list of this manual for ordering information. Provide as much of the information requested for'Equipment Being Returned to Nautel' on page two of this warranty as is practical. The informationidentified by an asterisk is the minimum required.

ON-LINE PART QUOTESNautel provides an on-line website service (www.nautel.com/in-service.html) where requests for part quotesmay be submitted. Requests will normally be responded to within one working day.


Warranty (Page 2)01 January 2002

FACTORY SUPPORT

TECHNICAL ASSISTANCENautel's field service department provides telephone technical assistance on a 24 hour, seven days a week basis. Requests by other media (facsimile or e-mail) will be responded to the next working day if received after Nautel'snormal working hours. Contact the appropriate field service centre from the following:

U.S.A. customers use: Nautel Maine Incorporated Telephone 207-947-8200 (24 hours)201 Target Industrial Circle Facsimile 207-947-3693Bangor, Maine 04401

All other customers use: Nautel Limited Telephone 902-823-3900 (24 hours)Hackett's Cove, RR#1 Tantallon Facsimile 902-823-3183Nova Scotia, Canada E-Mail [email protected] 3J0 Web www.nautel.com

MODULE EXCHANGE SERVICEIn order to provide Nautel customers with a fast and efficient service in the event of a problem, Nautel operates afactory rebuilt, module exchange service which takes full advantage of the high degree of module redundancy inNautel equipment. This module exchange service is operated from Nautels factory in Bangor, Maine and HackettsCove, Nova Scotia. These two locations allow us to provide a quick turn around service to keep our customers onthe air. During the transmitters warranty period, up to thirteen months from shipment, repair and exchange ofmodules is at no charge to the customer. When the warranty has expired, a charge of 80% of the list price for allexchanged modules is made. If the faulty module is returned to Nautel within 30 days, a credit is issued reducingthis charge by one half to 40% of the list price. U.S.A. customers are required to contact our Bangor, Maine facility. Canadian and overseas customers should contact our Nova Scotia, Canada facility.

EQUIPMENT BEING RETURNED TO NAUTELAll equipment being returned to Nautel and all requests for repairs or replacements should be marked 'field return'and addressed to the appropriate Nautel facility.

Complete and accurate information regarding the equipment being returned will ensure prompt attention and willexpedite the dispatch of replacements. Refer to the nameplate on the transmitter and/or the appropriatemodule/assembly to obtain name, type, part and serial number information. Refer to the parts list of this manual orthe appropriate service instruction manual for additional ordering information.

The following information should accompany each request:

* Model of Equipment* Serial number of Equipment* Name of Part/Assembly

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 UseNature of defect

* Return shipping address

* Denotes minimum information required to order spare/replacement parts


Contents (Page 1)01 January 2002

TABLE OF CONTENTSSection Page

1 GENERAL INFORMATION1.1 INTRODUCTION ...................................................................................................... 1-11.2 FACTORY SUPPORT............................................................................................... 1-11.3 PURPOSE AND SCOPE OF MANUAL ...................................................................... 1-11.3.1 FAMILY TREE ......................................................................................................... 1-11.4 PURPOSE OF EQUIPMENT ..................................................................................... 1-11.5 MECHANICAL DESCRIPTION .................................................................................. 1-11.6 TECHNICAL SUMMARY .......................................................................................... 1-11.7 SPECIAL TOOLS AND TEST EQUIPMENT ............................................................... 1-11.8 GLOSSARY OF TERMS .......................................................................................... 1-1

2 INSTALLATION2.1 PLANNING AND SITE PREPARATION...................................................................... 2-12.1.1 TRANSMITTER ROOM REQUIREMENTS................................................................... 2-12.1.1.1 Transmitter Dimensions ...................................................................................... 2-12.1.1.2 Transmitter Clearances ....................................................................................... 2-12.1.1.3 Air Flushing ....................................................................................................... 2-12.1.1.4 Cooling.............................................................................................................. 2-12.1.1.5 Heating.............................................................................................................. 2-12.1.1.6 Work Area ......................................................................................................... 2-12.1.2 LIGHTNING PROTECTION ........................................................................................ 2-12.1.2.1 Station Reference Ground ................................................................................... 2-22.1.2.2 AC Power Source............................................................................................... 2-22.1.2.3 Antenna Feed Cable ........................................................................................... 2-22.1.2.4 Antenna/RF Output Disconnect ........................................................................... 2-22.1.2.5 Antenna Tower ................................................................................................... 2-22.1.2.6 External Control/Monitor Wiring ........................................................................... 2-22.1.3 ELECTRICAL POWER.............................................................................................. 2-22.1.3.1 Nominal Voltage................................................................................................. 2-22.1.3.2 Voltage Stability................................................................................................. 2-22.1.3.3 Power Consumption............................................................................................ 2-32.1.3.4 External AC Switching ........................................................................................ 2-32.1.4 ANTENNA SYSTEM................................................................................................. 2-32.1.4.1 RF Feed Cable................................................................................................... 2-32.1.5 EXTERNAL RF DRIVE SOURCE ............................................................................... 2-32.1.6 MODULATING AUDIO............................................................................................... 2-32.1.6.1 Both Exciters Monaural (Internal or External RF Drive) ........................................... 2-32.1.6.2 Both Exciters AM Stereo (External RF Drive) ........................................................ 2-42.1.6.3 One Exciter AM Stereo (External RF Drive)/One Exciter Monaural .......................... 2-42.1.6.4 Exciter 'A' AM Stereo (Optional C-QUAM AM Stereo Exciter as RF Drive Source..... 2-42.1.7 SAFETY INTERLOCKS............................................................................................. 2-42.1.7.1 External Electrical Interlock................................................................................. 2-42.1.7.2 Internal Electrical Interlock .................................................................................. 2-52.1.7.3 Mechanical Safety Interlock................................................................................. 2-52.1.8 REMOTE CONTROL CIRCUITS ................................................................................. 2-52.1.8.1 On/Off Control .................................................................................................... 2-62.1.8.2 Main Exciter Selection........................................................................................ 2-62.1.8.3 Preset Power Level Selection .............................................................................. 2-6



TABLE OF CONTENTS (Continued)Section Page

2 INSTALLATION (Continued)2.1.8.4 Power Level Adjust Select................................................................................... 2-62.1.8.5 System Reset .................................................................................................... 2-72.1.8.6 Alarm Recall ...................................................................................................... 2-72.1.9 OTHER REMOTE CONTROLS .................................................................................. 2-72.1.9.1 External PDM (RF) Inhibit Control ........................................................................ 2-72.1.10 RF PERFORMANCE MONITORING........................................................................... 2-72.1.10.1 RF Monitor Sample............................................................................................. 2-72.1.10.2 Forward Power Level........................................................................................... 2-72.1.10.3 Reflected Power Level......................................................................................... 2-72.1.10.4 Power Amplifier Volts.......................................................................................... 2-72.1.11 REMOTE ALARM INDICATIONS................................................................................ 2-82.1.11.1 RF Stress Current Alarm..................................................................................... 2-82.1.11.2 Filter Over Temp Alarm ....................................................................................... 2-82.1.11.3 High Reflected Power Alarm ................................................................................ 2-82.1.11.4 RF Power Cutback Alarm.................................................................................... 2-82.1.11.5 RF Inhibit Alarm ................................................................................................. 2-82.1.11.6 Standby Exciter Alarm........................................................................................ 2-82.1.11.7 Modulation Protection Alarm................................................................................ 2-82.1.11.8 Power Module Fault Alarm .................................................................................. 2-82.1.11.9 B+ Power Supply Fault Alarm.............................................................................. 2-92.1.11.10 AC Fail Alarm .................................................................................................... 2-92.1.11.11 Power Supply Over Temp Alarm........................................................................... 2-92.1.11.12 Battery Low Alarm.............................................................................................. 2-92.1.11.13 External Interlock Alarm...................................................................................... 2-92.1.11.14 Internal Interlock Alarm ....................................................................................... 2-92.1.11.15 RF Power Shutback Alarm .................................................................................. 2-92.1.11.16 RF Drive B+ Fail Alarm ....................................................................................... 2-92.1.11.17 PDM Failure Alarm ............................................................................................. 2-92.1.11.18 RF Drive Fail Alarm............................................................................................. 2-92.1.11.19 Low DC Volts Fail Alarm ..................................................................................... 2-92.1.12 REMOTE STATUS INDICATIONS ............................................................................ 2-102.1.12.1 Remote Control Status...................................................................................... 2-102.1.12.2 RF Pwr On Status ............................................................................................ 2-102.1.12.3 Exciter B Status............................................................................................... 2-102.1.12.4 RF Power Level Status...................................................................................... 2-102.1.13 PARTS SUPPLIED BY NAUTEL.............................................................................. 2-102.1.13.1 Ancillary Parts ................................................................................................. 2-112.1.14 PARTS REQUIRED BUT NOT SUPPLIED BY NAUTEL ............................................. 2-112.1.14.1 Surge Protector Panel....................................................................................... 2-112.1.15 TEST EQUIPMENT AND SPECIAL TOOLS .............................................................. 2-112.2 NON-TECHNICAL PRE-COMMISSIONING............................................................... 2-122.2.1 ACCEPTANCE OF SHIPMENT................................................................................ 2-122.2.2 UNPACKING INSTRUCTIONS ................................................................................. 2-122.2.3 CABINET PRE-POSITIONING.................................................................................. 2-122.2.4 DISASSEMBLY REQUIRED.................................................................................... 2-132.2.5 VISUAL INSPECTION............................................................................................. 2-132.2.6 REASSEMBLY ...................................................................................................... 2-14



TABLE OF CONTENTS (Continued)Section Page

2 INSTALLATION (Continued)2.2.6.1 Installation of Reference Ground Stud................................................................. 2-142.2.6.2 Installation of Fan Trays .................................................................................... 2-142.2.6.3 Installation of RF Power Modules ....................................................................... 2-142.2.6.4 Installation of Main Power Transformer................................................................ 2-152.2.6.5 Connection of Power Transformer (A23A1) Wiring................................................ 2-152.2.7 AC POWER CONNECTION..................................................................................... 2-162.2.7.1 Installation of Circuit Breaker Enclosure.............................................................. 2-162.2.7.2 Installation of AC Power Wiring (Service Entrance to Enclosure) ........................... 2-162.2.7.3 Installation of AC Power Wiring (Enclosure to Transmitter) ................................... 2-162.2.8 INSTALLATION OF RF FEED CABLE ...................................................................... 2-172.2.9 INSTALLATION OF EXTERNAL WIRING................................................................... 2-172.2.9.1 External Control Wiring ..................................................................................... 2-182.2.9.2 RF Performance Monitoring Wiring..................................................................... 2-182.2.9.3 Alarm/Status Monitor Wiring.............................................................................. 2-182.2.9.4 Audio Wiring .................................................................................................... 2-192.2.9.5 External RF Drive Wiring ................................................................................... 2-192.2.10 REASSEMBLY ...................................................................................................... 2-192.2.11 REFERENCE GROUND INTERCONNECTION .......................................................... 2-192.3 TECHNICAL PRE-COMMISSIONING....................................................................... 2-212.3.1 AC POWER SOURCE VARIABLES......................................................................... 2-212.3.1.1 Main Power Transformer Primary Tap Selection................................................... 2-212.3.1.2 Low Volts Pwr Supply Transformer Primary Tap Selection.................................... 2-212.3.2 EXCITER RF DRIVE PWB OPTIONS ....................................................................... 2-222.3.2.1 Exciter A's RF Drive PWB................................................................................. 2-222.3.2.2 Exciter B's RF Drive PWB................................................................................. 2-222.3.3 INTERNAL/EXTERNAL RF DRIVE SOURCE............................................................. 2-222.3.4 FREQUENCY DEPENDENT VARIABLES ................................................................ 2-222.3.5 AUDIO PASS BAND SELECTION............................................................................ 2-232.3.6 AUDIO CHOICES................................................................................................... 2-232.3.7 REMOTE CONTROL CHOICES............................................................................... 2-232.3.7.1 Differential Inputs.............................................................................................. 2-232.3.7.2 Single Ended Inputs.......................................................................................... 2-232.3.8 ALARM/STATUS OUTPUT CHOICES....................................................................... 2-242.3.8.1 Logic False - Open Collector ............................................................................. 2-242.3.8.2 Logic False - +5VDC ........................................................................................ 2-242.3.9 ALARM DISPLAY OPTIONS ................................................................................... 2-252.3.9.1 Continuous Alarm Display ................................................................................. 2-252.3.9.2 Flashing Alarm Display ..................................................................................... 2-252.4 COMMISSIONING PROCEDURES .......................................................................... 2-262.4.1 PRECAUTIONS TO BE OBSERVED........................................................................ 2-262.4.2 TURN ON PREREQUISITES ................................................................................... 2-262.4.3 INITIAL TURN-ON................................................................................................... 2-272.4.4 RF DRIVE CHECKS ............................................................................................... 2-292.4.4.1 RF Drive Frequency .......................................................................................... 2-292.4.4.2 RF Drive Symmetry .......................................................................................... 2-292.4.4.3 RF Drive Level .................................................................................................. 2-302.4.5 CHECK OF RF POWER STAGES........................................................................... 2-30



TABLE OF CONTENTS (Continued)Section

2 INSTALLATION (Continued)2.4.5.1 RF Power Checks ............................................................................................ 2-302.4.5.2 Setting Preset RF Power Levels......................................................................... 2-312.4.5.3 Setting RF Monitoring Voltages ......................................................................... 2-312.4.6 MODULATION CHECKS ......................................................................................... 2-332.4.6.1 Modulation Envelope (Monaural Output).............................................................. 2-332.4.6.2 Modulation Checks (AM Stereo Output).............................................................. 2-342.4.6.3 Modulation Peak Limiting .................................................................................. 2-342.4.7 PLACING TRANSMITTER ON-AIR ........................................................................... 2-352.4.8 ON-AIR TESTS ...................................................................................................... 2-352.5 SPECIAL ADJUSTMENT PROCEDURES................................................................. 2-362.5.1 INCIDENTAL PHASE MODULATION (External AM Stereo Drive) COMPENSATION ..... 2-362.5.2 RF CURRENT LEVEL............................................................................................. 2-37

3 CONTROLS AND INDICATORS3.1 GENERAL ............................................................................................................... 3-13.2 CONTROL/MONITOR PANEL CONTROLS AND INDICATORS ................................... 3-13.3 EXCITER PANEL CONTROLS AND INDICATORS ..................................................... 3-13.4 RF DRIVE TUNING PWB CONTROLS....................................................................... 3-13.5 RF DRIVE STAGE CONTROLS AND INDICATORS .................................................... 3-13.6 AC/DC POWER SUPPLY CONTROLS AND INDICATORS.......................................... 3-13.7 8-INPUT RF COMBINER/FILTER ASSEMBLY............................................................ 3-23.8 FORWARD/REFLECTED POWER PROBE ASSEMBLY.............................................. 3-2

4 OPERATING INSTRUCTIONS4.1 GENERAL ............................................................................................................... 4-14.1.1 PRECAUTIONS TO BE OBSERVED.......................................................................... 4-14.2 CONTROLS AND INDICATORS ................................................................................ 4-14.3 EMERGENCY SHUTDOWN PROCEDURE.................................................................. 4-14.3.1 TURN OFF RF OUTPUT............................................................................................ 4-14.3.2 COMPLETE SHUTDOWN......................................................................................... 4-14.4 IEC215 ENTRY KIT OPTION..................................................................................... 4-14.5 ELECTROSTATIC PROTECTION.............................................................................. 4-24.5.1 PERSONAL DISCHARGING...................................................................................... 4-24.5.2 HANDLING/STORAGE.............................................................................................. 4-24.5.3 TOOLS/TEST EQUIPMENT....................................................................................... 4-24.5.4 STRESS CURRENT PROTECTION............................................................................ 4-24.6 PRE-STARTUP CHECKS.......................................................................................... 4-24.7 READING METERS.................................................................................................. 4-24.7.1 READING RF POWER METER................................................................................. 4-24.7.2 READING DC VOLTS METER................................................................................... 4-34.8 LOCAL/REMOTE CONTROL .................................................................................... 4-34.8.1 LOCAL CONTROL.................................................................................................... 4-34.8.2 REMOTE CONTROL................................................................................................. 4-34.9 OPERATIONAL CONTROLS .................................................................................... 4-44.9.1 ACTIVE EXCITER SELECTION.................................................................................. 4-44.9.1.1 Exciter 'A' Active ................................................................................................ 4-4




4 OPERATING INSTRUCTION (Continued)4.9.1.2 Exciter 'B' Active ................................................................................................ 4-44.9.1.3 Exciter Assemblies ............................................................................................ 4-44.9.2 PRESET RF POWER SELECTION............................................................................ 4-44.9.3 RF POWER TRIM .................................................................................................... 4-54.9.3.1 Increase RF Power ............................................................................................. 4-54.9.3.2 Decrease RF Power............................................................................................ 4-54.9.4 RF ON/OFF SELECTION .......................................................................................... 4-54.9.4.1 RF On Selection................................................................................................. 4-54.9.4.2 RF Off Selection................................................................................................. 4-54.9.5 LOCAL/REMOTE CONTROL SELECTION .................................................................. 4-54.9.6 ADJUST AUDIO LEVEL............................................................................................ 4-54.10 STATUS DISPLAYS ................................................................................................ 4-54.10.1 DISPLAY COLOUR .................................................................................................. 4-54.10.2 DISPLAY TYPE ....................................................................................................... 4-64.10.2.1 Latching Alarm Display ....................................................................................... 4-64.10.2.2 Non-Latching Alarm Displays............................................................................... 4-64.11 TESTING DISPLAYS ............................................................................................... 4-74.12 LATCHING PROTECTION CIRCUITS........................................................................ 4-74.12.1 B+ POWER SUPPLY OVER TEMP........................................................................... 4-74.12.2 PDM FAILURE ......................................................................................................... 4-74.12.3 RF POWER MODULE FAILURES ............................................................................. 4-74.12.3.1 RF Drive Failure Detectors................................................................................... 4-74.12.3.2 Over Temperature Detector.................................................................................. 4-84.12.3.3 Modulator Failure Detectors................................................................................. 4-84.12.4 RESETTING LATCHED PROTECTION CIRCUITS........................................................ 4-84.13 TURN-ON EXPECTATIONS ...................................................................................... 4-8

5 SYSTEM LEVEL TROUBLE SHOOTING5.1 GENERAL ............................................................................................................... 5-15.2 SCHEDULED MAINTENANCE................................................................................... 5-15.3 CORRECTIVE MAINTENANCE.................................................................................. 5-15.3.1 ON-AIR TROUBLE SHOOTING.................................................................................. 5-25.3.1.1 Remote Trouble Shooting .................................................................................... 5-25.3.1.2 Local Trouble Shooting........................................................................................ 5-25.3.2 OFF-AIR TROUBLE SHOOTING................................................................................ 5-25.4 ELECTROSTATIC PROTECTION.............................................................................. 5-25.5 TROUBLE SHOOTING FRONT PANEL ALARMS....................................................... 5-25.5.1 RF POWER MODULES ALARM................................................................................ 5-35.5.1.1 RF Power Module Fault Validation ....................................................................... 5-35.5.1.2 RF Power Module Trouble Shooting...................................................................... 5-35.5.2 EXTERNAL INTERLOCK ALARM............................................................................... 5-35.5.3 INTERNAL INTERLOCK ALARM................................................................................ 5-35.5.4 B+ POWER SUPPLY - AC FAIL ALARM ................................................................... 5-45.5.5 B+ POWER SUPPLY - OVER VOLTAGE ALARM ...................................................... 5-45.5.6 B+ POWER SUPPLY - UNDER VOLTAGE ALARM .................................................... 5-45.5.7 B+ POWER SUPPLY - TEMPERATURE ALARM ....................................................... 5-4




5 SYSTEM LEVEL TROUBLE SHOOTING (Continued)5.5.8 LOW VOLTAGE POWER SUPPLY - RF DRIVE AMP ALARM ..................................... 5-55.5.9 LOW VOLTAGE POWER SUPPLY - BATTERY LOW ALARM ..................................... 5-55.5.10 LOW VOLTAGE POWER SUPPLY - REGULATED VOLTAGE ALARM ........................ 5-55.5.11 EXCITER - RF DRIVE ALARM ................................................................................... 5-65.5.12 EXCITER - INTERPHASE PDM DRIVE ALARM........................................................... 5-75.5.13 EXCITER - MODULATOR PROTECTION ALARM ........................................................ 5-85.5.14 EXCITER - EXTERNAL PDM INHIBIT ALARM.............................................................. 5-95.5.15 EXCITER - STANDBY ALARM................................................................................... 5-95.5.16 RF POWER CUTBACK ALARM ................................................................................ 5-95.5.17 RF POWER SHUTBACK ALARM ............................................................................ 5-105.5.18 OUTPUT NETWORKS - RF CURRENT ALARM ........................................................ 5-105.5.19 OUTPUT NETWORKS - VSWR ALARM ................................................................... 5-105.5.20 OUTPUT NETWORKS - TEMPERATURE................................................................. 5-115.5.21 RF DRIVE TUNING PROCEDURE ........................................................................... 5-115.5.21.1 RF Drive Series Tuning...................................................................................... 5-115.5.21.2 RF Power Module Tuning .................................................................................. 5-125.5.21.3 RF Drive Level .................................................................................................. 5-125.6 REPLACEMENT OF RF POWER MODULE.............................................................. 5-135.6.1 RF POWER MODULE REMOVAL........................................................................... 5-135.6.2 RF POWER MODULE INSTALLATION..................................................................... 5-135.7 PWB REPLACEMENT/ADJUSTMENT ..................................................................... 5-145.7.1 SYSTEM CONTROL PWB REPLACEMENT............................................................. 5-145.7.2 DISTRIBUTION PWB REPLACEMENT/ADJUSTMENT............................................... 5-155.7.3 EXCITER INTERFACE PWB REPLACEMENT .......................................................... 5-155.7.4 DC POWER SUPPLY PWB REPLACEMENT........................................................... 5-155.7.5 RF DRIVE PWB REPLACEMENT............................................................................ 5-165.7.6 INTERPHASE PDM DRIVER PWB REPLACEMENT................................................. 5-165.7.7 POWER SUPPLY MONITOR PWB REPLACEMENT ................................................ 5-16

6 THEORY OF OPERATION6.1 GENERAL ............................................................................................................... 6-16.2 SYSTEM OVERVIEW ............................................................................................... 6-16.3 EXCITER STAGE..................................................................................................... 6-16.3.1 EXCITER INTERFACE PWB ..................................................................................... 6-16.3.1.1 Exciter Selection................................................................................................ 6-16.3.1.2 Audio Source..................................................................................................... 6-26.3.1.3 PDM Frequency Monitor.................................................................................... 6-26.3.1.4 IPM Correction ................................................................................................... 6-26.3.1.5 PDM Monitor...................................................................................................... 6-26.3.1.6 Low Voltage Supply Detector............................................................................... 6-36.3.2 RF DRIVE SOURCE................................................................................................. 6-36.3.2.1 RF Drive PWB.................................................................................................... 6-36.3.2.2 Frequency Synthesizer PWB .............................................................................. 6-36.3.2.3 C-QUAM1 AM Stereo Exciter PWB ...................................................................... 6-36.3.3 INTERPHASE PDM DRIVE PWB .............................................................................. 6-36.3.4 DC POWER SUPPLY PWBS.................................................................................... 6-3




6 THEORY OF OPERATION (Continued)6.4 RF DRIVE STAGE.................................................................................................... 6-46.4.1 REGULATED POWER SUPPLIES............................................................................. 6-36.4.2 RF DRIVE AMPLIFIER.............................................................................................. 6-36.4.3 RF DRIVE TUNING................................................................................................... 6-46.4.4 RF DRIVE TUNING PWB .......................................................................................... 6-46.5 RF POWER STAGE................................................................................................. 6-56.5.1 DISTRIBUTION PWB................................................................................................ 6-56.5.1.1 Fan Control........................................................................................................ 6-56.5.1.2 High Temperature Detector.................................................................................. 6-56.5.1.3 Stress Current Detector ...................................................................................... 6-56.5.1.4 Fan Current Limiters ........................................................................................... 6-66.5.1.5 Power Module Interlock....................................................................................... 6-66.5.2 RF POWER MODULE .............................................................................................. 6-66.5.3 RF COMBINER/OUTPUT FILTER............................................................................... 6-66.5.3.1 8-Input Combiner Filter ....................................................................................... 6-66.5.3.2 RF Output Filter ................................................................................................. 6-66.5.3.3 RF Current Probe PWB....................................................................................... 6-66.5.3.4 Forward/Reflected Power Probe ........................................................................... 6-66.5.3.5 Static Drain Assembly ........................................................................................ 6-66.5.3.6 Surge Arrestor Assembly .................................................................................... 6-76.5.3.7 Capacitive Divider Assembly................................................................................ 6-76.5.3.8 RF Current Probe Assembly................................................................................ 6-76.6 CONTROL/MONITOR FUNCTION ............................................................................. 6-76.6.1 SYSTEM CONTROL PWB (A1A3) ............................................................................. 6-76.6.2 RF POWER METER................................................................................................. 6-76.6.3 DC VOLTS METER .................................................................................................. 6-76.6.4 REMOTE CONTROL CIRCUITS ................................................................................. 6-76.6.5 RF ON/OFF CONTROL............................................................................................. 6-86.6.6 PRESET POWER LEVEL SELECT ........................................................................... 6-86.6.7 EXCITER A/B SELECT ............................................................................................. 6-86.6.8 RF POWER TRIM .................................................................................................... 6-86.6.9 SYSTEM RESET ..................................................................................................... 6-86.6.10 PWM INHIBIT CONTROL .......................................................................................... 6-86.6.11 ALARM RECALL...................................................................................................... 6-86.6.12 CUTBACK RESET.................................................................................................... 6-86.6.13 RF PERFORMANCE MONITORING........................................................................... 6-86.6.13.1 Forward Power Level........................................................................................... 6-96.6.13.2 Reflected Power Level......................................................................................... 6-96.6.13.3 RF Monitor Sample............................................................................................. 6-96.6.14 REMOTE ALARM INDICATIONS................................................................................ 6-96.6.14.1 RF Stress Current Alarm..................................................................................... 6-96.6.14.2 AC Fail Alarm .................................................................................................... 6-96.6.14.3 Battery Alarm..................................................................................................... 6-96.6.14.4 VSWR Shutback Alarm ...................................................................................... 6-96.6.14.5 Cutback Alarm ................................................................................................... 6-96.6.14.6 Internal interlock Alarm ..................................................................................... 6-106.6.14.7 External Interlock Alarm.................................................................................... 6-10




6 THEORY OF OPERATION (Continued)6.6.14.8 Filter Temperature Alarm................................................................................... 6-106.6.14.9 Power Supply Temperature Alarm ...................................................................... 6-106.6.14.10 Power Module Alarm......................................................................................... 6-106.6.14.11 Power Supply Alarm ......................................................................................... 6-106.6.14.12 Modulation Protection Alarm.............................................................................. 6-106.6.14.13 PDM Inhibit Alarm ............................................................................................ 6-106.6.14.14 Standby Alarm ................................................................................................. 6-106.6.15 REMOTE STATUS INDICATIONS ............................................................................ 6-106.6.15.1 Remote Status ................................................................................................. 6-106.6.15.2 RF On Status................................................................................................... 6-116.6.15.3 Exciter B Status............................................................................................... 6-116.6.15.4 Power Level Status ........................................................................................... 6-116.7 AC/DC POWER SUPPLY ....................................................................................... 6-116.7.1 MAIN POWER TRANSFORMER ............................................................................. 6-116.7.2 B+ POWER SUPPLY/DISTRIBUTION ...................................................................... 6-116.7.2.1 3 Rectifier ...................................................................................................... 6-126.7.2.2 Power Supply Monitor PWB .............................................................................. 6-126.7.3 DC POWER SUPPLY PWB.................................................................................... 6-126.7.3.1 Power Supply Temp Monitor.............................................................................. 6-126.7.3.2 B+ Monitor....................................................................................................... 6-126.7.3.3 Relay Controls ................................................................................................. 6-126.7.3.4 Low Voltage Supply.......................................................................................... 6-126.7.4 DC POWER SUPPLY MONITOR PWB .................................................................... 6-136.7.4.1 AC Fail Detector............................................................................................... 6-13

7 COMPONENT LEVEL TROUBLE SHOOTING7.1 TROUBLE SHOOTING REFERENCE DATA ............................................................... 7-17.2 AC/DC POWER SUPPLY ......................................................................................... 7-17.3 EXCITER STAGE..................................................................................................... 7-17.3.1 EXCITER INTERFACE PWB...................................................................................... 7-17.3.2 RF DRIVE PWB....................................................................................................... 7-17.3.3 DC POWER SUPPLY PWB...................................................................................... 7-17.3.4 INTERPHASE PDM DRIVER PWB ............................................................................ 7-17.3.5 FREQUENCY SYNTHESIZER PWB .......................................................................... 7-17.3.6 C-QUAM STEREO EXCITER PWB ............................................................................ 7-17.4 RF DRIVE STAGE.................................................................................................... 7-17.4.1 REGULATED POWER SUPPLY PWB....................................................................... 7-17.4.2 RF DRIVE AMPLIFIER.............................................................................................. 7-17.4.3 RF DRIVE TUNING PWB .......................................................................................... 7-17.5 RF POWER STAGE................................................................................................. 7-17.5.1 DISTRIBUTION PWB................................................................................................ 7-17.5.2 RF POWER MODULE .............................................................................................. 7-27.6 CONTROL/MONITOR FUNCTION ............................................................................. 7-27.6.1 SYSTEM CONTROL PWB ........................................................................................ 7-2




8 PARTS LIST8.1 INTRODUCTION ...................................................................................................... 8-18.2 FAMILY TREE ......................................................................................................... 8-18.3 MANUFACTURER'S INDEX ...................................................................................... 8-18.4 HOW TO LOCATE INFORMATION FOR A SPECIFIC PART....................................... 8-18.4.1 WHEN NAUTEL CONFIGURATION CONTROL NUMBER IS KNOWN........................... 8-18.4.2 WHEN REF DES IS KNOWN.................................................................................... 8-18.5 REFERENCE DESIGNATION INDEXES ..................................................................... 8-18.6 COLUMN CONTENT EXPLANATION ........................................................................ 8-18.6.1 USE CODE COLUMN............................................................................................... 8-18.6.2 REF DES COLUMN.................................................................................................. 8-28.6.3 NAME OF PART AND DESCRIPTION COLUMN......................................................... 8-28.6.4 NAUTEL'S PART NO. COLUMN ................................................................................ 8-28.6.5 JAN/MIL/OEM PART NO. COLUMN........................................................................... 8-28.6.6 X/Y GRID COLUMN.................................................................................................. 8-28.6.7 OEM CODE COLUMN.............................................................................................. 8-2

9 ELECTRICAL SCHEMATICS9.1 INTRODUCTION ...................................................................................................... 9-19.2 COMPONENT VALUES............................................................................................ 9-29.3 GRAPHIC SYMBOLS............................................................................................... 9-19.4 LOGIC SYMBOLS ................................................................................................... 9-19.5 REFERENCE DESIGNATIONS .................................................................................. 9-19.6 UNIQUE SYMBOLOGY............................................................................................. 9-19.6.1 TYPE OF INPUTS/OUTPUTS .................................................................................... 9-19.6.2 LOGIC LEVEL/CONVENTION.................................................................................... 9-19.7 IDENTIFICATION OF SCHEMATIC DIAGRAMS......................................................... 9-19.8 STRUCTURE OF SCHEMATICS ............................................................................... 9-19.9 LOCATING A PART/ASSEMBLY IDENTIFIED ON A SCHEMATIC .............................. 9-29.10 LOCATING THE SCHEMATIC DIAGRAM(S) FOR A FUNCTIONAL BLOCK ................. 9-29.10.1 WHEN FIGURE NUMBER IDENTIFIED ...................................................................... 9-29.10.2 WHEN REFERENCE DESIGNATION ASSIGNED TO BLOCK ...................................... 9-29.10.3 TITLE OF BLOCK..................................................................................................... 9-2

10 MECHANICAL DRAWINGS10.1 INTRODUCTION .................................................................................................... 10-110.2 CONTENT OF MECHANICAL DRAWINGS............................................................... 10-110.3 LOCATING ASSEMBLY DETAIL DRAWINGS.......................................................... 10-1



LIST OF ILLUSTRATIONS

Number Title Page

2-1 Single Ended Input Selected.................................................................................................. 2-52-2 Differential Input Selected...................................................................................................... 2-62-3 Ground Stud Assembly Detail.............................................................................................. 2-142-4 External Input/Output Interface............................................................................................. 2-202-5 Balanced Drive c Input Waveform........................................................................................ 2-292-6 Balanced RF Amplifier Output.............................................................................................. 2-302-7 2PDM Frequency Waveform............................................................................................... 2-302-8 RF Output with Positive Peak Limiting.................................................................................. 2-354-1 Latching Alarms ................................................................................................................... 4-64-2 Non-Latching Alarms (RF Inhibiting) ....................................................................................... 4-64-3 Non-Latching Alarms (No RF Inhibit)....................................................................................... 4-65-1 RF Drive Amplifier Output Waveform....................................................................................... 5-65-2 c Output Waveform ............................................................................................................. 5-65-3 RF Drive Waveform............................................................................................................... 5-75-4 Interphase PDM Waveform .................................................................................................... 5-75-5 Interphase PDM Waveform .................................................................................................... 5-85-6 pdm Waveform.................................................................................................................... 5-85-7 Chopper Control Waveform .................................................................................................... 5-97-1 c Unbalanced Drive ............................................................................................................. 7-47-2 2PDM Unbalanced Drive ......................................................................................................... 7-47-3 Carrier Frequency c............................................................................................................. 7-47-4 Mod Level Detector Input ....................................................................................................... 7-67-5 Mod Level Detector Output .................................................................................................... 7-67-6 Audio with Positive Peak Limiting........................................................................................... 7-77-7 Carrier Level Control Input...................................................................................................... 7-77-8 Carrier Level Control Output ................................................................................................... 7-77-9 Linear Integrator Output......................................................................................................... 7-77-10 Interphase Generator Input - PDM 1 ....................................................................................... 7-87-11 Interphase Generator Input - PDM 2 ....................................................................................... 7-87-12 PDM1 Output ....................................................................................................................... 7-87-13 PDM2 Output ....................................................................................................................... 7-87-14 PDM Output .......................................................................................................................... 7-97-15 RF Amplifier Output ............................................................................................................ 7-117-16 RF Amplifier Input ............................................................................................................... 7-117-17 Tuned RF Drive................................................................................................................... 7-127-18 PDM Carrier Reference ....................................................................................................... 7-147-19 Watchdog Timer Output ...................................................................................................... 7-148-1 Family Tree - XL12 12kW AM Broadcast Transmitter .............................................................. 8-6



LIST OF ILLUSTRATIONS (Continued)

Number Title Page

SD-1 Electrical Schematic - XL12 - 12 000 Watt AM Broadcast Transmitter.................................... SD-1SD-2 Electrical Schematic - Exciter Stage................................................................................... SD-2SD-3 Electrical Schematic - RF Drive Stage................................................................................. SD-3SD-4 Electrical Schematic - RF Power Stage............................................................................... SD-4SD-5 Electrical Schematic - Control/Monitor Functions ................................................................. SD-5SD-6 Electrical Schematic - AC/DC Power Stage ......................................................................... SD-6SD-7 Electrical Schematic - Remote Interface PWB (NAPI25A)..................................................... SD-7SD-8 Electrical Schematic - Exciter Interface PWB (NAPI22E)...................................................... SD-8SD-9 Electrical Schematic - RF Drive Tuning PWB (NAPI59) ......................................................... SD-9SD-10 Electrical Schematic - Distribution PWB (NAPI50B) ............................................................SD-10SD-11 Electrical Schematic - DC Power Supply PWB (NAPS16C)..................................................SD-11SD-12 Electrical Schematic - DC Power Supply Monitor PWB (NAPI48B) .......................................SD-12SD-13 Electrical Schematic - RF Combiner/Output Filter (NAF101A/NAF102)..................................SD-13MD-1 Assembly Detail - XL12 12 000 Watt AM Broadcast Transmitter (Top and Front).....................MD-1MD-2 Assembly Detail - XL12 12 000 Watt AM Broadcast Transmitter (Rear and Sides)...................MD-2MD-3 Assembly Detail - NAC101 Control/Monitor Panel.................................................................MD-3MD-4 Assembly Detail - NAPD07/01 and NAPD07/02 Meter/Switch Monitor PWBs .........................MD-4MD-5 Assembly Detail - NAPI25A Remote Interface PWB .............................................................MD-5MD-6 Assembly Detail - NAEE37A Exciter Panel..........................................................................MD-6MD-7 Assembly Detail - NAPI22E Exciter Interface PWB ..............................................................MD-7MD-8 Assembly Detail - NAE83 RF Drive Panel ............................................................................MD-8MD-9 Assembly Detail - NAAA02 RF Drive Amplifier......................................................................MD-9MD-10A Assembly Detail - NAPI60/01 and NAPI60/02 RF Drive Tuning PWB ..................................MD-10AMD-10B Assembly Detail - NAPI60/03 and NAPI60/04 RF Drive Tuning PWB ..................................MD-10BMD-11 Assembly Detail - NAPS10B Regulated Power Supply PWB............................................... MD-11MD-12 Assembly Detail - NAPI50B Distribution PWB.................................................................... MD-12MD-13 Assembly Detail - Fan Tray (P/N 183-8350) ....................................................................... MD-13MD-14 Assembly Detail - NAF102 RF Output Filter (Top View)....................................................... MD-14MD-15 Assembly Detail - NAF102 RF Output Filter (Rear View) ..................................................... MD-15MD-16 Assembly Detail - NAFP90 Forward/Reflected Power Probe ................................................ MD-16MD-17 Assembly Detail - NAX161 Static Drain Choke................................................................... MD-17MD-18 Assembly Detail - NAF101A 8-Input RF Combiner/Filter (Rear View) .................................... MD-18MD-19 Assembly Detail - NAF101A 8-Input RF Combiner/Filter (Side View) .................................... MD-19MD-20 Assembly Detail - NAPP02 RF Current Probe PWB ........................................................... MD-20MD-21 Assembly Detail - Capacative Divider Assembly (176-8253)................................................. MD-21MD-22 Assembly Detail - NAX202/04 Surge Arrestor Assembly (DWA00-555)................................. MD-22MD-23 Assembly Detail - NASR104A AC/DC Power Supply (Top View) .......................................... MD-23MD-24 Assembly Detail - NASR105 & /01 Power Transformer Assembly ........................................ MD-24MD-25 Assembly Detail - 3 Rectifier (UP28) ............................................................................... MD-25MD-26 Assembly Detail - NAPS16C DC Power Supply PWB......................................................... MD-26MD-27 Assembly Detail - NAPI48B DC Power Supply Monitor PWB............................................... MD-27MD-28 Dimensional Information - XL12 12 000 Watt AM Broadcast Transmitter ............................... MD-28MD-29 Assembly/Dimensional Information - NAX165 Circuit Breaker Enclosure ............................... MD-29



LIST OF TABLES

Number Title Page

1-1 Test Equipment .................................................................................................................... 1-21-2 Special Tools ....................................................................................................................... 1-31-3 Glossary of Terms ................................................................................................................ 1-32-1 Primary Winding Taps for A23A1T1 ...................................................................................... 2-212-2 Primary Winding Taps for A23A2T1 ...................................................................................... 2-222-3 Audio Pass Band Selection................................................................................................. 2-232-4 Grouping of Alarm/Status Outputs........................................................................................ 2-242-5 DC Volts Meter Readings .................................................................................................... 2-283-1 Control/Monitor Panel Controls and Indicators ......................................................................... 3-33-2 Exciter Panel Controls and Indicators ................................................................................... 3-193-3 RF Drive Tuning PWB Controls and Indicators ....................................................................... 3-223-4 RF Drive Stage Controls and Indicators................................................................................. 3-233-5 AC/DC Power Supply Controls and Indicators ....................................................................... 3-243-6 8-Input RF Combiner/Filter Controls and Indicators ................................................................ 3-273-7 Forward/Reflected Power Probe Controls and Indicators ......................................................... 3-287-1 Test Voltages for Exciter Interface PWB (A2A1)...................................................................... 7-37-2 Test Voltages/Waveforms for RF Drive PWB (A2A1A1/A2A1A4) ............................................... 7-47-3 Test Voltages for DC Power Supply PWB (A2A1A2/A2A1A3)................................................... 7-57-4 Test Voltages/Waveforms for Interphase PDM Driver PWB (A2A1A5/A2A1A6) ........................... 7-67-5 Test Voltages for Regulated Power Supply PWB (A11A4/A11A5) ........................................... 7-107-6 Test Voltages/Waveforms for RF Drive Amplifier (A11A1/A11A3)............................................. 7-117-7 Test Voltages/Waveforms for RF Drive Tuning PWB (A11A2).................................................. 7-127-8 Test Voltages/Waveforms for Distribution PWB (A16) ............................................................ 7-137-9 Test Voltages/Waveforms for System Control PWB (A1A3).................................................... 7-148-1 Manufacturer's Code to Address Index.................................................................................... 8-38-2 Reference Designation Index - XL12 12kW AM Broadcast Transmitter....................................... 8-98-3 Reference Designation Index - NAC101 Control/Monitor Panel ................................................ 8-138-4 Reference Designation Index - NARI25 Remote Interface PWB ............................................... 8-158-5 Reference Designation Index - NAPI22 Exciter Interface PWB ................................................ 8-218-6 Reference Designation Index - NAE83 RF Drive Panel........................................................... 8-258-7 Reference Designation Index - NAAA02 RF Drive Amplifier ..................................................... 8-268-8 Reference Designation Index - NAPI60 RF Drive Tuning PWB................................................. 8-278-9 Reference Designation Index - NAPS10 Regulated DC Power Supply PWB ............................. 8-308-10 Reference Designation Index - NAPI50 Distribution PWB ....................................................... 8-318-11 Reference Designation Index - NAF102 RF Output Filter ........................................................ 8-348-12 Reference Designation Index - NAFP90 Forward/Reflected Power Probe.................................. 8-368-13 Reference Designation Index - NAF101 8-Input RF Combiner/Filter.......................................... 8-388-14 Reference Designation Index - NAPP02 RF Current Probe PWB............................................. 8-418-15 Reference Designation Index - NAX202/04 Surge Arrestor Assembly....................................... 8-428-16 Reference Designation Index - NASR108 AC/DC Power Supply .............................................. 8-438-17 Reference Designation Index - NAPS16 DC Power Supply PWB............................................. 8-449-1 List of Electrical Schematics ................................................................................................. 9-310-1 List of Mechanical Drawings ................................................................................................ 10-2


Page 1-101 January 2002

SECTION 1GENERAL INFORMATION

INTRODUCTION1.1 The XL12 AM broadcast transmitter systemis a totally solid state, medium wave, amplitudemodulated, broadcast transmitter system. It may beoperated as a monaural or an AM stereo transmitter. The exciter stage contains duplicated RF drivePWBs, interphase PDM driver PWBs, exciter DCpower supplies, RF drive buffer amplifiers and RFdrive DC power supplies, which are connected as anactive and a reserve exciter. The transmittercontains eight RF power modules and a high currentAC/DC power supply. It operates at one presetfrequency, in the AM broadcast frequency band, intoa nominal 50 ohm, unbalanced, transmission line. Typically the transmitter will operate continuously at140 percent positive peak programme modulation at12 000 watts. Remote control interfacing is astandard feature.

FACTORY SUPPORT1.2 Nautel provides after sales factory support. Technical assistance is available on a 24 hour, sevendays a week basis. A factory service facility forrepair of modules/assemblies is also available. Referto the Factory Support portion of the Warrantypages at the front of this manual for additionalinformation.

PURPOSE AND SCOPE OF MANUAL1.3 This Technical Instruction Manualprovides the information required to install, operateand maintain the transmitter. Detailed informationfor modules/assemblies, which are normally removedfrom the transmitter for servicing, is not included. Service Instruction Manual appendices provideinformation for troubleshooting and maintainingbench-repairable modules/assemblies used in thetransmitter.

1.3.1 FAMILY TREE: The family tree for thistransmitter is depicted in figure 8-1. It identifies themajor assemblies and shows their hierarchicalassembly relationship. It also identifies the referencedesignation assigned to each assembly and wheretheir parts list is located.

PURPOSE OF EQUIPMENT1.4 The XL12 - 12 000 watt AM broadcasttransmitter system is intended to be used inconventional AM broadcasting stations. Remotecontrol facilities are incorporated to allow unattendedoperation at a transmitter site, remotely located fromstation studios.

MECHANICAL DESCRIPTION1.5 The transmitter's modules/assemblies arehoused in a single rack. Figures MD-1 thru MD-29provide assembly detail and identify the location of allelectrical parts. The mechanical drawings arepresented in order of the reference designationassigned to their assemblies. Refer to the list ofmechanical drawings in table 10-1 to locate aspecific illustration.

NOTESome modules/assemblies may have an alphasuffix on their designator (A, B, C, etc.). Thesuffix is assigned alphabetically and indicates themodule contains minor component or circuitvariations. Since a change that merits an alphasuffix change will normally enhance theoperation of the affected module/assembly orcompliment the operation of an external circuit, itis not recommended that later versions beinterchanged with earlier versions. All earlierversions can be replaced by later versions.

TECHNICAL SUMMARY1.6 A Technical Summary is provided at in thespecifications brochure at the front of this manual.

SPECIAL TOOLS AND TEST EQUIPMENT1.7 Table 1-1 - Test Equipment, lists the testequipment that is required to operate and maintainthe transmitter. Table 1-2 lists the special toolsrequired.

GLOSSARY OF TERMS:1.8 Table 1-3 - Glossary of Terms, provides alist of all unique terms, abbreviations and acronymsused in this publication.



Table 1-1 Test Equipment

NOMENCLATURE PART, MODEL, OR TYPE NUMBER APPLICATION(EQUIVALENTS MAY BE USED)

Dummy Load 50 ohms, 20,000 Watts (minimum) VSWR1.1

'off-air' testing

Digital Multimeter 3 1/2 digit, AC and DC volts (10M ohmsinput), ohms and amps, 0.5% accuracy,Beckman 3010

testing and maintenance

Frequency Counter 5ppm up to 10MHz Fluke Model 1900A measure carrier frequency

Oscilloscope Tektronix Model T922 testing and maintenance

Modulation Monitor 50-ohm input impedance, -100% to +125%mod depth TFT Model 375

to set up audio level

Audio Signal Generator 10Hz to 10MHz, 600 ohms, 0 to +15dBmHewlett Packard model 651B

simulates modulating audio inputduring testing and maintenance

Distortion Analyzer 20Hz to 20kHz Marconi Model TF231 measures audio distortion duringtesting and maintenance

RF Signal/FunctionGenerator

540kHz to 1700kHz Tektronix ModelCFG253

testing and maintenance



Table 1-2 Special Tools

NOMENCLATURE PART, MODEL, OR TYPE NUMBER APPLICATION(EQUIVALENTS MAY BE USED)

Torque Wrench Capable of torquing to four inch-pounds(0.532 Newton-Meters)

Installing power MOSFETs

HEX Wrench 5/32" or 4 mm Terminating wires on ACbreaker

Screwdriver HAZ79 (located in ancillary parts kit) Tuning RF drive

Table 1-3 Glossary of Terms

TERM DESCRIPTION

Integral Modular Reserve (IMR) Identical modules operating in an overall system design suchthat failure of individual modules results in a power reductiononly and not a complete system shutdown.

Modular Redundancy Identical modules operating in an overall system design suchthat failure of one module does not affect the output of thesystem.

PDM Pulse duration modulation.

PWB Printed wiring (circuit) board.

PWM Pulse width modulation.



SECTION 2 INSTALLATION

PLANNING AND SITE PREPARATION2.1 Transmitter sites for Nautel's XL12 - 12 000watt AM broadcast transmitters should be preparedto receive the transmitter prior to its delivery and/orinstallation. The following must be taken intoconsideration when preparing new sites. Theyshould be used as the evaluating criteria at existingsites. It is recommended that all requirements beincorporated to ensure optimum reliability andperformance is obtained.

NOTEFrequent reference is made to terminal boards onthe remote interface PWB, which is located on therear of the control/monitor panel. Refer to figureMD-3 as an aid in locating the remote interfacePWB and then, if necessary, to figure MD-5 forits assembly detail.

2.1.1 TRANSMITTER ROOMREQUIREMENTS: The following transmitterroom requirements must be addressed when thetransmitter site is being finalized.

2.1.1.1 Transmitter Dimensions : Refer to figureMD-28 for transmitter dimensions. Thesedimensions identify floor space requirements and willassist in determining cable lengths and routing.

2.1.1.2 Transmitter Clearances: A clearance ofat least 1.3 metres (4.0 feet) should be maintained atthe front and rear of the transmitter.

2.1.1.3 Air Flushing: Four fan trays pull coolingair through the cabinet's rear door, circulate itthrough the RF power modules and exhaust it as alow velocity stream through openings in the top ofthe cabinet.

2.1.1.4 Cooling: The transmitter room's ambientair temperature must not exceed 50C. A room airexchange rate of 1000 CFM should achieve anacceptable intake/exhaust temperature rise. For airconditioning requirements, it can be assumed 16% ofthe power being consumed, from the AC powersource, is converted to waste heat.

NOTEA simple method of determining the number ofBritish thermal units (BTUs) per hour beinggenerated as waste heat is to multiply the averageRF output power (in watts) by 0.1905 (waste heatfactor) and then multiply the product by 3.413(watts/BTU factor).

As an example: At 12 000 watts carrier powerwith 50% modulation, the average power outputis 13 500 watts. This represents an averagelong-term output power based on typicalprocessed program material. At 84% overallefficiency, the waste heat generated (13 500 x0.1905) is 2570 watts which equals (2570 x3.413) 8776 BTU's per hour.

Since 12 000 BTU's per hour requires one ton ofair conditioning in a closed system, if the examplewas in a closed system, it would require a 0.75ton air conditioner to remove the waste heat.

2.1.1.5 Heating: The transmitter room mustcontain a heating system that will ensure its ambientair temperature does not go below 0C.

2.1.1.6 Work Area: It is recommended that asuitable work area with an adequate tab

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