Transcript
Field Upgrade Instructions Current Meter Control PWB
1
INTRODUCTION
1.1 REASON FOR MODIFICATION: It has been noted that some transmitters experience a higher than normal failure of the current meter control FET. This modification adds an opto-isolator to prevent voltage spikes from damaging the control FET. 1.2 EQUIPMENT AFFECTED: This modification affects XL12 series transmitters up to and including serial number 196 (B and H versions) and all XL30 and XL60 transmitters. 1.3 RESPONSIBILITY FOR IMPLEMENTATION OF MODIFICATION: Implementation of this modification is to be carried out by suitably qualified transmitter maintenance personnel. 1.4 SCHEDULING: This modification may be implemented at the convenience of station maintenance personnel. 1.5 MANPOWER REQUIREMENTS: It is estimated that implementation of this modification will require one (1) man-hour to complete. Note that it is necessary for the transmitter to be placed in an off-air status for the duration of this procedure. 1.6 SPECIAL TOOLS/TEST EQUIPMENT: No test equipment should be required to complete this modification. Tools consist of standard electronic hand tools and a soldering iron. Static precautions should be observed when working on any solid state equipment. 1.7 MATERIALS REQUIRED: The parts listed in Table 2, part of 183-2012 Modification Kit, are required to do the modification. A second kit will be required if there is a spare System Control PWB. 1.8 IDENTIFICATION OF MODIFIED ASSEMBLIES/PARTS: The marking of modified assemblies will inform future maintainers of the current configuration. The following assemblies must be marked to show that they have been modified. This should be written, using indelible ink, on the modified assembly near the System Control PWB serial number label. NAPC103ALL marked to indicate FM01005 incorporated. 1.9 PUBLICATIONS AFFECTED: The parts list and schematic for the affected System Control PWB should be changed using pen and ink to indicate the following. A new schematic/parts list is included with this Modification Kit documentation for the piggy-back PWB. REF DES Q10 --
2
NAME OF PART AND DESCRIPTION
NAUTEL’s PART NO.
Not Used Current Meter Control PWB
184-2045
JAN/MIL/OEM PART NO.
OEM CODE
184-2045
37338
MODIFICATION INSTRUCTIONS
TRANSMITTER PREPARATION: The transmitter MUST be shut down for this upgrade. Record the preset power levels and DC Current Meter levels for power levels 1 through 6. Press LOCAL, RF OFF, and switch OFF the AC to the transmitter.
FM01005 (Page 1 of 6) 19 March 2001
Field Upgrade Instructions Current Meter Control PWB 2.2 Open the Control Panel door of the transmitter and remove the three AA size batteries from the System Control PWB (A1A3). The power levels will have to be reset once the modifications are finished. 2.2.1 Disconnect the five ribbon cables that connect to the System Control PWB. Three along the bottom edge and two along the top edge. Also disconnect the three ‘D’ plugs that connect to J6, J7 and J8 along the PWB’s right hand edge. 2.2.2. Remove and retain the eleven sets of cross-head (Philips) hardware that secure the System Control PWB to the chassis, noting that there is one set of hardware located near the center of the PWB. 2.2.3 Carefully remove the System Control PWB by pulling it away from the back of the door until the LEDs and switches are clear of their openings in the panel. 2.2.4 Remove the System Control PWB from the transmitter and take it to a suitably equipped workstation for the modification. 2.3 Remove and discard FET Q10, resistor R128, and capacitor C46 from the System Control PWB. Refer to the mechanical diagram in the System Control PWB handbook for component locations. The components are located in the following grid locations: Q10 in P/1, R128 in M/5, and C46 in M/2. 2.3.1 Install HAA45 micro pins, from the Modification Kit, in the pads at R128 RHS (right hand side) and C46 RHS (negative). 2.3.2 Install a resistor RAB31, 3320 Ohm resistor from the Modification Kit, in the R128 location, noting that the resistor’s RHS will be connected to the micro pin in the R128 RHS pad. 2.3.3 Install a capacitor CCP36, 10 uF at 35 Volts from the Modification Kit, in the C46 location, noting that the capacitor’s negative (-) lead will be connected to the pin in the C46 RHS pad and the capacitor’s positive (+) lead will be in the C46 LHS pad. 2.3.4 Obtain the black wire, WAP21, and the white wire, WAP30 from the Modification Kit. Cut the WAP30 (white wire) into four 20 cm (8 inch) long pieces. There should be some waste. 2.3.5 Connect the wires between the System Control PWB and the Current Meter Control PWB (Nautel part number 183-2045, from the Modification Kit) as listed in table 1. Also see figure 1. Refer to the schematic and mechanical diagrams of the Current Meter Control PWB for the wiring terminations (A thru D) listed in table 1. Table 1 – Interconnecting Wiring Between NAPC103 and 183-2045 PWBs Source 183-2045 – A (+24V) 183-2045 – B (Ground) 183-2045 – C (# Current Meter On) 183-2045 – D (Current +) 183-2045 – E (Current Meter +)
Destination NAPC103 R128 RHS NAPC103 C46 RHS NAPC103 Q1, Gate NAPC103 Q1, Source NAPC103 Q1, Drain
FM01005 (Page 2 of 6) 19 March 2001
Wire WAP30, # 22, White WAP21, # 22, Black WAP30, # 22, White WAP30, # 22, White WAP30, # 22, White
Field Upgrade Instructions Current Meter Control PWB
Source (to D)
Drain (to E) Gate (to C)
Figure 1 – System Control to Current Meter Control PWB Wiring 2.4
System Control PWB and Current Meter Control PWB installation.
2.4.1 Inspect the new wiring prior to installing the PWBs. Ensure there are no solder bridges and that none of the wires soldered into the Q10 pads are long enough to short against the chassis once the System Control PWB is installed in the transmitter. 2.4.2 Carefully align the LEDs and the switches with their respective openings and guide the System Control PWB into place. 2.4.3 Install four sets of hardware, that were removed in step 2.2.2, along the top edge of the System Control PWB, but do not tighten any of the screws. 2..4.4 Obtain two each HAJ25 (spacer) and HMSP12 (screw) from the Modification Kit. Mount the Current meter Control PWB on the two lower right System Control PWB mounting holes using the obtained hardware. Use the flat and split washers from two of the sets of hardware removed in step 2.2.2. The HAJ25 spacer is installed between the System Control PWB and the Current Meter Control PWB. Do not tighten the hardware. 2.4.5 Install five more sets of the System Control PWB mounting hardware that was removed in step 2.2.2 into the remaining positions. Once all of the mounting hardware is installed it can all be tightened.
2.5 Using the HT29 tyraps, from the Modification Kit, dress the new wires connecting the Current Meter Control PWB to the System Control PWB as neatly as possible. See Figure 2.
FM01005 (Page 3 of 6) 19 March 2001
Field Upgrade Instructions Current Meter Control PWB
Figure 2 – Current Meter Control PWB Mounted And Dressed 2.5.1 Reconnect the three ‘D’ connectors to the System Control PWB that were removed in step 2.2.1. The ‘D’ connectors are configured so that they cannot be connected incorrectly. Also reconnect the five ribbon cable connectors taking care to align all of the pins.
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TESTING: Testing is required to ensure the Current Meter is operational.
3.1
Turn ON the AC to the transmitter.
3.1.1 Press RF OFF, EXCITER A, SYSTEM RESET and METER ON/OFF. The Volt Meter should be displaying the selected voltage and only the BATTERY alarm LED should be red. 3.1.2 Reinstall the three AA size batteries in the battery holder located on the System Control PWB. Observe the correct polarity, as indicated on the battery holder, when installing the batteries. The BATTERY alarm LED should now be green. 3.2 Press RF ON and reset the preset power levels (1 through 6) to their normal operating levels that were recorded in step 2.1. Check the DC current, indicated by the DC Current Meter, and compare the displayed current to the level that was recorded in step 2.1. The displayed and recorded levels should be close. 3.3
Ensure the METER ON/OFF switch functions properly by cycling the meters off and on.
3.4
The transmitter can now be returned to on air status.
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Field Upgrade Instructions Current Meter Control PWB
Table 2 – Parts Included With FM01005 (183-2012) Modification Kit QTY
DESCRIPTION
PART NO.
2 1 1 0.5’ 3’ 10 1 2 2
Pin, Micro, 0.025 Diameter, FT Resistor, MF, 3320 Ohms, 1 %, ¼ W Capacitor, Elect, 10 uF, 35 Volt, 10 % Wire, 22 AWG, Stranded, Black Wire, 22 AWG, Stranded, White Tyrap, 0.091 Wide x 3.62 Long Current Meter Control PWB Spacer, 0.14 ID, 0.312 Long, ¼ Diameter Screw, Pan, Philips, M3 x 0.5 x 16 Long
HAA45 RAB31 CCP36 WAP21 WAP30 HT29 183-2045 HAJ25 HMSP12
NOTE The attached schematic is meant to be used as a visual aid only to aid in the proper mark-up of the NAPC103 (Sheet 5 of 5) schematic contained in the System Control PWB manual. This schematic may not be exactly the same as the sheet 5 of 5 schematic contained in your NAPC103 manual. It is not intended as a replacement page for the NAPC103 manual.
FM01005 (Page 5 of 6) 19 March 2001
Field Upgrade Instructions Current Meter Control PWB
Ref Des List – Current Meter Control PWB (183-2045) REF DES
NAME OF PART AND DESCRIPTION
NAUTEL’S PART NO.
C1 K1 Q1 R1 R2 XK1
Current Meter Control PWB Capacitor, Ceramic, 0.1 uF 10 % 100 V Relay, Photovoltaic, MOSFET, SP, NO, 60V, 1.5A Transistor, FET, N Channel, Plastic Resistor, Metal Film, 3300 Ohms, 2 %, ½ W Resistor, Metal Film, 4750 Ohms, 1 %, ¼ W Socket, Integrated Circuit, 8 Pin
183-2045 CCG07 KA44 QR52 RAP11 RAB33 UC01
JAN/MIL/OEM PART NO. 183-2045 CKR06BX104KRV PVDZ172N IRF540N RL20S332G MF55D4751F 2-641260-1
R1
NAUTEL ASSY 183-2045 CURRENT METER CONTROL
C1
E R2
A
Q1
B
G D S
C
1
D
USE CODE
X/Y GRID / B/1 D/1 C/1 B1 D/1 K/1
D
K1
M1830292 V1
A
C
B
D
E
Assembly Detail – Current Meter Control PWB (183-2045)
+24V GND
A B
E C1 R1 0.1 3300 0.5W
2
K1 PVDZ172N
R2 4750 3
# CURRENT METER ON + (FROM Q10-G) CURRENT (+) (FROM Q10-S/J6-13)
C
8
5
Q1 IRF540N
D S1830291 V1
Electrical Schematic - Current Meter Control PWB (183-2045) FM01005 (Page 6 of 6) 19 March 2001
CURRENT METER (+) (TO Q10-D/J6-25)
OEM CODE 37338 56289 81483 81483 35005 59124 00779
