APPLICATION NOTICE APPLICATION NOTICE
BULLETIN
FM-519-TLC
Platinum Z2, Z2R, Z3.5, Z5, Z7.5, NO:
EQUIPMENT:
and Z10 transmitters Part No:
DATE: October 2001
UNIT(S) ECO NO:
AFFECTED: PAGES: 3
PURPOSE: Controller Firmware Upgrade to revision AA (or higher)
Note: This firmware enhancement is part of the Harris Xtraware™ Software series of
products. Your transmitter’s current firmware will continue to operate normally without
this optional upgrade.
In the Platinum Z transmitters there are three types of controller circuit boards that contain
firmware IC’s that have been upgraded with enhancements. These boards are the Master
Controller, PA Controller, and Power Supply Controller. Depending on the configuration and
power level, the transmitter may have as many as four PA controllers and two Power Supply
Controllers. All transmitters have one Master controller and one Life Support Board. The Life
Support Board in the controller assembly does not use firmware.
Some features of the new firmware include: an isolation resistor and power amplifier system
test, added fault diagnostics, auto-maximization every 12 hours, fan auto/high speed selection,
an adjustable low power alarm for remote control, and the ability to address two types of Master
Controller U39 EEPROMs. In order to fully document the new firmware features, a current
Technical Manual is included. The original Technical Manual shipped with the transmitter must
be retained for the parts list it contains.
Another change is the removal of the Recall Settings function to restore Factory Defaults. The
new firmware will automatically load default calibration data to a blank EEPROM. The default
data that will be loaded can be found in Section V Replacing the EEPROM U39 of the new
Technical Manual. With this change, there is now the ability to view and edit all of the
transmitters’ calibration factors. Do not mix old and new revisions of firmware.
Upgrade firmware kits for your configuration and power level may be ordered through the
Service Parts department by calling +217-221-7500.
Parts Required:
Kit that includes firmware and new technical manual with new Diagnostic Display Menu Tree.
(See Table 1 to choose proper kit part number.)
Tools Required:
#2 Phillips Screwdriver.
Stepladder.
PLCC extraction tool or equivalent.
Anti-Static wrist strap.
FM-519-TLC
Page 2 of 8
Anti-Static mat or Static Safe Workstation.
Factory test data or complete set of normal transmitter readings.
External line section RF power meter (Bird THRULINE® or equivalent). May be used to verify
power calibration but is not required.
FM-519-TLC
Page 3 of 8
Procedure:
1. Determine the correct firmware kit, refer to Table 1. Use Tables 2, 3, and 4 to order partial
kits for spare boards. Replace all firmware at the same time.
Note:
When choosing a firmware kit, be sure to select a kit for the correct model and AC power
service (single phase or three phase), see Table 1.
Table 1. Controller Firmware Kit:
Model Single Phase Three Phase
Z2 990-2435-126 990-2435-125
Z2R 990-2435-166 990-2435-165
Z3.5 990-2435-168 990-2435-167
Z5 990-2435-124 990-2435-123
Z7.5 990-2435-170 990-2435-169
Z10 990-2435-122 990-2435-121
Note:
A kit contains all firmware needed in the controller except: The Z3.5 and Z5 models may
need an additional set of Power Supply (PS) Controller firmware. Check your unit to see if an
optional second power supply controller is installed in the PSC #2 slot or select
CONFIGURATION/SYSTEM CONFIG/SYSTEM SET/ AND PSC NUMBER (1 or 2) on the Diagnostic
Display. If 2 is displayed, see Table 2 for the part number of the additional set.
Table 2. Power Supply Controller Firmware Part Numbers:
One is required for an optional or spare Power Supply Controller board
Model Single Phase Three Phase
Z3.5 or Z5 922-1272-460 922-1272-452
Note:
Upgrade all spare boards or boards kits using Tables 2, 3, and 4.
Table 3. Master Controller Firmware Part Numbers:
One is required for each spare Master Controller board
Model Part Number
Z2 922-1272-461
Z2R 922-1272-498
Z3.5 922-1272-582
Z5 922-1272-398
Z7.5 922-1272-583
Z10 922-1272-425
Table 4. Power Amplifier (PA) Controller Firmware Part Numbers:
One is required for each spare PA Controller board
Model Part Number
All 922-1272-438
FM-519-TLC
Page 4 of 8
2. Familiarize yourself with all procedures and expected changes in the unit by thoroughly
reading this bulletin and the new technical manual Sections III (Operators Guide) and V
(Maintenance and Alignment).
3. Using a copy of the Transmitter Log Readings table found in Section V of the Technical
Manual, record the transmitters’ readings.
Follow all safety procedures contained in the technical manual.
Turn off all AC power to the entire transmitter.
This transmitter should only be serviced by qualified personnel.
WARNING: Be sure to use an anti-static wrist strap when handling PC boards or IC’s to
prevent damage to the components due to ElectroStatic Discharge (ESD).
4. Set S1-5 on the Master Controller.
Remove the two Phillips screws that hold the controller assembly (top front panel) in the
transmitter. Slide the controller assembly out to the end stops and allow it to rest downward at
the 45-degree service position. Silk Screened along the top, front portion of the controller
assembly is the location ID for each controller board. Locate the Master Controller board to the
far left. Locate the dip switch labeled S1 on the Master Controller. The fifth section of the
switch from the rear, denoted S1-5, when switched to the down (off) position configures the
firmware for the original EEPROM. In the up (on) position, the controller is configured for
the new version of the EEPROM.
On the Master Controller, locate and determine which version of the U39 EEPROM is installed.
Configure the dip switch S1-5 (see Figure 1) on the Master Controller board according to
original or new EEPROM as defined below.
The original EEPROM has vendor markings of 25C04 and came in two styles. The first style
was a DIP (dual inline package), Harris part number 383-0160-000. The second style is a
surface mount device attached onto a small board with DIP leads, Harris part number 992-9767-
500.
The new EEPROM Harris Part Number 392-0066-000 is also DIP and has a similar markings of
X25040P, 25C040 or 25040.
Note:
The key difference is the 04 vs. 040.
Note
In stand alone units, the only other switch that should be up (on) is S1-10.
5. Using a static wrist-strap, attach the ground side of the strap to the bottom of the controller
assembly. Set up a static safe work area within reach of static wrist strap. Using a stepladder
to access the controller assembly, remove the three screws retaining the shipping bracket
across the top.
FM-519-TLC
Page 5 of 8
6. Change the firmware on the Master Controller.
Note:
It may be difficult to remove the Master Controller due to the style of the edge connector.
Use care not to damage any of the surface mount capacitors on the board when
removing it from the controller.
Remove the Master Control Board from the controller assembly. Using a PLCC extraction tool
(a sharp meter lead or ice pick works well by carefully prying one corner slightly up-then
alternating to the other, back and forth until the IC is removed) remove U18 and U28. Replace
them with the two new IC’s labeled U18 and U28, respectively. Orient the IC so that the
beveled edge of the IC faces to the right or towards the edge connector. Refer to Figure 1.
Note:
These notes apply to all firmware IC’s. The “U” designator is printed on the label.
The beveled edge of the IC has a small dimple in the center, indicating pin 1
of the IC. Pin 1 is marked on the printed circuit board. Refer to figure 1 for an
example. Orient the IC as instructed, squarely align the IC and pins in the socket,
then gently press the IC into the socket.
Re-install the circuit board back into the controller assembly. The Master Controller edge
connector on the controllers’ display backplane assembly is a two step connector. When
inserting the board into the connector, you should feel two steps as it enters the connector.
Ensure that the board is fully seated. The gold edge contacts should be barely visible at the
controller connector when it is installed completely. This is the only connector of this type.
S1-5
Figure 1, Master Controller
FM-519-TLC
Page 6 of 8
7. Change the firmware on the Power Supply Controller(s).
The Power Supply Controller boards are located in card positions 4 and 5. As stated earlier, if
you have a Z3.5 or Z5, you may or may not have a Power Supply Controller in card position 4.
Note the cable numbers and position, then disconnect the two ribbon cables (if you have a Z2,
you may have only one cable present) from J1 and J2 on Power Supply Controller #1. Remove
the circuit board from the controller. Using an extraction tool remove U5 and U8. Replace them
with two new IC’s labeled U5 and U8, respectively. Orient the IC so that the beveled edge of
the IC faces to the right or towards the edge connector. Refer to Figure 2. Re-install the circuit
board back into the controller and re-connect the ribbon cables to their respective sockets.
Repeat this step for Power Supply Controller #2 (if installed).
Note:
These boards are addressed to their respective position. It is important to replace the boards in
the same position from which they were removed.
Note:
When Removing U5 be careful to not damage the red jumper plug with the extraction tool.
Figure 2, Power Supply Controller
FM-519-TLC
Page 7 of 8
8. Change the firmware on the PA Controller(s).
The PA Controller Boards are located in card positions 3, 6, 7, and 8. You may have one, two
or four PA Controllers depending on the model of the transmitter. Note the cable numbers and
position, then disconnect the four ribbon cables from J1, J2, J11, and J12 on PA controller
board #1.
Note:
A Z2 will only have 2 cables connected on the back of each
PA Controller if there are two PA controllers installed in it.
Remove the circuit board from the controller. Using the extraction tool remove U23 and U30.
Replace them with two new IC’s labeled U23 and U30. Orient the IC so that the beveled edge
of the IC faces toward the top edge of the board. Refer to Figure 3. Install the circuit board
back into the controller and re-connect the ribbon cables to J1, J2, J11 and J12. Repeat this
procedure for all PA Controller Boards one at a time.
Note: These boards are addressed to their respective position. Replace the boards in the same
position from which they were removed.
Figure 3, PA Controller
FM-519-TLC
Page 8 of 8
9. Double-check all circuit boards and cable connections. Ensure that they are fully seated and
that all cables are in their correct locations. Replace the support bracket. Slide the controller
assembly back into the transmitter.
10. Reapply AC power to the transmitter.
11. There should be a fault LED lit after power is re-applied. This is normal. Verify proper
operation of the Master, PA, and Power Supply Controllers by using the transmitters’ Diagnostic
Display to view the Fault Log. Select Fault and Fault Log. A single POWER_FAIL fault should
be logged. It is possible to have an EEPROM_DEF fault if the old version of firmware had fewer
configuration options than the new firmware, such as Auto Maximize. If there are no
communication or configuration faults, reset faults in the Fault Log by pressing Fault, Fault
Reset and Yes. If there are still active faults in the log, see the Troubleshooting Section VI in the
new technical manual.
12. Utilizing the new Menu Trees, navigate throughout the Diagnostic Display to view the value
stored under HOME, MORE, CONFIGURATION/POWER CAL/CAL VALUES/FORWARD FACTOR.
Record this value in Table 5. Press back to exit the FORWARD FACTOR screen. Repeat this
procedure for the reflected factor, ipa factor, exciter factor, calibrate frequency, and calibrate
apc factor. Store these values with the original test data.
Note:
Single letter versions of Master Controller firmware, prior to revision AA, relied on User
and Factory Default settings for transmitter calibration. Now, all calibration constants
can be viewed and edited. Due to this feature, it is important they be recorded and
retained for future use.
Store these calibration values with the transmitter factory test data.
For sites with multiple Z model transmitters, record the serial number located on the serial tag
found on the back of the rear door :_______________________
CAL VALUES:
FORWARD FACTOR=
REFLECT FACTOR=
IPA FACTOR=
EXC FACTOR=
CALIBRATE
FREQUENCY=
OP APC_F=
CAL APC_F=
Table 5
FM-519-TLC
Page 9 of 8
13. Transmitter Operation Verification
Turn the transmitter ON in the LOW power mode and check for any faults. If no faults are
logged, switch the transmitter to the HIGH power mode. Check all operating parameters
against those logged before the update. An alternate method would be to use an external
wattmeter to verify forward power.
14. If all readings are normal perform a System Test. The System Test will take approximately
20 minutes or less. The power level will vary and the system will mute many times for a short
duration. If the System Test passes return the transmitter to normal operation. If it does not,
record the fault and perform the test again. If the fault reoccurs, see Troubleshooting in Section
VI in the new technical manual. The new system test may discover faults that were not
previously detected in the old revision of firmware.
This completes the modification. Should you have any questions regarding this information,
please direct your inquires to:
Service Bulletins are also available on the GatesAir Web Site at http://www.gatesair.com
Should you have any questions relating to this bulletin, please contact:
Radio Field Service PO Box 4290 Quincy, Illinois 62305
[email protected], Fax +1 217 221-7086, Tel +1 217 222 8200
