Field Modification

FM10002A

Cooling
Modification
NV3.5 – NV10

Issue 1.0 ................................. 29 April 2010

Nautel Limited
10089 Peggy's Cove Road,
Hackett's Cove, NS, Canada B3Z 3J4
T.877 6 nautel (628835) or +1.902.823.2233
F.+1.902.823.3183 info@nautel.com

U.S. customers please contact:

Nautel Inc.
201 Target Industrial Circle, Bangor ME 04401
T.877 6 nautel (628835) or +1.207.947.8200
F.+1.207.947.3693 info@nautel.com

e-mail: support@nautel.com
www.nautel.com

© Copyright 2010 NAUTEL. All rights reserved.

 FM10002A – NV3.5 Through NV10 Cooling
Modification
FIELD MODIFICATION
1 INTRODUCTION
This document provides instructions to modify NV3.5 through NV10 transmitters in the field.

1.1 Reason For Modification

This modification increases air flow to the control/interface PWB, AUI and SBC sections of
the transmitter.

1.2 Equipment Affected

This modification applies to NV3.5 through NV10 transmitters with the following
configurations:
All NARF56 (NV3.5), NARF50 (NV5), NARF57 (NV7.5) and NARF51 (NV10) that do not
contain DWA 10-006.

1.3 Responsibility for Implementation of Procedure

This modification is written for qualified transmitter maintenance personnel.

1.4 Scheduling
Implement this modification as soon as possible as it improves transmitter performance and
reliability.

1.5 Manpower Requirements

This procedure will require one (1) hour for installation. The transmitter will need to be in an
off-air state for part of the modification process.

1.6 Special Tools/Test Equipment

Standard technician hand tools and other items including:

• Hand drill with 3/8” drill bit

• Screwdrivers
• Side or diagonal cutters
• X-acto or razor knife
• Masking tape
• Pencil

1.7 Materials Required

The parts required for this modification are contained in the provided field modification kit (Nautel
Part # 206-5920-01, see Table 1).

1.8 Identification of Modified Assemblies

Identifying modified assemblies will inform future maintainers of the updated configuration.
Use indelible ink to mark “FM10002A” near the serial number label on the upper, left, rear
corner of the transmitter frame (as viewed from the rear of the transmitter).

Field Modification Page 1

FM10002A Issue 1.0
Table 1: Parts List – NV3.5 through NV10 – Cooling Modification Kit (Nautel # 206-5920-01)
Qty Nautel # Description
1 FM10002A Documentation
1 ft HAH61 Tape, 3M VNB Acrylic Foam
1 206-5900-03 NV Door Air Duct Assembly
1 206-5916 Cableform Assy (Door Fans)
15 206-5914 Tyrap Anchor Assembly
15 HT29 Tyrap, 0.91 W x 3.62 lg
2 206-5911 Capacitor assembly (CCG09) for C6 and C7

1.9 Publications Affected

Refer to Table 2 (parts list), Table 3 (wiring list) and Figure 5 (electrical schematic) at the end
of this document for change details that affect the NV transmitter documentation.

2 MODIFICATIONS

(a) Open the front door of the transmitter.

(b) Locate the module identification silkscreen panel on the rear of the door. Drill out the four
rivets using a 3/8” drill bit to remove the rivet heads. NOTE: It is not necessary to drill out
the existing holes; only the rivet heads. Take precautions to prevent metal shavings from
falling into the transmitter. Remove and retain the silkscreen panel. See Figure 1.

NOTE
Ensure the lower half of the door is clean of dust and debris prior to taping on assemblies in
the following steps.

Drill
(4 places)

Figure 1: Silkscreen Panel Location

(c) Locate the upper section of the air duct assembly (Nautel Part # 206-5900-03), noting it is
the section that does not contain fans.

NOTE
The double-sided tape on the 206-5900-03 air duct assembly sections is very sticky. You will
not be able to re-position either section of the assembly after the tape contacts the door so
make sure that you position the sections carefully and accurately. Do not remove the backing
from the double-sided tape until instructed in step (d).

Page 2 Field Modification

Issue 1.0 FM10002A
 (d) Trial fit the air duct assembly (see Figure 2) by positioning the lip of the air duct assembly
on top of the door recess lip below the SBC (single board computer). Ensure the duct is
located as far to the right hand side as possible and perfectly vertical. This will allow the
door to close properly. Use masking tape to temporarily hold the duct in position. Verify
the duct position by temporarily closing the door and ensuring the duct does not interfere
with the RF power module handles. If the duct position is satisfactory, use a pencil to
mark its outline on the door panel. Peel the backing from the double-sided tape on the
underside of the duct and carefully attach the duct to the door. Use the X-Acto (razor)
knife to trim away any double-sided tape that extends beyond the bottom metal edge.
Failure to do so may result in an improper seal with the lower section of the duct
assembly installed in step (e).

(e) Locate the lower section of the air duct assembly (Nautel Part # 206-5900-03), noting it is
the section that contains the fans. Mount the assembly as close as possible to the upper
section (close off the seam), using the notches to align the assembly. Peel the backing
from the double-sided tape and attach the assembly to the door.

Figure 2: Upper Section Location

(f) Locate the HAH61 tape. Cut into four (4) pieces, peel and apply to all underside corners
of the silkscreen panel removed in step 2 (b). Install the panel on the rear of the door
adjacent to the duct assembly, in line with the original position.

(g) Press RF Off. Switch off and lock out ac power to the transmitter as per station safety
policy.

(h) Locate the 206-5916 cable assembly. Install B1 fan wiring connector P1 to the wire
harness connector P24. Install B1 fan wiring connector P2 to wire harness connector
P25.

(i) Remove the transmitter’s rear panels. From the transmitter front, route the wire harness
under IPA power supply ‘A’ (located in the lower, left corner) to the rear of the transmitter.
See Figure 3a.

(j) From the transmitter rear, routing the wire harness from step (i) to the power supply
distribution PWB (A7). See Figure 3b.

Field Modification Page 3

FM10002A Issue 1.0
 Route along
path
indicated

B1 Fan
Assembly
Figure 3a
Right-hand side view
(side panel removed)
with front door open

A7 – Power Supply
Distribution PWB

Route along
the inside
wall

Figure 3b
Rear view with rear
filter panels removed

Figure 3a and 3b: Harness Routing

Page 4 Field Modification

Issue 1.0 FM10002A
 +12 V power
supplies

Figure 4: +12 V Dc Power Supplies

(k) Temporarily loosen the terminal hardware and install the white wire on terminal E7 (+12V
SBC OUT) of the power supply distribution PWB (A7). Install the black wire on E8
(ground). Existing wires must remain installed on their associated terminals.

(l) Use HT29 tyraps and 206-5914 anchors (peel off the tape cover) to secure the fan wires.
Ensure the front door can be closed without damaging or interfering with the new fan
wires or harness.

(m) For NV7.5 or NV10 transmitters, remove the two right-hand RF power modules from the
front of the transmitter. For NV3.5 or NV5 transmitters, remove the blank panel on the
right-hand side of the RF power modules. See Figure 4.

(n) Obtain the C6 and C7 capacitor assemblies (Nautel Part # 206-5911) from the
modification kit.

(o) Temporarily remove the lexan guard in front of the +12 V power supply terminals. Add
one capacitor assembly between terminals U1-6 (V+) and U1-4 (V-) of the upper +12 V
power supply. Add the other capacitor assembly between terminals U2-6 (V+) and
U2-4 (V-) of the lower +12 V power supply. Loosen the terminal hardware to allow
mounting of the capacitor assemblies. Once they are installed, re-tighten terminal
hardware with the capacitor assemblies and any pre-existing wiring.

(p) Replace the RF power modules or the blank panel removed in step (m).

(q) Install the transmitter’s rear panels.

3 RETURNING TO SERVICE

(a) Apply ac power to the transmitter. Verify the new fans are spinning and forcing air up the
duct channel. The fan speeds are not available on the transmitter AUI.

(b) The transmitter can be returned to service.

Field Modification Page 5

FM10002A Issue 1.0
Table 2: Additions to NV3.5 through NV10 Transmitter’s Overall (NARF**) Parts List
(part of 206-5900-03 NV Door Duct Assembly and 206-5916 Cableform Assembly)

Ref
Description Nautel # Vendor # OEM Code
Des
B1 Fan Bracket Assembly, Dual Blower 206-8407 206-8407 37338
B1-A/B Fan, Dual, Brushless, 12 V dc, Tach, 91 CFM ZA55 SFB0412VH-F00 Delta
B1L1 Ferrite, Clip-On, Ni-Zn, 320 ohms @ 100 MHz LA52 28A2025-0A2 Steward
B1L2 Ferrite, Clip-On, Ni-Zn, 320 ohms @ 100 MHz LA52 28A2025-0A2 Steward
B1P1 Conn, Plug, 3-Pin, Mate-N-Lok, Mini JT39 172166-1 09482
B1P2 Conn, Plug, 3-Pin, Mate-N-Lok, Mini JT39 172166-1 09482
C1 Capacitor, Ceramic, 0.001 uF, 10%, 200 V CCG01 CKR05BX102KRV 91929
C2 Capacitor, Ceramic, 0.001 uF, 10%, 200 V CCG01 CKR05BX102KRV 91929
C3 Not Used
C4 Not Used
C5 Capacitor, Ceramic, 0.47 uF, 10%, 50 V CCG09 CKR06BX474KR 91929
C6 Capacitor Assembly (CCG09) 206-5911 206-5911 37338
C7 Capacitor Assembly (CCG09) 206-5911 206-5911 37338
E12 Lug, Crimp, Joint, Butt, 16-14 AWG, Blue HAR29 320562 09482
E13 Lug, Crimp, Joint, Butt, 16-14 AWG, Blue HAR29 320562 09482
P24 Conn, Recept, Mate-N-Lok, 3-pin, Mini JT40 172234-1 09482
P24 Conn, Contact, Socket, 22-18, Mate-N-Lok JT42 (qty 2) 770988-1 09482
P25 Conn, Recept, Mate-N-Lok, 3-pin, Mini JT40 172234-1 09482
P25 Conn, Contact, Socket, 22-18, Mate-N-Lok JT42 (qty 2) 770988-1 09482

Table 3: Wiring Changes/Additions – NV3.5 through NV10 Transmitters

Source Destination Wire # Color Size Remarks
P24-1 P24-3 - Capacitor - C1
P25-1 P25-3 - Capacitor - C2
A7E7 A7E8 - Capacitor - C5
U1-6 (+V) U1-4 (-V) - Capacitor - C6
U2-6 (+V) U2-4 (-V) - Capacitor - C7
A7E7 E12-A 251 White 16
A7E8 E13-A 252 Black 16
E12-B P24-1 253 White 22
E12-B P25-1 254 White 22
- - 255 Not Used -
- - 256 Not Used -
E13-B P24-3 257 Black 22
E13-B P25-3 258 Black 22
- - 259 Not Used -
- - 260 Not Used -

Page 6 Field Modification

Issue 1.0 FM10002A
 PART OF
A7
POWER SUPPLY
A6 DISTRIBUTION
PWB E7
AC DISTRIBUTION E4 +12V (COM) +
ASSY (2 x 3 WAY) +V +12V (A) + TO CONTROL/
C5
VAC P1 J1 J2 P2 L 0.47 MONITOR STAGE
L L L L
U1 +V C6 E8 SHEET 2
GND E E E E +12V SBC 0.47 GND
N N N N
PS A E6
VAC N -V GND
FROM TB2/TB3 W14P1
OR -V 1 +12V SAMPLE (A)
EXTERNAL AC TO CONTROL/
POWER SOURCE J8 MONITOR STAGE
OR 2 +12V SAMPLE (B) SHEET 1
OPTIONAL UPS E5 3 N/A
INTERFACE ASSY +V +12V (B) +
(SEE A100 BELOW) VAC P4 J5 J6 P5 L P24 B1P1 B1L1
L L L L
U2 +V C7
+12V FAN V OUT
E12
1 +12V
GND E E E E +12V SBC 0.47
N N N N
PS B C1 2 TACH 1- A B1-A
VAC N -V E13
+12V FAN V RTN 3 GND
-V
P25 B1P2 B1L2
1 +12V
C2 2 TACH 1- B B1-B
A100
UPS INTERFACE 3 GND
ASSY A100 A100
VAC J1 (OPTIONAL) J3 W1P1 W1P2
L L L L L
GND E E E E E TO A6J1 +5V (A)
N N N N N
FROM VAC E1 V1 +5V (A)
EXTERNAL A100 A100 J3 P3 L V2 +15V (A)
AC POWER VAC J2 J4 W2P1 W2P2
SOURCE L L L L L E
L
E
L U3 V3 -15V (A)
GND E E E E E TO A6J5 N N LVPS A
N N N N N N COM GND
VAC E2
COM TO CONTROL/
MONITOR STAGE
SHEET 1

+5V (B)
E1 V1 +5V (B)
J7 P6 L V2 +15V (B)
E
L
E
L U4 V3 -15V (B)
E2 N N LVPS B
N COM GND
COM

E3

J4 W7P1 VAC (3-2B4)

E4 L L
E E GND
N N
VAC (3-3B4) TO RF
DRIVE STAGE
J8 W8P1 VAC (2-1B3) SHEET 1
L L
E E GND
N N
VAC (2-2B3)
S2060231 V1

Figure 5: Additions/Changes for the applicable NV Transmitter Ac-Dc Power Stage (Sheet 1A, 1B or 1C of 3)

FM10002A 2010-04-29 SD-1A, SD-1B or SD-1C