Broadcast Electronics FM-5T User Manual Download

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FM–5T
FM–5TS
5 KILOWATT
FM BROADCAST
TRANSMITTERS

July, 1999

IM No. 597–0033–014

Summary of Contents for FM-5T

Page 1: ...FM 5T FM 5TS 5 KILOWATT FM BROADCAST TRANSMITTERS July 1999 IM No 597 0033 014 ...

Page 2: ...gency replacement parts may be ordered directly from the Broadcast Electronics stock room by fax at the number shown below FACILITY CONTACTS Broadcast Electronics Inc Quincy Facility 4100 N 24th St P O BOX 3606 Quincy Illinois 62305 Telephone 217 224 9600 Fax 217 224 9607 E Mail General bdcast bdcast com Web Site www bdcast com RF PRODUCT TECHNICAL ASSISTANCE REPAIR EMERGENCY WARRANTY REPLACEMENT ...

Page 3: ...ndness Cardiac pacemakers may be affected The effect of prolonged exposure to low level RF radiation continues to be a subject of investigation and controver sy It is generally agreed that prolonged exposure of personnel to RF radiation should be limited to an absolute mini mum It is also generally agreed that exposure should be reduced in working areas where personnel heat load is above normal A ...

Page 4: ...inal blocks and wires contain identification tags with information regarding reconnec tion Mounting hardware will be placed in small bags attached to each removed compo nent or inserted in the component mounting holes WARNING WARNING ENSURE NO PRIMARY POWER IS CONNECTED TO THE TRANSMITTER BEFORE PROCEEDING 1 7 INSTALLATION 1 8 TRANSMITTER BASE PLATE Install components removed from the transmitter ...

Page 5: ...TE CHOKE BASE IS PROPERLY CONNECTED TO THE CABINET GROUND STRAP C Connect wire 353 from the cabinet ground strap to the plate choke base as indi cated D Connect the appropriate wires to the plate choke terminals as indicated WARNING WARNING ENSURE NO PRIMARY POWER IS CONNECTED TO THE TRANSMITTER BEFORE PROCEEDING 1 11 EXCITER INSTALLATION Refer to Figure 2 and install the exciter Ensure no primary...

Page 8: ...1 7 TRANSMITTER CONFIGURATIONS 1 1 1 9 OPTIONAL EQUIPMENT AND SPARE PARTS KITS 1 1 1 11 EQUIPMENT SPECIFICATIONS 1 2 SECTION II INSTALLATION 2 1 INTRODUCTION 2 1 2 3 UNPACKING 2 1 2 6 ENVIRONMENTAL REQUIREMENTS 2 1 2 8 COOLING AIR REQUIREMENTS 2 1 2 12 INSTALLATION 2 1 2 14 PRIMARY AC POWER 2 1 2 15 FM 5T 2 1 2 18 FM 5TS 2 2 2 19 EQUIPMENT PLACEMENT 2 2 2 22 COMPONENT INSTALLATION 2 2 2 49 REMOTE ...

Page 9: ...4 SECOND HARMONIC SUPPRESSOR 4 2 4 15 OUTPUT CIRCUIT 4 2 4 16 TRANSMITTER CONTROLLER 4 2 4 22 AUTOMATIC RF OUTPUT LEVEL CONTROL 4 5 4 24 VSWR FOLDBACK PROTECTION 4 5 4 25 SOFT START 4 5 4 26 MOMENTARY POWER INTERRUPTION 4 5 4 27 OVERLOADS 4 5 4 28 INDICATORS 4 5 4 30 METERING 4 6 4 33 EXCITER METERING 4 6 4 34 POWER SUPPLIES 4 6 4 40 DETAILED DESCRIPTION 4 7 4 41 FM 5T POWER SUPPLY 4 7 4 43 SEQUEN...

Page 10: ...NEUTRALIZATION 5 9 5 96 TRANSMITTER POWER LEVEL CHANGE 5 13 5 98 TRANSMITTER FREQUENCY CHANGE 5 13 PROCEDURE 5 99 GENERAL 5 13 5 111 TROUBLESHOOTING 5 14 5 114 COMPONENT REPLACEMENT ON CIRCUIT 5 17 BOARDS SECTION VI PARTS LISTS 6 1 INTRODUCTION 6 1 SECTION VII DRAWINGS 7 1 INTRODUCTION 7 1 APPENDIX A MANUFACTURERS DATA A 1 INTRODUCTION A 1 LIST OF TABLES TABLE NO DESCRIPTION PAGE NO 1 1 ELECTRICAL...

Page 11: ...T POWER SUPPLY SIMPLIFIED SCHEMATIC 4 9 4 3 FM 5TS POWER SUPPLY SIMPLIFIED SCHEMATIC 4 13 4 4 RF CIRCUIT SIMPLIFIED SCHEMATIC 4 17 4 5 PA CAVITY 4 19 5 1 TYPICAL PA EFFICIENCY CURVE AT 98 1 MHZ 5 4 5 2 HUM NULL CONTROL LOCATION 5 6 5 3 SECOND HARMONIC SUPPRESSOR COARSE SETTING 5 8 5 4 NEUTRALIZATION STRAP COARSE SETTING 5 11 5 5 COARSE TUNING ADJUSTMENTS 5 15 5 6 FM 5T CABINET COMPONENT LOCATOR FR...

Page 12: ...50 watt solid state exciter with a digital frequency synthe sizer The following text presents ordering information for various transmitter configura tions optional equipment and recommended spare parts kits 1 7 TRANSMITTER CONFIGURATIONS 1 8 The FM 5T FM 5TS transmitters may be ordered in the following configurations MODEL NO PART NUMBER DESCRIPTION FM 5T 909 5000 215 FM 5T 5 kW FM transmitter com...

Page 13: ... transmitter only Does not include exciter spare semiconductors 979 0095 015 Recommended spare parts kit for the FM 5T FM 5TS transmitters only Includes selected meters switches relays etc Does not include semiconductors 979 0034 014 Recommended spare HV rectifier kit for the FM 5T FM 5TS transmitters 1 11 EQUIPMENT SPECIFICATIONS 1 12 Refer to Table 1 1 for electrical specifications or Table 1 2 ...

Page 15: ... no deemphasis FM modulation 75 kHz at 1 kHz RF HARMONIC SUPPRESSION Meets all FCC DOC requirements and CCIR rec ommendations POWER SUPPLY RECTIFIERS Silicon DISTORTION Mono Composite Harmonic 0 03 or less at 400 Hz SMPTE Intermodulation 0 05 or less 60 Hz 7 kHz Ratio Distortion 4 1 Monophonic 1 1 Composite CCIF Intermodulation Distortion Mono 0 02 or less 15 kHz 14 kHz 1 1 Ratio Composite 0 03 or...

Page 16: ...ac 50 Hz three phase closed delta or wye as specified 28 amperes per phase maximum FM 5TS 196 to 252V ac 50 60 Hz single phase as speci fied 55 amperes maximum AC POWER CONSUMPTION FM 5T 8500 Watts typical at a 5 kW RF power output 0 92 power factor FM 5TS 9600 Watts typical at a 5 kW RF power output 0 98 power factor OVERALL EFFICIENCY FM 5T 58 Typical ac line input to RF output FM 5TS 52 Typical...

Page 17: ...sing HEAT DISSIPATION 3500 Watts maximum 11 945 BTU Hr at 5000 Watts output COOLING AIR REQUIREMENT 800 ft3 min overall 22 6 m3 min SIZE WIDTH 34 5 Inches 87 63 cm DEPTH 37 25 Inches 94 61 cm HEIGHT 70 Inches 177 8 cm WEIGHT UNPACKED 1 000 Pounds 454 kg PACKED 1 200 Pounds 544 kg CUBAGE 60 Cubic Feet 1 7 m3 ...

Page 18: ...ystem must not intro duce any back pressure on the equipment Proper allowances for air flow will ensure that only a limited amount of heat is dissipated into the equipment interior The duct system must allow for a minimum air flow of 800 cubic feet of air per minute 22 6 m3 min 2 11 As a minimum requirement any duct work must have a cross sectional area equal to the exhaust area of the cabinet ref...

Page 19: ... Figure 2 1 The floor must be capable of support ing the total transmitter weight of approximately 130 pounds per square foot The floor support should be more than marginal to maintain the proper cabinet alignment and re duce vibration 2 21 After it has been determined where and how the cabinet will be positioned set the cabinet in place on a smooth and level location 2 22 COMPONENT INSTALLATION W...

Page 22: ...ing flange Ensure the tuning line is perpendicular to the top of the cabinet and secure the strap clamp 2 39 Ensure the coarse PA input tuning cyclometer on the rear of the PA input enclosure is set to the value listed on the factory final test data sheets and the control is locked 2 40 Remove the slide retainers from the exciter 2 41 Loosen the exciter front panel turn lock fasteners and extend t...

Page 25: ...tive or negative control Positive control requires the use of a momentary contact to a 5 volt to 15 volt dc signal to disable the 1 filaments and 2 high voltage if not previously disabled Negative control requires the use of a momen tary contact to ground to disable the 1 filaments and 2 high voltage if not previously dis abled 2 56 Remote High Voltage On Control The high voltage on function is lo...

Page 26: ...lament on indicator is located at TB1 16 The indicator will go LOW 0 volts dc to indicate when the filaments are enabled 2 65 Remote Disable Indicator The remote disable indicator provides a signal to indicate when the remote control inputs are disabled The remote disable indicator is located at TB1 17 The indicator will go LOW 0 volts dc to indicate when the remote control inputs are disabled 2 6...

Page 27: ...d for a 2 or 4 volt dc full scale meter indication The forward power full scale indication is 5500 watts In addition the forward power sample can be provided in a log or linear format The trans mitter is shipped with the sample programmed for a linear format The meter ground is recommended for remote metering connections TB2 6 through TB2 8 2 79 Remote Reflected Power Meter Indications Remote refl...

Page 28: ...PLY FOR OPTIONAL EQUIPMENT ENSURE ALL 220V AC AND 110V AC EQUIPMENT IS PROPERLY CONNECTED TO THE PANEL 2 88 OPTIONAL EQUIPMENT WIRING An ac distribution panel is provided for the application of ac power to the transmitter modular components Mount and wire any optional equip ment not provided with the transmitter to the distribution panel refer to Figure 2 5 The ac distribution panel provides a 220...

Page 30: ...gnostic system 2 92 TRANSMITTER MONITORING PRINTER CONNECTIONS The FM 5 FM 5TS trans mitters are equipped with a built in printer port The printer port allows transmitter pa rameters to be printed using a local printer and a future local remote diagnostic system WARNING WARNING ENSURE PRIMARY POWER IS DISCONNECTED BE FORE PROCEEDING 2 93 AC POWER CONNECTIONS The following text presents three phase...

Page 31: ... 96 FM 5TS A single phase source of 196V to 252V ac 50 or 60 Hz at 70 Amperes is required for the FM 5TS transmitter ac input For operating safety the power source must be routed to the transmitter through a fused power disconnect refer to Figure 2 7 2 97 Refer to Figure 2 7 and connect the 70 Ampere service to TB1 on the transmitter base plate through a fused service disconnect Ensure a utility c...

Page 33: ...ntrol fully counterclock wise minimum output 2 105 The following procedure will refer to the factory final test data sheets supplied with the transmitter Some differences in the actual operation may be noted due to differences in primary power or antenna systems Ensure all controls are preset to the positions indi cated on the final test data sheets 2 106 CONTROLLER AND INTERLOCK CHECKOUT Check th...

Page 34: ...r door interlock switch open the PA cavity ac cess door The controller TRANSMITTER STATUS INTERLOCK indicator will extinguish D Close the PA cavity access door The controller TRANSMITTER STATUS INTERLOCK indicator will illuminate E Close the transmitter rear door 2 114 If equipment is connected to the failsafe interlock circuit check the operation as follows A Open the failsafe interlock The contr...

Page 35: ...AND TUNING Operate and tune the transmitter by per forming the following procedure 2 127 Ensure the AC POWER and BLOWER circuit breakers are operated to ON The SCREEN and FILAMENT circuit breakers must remain OFF 2 128 Ensure the controller TRANSMITTER STATUS INTERLOCK indicator is illuminated If the indicator is extinguished open the wall mounted fused disconnect and check the fol lowing A All pa...

Page 36: ...lock operation as follows WARNING WARNING OBSERVE PROPER SAFETY PRECAUTIONS WHEN PERFORMING THE FOLLOWING PROCEDURE A Open the failsafe interlock The controller FAILSAFE TRANSMITTER STATUS and the HIGH VOLTAGE TRANSMITTER STATUS indicators will extinguish and the high voltage plate supply will be disabled B Close the failsafe interlock The plate supply will be restored the transmitter will resume ...

Page 37: ... RFL POWER and adjust the INPUT TUNING control to obtain a minimum reflected power indication on the MULTIMETER 2 156 Depress the controller RAISE switch indicator until a 50 indication is obtained on the OUTPUT POWER meter 2 157 Depress the controller VSWR switch indicator to illuminate the switch indicator 2 158 The OUTPUT POWER meter must indicate a VSWR of less than 1 8 1 An excessive VSWR ind...

Page 38: ... will illuminate and the trans mitter will maintain a constant 100 rated RF output 2 172 Apply programming to the exciter The presence of programming may be noted on the ex citer MODULATION meter 2 173 To adjust the automatic power control unit to maintain a level other than 100 the APC ON switch indicator must be illuminated Depress either the RAISE or the LOWER switch indicator as desired until ...

Page 39: ...ator will illuminate as it is depressed 3 10 If all interlocks are closed the transmitter will be operational after a short delay to allow PA tube filament warm up 3 11 Check and log all meter indications and the status of the various indicators to assure prop er equipment operation A sample log sheet is provided as Table 3 2 3 12 Depress the FWD switch indicator to illuminate the switch indicator...

Page 40: ...tion of the tube filament and will result in maximum tube life To maximize transmitter tube life imple ment the procedures and operations presented in the following tube management program TUBE MANAGEMENT PROGRAM 1 Refer to APPENDIX A and perform the procedures presented in the Eimac publication titled Extending Transmitter Tube Life Eimac Application Bulletin No 18 March 1990 2 Refer to APPENDIX ...

Page 42: ...L SWITCH In the automatic mode moves the APC RAISE reference upward when depressed In the Switch Indicator manual mode operates the screen control motor in a direction which will raise trans mitter RF output power when depressed INDICATOR Illuminates to indicate the screen control motor is operating in a direction which will raise the transmitter RF power output 11 POWER CONTROL SWITCH In the auto...

Page 43: ...eptacle for AM noise measurements Receptacle 19 HIGH VOLTAGE ON SWITCH Energizes the step start contactors when Switch Indicator depressed to activate the plate and screen power supplies and enables the exciter INDICATOR Indicates a high voltage on command has been received by the transmitter controller 20 HIGH VOLTAGE OFF SWITCH De energizes the plate and screen power supplies Switch Indicator an...

Page 44: ...or the blower flushing fans the automatic power control unit and the transmitter controller 28 FILAMENT Provides overload protection and primary power Circuit Breaker control for the PA tube filament supply the control grid bias supply and the hum null circuitry 29 DRIVER Provides overload protection and primary power Circuit Breakers control for the FM exciter and intermediate power amplifier 30 ...

Page 45: ... POWER Displays transmitter percentage of RF output Meter power or output VSWR as selected by the POWER CONTROL FWD and VSWR switch indicators 40 OUTPUT LOADING Adjusts the PA stage output loading Control and Cyclometer 41 OUTPUT TUNING Tunes the PA stage output circuit to resonance Control and Cyclometer 42 MODEM PORT 2 A modem port used with a future transmitter monitoring and diagnostic option ...

Page 46: ...3 9 TABLE 3 2 INDICATOR CHECKLIST 597 0098 412 ...

Page 47: ...T FM 5TS uses a single 4CX3500A tetrode to provide 5000 Watts of RF power on a single frequency within the FM broadcast band of 87 5 MHz to 108 MHz The power amplifier operates in a high gain grid driven class C configuration A patented input circuit matches the 50 Ohm output of the IPA up to the higher grid input impedance Use of a large coaxial cavity results in high PA efficiency for comparativ...

Page 48: ...ss filter is contained within the FM 5T FM 5TS cabinet to attenuate all residual second and higher order harmonics This filter functions over the entire FM broadcast band Three RF directional couplers are mounted after the filter in the output transmission line connection Two of these supply filtered forward and reflected power RF samples to the controller and the third port supplies a forward pow...

Page 50: ...ition which caused the high VSWR returns to normal RF power will be proportionately raised until full power is again restored 4 25 SOFT START The controller monitors PA plate voltage and reduces the screen voltage to zero upon its absence When the plate supply is energized as during initial turn on the controller will gradually increase the screen voltage until the stored power setting is achieved...

Page 51: ...transmitter is designed for operation from a 196 to 252 volt three phase ac in put The plate supply is a conventional three phase power supply circuit The remaining FM 5T transmitter power supplies are single phase circuits which are obtained from two phases of the three phase input The FM 5TS transmitter is designed for operation from a 196 to 252 volt single phase ac input All FM 5TS transmitter...

Page 52: ...ep contactor K7 After the current inrush to the plate supply has been limited by the step start resistors R1 R2 and R3 optically coupled relay K5 will energize start contactor K4 to apply full input to the plate and screen power supplies 4 46 If during a start sequence an internal interlock opens the entire start sequence will be cancelled and must be re initiated manually If an internal interlock...

Page 53: ...llisecond interval between the step start relay closures 4 53 PA SCREEN GRID POWER SUPPLY The screen power supply is a full wave bridge recti fied supply with a single L section filter The primary of the screen transformer is con nected through CB3 to the step start contactors The output of the screen supply is adjust able with a variable autotransformer connected in the primary of the screen tran...

Page 55: ... input to the plate and screen power supplies 4 62 If during a start sequence an internal interlock opens the entire start sequence will be cancelled and must be re initiated manually If an interlock opens during operation the entire power supply section will deenergize However if the interlock is promptly closed the blower and flushing fans will resume operation to cool the PA tube but a new star...

Page 56: ... and filament driver contactor K3 A bleeder resistor connected across this supply improves regulation and enhances safety by discharging C9 4 68 Hum Null Supply The ground path for the grid bias supply is routed through the hum null circuit which introduces a small 120 Hz pulsating dc component into the control grid bias supply to cancel hum in the PA tube from the screen supply The amount of volt...

Page 58: ...king capacitors and high current short ing contacts of conventional cavities by connecting the main transmission line conductor directly to the anode of the power tube see Figure 4 5 A grounded concentric transmis sion line center conductor tunes this cavity with a variable reentrant length inserted into the end of a main inner conductor The main inner conductor is insulated from ground and carrie...

Page 59: ...r low pass filter are applied to individual rectifier amplifier circuits in the controller The outputs from the rectifier am plifier circuits are routed to analog to digital A to D circuitry The A to D circuitry converts the signals to a digital format and routes the signals to the microprocessor The microprocessor uses the signals 1 to output forward power and VSWR samples to the out put power me...

Page 62: ...ch actions are not recommended The design of the equipment pro vides safety features such that when a door is opened or an access panel is removed inter lock switches will deenergize all dc power supplies and release the fail safe discharge sole noid across the plate supply Do not short out or bypass interlock switches as a mainte nance short cut 5 6 The PA cavity access door actuates an interlock...

Page 63: ...ng drives cables the PA tuning line right angle gear mechanism and the cyclometer drives behind the front panel The PA output loading screw drive should be opened four screws and lubricated every 36 months or more often if resistance is noted 5 12 CONTROLLER BATTERY 5 13 The transmitter controller is equipped with a Lithium battery The battery has a useful life of approximately two years After app...

Page 64: ...educed and unbalance will result with a possibility of damage to the blower or fans 5 21 SECOND LEVEL MAINTENANCE WARNING WARNING NEVER OPEN THE EQUIPMENT UNLESS ALL TRANS MITTER PRIMARY POWER IS DISCONNECTED 5 22 Second level maintenance consists of procedures required to restore the transmitter to sat isfactory operation after a fault has occurred The maintenance philosophy for the FM 5T FM 5TS ...

Page 65: ...s procedure will expedite immediate shipment of a new tube Contact the Broadcast Electronics Inc Customer Service Department for additional details as re quired It is recommended that the warranty report be filled out as soon as the new tube is placed in operation while the nominal voltages are known 5 26 ADJUSTMENTS WARNING WARNING NEVER OPEN THE EQUIPMENT UNLESS ALL TRANS MITTER PRIMARY POWER IS...

Page 66: ...stment of the circuit will not normally be required in the field However if it is certain that hum null circuit adjustment is re quired proceed as follows 5 31 Required Equipment The following equipment is required to adjust the hum null circuit A Distortion analyzer Tektronics Model AA501 or equivalent B One locally fabricated test cable consisting of the following A 10 feet 3 05 m of Belden RG58...

Page 67: ...dcast Electronics Customer Service Depart ment before attempting this adjustment If it is certain that adjustment of the second har monic suppressor is required proceed as follows 5 39 Required Equipment The following equipment is required to complete adjustment of the second harmonic suppressor A 1 16 inch 1 6 mm hex wrench B Tektronix Model 492 Spectrum Analyzer or the equivalent capable of disp...

Page 68: ...smitter at the normal power output and ensure all PA stage tuning and loading controls are correctly adjusted 5 48 Record the level of the second harmonic displayed on the spectrum analyzer WARNING WARNING DISCONNECT ALL TRANSMITTER PRIMARY POWER BEFORE PROCEEDING 5 49 Disconnect all transmitter primary power 5 50 Open the cabinet rear door 5 51 Loosen the two hex head lock screws securing the sec...

Page 69: ...djust ment rod slightly in or out as required to minimize the second harmonic indication WARNING WARNING DISCONNECT ALL TRANSMITTER PRIMARY POWER BEFORE PROCEEDING 5 56 After the correct setting of the second harmonic suppressor is determined disconnect all transmitter primary power 5 57 Open the cabinet rear door 5 58 Secure both hex head lock screws on the second harmonic suppressor bushing see ...

Page 70: ...hillips screwdriver 4 inch 10 2 cm blade F Flat tip screwdriver 4 inch 10 2 cm blade and 1 4 inch 0 64 cm tip G Exciter line cord P O exciter accessory pack BE P N 682 0001 H Electrical extension cord 3 wire 12 feet 3 7 m long I Six inch scale graduated in sixty fourths of an inch 5 63 Procedure To adjust PA neutralization proceed as follows 5 64 Operate the transmitter at the normal power output ...

Page 71: ... is operating independently of the transmitter 5 80 Connect the spectrum analyzer to the RF sample port J2 in the transmitter output trans mission line Adjust the analyzer to obtain a reference level display and position the ana lyzer so that it may be viewed from the rear of the transmitter 5 81 Note the position of the grounding stick in the rear of the cabinet WARNING WARNING USE THE GROUNDING ...

Page 73: ...ding stick on the hanger 5 87 Disconnect the spectrum analyzer from the output transmission line CAUTION CAUTION DO NOT CONNECT THE EXCITER TO THE LINE CORD WIRED INTO THE TRANSMITTER IN THE FOLLOWING STEP WARNING WARNING DISCONNECT ALL EXCITER PRIMARY POWER BE FORE PROCEEDING 5 88 Remove the electrical extension cord and exciter line cord Do not connect the exciter to the line cord wired into the...

Page 74: ...high reflected power conditions use the multimeter grid current function and maximum grid current information for indications of correct tuning operations C Refer to CONTROLLER SECTION II MAINTENANCE and perform the FORWARD POWER CALIBRATION and REFLECTED POWER CALIBRATION adjustment procedures 5 98 TRANSMITTER FREQUENCY CHANGE PROCEDURE CAUTION CAUTION CONSULT THE FACTORY BEFORE ATTEMPTING TO CHA...

Page 75: ...the preceding text and perform the NEUTRALIZA TION procedure 5 108 Refer to SECTION II INSTALLATION and complete the PRELIMINARY OPERATION AND TUNING procedure to obtain a 100 power indication from the transmitter 5 109 Refer to the adjustment procedures in the preceding text and perform the SECOND HAR MONIC SUPPRESSOR adjustment procedure 5 110 Refer to CONTROLLER SECTION II MAINTENANCE and perfo...

Page 77: ...GE 5 0 V EXCITER FORWARD POWER 140 W FM 5TS VSWR FWD OUTPUT POWER LESS THAN 1 2 100 PLATE CURRENT 1 3 A PLATE VOLTAGE 5300 V SCREEN VOLTAGE 525 V SCREEN CURRENT 60 mA GRID VOLTAGE 260 V GRID CURRENT 45 mA FILAMENT VOLTAGE 5 0 V EXCITER FORWARD POWER 140 W TABLE 5 2 TYPICAL POWER DEMAND 5 kW RF OUTPUT FM 5T AC Line Frequency 60 Hz 50 Hz 50 Hz AC Line Voltage 210 V 224 V 380 V AC Line Current 28 A 2...

Page 78: ...ng surface mount technology Therefore components on the controller main circuit and front panel circuit boards can not be re placed without destruction of the circuit board traces 5 115 On all circuit boards the adhesive securing the copper track to the board melts at almost the same temperature at which solder melts A circuit board track can be destroyed by ex cessive heat or lateral movement dur...

Page 79: ...RNING OBSERVE THE MANUFACTURER S CAUTIONARY IN STRUCTIONS 5 119 After soldering remove flux with a cotton swab moistened with a suitable solvent Rub bing alcohol is highly diluted and is not effective Solvents are available in electronic sup ply house which are useful 5 120 The board should be checked to ensure the flux has been removed and not just smeared about Rosin flux is not normally corrosi...

Page 83: ...5 22 WARNING DISCONNECT POWER PRIOR TO SERVICING BLANK PAGE ...

Page 86: ...ETER MULTIPLIER CIRCUIT BOARD FM 5TS 919 0079 6 6 6 9 METER PANEL ASSEMBLY 959 0271 105 6 6 6 10 MULTIMETER CIRCUIT BOARD ASSEMBLY 919 0049 001 6 7 6 11 PLATE CURRENT METER ASSEMBLY 959 0300 6 7 6 12 METER PROTECTION CIRCUIT BOARD ASSEMBLY 919 0109 002 6 7 6 13 FAN BLOWER ASSEMBLY 959 0271 006 6 7 6 14 DIODE STACK PANEL ASSEMBLY FM 5T 959 0271 008 6 7 6 15 DIODE STACK PANEL ASSEMBLY FM 5TS 959 027...

Page 87: ...ING ASSEMBLY 959 0151 6 13 6 30 INPUT MATCHING CIRCUIT BOARD ASSEMBLY 919 0064 6 13 6 31 RF ENCLOSURE ASSEMBLY 959 0272 6 13 6 32 PA CHIMNEY ASSEMBLY 959 0272 002 6 13 6 33 TRANSMISSION LINE ASSEMBLY 959 0272 003 6 14 6 34 SHIELD CELL TUNING LINE ASSEMBLY 959 0272 101 6 14 6 35 EXHAUST AIR TEMPERATURE CIRCUIT BOARD 919 0082 6 14 ASSEMBLY 6 36 ACCESSORY PARTS KIT 969 0013 6 14 ...

Page 88: ...Watt 220V 909 0251 304 1 Screen And Bias Panel Assembly 959 0271 001 1 Bleeder Panel Assembly 959 0271 003 1 Meter Panel Assembly FM 5T 959 0271 105 1 Fan and Blower Assembly 959 0271 006 1 Diode Stack Panel Assembly 959 0271 008 1 Contactor Panel Assembly 959 0271 109 1 Three Phase Voltmeter Assembly 959 0271 010 1 PA Metering Circuit Board Assembly FM 5T 919 0048 008 1 Basic Unit Cable Assembly ...

Page 89: ... 4CX3500A EIMAC SVETLANA 243 3500 1 Transformer Regulator Filament 370 0056 1 Counting Dial 0 9999 100 Turn 290 0002 1 Air Filter 16 X 20 X 1 Inch 40 64 X 50 8 X 2 54 cm 407 0062 1 FM 250C Exciter 50 TO 250 Watt 220V 909 0251 304 1 Screen and Bias Panel Assembly 959 0271 001 1 Bleeder Panel Assembly 959 0271 003 1 Meter Multiplier Circuit Board Assembly 919 0079 1 Meter Panel Assembly FM 5T 959 02...

Page 90: ... 0 2 Amperes Continuous 3 281V 0 2 Amperes Continuous 4 310V 0 2 Amperes Continuous 1500 Volt Insulation 70 Ohms dc Resistance TB9 Barrier Strip 6 Terminals 412 0008 1 TB10 Barrier Strip 5 Terminals 412 0005 1 1 Hum Null Circuit Board Assembly 919 0063 1 TABLE 6 5 HUM NULL ASSEMBLY 919 0063 REF DES DESCRIPTION PART NO QTY C1 Capacitor Electrolytic 470 uF 50V 024 4783 1 D1 D2 Diode 1N4005 Silicon 6...

Page 91: ...mperes BLOWER 341 0010 1 CB3 Circuit Breaker 2 Pole 250 Volt 1 Ampere SCREEN 341 0008 1 CB4A B Circuit Breaker 2 Pole 250 Volt 7 Amperes Push On DRIVER 341 0060 2 CB5 Circuit Breaker 2 Pole 250 Volt 10 Amperes FILAMENT 341 0030 1 M1 Meter 3 5 inch 8 89 cm Taut Band Type 310 0058 1 FS 200 uA 2 230 Ohm Movement OUTPUT POWER Meter FOR FM 5T AND FM 5TS 60 HZ TRANSMITTER MODELS ONLY M2 Meter 0 99 999 9...

Page 92: ...PART NO QTY C1 C2 Capacitor Ceramic 0 001 uF 1 kV 002 1034 2 D1 Diode Zener 1N4728 3 3V 5 1W 201 4728 1 E1 E2 Terminal Male Disconnect PC 410 0025 2 R1 Resistor 680 Ohm 5 1W 120 6833 1 R2 Resistor 182 Ohm 1 1 4W 103 1823 1 R3 Potentiometer 200 Ohm 10 1 2W 177 2034 1 Blank Meter Protection Circuit Board 519 0109 1 TABLE 6 13 FAN BLOWER ASSEMBLY 959 0271 006 REF DES DESCRIPTION PART NO QTY B1 Blower...

Page 93: ... R2 R3 Resistor 5 Ohm 5 25W W W 130 5013 3 TB6 Thru Barrier Strip 9 Terminal 412 0090 3 TB8 TB12 Barrier Strip 4 Terminal 412 0011 1 Interlock Switch For K4 Normally Open Contactor Mounted 341 0058 1 Screen Powerstat Assembly 959 0121 100 1 TABLE 6 17 CONTACTOR PANEL ASSEMBLY FM 5TS 959 0271 102 REF DES DESCRIPTION PART NO QTY K1 K2 Optically Coupled Relay Assembly OCR 919 0096 2 K3 Contactor 341 ...

Page 94: ...8233 1 R4 Resistor 51 1 Ohm 1 1 4W 103 5112 1 R5 Resistor 2 k Ohm 3 10W 130 2032 1 U1 Integrated Circuit 4N33 Optical Isolator Infared LED Photo 229 0033 1 NPN Darlington Transistor Coupled Pair 1500V Isolation XU1 Socket 6 Pin DIP 417 0600 1 Blank Circuit Board 519 0096 1 TABLE 6 19 POWERSTAT ASSEMBLY 959 0121 REF DES DESCRIPTION PART NO QTY B4 Motor and Gearhead Assembly 12V dc 235 mA 9 1 r min ...

Page 95: ... 100V 042 3922 1 C20 Capacitor Monolythic Ceramic 0 1 uF 20 50V 003 1054 1 C21 Capacitor Electrolytic 470 uF 50V 024 4783 1 D1 Thru D7 Diode Zener 1N4739A 9 1V 10 1W 200 0009 7 E1 Thru E10 Terminal Male Disconnect PC 410 0025 10 E11 E12 Terminal Turret Two Shoulder 413 1597 2 E13 Terminal Male Disconnect PC 410 0025 1 F1 F2 Fuse AGC 1 Ampere Fast Blow 330 0100 2 F3 Fuseable Link 28 AWG 630 2806 0 ...

Page 96: ...al Operational Amplifier 221 0358 2 8 Pin DIP XF1 XF2 Fuse Clip 415 2068 4 XU1 XU2 Socket 8 Pin DIP 417 0804 2 Blank PA Metering Circuit Board 519 0048 001 1 TABLE 6 22 BASIC UNIT CABLE ASSEMBLY 949 0161 100 REF DES DESCRIPTION PART NO QTY P1 P1 Connector Ribbon Cable 10 Pin PA Metering Circuit Board 417 1003 2 P1 P2 Connector Housing 6 Pin on Blower and Fans 418 0670 2 P2 Connector Housing 15 Pin...

Page 97: ... 26 REMOTE INTERFACE PANEL ASSEMBLY 959 0117 100 REF DES DESCRIPTION PART NO QTY Fail Safe Solenoid Assembly 959 0083 1 Remote Interface Circuit Board Assembly 919 0439 1 TABLE 6 27 FAIL SAFE SOLENOID ASSEMBLY 959 0083 REF DES DESCRIPTION PART NO QTY L5 Solenoid 230V ac 50 60 Hz DC Resistance 360 Ohm 10 281 0004 1 TB11 Barrier Strip 2 Terminal 412 0002 1 Barrier Strip Insulated 2 Terminal 407 0122...

Page 98: ...t Matching Circuit Board Assembly 919 0064 1 TABLE 6 30 INPUT MATCHING CIRCUIT BOARD ASSEMBLY 919 0064 REF DES DESCRIPTION PART NO QTY E1 Thru E8 Terminal Turret Two Shoulder 413 0025 8 J2 Receptacle BNC 417 0014 1 Blank PA Input Matching Circuit Board 519 0064 1 Matching Capacitor Circuit Board 519 0064 001 1 TABLE 6 31 RF ENCLOSURE ASSEMBLY 959 0272 REF DES DESCRIPTION PART NO QTY C9 Capacitor P...

Page 99: ...t Tuning Line 463 0043 1 Output Tuning Line 23 62 inches 60 cm X 1 5 8 inch OD 463 0042 1 Exhaust Air Temperature Circuit Board 919 0082 1 TABLE 6 35 EXHAUST AIR TEMPERATURE CIRCUIT BOARD ASSEMBLY 919 0082 REF DES DESCRIPTION PART NO QTY C1 C2 Capacitor Mica 390 pF 5 100V 042 3922 2 C3 C4 Capacitor Ceramic 0 001 uF 10 1 kV 002 1034 2 J1 Socket 4 Pin 418 0255 1 R1 Resistor 10 k Ohm 1 1 4W 100 1051 ...

Page 100: ... HUM NULL CIRCUIT BOARD SB919 0063 7 10 ASSEMBLY HUM NULL CIRCUIT BOARD AB919 0063 7 11 SCHEMATIC PLATE METER MULTIPLIER CIRCUIT SB919 0200 BOARD FM 5T 7 12 ASSEMBLY PLATE METER MULTIPLIER CIRCUIT AB919 0200 BOARD FM 5T 7 13 SCHEMATIC PLATE METER MULTIPLIER CIRCUIT SB919 0079 BOARD FM 5TS 7 14 ASSEMBLY PLATE METER MULTIPLIER CIRCUIT AB919 0079 BOARD FM 5TS 7 15 SCHEMATIC PA METERING CIRCUIT BOARD ...

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Page 131: ... 5T FM 5TS FM transmitters Information contained in this appendix is presented in the following order A Service Bulletin Furnas Contactor Size 25 Amp B Service Bulletin Furnas Contactor Size 1 3 4 C Technical Data Sheet Eimac 4CX3500A Tetrode D Application Note Eimac Extending Transmitter Tube Life E Schematic Diagram Power Supply Computer Products NFN40 7610 ...

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Page 147: ...SAFETY CONSIDERATIONS 2 1 2 5 MAINTENANCE 2 1 2 7 MAIN CIRCUIT BOARD CONTROL ADJUSTMENTS 2 1 2 8 OVERLOAD CONTROLS 2 1 2 9 VSWR OVERLOAD THRESHOLD ADJUST 2 1 2 27 PLATE OVERLOAD ADJUSTMENT 2 2 2 39 SCREEN OVERLOAD ADJUSTMENT 2 5 2 53 GRID OVERLOAD ADJUSTMENT 2 6 2 54 FILAMENT WARM UP ADJUSTMENT 2 6 2 62 COOL DOWN ADJUSTMENT 2 7 2 70 RECYCLE ADJUSTMENT 2 7 2 77 WARM UP DEFEAT ADJUSTMENT 2 7 2 84 FO...

Page 148: ... INTRODUCTION 4 1 LIST OF TABLES TABLE DESCRIPTION PAGE NO 3 1 Transmitter Controller Parts List Index 3 1 LIST OF ILLUSTRATIONS FIGURE DESCRIPTION PAGE NO 1 1 TRANSMITTER CONTROLLER BLOCK DIAGRAM 1 3 2 1 CONTROLLER MAIN CIRCUIT BOARD CONTROLS 2 3 2 2 CONTROLLER COMPONENT LOCATIONS 2 13 ...

Page 149: ...uture dual main alternate transmitter control sys tem 1 7 A Lithium battery back up system is included in the controller design The battery back up system will maintain the controller memory and other parameters during a power fail ure This system allows the transmitter to return to operation after the power failure in the exact same operating conditions 1 8 A modular switching power supply provid...

Page 150: ...limiting resistors are disconnected after 160 millisec onds 1 16 Simultaneous with generation of the high voltage on start signal the exciter will be en abled and the HIGH VOLTAGE status indicator will illuminate to indicate that the plate supply control signal has been output The high voltage supply is prevented from step starting under full load in this manner 1 17 TRANSMITTER TURN OFF 1 18 When...

Page 152: ... counter monitors the number of times an overload occurs during a 60 second interval A second overload recycle timer delays restoration of the transmitter to operation to allow the condition that prompted the overload to dissipate 1 27 When the timed interval delaying restoration of the transmitter to operation has expired the transmitter will recycle back into operation If no further overloads oc...

Page 153: ...es the RF output power by routing raise lower commands B4 A raise command rotates the motor in a manner which increases the screen voltage As a result of the increase in screen voltage the RF output power will increase A lower command rotates the motor in a manner which decreases the screen voltage Lim it switches on the motor prevent possible damage to the autotransformer by disconnecting the dri...

Page 154: ...will perform no correction If re flected power increases beyond the lower limit the raise feature will be inhibited to pre vent the forward power control function from raising power to avoid a transmitter over load If the PA reflected power continues to rise and is within the dead band no lowering of power will occur If the upper limit of the dead band is reached a lower command will be applied 1 ...

Page 155: ...he circuit will now function normally to control power and maintain operation within the deadband NOTE NOTE PRESET POWER IS ONLY USED FOR EMERGENCY OP ERATION AT LESS THAN LICENSED POWER OPERA TION 1 50 PRESET POWER 1 51 Preset power is normally used to automatically switch the transmitter to a predetermined power output level such as half power for periods of auxiliary generator operation The fol...

Page 156: ...nd level maintenance consisting of procedures required to restore the equipment to operation after a fault The following text presents the controller adjustments 2 7 MAIN CIRCUIT BOARD CONTROL ADJUSTMENTS 2 8 OVERLOAD CONTROLS The following text presents the overload adjustment proce dures If more than one control is adjusted adjust the controls as follows 1 VSWR 2 PLATE 3 SCREEN and 4 GRID 2 9 VS...

Page 157: ...e the switch indicator 2 21 Refer to Figure 2 1 and use up down switch S2 to lower the VSWR overload threshold un til the VSWR OVERLOAD indicator and the OVERLOAD RESET switch indicator illu minate and the transmitter cycles off 2 22 Depress the HIGH VOLTAGE OFF switch then depress the LOWER switch indicator for approximately 4 seconds to lower the transmitter power 2 23 Depress the OVERLOAD RESET...

Page 159: ...lumi nate and the transmitter cycles off 2 34 Depress the HIGH VOLTAGE OFF switch then depress and hold the LOWER switch in dicator for approximately four seconds 2 35 Depress the OVERLOAD RESET and the HIGH VOLTAGE ON switch indicators 2 36 Observe the PLATE CURRENT meter and operate the RAISE switch indicator until the transmitter deenergizes Correct adjustment is obtained when the transmitter d...

Page 160: ...h indicator then depress and hold the LOWER switch indicator for approximately four seconds 2 49 Depress the OVERLOAD RESET and the HIGH VOLTAGE ON switch indicators 2 50 Observe the MULTIMETER and operate the RAISE switch indicator until the transmit ter deenergizes Correct adjustment is obtained when the transmitter deenergizes and the MULTIMETER indicates 145 milliamperes Repeat the procedure i...

Page 161: ...decrease the blower run down interval Check the adjustment by repeating the procedure The control is factory set for 30 seconds Each click of S2 is equal to 1 second 2 70 RECYCLE ADJUSTMENT The recycle adjustment controls the amount of time the trans mitter will remain deenergized to allow an overload to dissipate The recycle time can be adjusted from 100 milliseconds to 15 seconds The factory def...

Page 162: ...Adjustment is required only if repairs have been made to the directional coupler forward port controller main circuit board or low pass filter To adjust the con trol proceed as follows 2 85 Required Equipment The following equipment is required to adjust the forward power calibration control A 1 16 inch jewelers screw driver flat tip B Digital multimeter Fluke 77 or equivalent C Test load and conn...

Page 163: ...WARNING WARNING DISCONNECT ALL TRANSMITTER PRIMARY POWER BEFORE PROCEEDING 2 99 Disconnect the transmitter primary power 2 100 Connect the test load and wattmeter to the transmitter output 2 101 Apply power and operate the transmitter in the local manual mode REMOTE DISABLE illuminated APC ON extinguished at the desired 100 RF power output as indicated by the in line wattmeter 2 102 Refer to Figur...

Page 164: ... ON extinguished at the desired 100 RF power output as indicated by the in line wattmeter 5 Refer to Figure 2 1 and adjust VSWR null control R119 for a 0 0 volt dc indication on the multimeter WARNING WARNING DISCONNECT ALL TRANSMITTER PRIMARY POWER BEFORE PROCEEDING 2 110 Disconnect the transmitter primary power 2 111 Disconnect cable 131 from the reflected power directional coupler port on the t...

Page 165: ... and operate the transmitter in the local manual mode REMOTE DISABLE illuminated APC ON extinguished at the desired 100 RF power output as indicated by the front panel OUTPUT POWER meter 2 127 Refer to Figure 2 1 and adjust AM noise calibration control R27 for a 1 09 volt dc indica tion on the multimeter 2 128 Disconnect the transmitter primary power 2 129 Remove the test equipment and return the ...

Page 166: ...epaired locally or the entire device may be returned to Broadcast Electronics Inc for exchange alignment or replacement 2 137 CONTROLLER COMPONENT LOCATIONS Figure 2 2 presents the controller compo nent locations Refer to Figure 2 2 as required during the troubleshooting procedures to locate components within the controller CAUTION CAUTION TO PREVENT DAMAGE TO THE MAIN CIRCUIT BOARD DO NOT REMOVE ...

Page 168: ... and 5V power sup plies Use the indicators to check the status of the power supply module 2 147 CONTROLLER POWER SUPPLY MODULE The transmitter controller is equipped with a modular switching power supply assembly The power supply module is equipped with an ac line fuse and is not manufactured by Broadcast Electronics 2 148 If the power supply is suspected as being faulty check the power supply fus...

Page 169: ...this section is indexed by reference designators appearing on the applicable schematic diagram TABLE 3 1 TRANSMITTER CONTROLLER PARTS LIST INDEX TABLE DESCRIPTION PART NO PAGE 3 2 FM TRANSMITTER DIGITAL CONTROLLER ASSEMBLY 959 0430 3 2 3 3 MAIN BOARD CONTROLLER CIRCUIT BOARD ASSEMBLY 919 0436 3 2 3 4 FRONT PANEL CONTROLLER CIRCUIT BOARD 919 0437 3 5 ASSEMBLY 3 5 I O BOARD CONTROLLER CIRCUIT BOARD ...

Page 170: ... 10 50V SMD 007 1044 2 C33 Capacitor Ceramic 1 uF 10 50V SMD 007 1054 1 C34 Capacitor Electrolytic 330 uF 20 25V SMD 007 0331 1 C35 C36 Capacitor Ceramic 0 1 uF 10 50V SMD 007 1044 2 C37 thru C52 Capacitor Ceramic 390 pF 5 100V SMD 007 3923 16 C53 Capacitor Ceramic 0 1 uF 10 50V SMD 007 1044 1 C54 C55 Capacitor Tantalum 15 uF 10 35V SMD 070 1564 2 C56 C57 Capacitor Ceramic 0 1 uF 10 50V SMD 007 10...

Page 171: ...95 Potentiometer 100 k Top Adjust SMD 198 0104 1 R96 Resistor Chip 10 0 k Ohm 1 1 10W SMD 102 1002 1 R99 Resistor Chip 768 Ohm 1 1 10W SMD 102 7680 1 R100 Resistor Chip 1 00 k Ohm 1 1 10W SMD 102 1001 1 R101 R103 Resistor Chip 332 k Ohm 1 1 10W SMD 102 3323 2 R104 Resistor Chip 10 0 k Ohm 1 1 10W SMD 102 1002 1 R106 Resistor Chip 20 0 k Ohm 1 1 10W SMD 102 2002 1 R107 Resistor Chip 10 0 k Ohm 1 1 ...

Page 172: ...10 U22A U25A U19B thru U22B U25B U24A U25A Integrated Circuit 4N33 Optical Isolator NPN Photo 229 0033 9 U26A thru Transistor Infared Emitting Diode Type 1500V Isolation U28A U24B Response 30 kHz Maximum Current 50 mA Maximum 6 Pin DIP U26B thru U28B U29 U31 Integrated Circuit LT1491CS OP Amp Quad Micropower 224 1491 2 Rail To Rail Input and Output 14 Pin SO Package SMD U32 thru U34 Integrated Cir...

Page 173: ...10 Ohm 1 1 4W 103 1021 1 R31 Resistor 10 Ohm 1 1 4W 103 1021 1 R33 Resistor 536 Ohm 1 1 4W 103 5363 1 R34 Resistor 150 Ohm 1 1 4W 100 1531 1 R35 Resistor 442 Ohm 1 1 4W 103 4423 1 SW1 Switch TL 1251 G Pushbutton Momentary LED Illuminated 340 0140 1 Green SW2 Switch TL 1251 Y Pushbutton Momentary LED Illuminated 340 0139 1 Yellow SW3 Switch TL 1251 R Pushbutton Momentary LED Illuminated Red 340 014...

Page 174: ... 0027 2 27V D76 D77 Bidirectional Zener Transient Voltage Suppressor P6KE15CA RL 201 0015 2 15V D78 D79 Bidirectional Zener Transient Voltage Suppressor P6KE15CA RL 201 0015 2 15V D80 Diode HP5082 2800 High Voltage Schottky Barrier Type 201 2800 1 70V 15 mA D81 Diode 1N4005 Silicon 600V 1 Ampere 203 4005 1 FL1 thru FL46 Filter EMI 10 000 pF 3 Pin 411 0001 71 FL47 thru FL71 J1 Receptacle 37 Pin D F...

Page 175: ...r 4 32 k Ohm 1 1 4W 103 4324 1 R82 Resistor 8 66 k Ohm 1 1 4W 100 8641 1 R90 thru R92 Resistor 51 1 Ohm 1 1 4W 103 5112 3 R94 thru R98 Resistor 51 1 Ohm 1 1 4W 103 5112 5 Blank I O Board Controller Circuit Board 519 0438 1 TABLE 3 6 HARNESS FM DIGITAL CONTROLLER ASSEMBLY 949 0423 REF DES DESCRIPTION PART NO QTY Connector Male 9 Pin 417 0181 1 Socket Connector 50 Pin 417 0228 4 Housing SL 156 3 Pos...

Page 176: ...SMITTER CONTROLLER SB959 0430 4 2 SCHEMATIC DIAGRAM EMI FILTER CIRCUIT BOARD SB919 0438 4 3 ASSEMBLY DIAGRAM EMI FILTER CIRCUIT BOARD AC919 0438 4 4 SCHEMATIC DIAGRAM MAIN CIRCUIT BOARD SB919 0436 4 5 ASSEMBLY DIAGRAM MAIN CIRCUIT BOARD AC919 0436 4 6 SCHEMATIC DIAGRAM FRONT PANEL CIRCUIT BOARD SB919 0437 4 7 ASSEMBLY DIAGRAM FRONT PANEL CIRCUIT BOARD AC919 0437 4 8 ASSEMBLY DIAGRAM TRANSMITTER CO...

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