User ManualTable of ContentsWARNINGS1SCOPE OF MANUAL5PART I - TABLE OF CONTENTS5PART II - TABLE OF CONTENTS9GENERAL INFORMATION10INTRODUCTION SECTION I10EQUIPMENT DESCRIPTION10GENERAL10EXCITER/CONTROL UNIT10Stereo Circuit Board10Exciter Circuit Board13Controller Circuit Board13OUTPUT NETWORK ASSEMBLY13RF POWER MODULE13POWER SUPPLY13COMBINER ASSEMBLY13TRANSMITTER CONFIGURATIONS14ACCESSORIES AND SPARE PARTS KITS14EQUIPMENT SPECIFICATIONS14INSTALLATION20INTRODUCTION SECTION II20UNPACKING20ENVIRONMENTAL REQUIREMENTS20COOLING AIR REQUIREMENTS20PRIMARY POWER20INSTALLATION20EQUIPMENT PLACEMENT21COMPONENT INSTALLATION21ECU CIRCUIT BOARDS21RF POWER MODULES21POWER SUPPLY24BATTERY INSTALLATION25CIRCUIT BOARD PROGRAMMING25EXCITER CIRCUIT BOARD25External Stereo Generator Select25Carrier Frequency Programming25PWM Frequency Programming25Frequency Synthesizer Programming25Pilot Tone Programming25High-Pass Filter Defeat25High Frequency Boost Defeat25Monophonic Transmitter Operation Channel Select28STEREO CIRCUIT BOARD28Antenna C Equalization Select28Bandpass Filter Alignment28Bandpass Filter Programming28Equalization Control Select28CONTROLLER CIRCUIT BOARD28Power Level Trim Reset Select28Antenna Power Level Programming28AC Power Failure Automatic Transmitter Shutdown Time28Antenna Interlock Control Select28Power Level Reference31Power Level 3 Assignment31Remote Reflected Power Sample Voltage Programming31Remote Forward Power Sample Voltage Programming31High Forward Power Defeat31Reflected/Forward Power Sample Programming31Forward Power Reference Voltage Programming31Temperature Sense31POWER SUPPLY CIRCUIT BOARD31Future Corrector Circuit31Model Programming31REMOTE CONTROL32GENERAL32Power Level Controls/Indicators32Transmitter Off Control/Indicator32Power Level Raise/Lower Controls32Antenna Interlock Input32Transmitter Mute Input32Remote Failsafe Input32External Interlock Input32Interlock +5V32Exciter Mode Controls/Indicators32Remote Forward/Reflected Power Meter Indications32Remote Enabled Indications35Maintenance Indications35Lightning Indications351.2:1 VSWR Indications35Exciter/PWR Supply/PWR Module Fault Indications35RFL PWR High Indications35RFL PWR Emergency Indications35Overtemp Indications35Foldback Indications35Alarm Status Indications35Alarm Reset Control35Emergency Off Indications36WIRING36AUDIO INPUT CONNECTION36EXTERNAL STEREO RF INPUT36AM-2.5E/AM-5E RF TRANSMISSION LINE CONNECTION36EXTERNAL INTERLOCK36MODULATION MONITOR36AC POWER CONNECTIONS38Main ac Input - AM-2.5E38Main ac Input - AM-5E38GROUND38TRANSMITTER SITE LIGHTNING PROTECTION SYSTEM CHECKOUT38ANTENNA BALL-GAP LIGHTNING ARRESTOR41Ball-Gap Position41Ball-Gap Separation41ANTENNA-TUNING-UNIT SPARK-GAP LIGHTNING ARRESTOR41TRANSMITTER SITE GROUNDING SYSTEM41CABLE PROTECTION42Ferrite Core42Modulation Monitor Core42Audio/Remote Control/Status Core42Ac Input core42RF Output Core42ANTENNA RF FEED LINE42TRANSMISSION LINE AND ANTENNA CHECKOUT42ANTENNA VSWR42COAXIAL SWITCH CONTROLLER42ATU AND PHASOR CHECKOUT44INITIAL CHECKOUT44PRELIMINARY OPERATION AND ADJUSTMENT44TUNING44POWER LEVEL AND MODULATION MONITOR CALIBRATION ADJUSTMENTS45STEREO ADJUSTMENT46SINGLE CHANNEL LEVEL48OPERATION51INTRODUCTION SECTION III51CONTROLS AND INDICATORS51OPERATION61TURN-ON61TURN-OFF62METERING62FORWARD POWER62REFLECTED POWER62POWER ADJUST62MONO/STEREO OPERATION63STEREO OPERATION63MONO OPERATION63Mono Operation - Stereo Circuit Board63Mono Operation - No Stereo Circuit Board63PILOT CONTROL63EXCITER MONITOR OPERATION63MONO/STEREO INDICATIONS63INPUT SELECTION63POLARITY SELECTION64X10 AUTORANGE INDICATIONS64FAULT RESET64POWER SUPPLY FAULT RESET64OVER-CYCLE OFF64OVER-MODULATION PWM MUTE64TRANSMITTER MONITOR64BATTERY TEST64CONTROLLER PWM MUTE INDICATOR65CONTROLLER REMOTE FAIL-SAFE INDICATOR65EXCITER LOCK INDICATOR65EXCITER +5V/+15V/-15V INDICATORS65STEREO EQUALIZATION INDICATORS65RF POWER MODULE INDICATORS65POWER SUPPLY INDICATORS65EXCITER NEGATIVE LIMITER INDICATOR65HIGH/LOW AC LINE CONDITIONS65THEORY OF OPERATION66INTRODUCTION SECTION IV66FUNCTIONAL DESCRIPTION66ECU66GENERAL66STEREO CIRCUIT BOARD66EXCITER CIRCUIT BOARD66CONTROLLER CIRCUIT BOARD67POWER SUPPLY67RF POWER MODULE67RF COMBINER70OUTPUT NETWORK70POWER SUPPLY71POWER SUPPLY CIRCUIT BOARD71METERING72COOLING FANS72INTERFACE CIRCUIT BOARD (AM-5E ONLY)72DETAILED DESCRIPTION72POWER SUPPLIES72AC INPUT CIRCUITRY72ECU POWER SUPPLY ASSEMBLY73TRANSMITTER FLUSHING FANS73LOW-VOLTAGE POWER SUPPLY TRANSFORMER73POWER SUPPLY CIRCUIT BOARD73CONVENTIONAL RECTIFIER CIRCUITRY75SWITCHING POWER SUPPLY CIRCUIT75Rectifier/Soft-Start Circuit75Switching Regulator Circuit75MODULATOR CIRCUIT BOARD76POWER AMPLIFIER CIRCUIT BOARDS77SEQUENCE OF OPERATION77RF CIRCUITRY78EXCITER CIRCUIT BOARD78STEREO CIRCUIT BOARD79RF POWER MODULE79Modulator Circuit Board82Power Amplifier Circuit Boards82RF COMBINER82HARMONIC BAND-PASS FILTER83DIRECTIONAL COUPLER CIRCUIT BOARD83Forward and Reflected Power Sample Circuit83Modulation Monitor Calibration Circuit83T-MATCHING NETWORK83LIGHTNING PROTECTION CIRCUIT BOARD83LIGHTNING DETECTION CIRCUIT BOARD84RF OUTPUT POWER CONTROL CIRCUITRY84RF Output Power Control - Controller Circuit Board84Automatic Power Control Circuitry84Forward/Reflected Power Circuitry85Meter Switch Circuit Board85RF Output Power Control - Power Supply Circuit Board/RF Power Modules85MAINTENANCE86INTRODUCTION SECTION V86SAFETY CONSIDERATIONS86FIRST LEVEL MAINTENANCE86ROUTINE MAINTENANCE86INSPECTION AND CLEANING87CONTROLLER BATTERY87AIR FILTERS87FLUSHING FANS87SPARK GAP87SECOND LEVEL MAINTENANCE87ELECTRICAL ADJUSTMENTS89TRANSMITTER FREQUENCY RE-PROGRAMMING89TROUBLESHOOTING89TRANSMITTER INDICATORS90RF POWER MODULE REMOVAL93TRANSMITTER TROUBLESHOOTING PROCEDURES93TRANSMITTER COMPONENT LOCATIONS93COMPONENT REPLACEMENT PROCEDURE98INTEGRATED CIRCUITS99PARTS LIST108INTRODUCTION SECTION VI108DRAWINGS120INTRODUCTION SECTION VII120TABLE OF CONTENTS POWER SUPPLY138POWER SUPPLY THEORY OF OPERATION139INTRODUCTION SECTION I139GENERAL DESCRIPTION139AC INPUT139CONVENTIONAL RECTIFIER CIRCUITRY139SOFT-START CIRCUIT139AC LINE DETECTION/SYNCHRONIZATION140SOFT-START CONTROL CIRCUIT140POWER FACTOR CORRECTOR CIRCUIT BOARD CONTROL CIRCUIT140SCR CONTROLLED RECTIFIER CIRCUIT142FILTER CIRCUIT142POWER SUPPLY ENABLE CIRCUIT142SWITCHING REGULATOR CIRCUIT142LOW VOLTAGE POWER SUPPLY143SWITCHING REGULATOR CONTROL CIRCUIT143SWITCHING REGULATOR CIRCUIT OPERATION143POWER CONTROL/CORRECTION CIRCUIT143FAULT DETECTION144CROWBAR CIRCUIT144POWER SUPPLY CIRCUIT GROUNDS145POWER SUPPLY CIRCUIT BOARD MAINTENANCE146INTRODUCTION SECTION II146SAFETY CONSIDERATIONS146FIRST LEVEL MAINTENANCE146CLEANING AND INSPECTION146SECOND LEVEL MAINTENANCE147TROUBLESHOOTING147SAFETY CONSIDERATIONS147REMOVING/INSTALLING A POWER SUPPLY CIRCUIT BOARD147TROUBLESHOOTING PROCEDURES148COMPONENT REPLACEMENT PROCEDURE149POWER SUPPLY CIRCUIT BOARD PARTS LIST150INTRODUCTION SECTION III150POWER SUPPLY CIRCUIT BOARD DRAWINGS159INTRODUCTION SECTION IV159TABLE OF CONTENTS RF POWER MODULE165RF POWER MODULE THEORY OF OPERATION166INTRODUCTION SECTION I166GENERAL DESCRIPTION166MODULATOR CIRCUIT BOARD166MODULATOR CIRCUIT166FAULT DETECTION CIRCUITS166PWM Drive Fault Detector167Modulator Fault Detector167B+ Supply Fuse Fault Detector167B+ Power Supply Fault Detector167Modulator Status Circuit167POWER SUPPLY167RF AMPLIFIER CIRCUIT BOARD169PRE-DRIVER CIRCUIT169DRIVER CIRCUIT169RF AMPLIFIER CIRCUIT169RF DRIVE STATUS CIRCUIT170FAULT DETECTOR CIRCUIT170POWER SUPPLY CIRCUIT170RF POWER MODULE MAINTENANCE172INTRODUCTION SECTION II172SAFETY CONSIDERATIONS172FIRST LEVEL MAINTENANCE172CLEANING AND INSPECTION172SECOND LEVEL MAINTENANCE173TROUBLESHOOTING173SAFETY CONSIDERATIONS173RF POWER MODULE ASSEMBLY PROCEDURE174RF POWER MODULE EXCHANGE PROGRAM174TROUBLESHOOTING PROCEDURES174COMPONENT REPLACEMENT PROCEDURE174RF POWER MODULE PARTS LIST178INTRODUCTION SECTION III178RF POWER MODULE DRAWINGS187INTRODUCTION SECTION IV187TABLE OF CONTENTS OUTPUT NETWORK192OUTPUT NETWORK THEORY OF OPERATION193INTRODUCTION SECTION I193FUNCTIONAL DESCRIPTION193OUTPUT NETWORK MAINTENANCE194INTRODUCTION SECTION II194SAFETY CONSIDERATIONS194FIRST LEVEL MAINTENANCE194CLEANING AND INSPECTION194SECOND LEVEL MAINTENANCE195ELECTRICAL ADJUSTMENTS195MODULATION CALIBRATION CONTROLS195DIRECTIONAL COUPLER NULL CONTROLS195TROUBLESHOOTING195SAFETY CONSIDERATIONS195OUTPUT NETWORK ASSEMBLY COMPONENT LOCATIONS195TROUBLESHOOTING PROCEDURES196COMPONENT REPLACEMENT PROCEDURE196OUTPUT NETWORK ASSEMBLY PARTS LIST197INTRODUCTION SECTION III197OUTPUT NETWORK ASSEMBLY DRAWINGS207INTRODUCTION SECTION IV207TABLE OF CONTENTS ECU212ECU THEORY OF OPERATION215INTRODUCTION SECTION I215GENERAL DESCRIPTION215FUNCTIONAL DESCRIPTION215ECU DISPLAY CIRCUIT BOARD215EXCITER MONITOR MODE CONTROL CIRCUIT215AUTORANGE CIRCUIT216POLARITY CONTROL CIRCUIT216HALF-WAVE RECTIFIER CIRCUIT216METER CIRCUITRY216INDICATOR CIRCUITRY216RESET SWITCH216ECU SWITCH CIRCUIT BOARD216ECU METER SWITCH CIRCUIT BOARD217MOTHERBOARD217CONTROLLER CIRCUIT BOARD217CABINET/EXTERNAL INTERLOCK AND REMOTE CONTROL FAIL-SAFE217External Interlock217Remote Control Fail-safe218EXTERNAL MUTE218ANTENNA INTERLOCK218REMOTE CONTROL221POWER ON221POWER CONTROL CIRCUIT222Power Control Driver Circuit223POWER CONTROL TRIM CIRCUIT223Trim Reset223TRANSMITTER OFF223AC POWER INTERRUPTIONS224FORWARD AND REFLECTED POWER CIRCUITRY224FOLDBACK PROTECTION225High Forward Power Circuitry225High Reflected Power Circuitry226Over-temperature Circuitry226Reflected Power Emergency227Lightning Conditions227Foldback Indication227ATTACK SIGNAL OPERATION2281.2:1 VSWR CONDITIONS228FOLDBACK RECOVERY228High Reflected Power Recovery228High Forward Power Recovery228High Reflected Power Release Signal229Over-Temperature Recovery229Reflected Power Emergency/Lightning Recovery229EXCITER MONITORING229POWER SUPPLY MONITORING230Power Supply Fault230Power Supply Emergency Condition230Power Supply Maintenance Condition230RF POWER MODULE MONITORING230RF Power Module Fault230RF Power Module Maintenance Condition230FAULT CIRCUIT231OSCILLATOR CIRCUIT231OVER-CYCLE OFF CIRCUIT231POWER SUPPLY CIRCUIT231EXCITER CIRCUIT BOARD232LEFT/RIGHT CHANNEL INPUT CIRCUIT232MONO MODE SWITCHING23424 uS DELAY CIRCUIT234NEGATIVE LIMITER234IPM CORRECTION CIRCUIT234PWM CIRCUIT234PWM DRIVER CIRCUIT235FREQUENCY SYNTHESIZER235PWM REFERENCE CIRCUIT235LOCK DETECTOR CIRCUIT236STEREO DETECTION CIRCUIT236IPM WAVE SHAPE CIRCUIT236PHASE MODULATOR CIRCUIT236RF DRIVE CIRCUIT237EXCITER FAILURE DETECTOR CIRCUIT237POWER SUPPLY CIRCUITS237STEREO CIRCUIT BOARD237EQUALIZATION CIRCUITRY2378 MICROSECOND DELAY CIRCUIT2394 MICROSECOND DELAY CIRCUIT239ALL-PASS FILTER239EQUALIZATION SELECTION CIRCUIT239L+R AND L-R MATRIX CIRCUIT239PHASE MODULATOR CIRCUIT240BAND-PASS FILTER241TRANSISTOR AMPLIFIER CIRCUIT241AMPLITUDE LIMITER CIRCUIT241OUTPUT NETWORK241OPERATING MODE SELECTION AND INDICATION CIRCUIT241EQUALIZATION SELECTION242PILOT SIGNAL242POWER SUPPLY FILTER NETWORK242ECU POWER SUPPLY ASSEMBLY242TRANSMITTER ECU MAINTENANCE244INTRODUCTION SECTION II244SAFETY CONSIDERATIONS244ECU CIRCUIT BOARD INSTALLATION/REMOVAL244FIRST LEVEL MAINTENANCE245CLEANING AND INSPECTION245SECOND LEVEL MAINTENANCE245ELECTRICAL ADJUSTMENTS245ECU EXTENDER CIRCUIT BOARD OPERATION246CONTROLLER CIRCUIT BOARD ADJUSTMENTS246P1 SET - P5 SET CONTROLS246FWD AND RFL CALIBRATIONS246ECU METER SWITCH CIRCUIT BOARD ADJUSTMENTS246FORWARD POWER METER LOW AND HIGH SCALE CALIBRATIONS246REFLECTED POWER METER LOW AND HIGH SCALE CALIBRATIONS246FWD AND RFL CALIBRATIONS247STEREO CIRCUIT BOARD ADJUSTMENTS247STEREO ADJUSTMENT247EXCITER CIRCUIT BOARD ADJUSTMENTS247MODULATION CALIBRATION247PHASE MODULATOR CALIBRATION247SYMMETRY CONTROL247IPM CORRECTION CIRCUIT CONTROLS247SINGLE CHAN MONO LEVEL CONTROL247AVERAGE MODULATION LIMIT CONTROL247NEG LIMIT CONTROL247Procedure248FREQUENCY CALIBRATION CONTROL248Procedure248DISPLAY CIRCUIT BOARD ADJUSTMENTS249L/L+R AND R/L-R DISPLAY CALIBRATION CONTROL249Procedure249TROUBLESHOOTING249SAFETY CONSIDERATIONS249TROUBLESHOOTING PROCEDURES250COMPONENT REPLACEMENT PROCEDURE254ECU ASSEMBLY PARTS LIST255INTRODUCTION SECTION III255ECU ASSEMBLY DRAWINGS290INTRODUCTION SECTION IV290Size: 5.69 MBPages: 320Language: EnglishOpen manual
