Broadcast Electronics AM-6A Manuale utente
AM–10A 10 KILOWATT
AM–6A 6 KILOWATT
AM BROADCAST
TRANSMITTERS
July, 1999 IM No. 597–1113
IMPORTANT INFORMATION
EQUIPMENT LOST OR DAMAGED IN TRANSIT.
When delivering the equipment to you, the truck driver or carrier’s agent will present a receipt for your signature.
Do not sign it until you have: 1) inspected the containers for visible signs of damage and 2) counted the containers
and compared with the amount shown on the shipping papers. If a shortage or evidence of damage is noted, insist
that notation to that effect be made on the shipping papers before you sign them.
Further, after receiving the equipment, unpack it and inspect thoroughly for concealed damage. If concealed dam-
age is discovered, immediately notify the carrier, confirming the notification in writing, and secure an inspection re-
port. This item should be unpacked and inspected for damage WITHIN 15 DAYS after receipt. Claims for loss or
damage will not be honored without proper notification of inspection by the carrier.
RF PRODUCT TECHNICAL ASSISTANCE – REPAIR SERVICE – REPLACEMENT PARTS.
Technical assistance is available from Broadcast Electronics by letter, prepaid telephone, fax, or E–mail. Equip-
ment requiring repair or overhaul should be sent by common carrier, prepaid, insured, and well protected. If proper
shipping materials are not available, contact the Customer Service Department for a shipping container. Do not the
mail equipment. We can assume no liability for inbound damage, and necessary repairs become the obligation of
the shipper. Prior arrangement is necessary. Contact the Customer Service Department for a Return Authoriza-
tion.
Emergency and warranty replacement parts may be ordered from the following address. Be sure to include the
equipment model number, serial number, part description, and part number. Non–emergency 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
Web Site: www.bdcast.com
RF PRODUCT TECHNICAL ASSISTANCE – REPAIR – EMERGENCY/WARRANTY REPLACEMENT PARTS –
Telephone: (217) 224–9600
E–Mail: [email protected]
Fax: (217) 224–9607
NON–EMERGENCY REPLACEMENT PARTS –
Fax: (217) 224–9609
RETURN, REPAIR, AND EXCHANGES.
Do not return any merchandise without our written approval and Return Authorization. We will provide special ship-
ping instructions and a code number that will assure proper handling and prompt issuance of credit. Please furnish
complete details as to circumstances and reasons when requesting return of merchandise. All returned merchan-
dise must be sent freight prepaid and properly insured by the customer.
WARRANTY ADJUSTMENT.
Broadcast Electronics, Inc. warranty is included in the Terms and Conditions of Sale. In the event of a warranty
claim, replacement or repair parts will be supplied F.O.B. factory. At the discretion of Broadcast Electronics, the
customer may be required to return the defective part or equipment to Broadcast Electronics, Inc. F.O.B. Quincy,
Illinois. Warranty replacements of defective merchandise will be billed to your account. This billing will be cleared
by a credit issued upon return of the defective item.
PROPRIETARY NOTICE.
This document contains proprietary data of Broadcast Electronics, Inc. No disclosure, reproduction, or use of any
part thereof may be made except by prior written permission.
MODIFICATIONS.
Broadcast Electronics, Inc. reserves the right to modify the design and specifications of the equipment in this manu-
al without notice. Any modifications shall not adversely affect performance of the equipment so modified.
WARNING
OPERATING HAZARDS
READ THIS SHEET AND OBSERVE ALL SAFETY PRECAUTIONS
ALL PERSONS WHO WORK WITH OR ARE EXPOSED TO POWER TRANSISTORS MUST TAKE PRECAUTIONS
TO PROTECT THEMSELVES AGAINST POSSIBLE SERIOUS BODILY INJURY. EXERCISE EXTREME CARE
AROUND SUCH PRODUCTS. UNINFORMED OR CARELESS OPERATION OF THESE DEVICES CAN RESULT
IN POOR PERFORMANCE, DAMAGE TO THE DEVICE OR PROPERTY, SERIOUS BODILY INJURY, AND POSSI-
BLY DEATH.
DANGEROUS HAZARDS EXIST IN THE OPERATION OF POWER TRANSISTORS
The operation of power tubes and power transistors involves one or more of the following hazards, any one of which,
in the absence of safe operating practices and precautions, could result in serious harm to personnel.
A. HIGH VOLTAGE – Normal operating voltages can be deadly. Additional information follows.
B. RF RADIATION – Exposure to RF radiation may cause serious bodily injury possibly resulting in
blindness or death. Cardiac pacemakers may be affected. Additional information follows.
C. BERYLLIUM – OXIDE POISONING – Dust or fumes from BeO ceramics used as thermal links with
power transistors are highly toxic and can cause serious injury or death. Additional information follows.
D. HOT SURFACES – Surfaces of air–cooled heat sinks radiators can reach temperatures of 100 degrees
centigrade and cause burns if touched. Additional information follows.
E. RF BURNS – Circuit boards with RF power transistors contain high RF potentials. Do not operate an RF
power module with the cover removed.
HIGH VOLTAGE
The transmitter operates at voltages high enough to kill through electrocution. Personnel should always break the
primary circuits when access to the transmitter is required.
RADIO FREQUENCY RADIATION
Exposure of personnel to RF radiation should be minimized, personnel should not be permitted in the vicinity of open
energized RF generating circuits, or RF transmission systems (waveguides, cables, connectors, etc.), or energized
antennas. It is generally accepted that exposure to “high levels” of radiation can result in severe bodily injury includ-
ing blindness. 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 10 mW/cm2per one tenth hour average level has been adopted by several U.S. Government agen-
cies including the Occupational Safety and Health Administration (OSHA) as the standard protection guide for em-
ployee work environments. An even stricter standard is recommended by the American National Standards Institute
which recommends a 1.0 mW/cm2per one tenth hour average level exposure between 30 Hz and 300 MHz as the
standard employee protection guide (ANSI C95.1–1982).
RF energy must be contained properly by shielding and transmission lines. All input and output RF connections, such
as cables, flanges and gaskets must be RF leakproof. Never operate a power tube without a properly matched RF
energy absorbing load attached. Never look into or expose any part of the body to an antenna, open RF generating
circuit, or RF transmission system while energized. Monitor the tube and RF system for RF radiation leakage at regu-
lar intervals and after servicing.
DANGER –– BERYLLIUM OXIDE CERAMICS (BeO) – AVOID BREATHING DUST OR FUMES
BeO ceramic material is used as a thermal link to carry heat from a transistor to the heat sink. Do not perform any
operation on any BeO ceramic which might produce dust or fumes, such as grinding, grit blasting, or acid cleaning.
Beryllium oxide dust or fumes are highly toxic and breathing them can result in serious personal injury or death. BeO
ceramics must be disposed of only in a manner prescribed by the device manufacturer.
HOT SURFACES
Heat sinks and reject loads are air–cooled or conduction–cooled. The air–cooled external surface can operate at a
high temperature (up to 100°C). All hot surfaces may remain hot for an extended time after the transmitter is oper-
ated to off. To prevent serious burns, take care to prevent and avoid any bodily contact with these surfaces both dur-
ing and for a reasonable cooling down period after operation.
TRANSMITTER WARRANTY VOID NOTICE
THE PRODUCT WARRANTY WILL BE VOID IF THE
TRANSMITTER IS INSTALLED AT A SITE WITH
INADEQUATE LIGHTNING PROTECTION AND A
DEFECTIVE TRANSMISSION LINE SYSTEM.
The transmitter is covered by a two year limited product warranty from Broadcast ElecĆ
tronics. However, the transmitter must be properly installed at a site with adequate
lightning protection and transmission line systems. TO ENSURE THE TRANSMITĆ
TER WARRANTY IS VALID, the transmitter must be installed: ) as described by the
INSTALLATION procedures presented in SECTION II of this manual, 2) at a transmitter
site with a lightning protection system described in TRANSMITTER SITE LIGHTNING
PROTECTION SYSTEM CHECKOUT (refer to SECTION II of this manual), and 3) at a
transmitter site with a transmission line system described in TRANSMISSION LINE
AND ANTENNA CHECKOUT (refer to SECTION II of this manual). FAILURE TO
PROPERLY INSTALL THE TRANSMITTER, PROVIDE AN ADEQUATE LIGHTĆ
NING PROTECTION SYSTEM, OR PROVIDE AN ADEQUATE TRANSMISSION
LINE SYSTEM WILL VOID THE WARRANTY ON THE TRANSMITTER. If any
questions develop concerning the transmitter warranty and installation site systems, conĆ
tact the Broadcast Electronics Customer Service Department.
BROADCAST ELECTRONICS, INC.
NOTICE TO THE EQUIPMENT USER
FCC Rule 73. 590 mandates the licensee of each AM station to make measurements for
spurious and harmonic emissions to show compliance with the transmission system reĆ
quirements of Section 73.44 of the Commission's Rules. It is the broadcast station's responĆ
sibility to ensure that the audio signal applied to a Broadcast Electronics A-Series AM
transmitter conforms to the audio standard NRSC- (published as ANSI/EIA-549- 988).
This is a mandatory requirement to ensure that the equipment complies to Section 73.44
and Section 73. 28(C) of the Commission's Rules.
BROADCAST ELECTRONICS, INC.
WARNING WARNING
OPERATING HAZARDS
WARNING
WARNING
THE TRANSMITTER CONTAINS MULTIPLE CIRCUIT
GROUNDS WITH HIGH AC AND DC POTENTIALS WITH
RESPECT TO THE CABINET WHICH IS AT EARTH POĆ
TENTIAL. DO NOT ENERGIZE THE TRANSMITTER
WITH TEST EQUIPMENT CONNECTED TO THE
TRANSMITTER OUTPUT NETWORK, RF POWER MODĆ
ULE, RF COMBINER, OR POWER SUPPLY COMPOĆ
NENTS.
The Broadcast Electronics AM transmitters contain high voltages and currents. If safety precautions are
not practiced, contact with the high voltages and currents could cause serious injury or death. The transĆ
mitter is equipped with many built-in safety features, however good judgement, care, and common sense
must be practiced to prevent accidents.
In addition to high voltages and currents, the AM transmitters contain multiple circuit grounds with
high ac and dc potentials with respect to the cabinet which is at earth potential. The potentials could
cause serious injury or death if maintenance personnel simultaneously touch a circuit ground and the
cabinet. As a result, operation of the transmitter with test equipment connected to transmitter output
network, RF power module, RF combiner, or power supply components is extremely dangerous and must
not be attempted. Therefore, never energize the transmitter with test equipment connected to the transĆ
mitter output network, RF power module, RF combiner, or power supply components. Test equipment
may be connected to the ECU circuit boards from the front of the transmitter using the supplied extender
circuit board with power energized if required.
Broadcast Electronics 997
ALL RIGHTS RESERVED
Printed in the U.S.A.
-i -
SCOPE OF MANUAL
This manual consists of two sections which provides the following information for the Broadcast
Electronics AM- 0A and AM-6A AM Broadcast Transmitters.
A. PART I - Contains information relative to installation, operation, and
maintenance applicable to the overall transmitter.
B. PART II - Contains detailed information for the following transmitter
modular units.
. POWER SUPPLY ASSEMBLY
2. RF POWER MODULE
3. OUTPUT NETWORK
4. EXCITER/CONTROLLER UNIT (ECU)
PART I - TABLE OF CONTENTS
PARAGRAPH PAGE NO.
SECTION I GENERAL INFORMATION
- INTRODUCTION -
-3 EQUIPMENT DESCRIPTION -
-4 GENERAL -
-6 EXCITER/CONTROL UNIT -
- 2 OUTPUT NETWORK ASSEMBLY -4
- 3 RF POWER MODULE -4
- 5 POWER SUPPLY -4
- 6 COMBINER ASSEMBLY -4
- 7 TRANSMITTER CONFIGURATIONS -5
- 9 ACCESSORIES AND SPARE PARTS KITS -5
-2 EQUIPMENT SPECIFICATIONS -5
SECTION II INSTALLATION
2- INTRODUCTION 2-
2-3 UNPACKING 2-
2-6 ENVIRONMENTAL REQUIREMENTS 2-
2-8 COOLING AIR REQUIREMENTS 2-
2- 2 PRIMARY POWER 2-
2- 3 THREE-PHASE AM- 0A/AM-6A 2-
2- 6 SINGLE-PHASE AM- 0A/AM-6A 2-2
2- 7 INSTALLATION 2-2
2- 9 EQUIPMENT PLACEMENT 2-2
2-22 COMPONENT INSTALLATION 2-2
2-25 ECU CIRCUIT BOARDS 2-8
2-26 RF POWER MODULES 2-8
2-27 POWER SUPPLY 2-8
2-28 BATTERY INSTALLATION 2-
2-29 CIRCUIT BOARD PROGRAMMING 2-
2-3 EXCITER CIRCUIT BOARD 2-
-ii -
PARAGRAPH PAGE NO.
2-40 STEREO CIRCUIT BOARD 2- 3
2-45 CONTROLLER CIRCUIT BOARD 2- 3
2-58 POWER SUPPLY CIRCUIT BOARD 2- 7
2-6 REMOTE CONTROL 2- 7
2-62 GENERAL 2- 7
2-87 WIRING 2-20
2-89 AUDIO INPUT CONNECTION 2-20
2-9 EXTERNAL STEREO RF INPUT 2-20
2-92 AM- 0A RF TRANSMISSION LINE CONNECTION 2-20
2-93 AM-6A RF TRANSMISSION LINE CONNECTION 2-2
2-94 EXTERNAL INTERLOCK 2-23
2-95 MODULATION MONITOR 2-23
2-96 AC POWER CONNECTIONS 2-23
2- 0 GROUND 2-24
2- 02 TRANSMITTER SITE LIGHTNING PROTECTION 2-29
SYSTEM CHECKOUT
2- 04 ANTENNA BALL-GAP LIGHTNING ARRESTOR 2-29
2- 08 ANTENNA-TUNING-UNIT SPARK-GAP 2-29
LIGHTNING ARRESTOR
2- 09 TRANSMITTER SITE GROUNDING SYSTEM 2-3
2- 0 CABLE PROTECTION 2-3
2- 6 ANTENNA RF FEED LINE 2-3
2- 7 TRANSMISSION LINE AND ANTENNA CHECKOUT 2-3
2- 9 ANTENNA VSWR 2-32
2- 20 COAXIAL SWITCH CONTROLLER 2-32
2- 2 ATU AND PHASOR CHECKOUT 2-32
2- 22 INITIAL CHECKOUT 2-32
2- 24 PRELIMINARY OPERATION AND ADJUSTMENT 2-32
2- 26 TUNING 2-33
2- 32 POWER LEVEL AND MODULATION MONITOR 2-33
CALIBRATION ADJUSTMENTS
2- 44 STEREO ADJUSTMENT 2-35
2- 55 SINGLE CHANNEL LEVEL 2-37
SECTION III OPERATION
3- INTRODUCTION 3-
3-3 CONTROLS AND INDICATORS 3-
3-5 OPERATION 3- 3
3-6 TURN-ON 3- 3
3- 4 TURN OFF 3- 4
3- 6 METERING 3- 4
3- 7 FORWARD POWER 3- 4
3- 8 REFLECTED POWER 3- 4
3- 9 POWER ADJUST 3- 4
3-2 MONO/STEREO OPERATION 3- 5
3-23 STEREO OPERATION 3- 5
3-24 MONO OPERATION 3- 5
3-27 PILOT CONTROL 3- 5
3-29 EXCITER MONITOR OPERATION 3- 5
3-3 MONO/STEREO INDICATIONS 3- 5
3-32 INPUT SELECTION 3- 5
-iii-
PARAGRAPH PAGE NO.
3-33 POLARITY SELECTION 3- 5
3-34 X 0 AUTORANGE INDICATIONS 3- 6
3-35 FAULT RESET 3- 6
3-37 POWER SUPPLY FAULT RESET 3- 6
3-39 OVER-CYCLE OFF 3- 6
3-4 OVER-MODULATION PWM MUTE 3- 6
3-43 TRANSMITTER MONITOR 3- 6
3-45 BATTERY TEST 3- 6
3-47 CONTROLLER PWM MUTE INDICATOR 3- 7
3-49 CONTROLLER REMOTE FAIL-SAFE INDICATOR 3- 7
3-5 EXCITER LOCK INDICATOR 3- 7
3-53 EXCITER +5V/+ 5V/- 5V INDICATORS 3- 7
3-55 STEREO EQUALIZATION INDICATORS 3- 7
3-57 RF POWER MODULE INDICATORS 3- 7
3-59 POWER SUPPLY INDICATORS 3- 7
3-6 EXCITER NEGATIVE LIMITER INDICATOR 3- 7
3-63 HIGH AC LINE CONDITIONS 3- 7
SECTION IV THEORY OF OPERATION
4- INTRODUCTION 4-
4-5 FUNCTIONAL DESCRIPTION 4-
4-6 ECU 4-
4-7 GENERAL 4-
4-8 STEREO CIRCUIT BOARD 4-
4- EXCITER CIRCUIT BOARD 4-
4- 3 CONTROLLER CIRCUIT BOARD 4-2
4- 8 POWER SUPPLY 4-2
4- 9 RF POWER MODULE 4-2
4-24 RF COMBINER 4-7
4-27 OUTPUT NETWORK 4-7
4-3 POWER SUPPLY 4-8
4-34 POWER SUPPLY CIRCUIT BOARD 4-8
4-39 METERING 4-8
4-42 COOLING FANS 4-9
4-44 INTERFACE CIRCUIT BOARD 4-9
4-46 DETAILED DESCRIPTION 4-9
4-47 POWER SUPPLIES 4-9
4-49 AC INPUT CIRCUITRY 4-9
4-5 ECU POWER SUPPLY ASSEMBLY 4-9
4-55 TRANSMITTER FLUSHING FANS 4- 0
4-58 LOW-VOLTAGE POWER SUPPLY TRANSFORMER 4- 0
4-60 POWER SUPPLY CIRCUIT BOARD 4- 0
4-63 CONVENTIONAL RECTIFIER CIRCUITRY 4- 0
4-66 SWITCHING POWER SUPPLY CIRCUIT 4- 3
4-74 MODULATOR CIRCUIT BOARD 4- 4
4-79 POWER AMPLIFIER CIRCUIT BOARDS 4- 4
4-84 SEQUENCE OF OPERATION 4- 5
4-89 RF CIRCUITRY 4- 5
4-90 EXCITER CIRCUIT BOARD 4- 5
4-96 STEREO CIRCUIT BOARD 4- 9
4- 00 RF POWER MODULE 4-20
-iv-
PARAGRAPH PAGE NO.
4- 07 RF COMBINER 4-2
4- 08 HARMONIC BAND-PASS FILTER 4-2
4- 09 DIRECTIONAL COUPLER CIRCUIT BOARD 4-2
4- 3 T-MATCHING NETWORK 4-22
4- 4 LIGHTNING PROTECTION CIRCUIT BOARD 4-22
4- 5 LIGHTNING DETECTION CIRCUIT BOARD 4-22
4- 7 RF OUTPUT POWER CONTROL CIRCUITRY 4-22
SECTION V MAINTENANCE
5- INTRODUCTION 5-
5-3 SAFETY CONSIDERATIONS 5-
5-6 FIRST LEVEL MAINTENANCE 5-
5-8 ROUTINE MAINTENANCE 5-
5-9 INSPECTION AND CLEANING 5-2
5- 0 CONTROLLER BATTERY 5-2
5- AIR FILTERS 5-2
5- 2 FLUSHING FANS 5-2
5- 4 SPARK GAP 5-2
5- 5 SECOND LEVEL MAINTENANCE 5-2
5- 8 ELECTRICAL ADJUSTMENTS 5-4
5-20 TRANSMITTER FREQUENCY RE-PROGRAMMING 5-4
5-22 TROUBLESHOOTING 5-4
5-24 TRANSMITTER INDICATORS 5-5
5-25 RF POWER MODULE REMOVAL 5-8
5-26 TRANSMITTER TROUBLESHOOTING 5-9
PROCEDURES
5-27 TRANSMITTER COMPONENT LOCATIONS 5-9
5-28 COMPONENT REPLACEMENT PROCEDURE 5- 3
5-34 INTEGRATED CIRCUITS 5- 4
SECTION VI PARTS LIST
6- INTRODUCTION 6-
SECTION VII DRAWINGS
7- INTRODUCTION 7-
LIST OF TABLES
TABLE DESCRIPTION PAGE NO.
- ELECTRICAL CHARACTERISTICS -6
-2 PHYSICAL AND ENVIRONMENTAL -9
CHARACTERISTICS
3- AM- 0A/AM-6A CONTROLS AND INDICATORS 3-
3-2 ECU CONTROLS AND INDICATORS 3-5
3-3 POWER MODULE CONTROLS AND INDICATORS 3- 2
5- AM- 0A INDICATORS 5-5
5-2 AM- 0A/AM-6A TROUBLESHOOTING 5-9
6- AM- 0/AM-6A REPLACEABLE PARTS LIST INDEX 6-
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