® FM10000 RF Transmitter Package User's Manual ©2006 Crown Broadcast, a division of International Radio and Electronics, Inc. 25166 Leer Drive, Elkhart, Indiana, 46514-5425 U.S.A.
Revision Control Revision Print Date Initial Release (Rev. 1) April 2006 Important Notices ©2006, Crown Broadcast, a division of International Radio and Electronics Corp. All rights reserved. No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any language in any form by any means without the written permission of Crown Broadcast. Printed in U.S.A. Crown attempts to provide information that is accurate, complete, and useful.
Contents Section 1 – Getting Acquainted 1.1 Your Transmitter Package ……………………………………… 1.2 Transmitter Package Specifications ……………………………. 1.3 Safety Considerations ………………………………………….. 1.3.1 Dangers ………………………………………………………. 1.3.2 Warnings ……………………………………………………… 1.3.3 Cautions ………………………………………………………. 1-2 1-3 1-4 1-4 1-4 1-4 Section 2 – Installation 2.1 Operating Environment ………………………………………… 2.2 Tools Required ………………………………………………… 2.3 Unpacking ……………………………………………………… 2.4 Installation ……………………………………………………… 2.4.
Section 4 – Reference Drawings 4.1 4.2 4.3 4.4 Views ……………………………………………………………. System Block Diagram ………………………………………….. Transmitter Controller Board Component ID …………………… Transmitter Controller Board Schematic ………………………... 4-2 4-4 4-5 4-6 Section 5 – Service and Support 5.1 Service …………………………………………………………… 5-2 5.2 24-Hour Support ………………………………………………… 5-2 5.3 Spare Parts ………………………………………………………. 5-2 Warranty Statement …………………………………………………..
I INFORMATION Section 1—Getting Acquainted This section provides a general description of the FM10000 transmitter system and introduces you to safety conventions used within this document. Review this material before installing or operating the system.
I 1.1 Your Transmitter Package The FM10000 is a highly efficient transmitter package designed to set a new standard in FM transmitter design offering modularity, ease of use, and long-term reliability. The FM10000 package has five (5) PA2000-10K amplifiers, three (3) 5,600 watt power supplies, a transmitter controller, a low pass filter and an optional FM250. The FM10000 transmitter package requires no tuning and typically provides 80% RF efficiency.
1.2 Transmitter Package Specifications RF Power Output: 2500 to 11000 watts continuous with remote controlled power adjust RF Drive Requirement: 250 watts for full output RF Output Impedance: 50 ohms (unbalanced) Maximum SWR: 2.
I 1.3 Safety Considerations Crown Broadcast assumes the responsibility for providing you a safe product and safety guidelines during its use. “Safety” means protection to all individuals who install, operate, and service the transmitter as well as protection of the transmitter itself. To promote safety, we use standard hazard alert labeling on the product and in this manual. Follow the associated guidelines to avoid potential hazard. 1.3.1 Dangers DANGER represents the most severe hazard alert.
® Section 2—Installation This section provides important guidelines for installing your transmitter. Review this information carefully for proper installation.
2.1 Operating Environment You can install the FM10000 transmitter on any flat surface which should be clean and well-ventillated as possible. 2.2 Tools Required To install the FM10000, you will need the following tools: ❑ Medium phillips screwdriver ❑ Small flat-blade screwdriver ❑ 3/16 / inch hex driver ❑ 1/2 inch wrench and/or nut driver ❑ ESD (Electrostatic Discharge) protection grounding strap and/or mat. 2.3 Unpacking 1) Remove outer crate.
2.4 Installation 2.4.1 AC Power Input Block WARNING Possible Electric Shock Hazard! Do not connect AC source until all other connections are made and installation is complete. Remove the 4 screws and the AC block cover as shown in Illustration 2-11 for access to the AC input block. Save these screws and cover for later re-installation. Illustration 2-11 AC block access Attach main AC feed to the appropriate points as labled in Illustration 2-12.
2.4.2 Voltage Surge Protection Device Install the Voltage Surge Protection Device in accordance with the installation procedures provided with the device. Consult National Electrical Code for your area for proper conductor size and colors of wire. 2.4.3 Low Pass Filter and RF Output 1) Remove Low Pass Filter from shipping container being careful not to drop or damage the filter during the process of removal.
2.5 Remote I/O Connections The I/O connections on the back of the controller consist of 3 main ports; Port A (DB-25 Female), Port B (DB-37 Female), and Port C (DB-37). Port A has the metering and control of the System as well as the metering for PA5 (bottom PA). Port B and Port C have the amplifier metering for PA1 (top) through PA4 (next to bottom). I/O port A is described in illustration 2-15, I/O port B is described in illustration 2-16, and I/O port C is described in illustration 2-17.
Port B Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 Description (PA1) RF Power - 1V = 1000 Watts of power (PA1) SWR - Calculated reading of SWR in VDC (1.00 VDC = 1.0 to 1.
Port C Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 Description PA # 3 - RF Power - 1V = 1000 Watts of power PA # 3 - SWR PA # 3 - PA Volts - 1V = 10 V PA # 3 - PA Temperature - 1V = 20 degrees Celsius on the PA Ground PA # 3 - PA Total Current - 1V = 20 A on the PA PA # 3 - PA#1 current - 1V = 2A of current PA # 3 - PA#2 current - 1V = 2A of current PA # 3 - PA#3 current - 1V = 2A of current Ground PA # 3 - PA#4 current - 1V = 2A of current PA #
Section 3—Operation This section provides general operating parameters of your transmitter system and a detailed description of the front panel displays.
3.1 Initial Power-up Procedures These steps summarize the operating procedures you should use for the initial operation of the power amplifier and power supply. More detailed information follows. 1. Ensure that the external remote control unit is properly connected to the transmitter controller port A (see illustration 2-15, Section 2.5, page 2–5 for proper pin configuration). 2. Connect Antenna feed-line to the output of the Low Pass Filter.
Note : If no RF power is achieved, check the DPM display for a flashing dot in the lower right corner of the display. If this is present, the system needs to be reset before power can be restored. Refer to illustration 2-15, section 2.5, Remote I/O connections pin 3 of Port A for further information. 9. Using the 'raise/lower RF power' buttons, raise or lower the RF power to the desired setting (unless the power was specified at time of order). 10.
3.3 Front Panel Controls and Display Refer to illustration 3-1 for additional information when going through section 3.3. 3.3.1 Remote/Local Switch The Remote/Local switch is used to be able to 'break' the interlock line from the remote control unit to allow for local control of the High Voltage supply that feeds the PA's.
3.3.3 Transmitter RF Power Control The Transmitter Controller has the ability to internally set the maximum RF output power for the 10000 watt system using the power control setting for each PA. These controls are located behind the front panel and have an access hole in front of each control. A small flat blade screwdriver is needed to adjust each control. For maximum output level, these controls need to be set fully Clock-wise.
3.3.5 RF power reading and selector switch The Transmitter Controller has a digital panel meter which displays Forward RF Power and Reverse RF Power as detected by the RF power sampler built into the output combiner. The reading on the display is determined by the setting of the selector switch and accompanying green LED indicator. The readings are in Kilowatts and have an accuracy of better that 2% at the specified RF level and frequency at the time of order.
3.4 Rear Panel connections The Transmitter Controller has several types of connections on the rear panel of the unit. The following will describe each type and what it is used for. See illustration 3-6 for location of each connector. Refer to Section 2.4.5 illustrations 2-15, 2-16 and 2-17 for detailed descriptions of each applicable remote control connector. Illustration 3-6 Rear panel connections 3.4.
3.4.4 BNC Connectors The Transmitter Controller has provisions for two BNC connectors on the back panel labeled Fwd and Rev. Both of these connectors are used in the FM10000 to receive DC voltage readings from the directional coupler located internal to the output combiner. 3.4.5 Chassis Ground The Transmitter Controller has a provision to connect the chassis to the cabinet ground. A ground strap is pre-wired to the chassis ground.
Section 4—Reference Drawings The illustrations in this section may be useful for making adjustments, taking measurements, troubleshooting, or understanding the circuitry of your RF power amplifier and power supply.
4.
Fault Metering In Ref SWR ALC Power Out PA Temp PA Voltage Tot Current PA1 PA2 PA5 PA6 PA3 PA4 PA7 PA8 Fuses Antenna RF Drive PA Temp PA DC PA1 PA2 PA3 PA4 PA5 PA6 PA8 PA7 ® Illustration 4-4 Power Amplifier Front View DC input + DC Input - RF Input RF Monitor RF Output I/O Control Illustration 4-5 Power Amplifier Rear View Illustration 4-6 Power supply Front View Illustration 4-7 Power Supply Rear View Reference Drawings 4-3
4.
4.
4.4 Transmitter controller Board Schematic 3 J6 REV. 201233-SCH A 5 9 14 P/S CONTROL .1 U10D D23 13 R68 12 TL074 14 1K U11D 9 R65 8 U11C 10K 12 1K REV METER DS2 -5V R39 POLY G C79 .1 +5V GRN TO R34 220 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 470K C78 .
Section 5—Service and Support We understand that you may need various levels of support or that the product could require servicing at some point in time. This section provides information for both of these scenarios.
5.1 Service The product warranty (see opposite page) outlines our responsibility for defective products. Before returning a product for repair or replacement (our choice), call our Customer Service department using the following telephone number: (866) 262-8917 Our Customer Service Representative will give you further instructions regarding the return of your product. Use the original shipping carton or a new one obtained from Crown.
Crown Broadcast Three Year Limited Product Warranty SUMMARY OF WARRANTY Crown Broadcast, IREC warrants its broadcast products to the ORIGINAL PURCHASER of a NEW Crown Broadcast product, for a period of three (3) years after shipment from Crown Broadcast. All products are warranted to be free of defects in materials and workmanship and meet or exeed all specifications published by Crown Broadcast. Product nameplate with serial number must be intact and not altered in any way.
Factory Service Instructions To obtain factory service, complete the bottom half of this page, include it with the unit, and ship to: International Radio and Electronics Corp. 25166 Leer Drive Elkhart, Indiana, U.S.A. 46514-5425 For units in warranty (within 3 years of purchase from any authorized Crown Dealer): We pay for ground UPS shipments from anywhere in the continental U.S. and Federal Express Second Day service from Hawaii and Alaska to the factory and back to you.
A B C Glossary The following pages define terms and abbreviations used throughout this and other Crown Broadcast manuals.
A B C AF Audio Frequency; the frequencies between 20 Hz and 20 kHz in the electromagnetic spectrum. ALC Automatic Level Control AM Amplitude Modulation; the process of impressing information on a radio-frequency signal by varying its amplitude. bandwidth The range of frequencies available for signalling. BCD Binary-Coded Decimal; a digital system that uses binary codes to represent decimal digits.
exciter FET (1) A circuit that supplies the initial oscillator used in the driver stage. (2) A transmitter configuration which excludes stereo generation and audio processing. Field-Effect Transistor frequency synthesizer A circuit that generates precise frequency signals by means of a single crystal oscillator in conjunction with frequency dividers and multipliers. FM Frequency Modulation; the process of impressing information on a radio signal by varying its frequency.
A B C PAI Power Amplifier Current PAV Power Amplifier Voltage pilot A 19–kHz signal used for stereo transmissions. pre-emphasis The deliberate accentuation of the higher audio frequencies; made possible by a high-pass filter. processing The procedure and/or circuits used to modify incoming audio (keeping its level around 75 kHz deviation) to make it suitable for transmission. receiver An option which adds incoming RF capability to an existing transmitter. See also "Translator.
SWR Standing-Wave Ratio; on a transmission line, the ratio of the maximum voltage to the minimum voltage or maximum current to the minimum current; also the ratio of load impedance to intended (50 ohms) load impedance. THD Total Harmonic Distortion translator A transmitter designed to internally change an FM signal from one frequency to another for retransmission. Used in conjunction with terrestrial-fed networks.
