® FM4000 RF Transmitter Package User's Manual ©2005 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) September 2005 Important Notices ©2005, Crown Broadcast, a division of International Radio and Electronics, Inc. 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 International, Inc. Printed in U.S.A.
Contents Section 1—Getting Acquainted 1.1 Your Amplifier Package .................................................................................... 1–2 1.2 Amplifier Package Specifications ...................................................................... 1–3 1.3 Safety Considerations ....................................................................................... 1–4 1.3.1 Dangers .......................................................................................................... 1–4 1.
Glossary Index iv
I INFORMATION Section 1—Getting Acquainted This section provides a general description of the FM4000 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 FM4000 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 FM4000 package includes two (2) PA2000 amplifiers, two (2) PS2000 power supplies, a combiner with coupler, a transmitter controller, and all necessary cabling. The PA4000 transmitter package requires no tuning and typically provides 75% RF efficiency across the band.
1.2 Transmitter Package Specifications RF Power Output: 400 to 4400 watts continuous with remote controlled power adjust RF Drive Requirement: 140 watts for full output RF Output Impedance: 50 ohms (unbalanced) Maximum SWR: 1.
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 FM4000 transmitter in a standard 19–inch component rack or a cabinet or our own pre-wired cabinet on any flat surface. In any case, the area should should be as clean and well-ventillated as possible. The power supply must be installed directly below the power amplifier (for the included dressed cables to reach their respective connectors). 2.
2.4 Pre-installation 2.4.1 Power Amplifier Modules If you have ordered a cabinet system, proceed to step 2.5. Each PA2000 incorporates eight power amplifiers (two each in four modules. Due to possible damage during shipment, the modules have been removed. Follow these steps to install the modules: 1. Remove each front panel of each PA2000 (four screws). 2. Taking ESD precautions (see page 2–2), unpack the power modules and place them on your work area with the circuit sides up.
2.4.2 Hubble Twist Lock® Connector Wiring Prepare the wiring for the Hubble Twist-Lock® connector in the following manner before connecting to your AC power source: 1. Use round cord with a diameter of 0.385–0.780 inches (10–20 mm), Type SJ 12/3 – 10/3; Type S 16/3 – 10/3. 2. Select conductor size from your National Electrical Code®. 3. Slide the cover onto the cord. Remove insulation from cable and conductors as shown in Illustration 2–3. Do not tin conductors.
2.4.3 System Wiring Refer to page 4-3 Section 4.2 Block diagram when connecting together the different components of the FM4000 system. 1) Mount each of the components of the FM4000 system in an appropriate 19" rack as shown in illustration 2-6. Transmitter Controller FMX250 or equivalent PA2000 1 RU Spacer PS2000 PA2000 PS2000 Illustration 2-6 FM4000 Rack definition 2) Locate the DB-9 Male-to-Male cable and connect between 'Control' on both the PA and PS.
3) Locate the DB-25 Male-to-Male cables and connect between 'I/O' port on both of the PA's and the ports labled PA1 and PA2 on the Transmitter Controller with the top PA going to PA1. The I/O ports and PA input ports for each is shown in Illustration 2-8. Back of Power Amp Back of Transmitter Controller RF Input DB-25 I/O port DB-25 I/O port Illustration 2-8 I/O port locations 4) Locate the cable assembly with the "N" type connectors that are connected together with a "N" style Female "T".
5) Locate and mount the combiner assembly, including the directional coupler, in a location so that the RF input connectors on the combiner are in close proximity to the RF output connectors of each of the PA's. See Illustration 2-9 for a suggested mounting technique and location. Illustration 2-9 Output Combiner Mounting recommendation 6) Locate the RF Output cables (labeled 200797-CBL) and attach one end to the RF output connector on the back of each PA. Do not tighten the connectors at this point.
2.5 Installation 2.5.1 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.
2.5.2 RF Output Connection The RF Output connection is on the end of the combiner that has the cooling fan block installed on it. See illustration 2-13 for the location of the connector. It comes standard as a 7/8" EIA Flanged connector. An optional 7/16" DIN connector can be ordered if desired. RF Output (7/8" EIA Flanged) Illustration 2-13 RF Output connection 2.5.
2.6 Remote I/O Connection The DB-25 pin connections PA1-PA5 (on the back of the controller) are where the DB-25 Male-to-Male cables are attached from the individual PA2000's. Use PA1 for the top amplifier and PA2 for the bottom amplifier. The additional I/O connections on the back of the controller consist of 2 main ports; Port A (DB-25 Female) and Port C (DB-37 Female) . Port B (DB-37) is not used in the FM4000.
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.
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 2.6, page 2–10 for proper pin configuration). 2. Connect Antenna feed-line to the output of the directional coupler. 3.
6. Turn on each main power switch located on the front panel of each power supply. Air Intakes/Filters 7. Power I O ® Power Switch Illustration 3–3 PS2000 Front Panel Functions 7. If a remote control is being used, enable the power supply using the remote control unit. If not, one of two methods should be done.
9. Verify that the following conditions are present as indicated by each PA2000’s Digital Multimeter: a. In Ref—Should read between 0.4 and 0.8 volts (0.5 nominal, dependent upon power input level). b. SWR—Should read 1.05 to 1.5. c. ALC—Should read between 4.00 and 6.00 volts for 2.2 kW output (less for lower output or danger conditions, i.e. high SWR). d. Power Out—Should read 2.20 for 2.2 kW output. e. PA Temp—Should read 35 to 50°C with ambient temperature of 25°C.
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 4000 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 attached to the end of the combiner. The reading on the display is determined by the setting of the selector switch and accompaning green LED indicator. The readings are in KiloWatts and have an accuracy of better that 2%. However, it is recommended that an external watt meter be used for a more accurate reading.
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 3-8 for location of each connector. Refer to Section 2.6 illustrations 2-7 and 2-8 for detailed descriptions of each applicable remote control connector. Illustration 3-8 Rear panel connections 3.4.
3.4.4 BNC Connectors The Transmitter Controller has provisions for two BNC connectors on the back panel labled Fwd and Rev. Neither of these connectors are used in the FM4000, therefore, hole plugs are used in their place. 3.4.5 Chassis Ground The Transmitter Controller has a provision to connect the chassis to your station gound. Use a copper strap or braid to connect the station ground to the 1/4-20 brass stud provided on the back panel of the unit.
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.
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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 .
4– 6 FM4000 User's Manual
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 Company, Inc. 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 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.
H Humidity Range 1–3 Index A AC Power 1–5, 2-8 AC power 2–4, 3-4 ALC 2-11, 3-4, G-2 Antenna 3–2, 4-3 antenna 5–3 I In Ref 3–4, 5–3 Input Divider Board 4–3 Installation 2–5 Interlock Switch 3–5 L labels 1–4 M Board Layouts 4-4 Metering and Control Board 4–4 multimeter display 3–4 C O Circuit Breaker 3–2 Combiner 1–2, 2-7, 2-9, 3-3, 3-8, 4-3 Connections 2–10 Connectors Hubble Twist Lock® 2–4 connectors 2–3, 2-6, 2-7, 3-8, 3-9 operation 3–2 Output Combiner Board 4–3 Output Filter & Reflectometer 4–3
R T remote I/O 2–7 RF Drive Requirement 1–3 RF Harmonics 1–3 RF Output Impedance 1–3 RF output power 1–2 RF Power Output 1–3 RF power output 1–2 RU spaces 1–2 Tot Current 5–4 transmitter package 1–2 Troubleshooting Flow Chart 5–2 U S Weight 1–3 S/N Ratio 1–3 Safety 1–4 Schematics 6–3 Spurious Products 1–3 SWR 1–3, 3–4, 5–3 Index-ii Unpacking 2–2 W