BEI Electronics 7EPTX-AM2-5E AM-2.5E, 2.5 KW AM Stereo Transmitter User Manual WARNINGS
BEI Electronics, LLC AM-2.5E, 2.5 KW AM Stereo Transmitter WARNINGS
Users Manual
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| Mirror Download [FCC.gov] | |
| Document ID | 71686 |
| Application ID | zdNrFfZKLOE6bJnAzpHDEg== |
| Document Description | Users Manual |
| Short Term Confidential | No |
| Permanent Confidential | No |
| Supercede | No |
| Document Type | User Manual |
| Display Format | Adobe Acrobat PDF - pdf |
| Filesize | 501.7kB (6271221 bits) |
| Date Submitted | 1999-11-23 00:00:00 |
| Date Available | 1999-12-27 00:00:00 |
| Creation Date | 1999-11-19 15:50:28 |
| Producing Software | Acrobat Distiller 3.01 for Windows |
| Document Lastmod | 1999-11-22 11:08:01 |
| Document Title | WARNINGS |
| Document Creator | Interleaf, Inc. |
| Document Author: | ANelson |
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 POSSIBLY 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 including blindness. Cardiac pacemakers may be affected.
The effect of prolonged exposure to “low level” RF radiation continues to be a subject of investigation and controversy. It is generally agreed that prolonged exposure of personnel to RF radiation should be limited to an absolute minimum. It is also generally agreed that exposure should be reduced in working areas where personnel heat load is
above normal. A 10 mW/cm2 per one tenth hour average level has been adopted by several U.S. Government agencies including the Occupational Safety and Health Administration (OSHA) as the standard protection guide for employee work environments. An even stricter standard is recommended by the American National Standards Institute
which recommends a 1.0 mW/cm2 per 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 regular 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 operated to off. To prevent serious burns, take care to prevent and avoid any bodily contact with these surfaces both during and for a reasonable cooling down period after operation.
BROADCAST ELECTRONICS, INC.
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 Elec
tronics. However, the transmitter must be properly installed at a site with adequate
lightning protection and transmission line systems. TO ENSURE THE TRANSMIT
TER WARRANTY IS VALID, the transmitter must be installed: 1) 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 LIGHT
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, con
tact the Broadcast Electronics Customer Service Department.
BROADCAST ELECTRONICS, INC.
NOTICE TO THE EQUIPMENT USER
FCC Rule 73.1590 mandates the licensee of each AM station to make measurements for
spurious and harmonic emissions to show compliance with the transmission system re
quirements of Section 73.44 of the Commission's Rules. It is the broadcast station's respon
sibility to ensure that the audio signal applied to a Broadcast Electronics E-Series AM
transmitter conforms to the audio standard NRSC-1 (published as ANSI/EIA-549-1988).
This is a mandatory requirement to ensure that the equipment complies to Section 73.44
and Section 73.128(C) of the Commission's Rules.
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 PO
TENTIAL. DO NOT ENERGIZE THE TRANSMITTER
WITH TEST EQUIPMENT CONNECTED TO THE
TRANSMITTER OUTPUT NETWORK, RF POWER MOD
ULE, RF COMBINER, OR POWER SUPPLY COMPO
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 trans
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 trans
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.
SCOPE OF MANUAL
This manual consists of two sections which provides the following information for the Broadcast
Electronics AM-2.5E and AM-5E 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.
1. POWER SUPPLY ASSEMBLY
2. RF POWER MODULE
3. OUTPUT NETWORK
4. EXCITER/CONTROLLER UNIT (ECU)
PART I - TABLE OF CONTENTS
PARAGRAPH
SECTION I
1-1
1-3
1-4
1-6
1-12
1-13
1-15
1-16
1-17
1-19
1-21
SECTION II
2-1
2-3
2-6
2-8
2-12
2-14
2-16
2-19
2-22
2-23
2-24
2-25
2-26
2-28
2-37
2-42
Broadcast Electronics 1999
ALL RIGHTS RESERVED
Printed in the U.S.A.
PAGE NO.
GENERAL INFORMATION
INTRODUCTION
EQUIPMENT DESCRIPTION
GENERAL
EXCITER/CONTROL UNIT
OUTPUT NETWORK ASSEMBLY
RF POWER MODULE
POWER SUPPLY
COMBINER ASSEMBLY
TRANSMITTER CONFIGURATIONS
ACCESSORIES AND SPARE PARTS KITS
EQUIPMENT SPECIFICATIONS
1-1
1-1
1-1
1-1
1-4
1-4
1-4
1-4
1-5
1-5
1-5
INSTALLATION
INTRODUCTION
UNPACKING
ENVIRONMENTAL REQUIREMENTS
COOLING AIR REQUIREMENTS
PRIMARY POWER
INSTALLATION
EQUIPMENT PLACEMENT
COMPONENT INSTALLATION
ECU CIRCUIT BOARDS
RF POWER MODULES
POWER SUPPLY
BATTERY INSTALLATION
CIRCUIT BOARD PROGRAMMING
EXCITER CIRCUIT BOARD
STEREO CIRCUIT BOARD
CONTROLLER CIRCUIT BOARD
-i -
2-1
2-1
2-1
2-1
2-1
2-1
2-2
2-2
2-2
2-2
2-7
2-8
2-8
2-8
2-12
2-12
PARAGRAPH
2-55
2-58
2-59
2-84
2-86
2-88
2-89
2-90
2-91
2-92
2-95
2-96
2-98
2-102
2-103
2-104
2-110
2-111
2-113
2-114
2-115
2-116
2-118
2-120
2-126
2-138
2-149
SECTION III
3-1
3-3
3-5
3-6
3-14
3-16
3-17
3-18
3-19
3-21
3-23
3-24
3-27
3-29
3-31
3-32
3-33
3-34
PAGE NO.
POWER SUPPLY CIRCUIT BOARD
REMOTE CONTROL
GENERAL
WIRING
AUDIO INPUT CONNECTION
EXTERNAL STEREO RF INPUT
AM-2.5E/AM-5E RF TRANSMISSION
LINE CONNECTION
EXTERNAL INTERLOCK
MODULATION MONITOR
AC POWER CONNECTIONS
GROUND
TRANSMITTER SITE LIGHTNING PROTECTION
SYSTEM CHECKOUT
ANTENNA BALL-GAP LIGHTNING ARRESTOR
ANTENNA-TUNING-UNIT SPARK-GAP
LIGHTNING ARRESTOR
TRANSMITTER SITE GROUNDING SYSTEM
CABLE PROTECTION
ANTENNA RF FEED LINE
TRANSMISSION LINE AND ANTENNA CHECKOUT
ANTENNA VSWR
COAXIAL SWITCH CONTROLLER
ATU AND PHASOR CHECKOUT
INITIAL CHECKOUT
PRELIMINARY OPERATION AND ADJUSTMENT
TUNING
POWER LEVEL AND MODULATION MONITOR
CALIBRATION ADJUSTMENTS
STEREO ADJUSTMENT
SINGLE CHANNEL LEVEL
2-15
2-16
2-16
2-20
2-20
2-20
2-20
2-20
2-20
2-22
2-22
2-22
2-25
2-25
2-25
2-26
2-26
2-26
2-26
2-26
2-28
2-28
2-28
2-28
2-29
2-30
2-32
OPERATION
INTRODUCTION
CONTROLS AND INDICATORS
OPERATION
TURN-ON
TURN OFF
METERING
FORWARD POWER
REFLECTED POWER
POWER ADJUST
MONO/STEREO OPERATION
STEREO OPERATION
MONO OPERATION
PILOT CONTROL
EXCITER MONITOR OPERATION
MONO/STEREO INDICATIONS
INPUT SELECTION
POLARITY SELECTION
X10 AUTORANGE INDICATIONS
-ii -
3-1
3-1
3-12
3-12
3-13
3-13
3-13
3-13
3-13
3-14
3-14
3-14
3-14
3-14
3-14
3-14
3-15
3-15
PARAGRAPH
3-35
3-37
3-39
3-41
3-43
3-45
3-47
3-49
3-51
3-53
3-55
3-57
3-59
3-61
3-63
SECTION IV
4-1
4-5
4-6
4-7
4-8
4-11
4-13
4-18
4-19
4-24
4-27
4-31
4-34
4-39
4-42
4-44
4-46
4-47
4-49
4-53
4-57
4-60
4-62
4-65
4-68
4-76
4-81
4-86
4-91
4-92
4-98
4-102
4-109
4-110
PAGE NO.
FAULT RESET
POWER SUPPLY FAULT RESET
OVER-CYCLE OFF
OVER-MODULATION PWM MUTE
TRANSMITTER MONITOR
BATTERY TEST
CONTROLLER PWM MUTE INDICATOR
CONTROLLER REMOTE FAIL-SAFE INDICATOR
EXCITER LOCK INDICATOR
EXCITER +5V/+15V/-15V INDICATORS
STEREO EQUALIZATION INDICATORS
RF POWER MODULE INDICATORS
POWER SUPPLY INDICATORS
EXCITER NEGATIVE LIMITER INDICATOR
HIGH/LOW AC LINE CONDITIONS
3-15
3-15
3-15
3-15
3-15
3-15
3-16
3-16
3-16
3-16
3-16
3-16
3-16
3-16
3-16
THEORY OF OPERATION
INTRODUCTION
FUNCTIONAL DESCRIPTION
ECU
GENERAL
STEREO CIRCUIT BOARD
EXCITER CIRCUIT BOARD
CONTROLLER CIRCUIT BOARD
POWER SUPPLY
RF POWER MODULE
RF COMBINER
OUTPUT NETWORK
POWER SUPPLY
POWER SUPPLY CIRCUIT BOARD
METERING
COOLING FANS
INTERFACE CIRCUIT BOARD (AM-5E ONLY)
DETAILED DESCRIPTION
POWER SUPPLIES
AC INPUT CIRCUITRY
ECU POWER SUPPLY ASSEMBLY
TRANSMITTER FLUSHING FANS
LOW-VOLTAGE POWER SUPPLY TRANSFORMER
POWER SUPPLY CIRCUIT BOARD
CONVENTIONAL RECTIFIER CIRCUITRY
SWITCHING POWER SUPPLY CIRCUIT
MODULATOR CIRCUIT BOARD
POWER AMPLIFIER CIRCUIT BOARDS
SEQUENCE OF OPERATION
RF CIRCUITRY
EXCITER CIRCUIT BOARD
STEREO CIRCUIT BOARD
RF POWER MODULE
RF COMBINER
HARMONIC BAND-PASS FILTER
-iii-
4-1
4-1
4-1
4-1
4-1
4-1
4-2
4-2
4-2
4-7
4-7
4-8
4-8
4-9
4-9
4-9
4-9
4-9
4-9
4-10
4-10
4-10
4-10
4-13
4-13
4-14
4-15
4-15
4-16
4-16
4-17
4-17
4-21
4-22
PARAGRAPH
4-111
4-115
4-116
4-117
4-119
SECTION V
5-1
5-3
5-6
5-8
5-9
5-10
5-11
5-12
5-14
5-15
5-18
5-20
5-22
5-24
5-25
5-26
5-27
5-28
5-34
SECTION VI
6-1
SECTION VII
7-1
PAGE NO.
DIRECTIONAL COUPLER CIRCUIT BOARD
T-MATCHING NETWORK
LIGHTNING PROTECTION CIRCUIT BOARD
LIGHTNING DETECTION CIRCUIT BOARD
RF OUTPUT POWER CONTROL CIRCUITRY
4-22
4-22
4-22
4-23
4-23
MAINTENANCE
INTRODUCTION
SAFETY CONSIDERATIONS
FIRST LEVEL MAINTENANCE
ROUTINE MAINTENANCE
INSPECTION AND CLEANING
CONTROLLER BATTERY
AIR FILTERS
FLUSHING FANS
SPARK GAP
SECOND LEVEL MAINTENANCE
ELECTRICAL ADJUSTMENTS
TRANSMITTER FREQUENCY RE-PROGRAMMING
TROUBLESHOOTING
TRANSMITTER INDICATORS
RF POWER MODULE REMOVAL
TRANSMITTER TROUBLESHOOTING
PROCEDURES
TRANSMITTER COMPONENT LOCATIONS
COMPONENT REPLACEMENT PROCEDURE
INTEGRATED CIRCUITS
5-1
5-1
5-1
5-1
5-2
5-2
5-2
5-2
5-2
5-2
5-4
5-4
5-4
5-5
5-8
5-8
5-8
5-13
5-14
PARTS LIST
INTRODUCTION
6-1
DRAWINGS
INTRODUCTION
7-1
LIST OF TABLES
TABLE
1-1
1-2
3-1
3-2
3-3
5-1
5-2
6-1
DESCRIPTION
PAGE NO.
ELECTRICAL CHARACTERISTICS
PHYSICAL AND ENVIRONMENTAL
CHARACTERISTICS
AM-2.5E/AM-5E CONTROLS AND INDICATORS
ECU CONTROLS AND INDICATORS
POWER MODULE CONTROLS AND INDICATORS
AM-2.5E/AM-5E INDICATORS
AM-2.5E/AM-5E TROUBLESHOOTING
AM-2.5E/AM-5E REPLACEABLE PARTS LIST INDEX
-iv-
1-5
1-9
3-1
3-3
3-11
5-5
5-9
6-1
LIST OF ILLUSTRATIONS
FIGURE
1-1
1-2
2-1
2-2
2-3
2-4
2-5
2-6
2-7
2-8
2-9
2-10
2-11
2-12
2-13
2-14
2-15
3-1
3-2
3-3
4-1
4-2
4-3
4-4
5-1
5-2
5-3
5-4
DESCRIPTION
PAGE NO.
AM-2.5E TRANSMITTER
AM-5E TRANSMITTER
AM-2.5E TRANSMITTER INSTALLATION
AM-5E TRANSMITTER INSTALLATION
TRANSMITTER MOVING
COMPONENT INSTALLATION
EXCITER CIRCUIT BOARD PROGRAMMING
STEREO CIRCUIT BOARD PROGRAMMING
CONTROLLER CIRCUIT BOARD PROGRAMMING
REMOTE CONTROL AND AUDIO CONNECTIONS
AM-2.5E/AM-5E RF OUTPUT CONNECTIONS
AM-2.5E PRIMARY AC WIRING
AM-5E PRIMARY AC WIRING
ANTENNA LIGHTNING PROTECTION SYSTEM
TEST EQUIPMENT CONNECTIONS, POWER LEVEL
CALIBRATION
TEST EQUIPMENT CONNECTIONS, SEPARATION
EQUALIZATION LISSAJOUS PATTERNS
AM-2.5E/AM-5E CONTROLS AND INDICATORS
ECU CONTROLS AND INDICATORS
POWER MODULE CONTROLS AND INDICATORS
AM-2.5E BLOCK DIAGRAM
AM-5E BLOCK DIAGRAM
AM-2.5E/AM-5E POWER SUPPLY SIMPLIFIED
SCHEMATIC
AM-2.5E/AM-5E RF CIRCUITRY SIMPLIFIED
SCHEMATIC
REMOVING THE AIR FILTER
AM-2.5E COMPONENT LOCATOR
AM-5E COMPONENT LOCATOR
AM-2.5E/AM-5E ECU/POWER BLOCK/OUTPUT
NETWORK ASSEMBLY COMPONENT LOCATOR
PART II - TABLE OF CONTENTS
I - POWER SUPPLY ASSEMBLY
II - RF POWER MODULE
III - OUTPUT NETWORK
IV - EXCITER/CONTROLLER UNIT (ECU)
-v -
1-2
1-3
2-3
2-5
2-7
2-9
2-11
2-13
2-14
2-17
2-21
2-23
2-24
2-27
2-30
2-31
2-33
3-2
3-7
3-11
4-3
4-5
4-11
4-18
5-3
5-15
5-18
5-21
SECTION I
GENERAL INFORMATION
1-1.
INTRODUCTION.
1-2.
Information presented by this section provides a general description of the Broadcast
Electronics AM-2.5E and AM-5E transmitters and lists equipment specifications.
1-3.
EQUIPMENT DESCRIPTION.
1-4.
GENERAL.
1-5.
The Broadcast Electronics AM-2.5E transmitter is a CE compliant 2.5 kW solid-state
C-QUAM stereo AM transmitter designed for continuous operation in the 522 kHz to
1705 kHz broadcast band (refer to Figure 1-1). The Broadcast Electronics AM-5E trans
mitter is a CE compliant 5 kW solid-state C-QUAM stereo AM transmitter designed for
continuous operation in the 522 kHz to 1705 kHz broadcast band (refer to Figure 1-2). The
AM-2.5E and AM-5E transmitters consists of modular components assembled in a single
cabinet. The modular components include: 1) an exciter/control unit, 2) an output network
assembly, 3) power block assemblies containing two RF power modules and a star combiner
assembly, 4) power supply panel assemblies, and 5) an AC distribution panel assembly.
Specific AM-2.5E/AM-5E features include:
1. Built-in C-QUAM AM stereo circuitry.
2. High efficiency Class E solid-state RF power amplifier modules.
3. A high efficiency switching power supply.
4. Star combiner assembly. Each star combiner allows the removal of RF power modules without the use of dummy modules or bypass switches.
5. A built-in output matching network.
6. A CMOS digital controller with extensive VSWR detection and foldback circuitry
which reduces carrier interruptions by weather conditions.
7. CE compliant design.
1-6.
EXCITER/CONTROL UNIT. The transmitter exciter/control unit (ECU) is a modular as
1-7.
Stereo Circuit Board. The ECU stereo circuit board is a modular plug-in assembly con
taining C-QUAM AM stereo circuitry. The C-QUAM stereo system is a mode of AM
stereo transmission utilizing amplitude modulated monaural (L+R) information and inde
pendently quadrature modulated stereo (L-R) information. The results produce a stereo
transmission system compatible with mono receivers.
1-8.
The stereo circuit board is designed with remote/local controlled mono left, mono right,
mono L+R, and stereo modes of operation. Two equalization circuits are provided to allow
the transmitter to be configured for operation into two different antennas.
sembly containing plug-in stereo, exciter, and controller circuit boards. In addition to the
circuit boards, the ECU is equipped with forward and reflected power meters to provide
transmitter output power status indications.
C-QUAM is a registered trademark of Motorola Inc.
1-1
COPYRIGHT
FIGURE 1-1. AM-2.5E TRANSMITTER
1-2
1999 BROADCAST ELECTRONICS, INC
597-1114-1
COPYRIGHT
FIGURE 1-2. AM-5E TRANSMITTER
1-3
1999 BROADCAST ELECTRONICS, INC
597-1114-2
1-9.
Exciter Circuit Board. The ECU exciter circuit board is a modular plug-in exciter assem
bly. Instrumentation amplifiers provide balanced left and right channel transformerless
audio inputs. The exciter carrier frequency is established by a digital frequency synthesiz
er. The synthesizer is a phase-locked-loop circuit which provides extremely accurate and
reliable carrier frequency operation. A PWM (pulse-width-modulation) circuit is used to
generate an RF drive signal for application to a modulator circuit board in an RF power
module. If a stereo circuit board failure is encountered or when the stereo circuit board is
removed from the ECU chassis, the exciter circuitry is designed to automatically configure
to monophonic operation.
1-10.
Controller Circuit Board. All transmitter control operations are directed by the ECU con
troller circuit board. The controller circuit board consists of CMOS logic control and moni
toring circuitry. The circuitry is designed to interface to all popular remote control systems
such as the Broadcast Electronics VMC-16 remote control system.
1-11.
The transmitter power is controlled by a power control circuit. The circuit allows the
transmitter to be operated at five power levels. A power trim circuit allows the transmitter
output power to be adjusted to a precise level. An antenna interlock circuit is provided to
prevent the transmitter from operating into an incorrect antenna. A reflected power detec
tion circuit operates in association with the power control circuit to foldback the transmit
ter power during high VSWR conditions. In addition to the reflected power detector, a
lightning detector circuit is provided to mute the transmitter when high voltage is present
at the transmitter output during a lightning storm.
1-12.
OUTPUT NETWORK ASSEMBLY. Matching of the transmitter impedance to the antenna is
1-13.
RF POWER MODULE. The AM-2.5E and AM-5E transmitters are equipped with RF pow
1-14.
The RF power modules are designed using Class E amplifier technology. A Class E ampli
fier exhibits high efficiency and provides superior audio performance. In addition to the
superior efficiency and audio performance, the power modules are designed to be removed
from the chassis for maintenance. The remaining power modules will provide full power to
maintain on-air operation.
1-15.
POWER SUPPLY. A modular switching power supply provides operating potentials for two
1-16.
COMBINER ASSEMBLY. The AM-2.5E and AM-5E are equipped with a star combining
system. The system combines the outputs of the RF power modules to provide: 1) a 2.5
kW output in AM-2.5E models and 2) a 5 kW output in AM-5E models. If a power module
is removed from the chassis, the remaining power modules will continue operation to main
tain on-air operation.
accomplished by the output network assembly. The assembly is equipped with an
LC T network to match the transmitter output to the antenna. A bandpass filter is pro
vided to attenuate all harmonic frequencies to FCC, DOC, and CCIR levels. The assembly
also contains the lightning detection circuit board, a lightning protection circuit board, and
a directional coupler assembly.
er modules. A power module is a modular plug-in assembly containing two RF power am
plifier circuit boards and one modulator circuit board. Each power module is equipped
with MOSFET transistors to produce approximately 1375 watts of RF power.
RF power modules. The power supply design uses an SCR controlled bridge to rectify the
ac line voltage into a dc potential. The supply is filtered and routed to the RF power mod
ules for control and regulation. A fault detection circuit monitors power supply activity for
failure conditions. A separate modular switching power supply provides operating poten
tials for the ECU circuitry.
1-4
1-17.
TRANSMITTER CONFIGURATIONS.
1-18.
The AM-2.5E and AM-5E transmitters can be ordered in the following configurations:
P/N
DESCRIPTION
907-2500-100
AM-2.5E 2.5 kW AM Transmitter for operation in
the 522 kHz to 1705 kHz broadcast band, 10 kHz
spacing, 196V - 256V ac single phase supply.
907-5000-100
AM-5E 5 kW AM Transmitter for operation in
the 522 kHz to 1705 kHz broadcast band, 10 kHz
spacing, 196V - 256V ac single phase supply.
1-19.
ACCESSORIES AND SPARE PARTS KITS.
1-20.
The following text presents accessories and spare parts kits available for use with the
AM-2.5E and AM-5E transmitters.
P/N
DESCRIPTION
977-0038
AM-2.5E/AM-5E recommended semi-conductor
kit.
977-0039
AM-2.5E 100% semi-conductor kit.
977-0040
AM-2.5E/AM-5E recommended spare parts kit.
Includes selected meters, switches, fuses, filters,
etc. Does not include semi-conductors.
977-0041
AM-5E 100% semi-conductor kit.
907-0016-110
VMC-16 Voice Remote Control Unit, AM-10A/
AM-6A/AM-2.5E/AM-5E.
977-0037
Basic semi-conductor kit, AM-10A/AM-6A/
AM-1A/AM-2.5E/AM-5E.
1-21.
EQUIPMENT SPECIFICATIONS.
1-22.
Refer to Table 1-1 for electrical specifications or Table 1-2 for physical specifications of the
AM-2.5E and AM-5E transmitters.
TABLE 1-1. ELECTRICAL CHARACTERISTICS
(Sheet 1 of 5)
PARAMETER
RF POWER OUTPUT
AM-2.5E
AM-5E
SPECIFICATION
12.5 W to 2.8 kW. Five preset power levels
available by local or remote control. Will operate
at a reduced power output (30-50% typical) with
one-half of the power modules.
25 W to 5.6 kW. Five preset power levels
available by local or remote control. Will operate
at a reduced power output (30-50% typical) with
one-half of the power modules.
1-5
TABLE 1-1. ELECTRICAL CHARACTERISTICS
(Sheet 2 of 5)
PARAMETER
SPECIFICATION
OUTPUT POWER REGULATION
Less than 1% change in output power with variation of ac line input voltage from 196V to 252V
ac.
RF CARRIER FREQUENCY
RANGE
522 kHz to 1705 kHz (as ordered).
Accommodates 9 kHz or 10 kHz channel spacing
(9 kHz spacing requires an optional crystal).
RF OUTPUT IMPEDANCE
50 Ohms, unbalanced. Matching network to
optimize VSWR of 1.5 : 1 at any phase angle and
carrier frequency.
OUTPUT CONNECTOR
AM-5E
Female 7/16 DIN connector.
Requires 7/8 inch RF transmission line with 7/16
male DIN connector.
Requires 1/2 inch RF transmission line with 7/16
male DIN connector.
AM-2.5E
LOAD VSWR
1.5 : 1 at full carrier power. Will operate into a
higher VSWR with automatic power reduction.
Open and short circuit protected.
HARMONIC AND SPURIOUS
SUPPRESSION
Meets or exceeds FCC, DOC, and CCIR requirements when preceded by external NRSC-1 compatible audio low-pass filters.
CARRIER FREQUENCY
STABILITY
±3ppm, 0° to 50° C (+32° to +122° F).
CARRIER SHIFT
Less than 1% at 95% negative modulation at
1 kHz.
TYPE OF MODULATION
Pulse Width Modulation of L+R envelope with
integrated C-QUAM AM stereo. An RF input
connector is also provided for an external stereo
exciter.
OPERATING MODES
Stereo, mono L+R, mono L, mono R, by local or
remote control.
MODULATION CAPABILITY
AM-2.5E
AM-5E
Greater than 145% peak positive capability at
2.5 kW.
Greater than 145% peak positive capability at
5 kW.
MODULATION INPUT INDICATION
Peak reading, color coded, LED bar graph display
with an autorange feature for monitoring positive
or negative input levels of four different audio
channels (L/R or L+R/L-R).
AUDIO INPUT LEVEL
+10 dBm, ±1 dB, L=R (or mono) to produce 100%
L+R envelope modulation. Other input levels can
be accommodated.
1-6
TABLE 1-1. ELECTRICAL CHARACTERISTICS
(Sheet 3 of 5)
PARAMETER
SPECIFICATION
AUDIO INPUT IMPEDANCE
600 Ohms. Inputs are balanced, transformerless,
and resistive with passive RFI filtering. Other
impedances can be accommodated.
AUDIO FREQUENCY
RESPONSE (MONOPHONIC)
±0.5 dB, 20 Hz to 10 kHz at 90% negative
modulation (linear phase mode). +0.1 dB
-3 dB, 20 Hz to 10 kHz at 90% negative
modulation, standard configuration.
AUDIO HARMONIC DISTORTION
Mono
Less than 0.8%, 20 Hz to 10 kHz at rated power.
Less than 1.5%, 20 Hz to 10 kHz at 50% power.
Less than 2.0%, 20 Hz to 10 kHz at 25% power.
Less than 3.0%, 20 Hz to 10 kHz at 10% power.
All mono audio harmonic distortion specifications
are referenced to an audio input level which
generates 90% modulation at 1 kHz (9 dBm).
Stereo
Less than 1.5% at 50% single channel
modulation, 50 Hz to 10 kHz at rated power.
INTERMODULATION DISTORTION
(MONO)
1.2% or less at 1:1 ratio. 1.7% or less at 4:1 ratio.
60/7000 Hz SMPTE standards with 85%
modulation at rated power.
CCIF INTERMODULATION
DISTORTION (MONO)
1.0% or less at 1:1 ratio. 4 kHz/5 kHz with 85%
modulation at rated power.
TRANSIENT INTERMODULATION
DISTORTION (MONO)
1.0% or less at 4:1 ratio. 2.96 kHz square wave
8 kHz sinewave with 85% modulation at rated
power.
INCIDENTAL PHASE
MODULATION
(STEREOPHONIC)
Less than 2.0 degrees (0.035 radians) average or 30
dB (40 dB typical) below equivalent 100% L-R
C-QUAM modulation, 50 Hz to 10 kHz at rated
power. Measured with an audio input level which
generates 95% negative L+R envelope modulation
at 1 kHz (9.5 dBm).
STEREO SEPARATION
-30 dB or greater, 50 Hz to 10 kHz. Measured
with 50% single channel modulation into a 50 ohm
resistive load at rated power.
SQUAREWAVE OVERSHOOT
Mono
Stereo
0.1% or less at 400 Hz, 90% modulation with high
frequency boost disabled.
1.0% or less at 400 Hz, 50% single channel modulation with high frequency boost disabled.
1-7
TABLE 1-1. ELECTRICAL CHARACTERISTICS
(Sheet 4 of 5)
PARAMETER
SQUAREWAVE TILT
SPECIFICATION
1.0% or less at 40 Hz. 1.5% or less at 20 Hz.
Measured with 90% negative modulation.
NOISE
Mono
Greater than 65 dB below a reference level
equivalent to 100% negative modulation in a 22
Hz to 30 kHz bandwidth, unweighted.
Stereo
Greater than 55 dB below a reference level
equivalent to 100% negative modulation of
either left or right channel in a 22 Hz to
30 kHz bandwidth, unweighted.
AC INPUT VOLTAGE
AC POWER CONSUMPTION
AM-2.5E
AM-5E
OVERALL EFFICIENCY
AM-2.5E
AM-5E
196V to 252V ac 50/60 Hz, single phase.
Includes built-in MOVs for surge suppression.
3.3 kW, no modulation of 2.5 kW carrier.
2.05 kW, 100% modulation of 2.5 kW carrier.
Measured at 2.5 kW into a 50 ohm resistive
load at 220V ac. 0.9 power factor.
6.7 kW, no modulation of 5 kW carrier.
10 kW, 100% modulation of 5 kW carrier.
Measured at 5 kW into a 50 ohm resistive
load at 220V ac. 0.9 power factor.
75% or greater, 100% sinusoidal modulation
of carrier, ac line to RF output. Measured
at into 2.5 kW a 50 ohm resistive load at
220V ac.
75% or greater, 100% sinusoidal modulation of
carrier, ac line to RF output. Measured at 5 kW
into a 50 ohm resistive load at 220V ac.
SAFETY
Meets IEC 215 specifications.
REGULATORY
Meets CE specifications.
METERING
AM-2.5E
Output Forward Power: 1) High scale - 0 to
3000 watts and 2) Low scale - 0 to 750 watts.
Output Reflected Power: 1) High scale - 0 to 300
watts and 2) Low scale - 0 to 60 watts. Ac Line
Voltage: Scale - 150 to 300 volts. AM-2.5
Forward Power Meter complies with FCC rule
78.1215 (a) within the 150 watt to 2800 watt range.
1-8
TABLE 1-1. ELECTRICAL CHARACTERISTICS
(Sheet 5 of 5)
PARAMETER
SPECIFICATION
METERING (CONT'D)
AM-5E
Output Forward Power: 1) High scale - 0 to 6000
watts and 2) Low scale - 0 to 1500 watts.
Output Reflected Power: 1) High scale - 0 to
600 watts and 2) Low scale - 0 to 150 watts. Ac
Line Voltage: Scale - 150 to 300 volts. AM-5
Forward Power Meter complies with FCC rule
73.1215 (a) within the 300 watt to 5600 watt
range.
RF MONITORING PROVISIONS
2 volts RMS nominal RF output sample into a 50
Ohm input. Adjustable from the transmitter
front panel for each of the five power levels.
REMOTE INTERFACE
Built-in interface for most control and monitoring
systems.
TABLE 1-2. PHYSICAL AND ENVIRONMENTAL CHARACTERISTICS
(Sheet 1 of 2)
PARAMETER
SPECIFICATION
PHYSICAL
DIMENSIONS
Width: 24.82 Inches (63.0 cm).
Height: 71.32 Inches (181.2 cm)
Depth: 31.55 Inches (80.1 cm)
WEIGHT
AM-2.5E
AM-5E
410 Pounds (186 kg), unpacked.
525 Pounds (238 kg), unpacked.
CUBAGE
42.8Ft3 (1.2 m3).
ENVIRONMENTAL
COOLING
Type
Low velocity air with disposable filters.
Requirements - AM2.5E/AM-5E
500 Cubic Feet Per Minute (14.15 m3/min).
OPERATING TEMPERATURE
0° to 50° C (+32° to +122° F)
OPERATING HUMIDITY
0 TO 95% (non-condensing)
1-9
TABLE 1-2. PHYSICAL AND ENVIRONMENTAL CHARACTERISTICS
(Sheet 2 of 2)
PARAMETER
SPECIFICATION
MAXIMUM ALTITUDE
60 Hz Models
0 to 10,000 feet above sea level (0 to 3048 Meters).
50 Hz Models
0 to 7,500 feet above sea level (0 to 2286 Meters).
NOTE -
For AM-2.5E, All specifications measured at 2.5 kW into a 50 ohm resistive load using
Broadcast Electronics AS-10 modulation monitor.
For AM-5E, All specifications measured at 5 kW into a 50 ohm resistive load using
Broadcast Electronics AS-10 modulation monitor.
1-10
SECTION II
INSTALLATION
2-1.
INTRODUCTION.
2-2.
This section contains information required for the installation and preliminary checkout of
the Broadcast Electronics AM-2.5E and AM-5E transmitters.
2-3.
UNPACKING.
2-4.
The equipment becomes the property of the customer when the equipment is delivered to
the carrier. Carefully unpack the transmitter. Perform a visual inspection to determine
that no apparent damage has been incurred during shipment. All shipping materials
should be retained until it is determined that the unit has not been damaged. Claims for
damaged equipment must be promptly filed with the carrier or the carrier may not accept
the claim.
2-5.
The contents of the shipment should be as indicated on the packing list. If the contents are
incomplete, or if the unit is damaged electrically or mechanically, notify both the carrier
and Broadcast Electronics.
2-6.
ENVIRONMENTAL REQUIREMENTS.
2-7.
Table 1-2 provides environmental conditions which must be considered prior to transmit
ter installation. Refer to Table 1-2 in SECTION I, INTRODUCTION and ensure the
transmitter is to be installed in an acceptable environment.
2-8.
COOLING AIR REQUIREMENTS.
2-9.
If outside air is to be used to cool the transmitter, the air inlet duct must be sized to allow
adequate air flow. The air must be dry and well filtered. If intake louvers are used, opera
tion of the louvers must be electrically interlocked with the transmitter operation.
2-10.
If the heated transmitter air is to be ducted from the room, the duct system must not
introduce 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 sys
tem must allow for a minimum air flow of: 1) 500 cubic feet of air per minute for AM-2.5E
models and 2) 700 cubic feet of air per minute for AM-5E models.
2-11.
As a minimum requirement, any duct work must have a cross-sectional area equal to the
exhaust area of the cabinet (refer to Figure 2-1 and 2-2). Sharp bends in the duct system
will introduce back pressure and are not permissible. A radius bend must be used if a
right angle turn is required. An exhaust fan may be used to overcome duct losses or over
come wind pressures if the duct is vented to the outside.
2-12.
PRIMARY POWER.
2-13.
The AM-2.5E and AM-5E transmitters are designed for operation from a 196V to 252V ac
50/60 Hz single phase power source. Consult the local electric utility company to ensure
that the correct service is provided before connection of the transmitter to the primary
power source.
2-14.
INSTALLATION.
2-15.
Each transmitter is wired, operated, tested, and inspected at the factory prior to shipment
and is ready for installation when received. Prior to installation, this publication should be
studied to obtain an understanding of the operation, circuitry, nomenclature, and installa
tion requirements. Installation is accomplished as follows: 1) placement, 2) component
installation, 3) circuit board programming, 4) remote control connections, 5) wiring,
6) initial checkout, and 7) preliminary operation and tuning.
2-1
2-16.
EQUIPMENT PLACEMENT.
2-17.
The transmitter is designed with access holes in the top of the cabinet to allow for the
over-head ducting of ac power, RF transmission line, and ground strap wiring (refer to
Figure 2-1/2-2). The floor must be capable of supporting the total transmitter weight of
approximately 90 pounds per square foot. The floor support should be more than marginal
to maintain proper cabinet alignment and reduce vibration.
2-18.
Evaluate the installation site and determine the location of the transmitter. Once the
location is determined, refer to Figure 2-3 and use a forklift to move the transmitter to the
desired location. After the transmitter is placed in the desired location, remove the ship
ping skid as follows:
1. Refer to Figure 2-3 and remove the 5/16 inch shipping bolts securing the
transmitter to the skid.
2. Once the bolts are removed, slide the transmitter off the skid.
3. Slide the transmitter to the exact location.
2-19.
COMPONENT INSTALLATION.
WARNING
WARNING
ENSURE NO PRIMARY POWER IS CONNECTED TO
THE TRANSMITTER BEFORE PROCEEDING.
2-20.
Selected components of the AM-2.5E and AM-5E transmitters have been removed to pre
vent damage during shipment. The components removed from the transmitter are shipped
in separate containers.
2-21.
Remove all tape, wire ties, string, and packing material used for shipment. In addition,
locate the component containers. To install the components, perform the following proce
dures.
2-22.
ECU CIRCUIT BOARDS. The ECU circuit boards are removed for shipment. Locate the
circuit board shipping container. To re-install the circuit boards, proceed as follows:
CAUTION
CAUTION
THE TRANSMITTER MAY BE DAMAGED
IF THE ECU CIRCUIT BOARDS ARE NOT
SECURELY SEATED INTO THE CONNECTORS.
1. Refer to Figure 2-4 to determine the circuit board location.
2. Insert the circuit board in the appropriate location.
3. Firmly press the circuit board into the connector.
4. Firmly press the circuit board into the connector again to ensure the circuit board
is seated.
5. Repeat the procedure for each ECU circuit board.
CAUTION
CAUTION
2-23.
REMOVING OR INSTALLING AN RF POWER MODULE
WITH THE TRANSMITTER ENERGIZED MAY RESULT
IN DAMAGE TO THE MODULE.
RF POWER MODULES. Each RF power module is removed for shipment. Locate the RF
power module shipping containers. Refer to Figure 2-4 and re-install the modules.
2-2
COPYRIGHT
1999 BROADCAST ELECTRONICS, INC
597-1114-7
FIGURE 2-1. AM-2.5E TRANSMITTER INSTALLATION
(2-3/2-4)
COPYRIGHT
1999 BROADCAST ELECTRONICS, INC
597-1114-8
FIGURE 2-2. AM-5E TRANSMITTER INSTALLATION
(2-5/2-6)
COPYRIGHT 1999 BROADCAST ELECTRONICS, INC
FIGURE 2-3. TRANSMITTER MOVING
2-24.
597-1114-27
POWER SUPPLY. The transmitter power supply circuit boards may be removed for ship
ment. If the power supply circuit boards have been removed, locate the shipping container.
Install each circuit board as follows:
CAUTION
CAUTION
CAUTION
CAUTION
CAUTION
CAUTION
THE TRANSMITTER MAY BE DAMAGED IF THE
POWER SUPPLY CONNECTORS ARE NOT SE
CURELY SEATED INTO THE POWER SUPPLY
CIRCUIT BOARD RECEPTACLES.
TO PREVENT DAMAGE TO THE POWER SUP
PLY CIRCUIT BOARD, ENSURE THE CIRCUIT
BOARD IS INSERTED INTO THE MOUNTING
PINS AND THE CAPACITORS ON THE CIRCUIT
SIDE OF THE BOARD ARE PLACED INTO THE
PANEL CUTOUT PRIOR TO SLIDING THE CIR
CUIT BOARD TO SEAT THE MOUNTING SLOTS
INTO THE PINS.
1. Locate the mounting slots in the power supply circuit board and insert the board
into the power supply mounting pins on the power supply panel. Ensure the circuit
board is inserted with the capacitors on the circuit side of the board placed into the
panel cutout prior to seating the circuit board in the mounting pins.
2. Slide the circuit board in a position to seat the circuit board slots in the mounting
pins.
2-7
3. Secure the power supply circuit board mounting hardware.
4. Connect the power supply circuit board cables as follows:
A. Securely connect 16-pin connector P1 to J1 on the power supply circuit board.
B. Securely connect 12-pin connector P2 to J2 on the power supply circuit board.
C. Securely connect 24-pin connector P3 to J3 on the power supply circuit board.
5. Repeat the procedure for each power supply circuit board.
2-25.
BATTERY INSTALLATION. The ECU is equipped with a battery system. Refer to Figure
2-26.
CIRCUIT BOARD PROGRAMMING.
2-27.
The AM-2.5E and AM-5E transmitters are designed with programmable transmitter oper
ating characteristics. The operating characteristics are determined by the programmable
circuitry on the ECU circuit boards (refer to Figure 2-4). Refer to the following text and
program the circuitry for the desired operating characteristics.
2-28.
EXCITER CIRCUIT BOARD. Exciter circuit board programming is presented in Figure
2-29.
External Stereo Generator Select. Programmable header J7 programs the circuitry if:
1) an external stereo generator is to be used with the transmitter or 2) the internal stereo
circuit board is to be used with the transmitter. The transmitter is shipped with the circuit
programmed for the internal stereo circuit board operation.
2-30.
Carrier Frequency Programming. Eight position switch S2 programs the exciter carrier
frequency. The switch is programmed for the station frequency at the factory. Refer to the
factory test data sheets to check the programming of the switch. If the switch program
ming is not identical to programming recorded in the factory test data sheets, contact the
Broadcast Electronics Customer Service Department.
2-31.
PWM Frequency Programming. Four position switch S1 programs the PWM frequency.
Refer to the factory test data sheets to check the programming of the switch.
2-32.
Frequency Synthesizer Programming. Programmable header J6 determines the frequency
synthesizer band of operation. Refer to the factory test data sheets to check the program
ming of the header.
2-33.
Pilot Tone Programming. Programmable header J5 establishes the pilot tone frequency for
10 kHz carrier frequency operation and 9 kHz carrier frequency operation. Refer to the
factory test data sheets to check the programming of the header.
2-34.
High-Pass Filter Defeat. Left channel programmable header J12 and right channel pro
grammable header J13 control an exciter second order 10 Hz high-pass filter. The highpass filter is provided to remove low frequency residual products from specific audio pro
cessing units. The filter is shipped from the factory in the enabled position. Evaluate the
audio processor and determine if low frequency residual products are present at the output
of the audio processing unit. If no low frequency residual products are present, refer to
Figure 2-5 and disable the high pass filter.
2-35.
High Frequency Boost Defeat. Left channel programmable header J2 and right channel
programmable header J3 control an exciter high frequency boost circuit. The high frequen
cy boost circuit provides increased high frequency response to compensate for a Bessel fil
ter in the PWM modulator. If the high frequency boost circuit is enabled to compensate for
the filter, the circuit will result in a compromise between the frequency and transient re
sponse performance. If the high frequency boost circuit is enabled, the transmitter fre
quency response will increase approximately 2 dB at 10 kHz and the transient response
will degrade. If the high frequency boost circuit is disabled, the transmitter frequency re
sponse will decrease approximately 2 dB at 10 kHz and the transient response will im
prove. The high frequency boost circuit is shipped from the factory in the disabled posi
tion.
2-4 and install the battery in the battery receptacle.
2-5. Refer to Figure 2-5 and program the circuit board as required.
2-8
COPYRIGHT
1999 BROADCAST ELECTRONICS, INC
597-1114-14
FIGURE 2-5. COMPONENT INSTALLATION
(2-9/2-10)
2-11
COPYRIGHT
FIGURE 2-5. EXCITER CIRCUIT BOARD PROGRAMMING
1999 BROADCAST ELECTRONICS, INC
597-1111-11
2-36.
Monophonic Transmitter Operation Channel Select. Programmable header J4 selects
either the left or right audio channel when the transmitter is operating in the monophonic
mode with the stereo circuit board removed. The transmitter is shipped with the left chan
nel audio selected for monophonic operations.
2-37.
STEREO CIRCUIT BOARD. Stereo circuit board programming is presented in Figure 2-6.
Refer to Figure 2-6 and program the circuit board as required.
2-38.
Antenna C Equalization Select. Programmable header J6 selects equalization circuit 1 or
equalization circuit 2 for operation with antenna C. The transmitter is shipped with equal
ization circuit 2 configured for operation with antenna C.
2-39.
Bandpass Filter Alignment. Programmable header J5 configures the bandpass filter for
alignment. The jumper must be installed in position 1-2.
2-40.
Bandpass Filter Programming. Four position switches S2 through S4 program the band
pass filter. Refer to the factory test data sheets to check the programming of the switches.
2-41.
Equalization Control Select. Programmable header J7 configures the equalization circuit
ry for either a momentary or constant antenna status signal. The transmitter is shipped
with equalization control circuitry configured for a constant status signal.
2-42.
CONTROLLER CIRCUIT BOARD. Controller circuit board programming is presented in
2-43.
Power Level Trim Reset Select. Programmable header J12 determines if the power level
control circuit is to reset when a power level switch/indicator is depressed. If the circuit is
programmed to reset, the previous raise/lower information will be deleted and the trans
mitter will operate at the selected power level. If the circuit is programmed to retain the
previous raise/lower information, the transmitter will operate above or below the selected
power level as determined by previous raise/lower operations. For example, the transmit
ter is operating at power level 4 with the power level raised 5% by the power level raise/
lower circuit. When power level 5 switch/indicator is depressed, the transmitter will oper
ate at 5% above the power level 5 output due to the previously retained raise/lower in
formation. The transmitter is shipped with power level trim reset circuit configured to re
set.
2-44.
Antenna Power Level Programming. Switches S1, S2, and S3 assign power levels to a spe
cific antenna. This programs the antenna interlock circuit to the station antenna system
to prevent the transmitter from operating into an antenna at an incorrect power level.
Switch S1 programs the power levels for antenna A. Switch S2 programs the power levels
for antenna B. Switch S3 programs the power levels for antenna C. Power level 2 is as
signed to an antenna by switch 1 on S1, S2, and S3. Power level 3 is assigned to an anten
na by switch 2 on S1, S2, and S3. Power level 4 is assigned to an antenna by switch 3 on
S1, S2, and S3. Power level 5 is assigned to an antenna by switch 4 on S1, S2, and S3.
Power level 1 is assigned to each antenna. Evaluate the antenna system and program the
circuit as required.
2-45.
AC Power Failure Automatic Transmitter Shutdown Time. Programmable headers J4, J5,
J6, and J7 program the transmitter ac power failure automatic transmitter shutdown
timer circuit. The circuit is designed to automatically operate the transmitter to off during
a power failure after a specific time delay programmed by headers J4, J5, J6, and J7. J4
programs the circuit for a 1 minute shutdown time. J5 programs the circuit for a 4.5 min
ute shutdown time. J6 programs the circuit for a 17 minute shutdown time. J7 programs
the circuit for a 68 minute shutdown time. The transmitter is shipped from the factory for
a 1 minute shutdown time.
2-46.
Antenna Interlock Control Select. Programmable header J1 controls the antenna inter
lock circuit. The circuit can be disabled if the transmitter is to operate into only one anten
na. The transmitter is shipped from the factory with the antenna interlock circuit dis
abled.
Figure 2-7. Refer to Figure 2-7 and program the circuit board as required.
2-12
COPYRIGHT 1999 BROADCAST ELECTRONICS, INC
597-1111-6
FIGURE 2-6. STEREO CIRCUIT BOARD PROGRAMMING
2-13
2-14
COPYRIGHT
1999 BROADCAST ELECTRONICS, INC
597-1112-5
FIGURE 2-7. CONTROLLER CIRCUIT BOARD PROGRAMMING
2-47.
Power Level Reference. Programmable headers J10 and J19 provide a reference for the
power level circuit. For AM-2.5E/AM-5E transmitters, ensure jumpers P10 and P19 are
removed.
2-48.
Power Level 3 Assignment. Programmable header J8 and J9 control the assignment for
the power level 3 switch/indicator. For the AM-2.5E, the power level 3 switch/indicator
can be programmed to control power from: 1) 250 watts to 1250 watts or 2) 750 watts to
2800 watts. For the AM-5E, the power level 3 switch/indicator can be programmed to con
trol power from: 1) 500 watts to 2500 watts or 2) 1500 watts to 5600 watts. The power
level 3 switch/indicator is shipped from the factory to control power from: 1) 250 watts to
1250 watts on AM-2.5E models and 2) 500 watts to 2500 watts on AM-5E models. Pro
gram jumpers P8 and P9 as required.
2-49.
Remote Reflected Power Sample Voltage Programming. Programmable header J3 con
trols the remote reflected power meter sample voltage. The remote reflected power sample
can be programmed for a +5.0 volt dc or +2.5 volt dc full-scale meter indications. The
transmitter is shipped from the factory programmed for +5.0 volt dc full-scale remote re
flected power meter indications.
2-50.
Remote Forward Power Sample Voltage Programming. Programmable header J2 con
trols the remote forward power meter sample voltage. The remote forward power sample
can be programmed for a +5.0 volt dc or +2.5 volt dc full-scale meter indications. The
transmitter is shipped from the factory programmed for +5.0 volt dc full-scale remote for
ward power meter indications.
2-51.
High Forward Power Defeat. Programmable header J11 controls the high forward power
detector circuit. Ensure jumper P11 is removed.
2-52.
Reflected/Forward Power Sample Programming. Programmable headers J15, J16, J17,
and J18 control the reflected and forward power sample levels. Headers J15 and J17 con
trol the forward power sample. Headers J16 and J18 control the reflected power sample.
For AM-2.5E models: 1) remove jumpers P15 and P16 and 2) install jumpers P17 and P18.
For AM-5E models: 1) install jumpers P15 and P16 and 2) remove jumpers P17 and P18.
2-53.
Forward Power Reference Voltage Programming. Programmable headers J13 and J14
establish the forward power reference level for a comparator circuit. For AM-2.5E/AM-5E
models, ensure jumpers P13 and P14 are installed.
2-54.
Temperature Sense. Header J20 controls the temperature sense sample voltage. Ensure
P20 is removed for all models.
2-55.
POWER SUPPLY CIRCUIT BOARD. The power supply circuit board programming is pre
2-56.
Future Corrector Circuit. Programmable headers J9 and J10 establish parameters for a
future corrector circuit. Ensure jumper P9 is removed and P10 is installed.
2-57.
Model Programming. Programmable headers J5 through J8 establish parameters for dif
ferent AM E-Series transmitters. Refer to the following text for the programming
information.
sented in the following text. Refer to the following text to check the power supply circuit
board programming.
TRANSMITTER
J5
J6
J7
J8
AM-2.5E
Not Used
Not Used
Not Used
Not Used
AM-5E
Not Used
Not Used
Not Used
Not Used
2-15
2-58.
REMOTE CONTROL.
WARNING
WARNING
ENSURE PRIMARY POWER IS DISCONNECTED BE
FORE PROCEEDING.
2-59.
GENERAL. The AM-2.5E and AM-5E transmitters are designed for complete remote con
2-60.
Power Level Controls/Indicators. The transmitter is designed with five customer adjust
able operating power controls. The controls are located at J1-1 through J1-5. A +5 to +15
volt dc signal is required to activate the desired function.
Indications of power level control operations are located at J1-7 through J1-11. The power
level status indicators will go LOW (0 volts dc) when activated.
2-61.
trol operations (refer to Figure 2-8 ). The transmitters will interface with almost any re
mote control unit such as the Broadcast Electronics model VMC-16 voice remote control
system. The following text presents a description of the transmitter remote control func
tions and indications. The remote control connections are located at 25-pin D-type con
nectors J1 and J2. J1/J2 are located on the transmitter top-panel. The remote control
functions are activated using a +5 to +15 volt dc signal. The remote indication functions:
1) require current limiting resistors and 2) provide up to 100 mA for indicators. A +5 volt
supply is provided at J1 for remote control operations.
2-62.
Transmitter Off Control/Indicator. The transmitter off control is located at J1-6. A +5 to
+15 volt dc signal is required to operate the transmitter to off. The indicator for the trans
mitter off control is located at J1-14. The off indicator will go LOW (0 volts dc) when acti
vated.
2-63.
Power Level Raise/Lower Controls. The transmitter is designed with raise and lower con
trols to adjust the transmitter output power level. The controls are equipped with ability
to raise/lower power from 10% to 15% of the selected output power level. The controls are
located at J1-15 and J1-16. A +5 to +15 volt dc signal is required to activate the desired
function.
2-64.
Antenna Interlock Input. The antenna interlock inputs are designed for the connection of
the status signals from antenna A, B, and C. The inputs are located at J1-19 through
J1-21. The inputs require a +5 to +15 volt dc signal to indicate an antenna ready status.
2-65.
Transmitter Mute Input. The transmitter mute input is designed to mute the transmitter
when activated. The input is located at J1-22. The input requires a +5 to +15 volt dc sig
nal to mute the transmitter.
2-66.
Remote Failsafe Input. The remote failsafe input is designed for the remote control unit
failsafe control line. The input is located at J1-23. The input requires a +5 to +15 volt dc
signal to indicate an enabled remote control unit.
2-67.
External Interlock Input. The external interlock input is for the connection of an interlock
external to the transmitter. The input is located at J1-24. The input requires a +5 to +15
volt dc signal to indicate a closed interlock.
2-68.
Interlock +5V. The interlock +5 volt supply is provided for the external interlock. The +5
volt supply is located at J1-25.
2-69.
Exciter Mode Controls/Indicators. The transmitter exciter is designed to be operated in
the mono left, mono right, mono L+R, or stereo modes of operation. The controls are lo
cated at J2-1 through J2-4. A +5 to +15 volt dc signal is required to activate the desired
function.
Indications of exciter modes of operations are located at J2-5 though J2-8. The exciter
mode indicators will go LOW when activated.
2-70.
2-71.
Remote Forward/Reflected Power Meter Indications. Remote reflected power meter indi
cations are located at J2-9 and J2-10. The indications are designed to be programmed for
+5 volt dc full-scale meter indications or +2.5 volt dc full-scale meter indications.
2-16
COPYRIGHT
1999 BROADCAST ELECTRONICS, INC
597-1114-3
FIGURE 2-8. REMOTE CONTROL AND AUDIO CONNECTIONS (SHEET 1 OF 2)
2-17
COPYRIGHT
1999 BROADCAST ELECTRONICS, INC
597-1114-3A
FIGURE 2-8. REMOTE CONTROL AND AUDIO CONNECTIONS (SHEET 2 OF 2)
2-18
2-72.
Remote Enabled Indications. The remote enabled indicator provides a signal to indicate
the status of transmitter remote control operations. The remote enabled indicator is lo
cated at J2-11. The indicator will go LOW to indicate when remote control operations are
enabled.
2-73.
Maintenance Indications. The maintenance indicator provides a signal to indicate when
a transmitter power supply or an RF power module is removed from the transmitter for
maintenance. The maintenance indicator is located at J2-12. The indicator will go LOW
(0 volts dc) to indicate when a power supply is removed for maintenance.
2-74.
Lightning Indications. The lightning indicator provides a signal to indicate when a greater
than: 1) 1500 volt potential is present at the output for AM-2.5E models or 2) 2100 volt
potential is present at the output for AM-5E models. The lightning indicator is located at
J2-13. The indicator will go LOW (0 volts dc) to indicate when a lightning potential is pre
sent at the transmitter output.
2-75.
1.2 : 1 VSWR Indications. The 1.2 : 1 VSWR indicator provides a signal to indicate when a
greater than 1.2 : 1 VSWR condition is present at the transmitter output. The 1.2 : 1 indi
cator is located at J2-14. The indicator will go LOW (0 volts dc) to indicate when a 1.2 : 1
VSWR condition is present at the transmitter output.
2-76.
Exciter/PWR Supply/PWR Module Fault Indications. The exciter, power supply, and power
module fault indicators provide signals to indicate when an exciter, power supply, or a
power module fault has occurred. The exciter, power supply, and power module fault indi
cators are located at J2-15 through J2-17. The indicators will go LOW (0 volts dc) to
indicate when an exciter, power supply, or a power module fault has occurred.
2-77.
RFL PWR High Indications. The reflected power high indicator provides a signal to indicate
when: 1) 100 watts of reflected power is present at the transmitter output for AM-2.5E
models or 2) 200 watts of reflected power is present at the transmitter output for AM-5E
models. The high reflected power indicator is located at J2-18. The indicator will go LOW
(0 volts dc) to indicate when a reflected power high condition is present at the transmitter
output.
2-78.
RFL PWR Emergency Indications. The reflected power emergency indicator provides a sig
nal to indicate when greater than: 1) 500 watts of reflected power is present at the output
of the AM-2.5E transmitter or 2) 1000 watts of reflected power is present at the output of
the AM-5E transmitter. The reflected power emergency indicator is located at J2-19. The
indicator will go LOW (0 volts dc) to indicate when a reflected power emergency condition
is present at the transmitter output.
2-79.
Overtemp Indications. The overtemp indicator provides a signal to indicate when the
transmitter temperature is greater than 70°C. The overtemp indicator is located at J2-20.
The indicator will go LOW (0 volts dc) to indicate when the transmitter temperature is
greater than 70°C.
2-80.
Foldback Indications. The transmitter is designed to automatically reduce power when
one of the following fault condition occurs: 1) high reflected power, 2) high forward power,
3) high temperature, or 4) detection of a high voltage by the lightning circuit. The foldback
indicator is located at J2-21. The indicator will go LOW (0 volts dc) to indicate when the
transmitter is in a foldback condition.
2-81.
Alarm Status Indications. The alarm status provides a signal to indicate when a fault or
foldback condition occurs. The alarm status indicator is located at J2-22. The indicator
will go LOW (0 volts dc) to indicate when the transmitter is in a fault or foldback condition.
2-82.
Alarm Reset Control. The alarm reset control is designed to reset the fault detection cir
cuitry. The alarm reset control is located at J2-23. A +5 to +15 volt dc signal is required to
activate the function.
2-19
2-83.
Emergency Off Indications. The emergency off indicator provides a signal to indicate
when the transmitter is operated to off by any condition or event other than the use of the
off switch. These conditions/events include: 1) an overcycle off condition, 2) a power sup
ply emergency condition, or 3) an open interlock condition. A power supply emergency con
dition is when all the power supplies in the transmitter encounter faults. The emergency
off indicator is located at J2-24. The indicator will go LOW (0 volts dc) to indicate when an
emergency off condition is encountered.
2-84.
WIRING.
2-85.
Wiring consists of connecting audio, the RF transmission line, and ac power to the trans
mitter. Refer to the following text and connect the wiring to the transmitter.
2-86.
AUDIO INPUT CONNECTION. The AM-2.5E and AM-5E transmitters are equipped
with electronically balanced 600 Ohm left and right channel audio inputs. The audio in
puts are located on the transmitter top-panel at J3 (refer to Figure 2-8). The inputs are
designed to accept a +10 dBm signal at 600 Ohms.
WARNING
WARNING
2-87.
ENSURE PRIMARY POWER IS DISCONNECTED BE
FORE PROCEEDING.
Audio is interfaced to the transmitter by: 1) selecting the appropriate cable and 2) connect
ing the cable to the terminals of 9-pin D-type connector J3. J3 is located on the transmit
ter top-panel. To interface audio to the transmitter: 1) use Belden 8760 cable or equiva
lent and 2) refer to Figure 2-8 and connect the audio to the transmitter as follows:
1. Connect the plus signal line to the + terminal.
2. Connect the minus signal line to the - terminal.
3. Connect the shield to ground at the audio source end.
2-88.
EXTERNAL STEREO RF INPUT. The transmitter is equipped with an external stereo RF
2-89.
AM-2.5E/AM-5E RF TRANSMISSION LINE CONNECTION. The AM-2.5E/AM-5E
2-90.
EXTERNAL INTERLOCK. The AM-2.5E/AM-5E is equipped with an external interlock
2-91.
MODULATION MONITOR. The modulation monitor connection is located on the trans
input on the transmitter top-panel (refer to Figure 2-9). The input is designed for the con
nection of an external stereo generator or reference oscillator with a signal level from 5 to
15 volts peak-to-peak. If an external stereo signal/reference is to be applied to the trans
mitter, connect the signal to the EXTERNAL RF INPUT connector on the transmitter
top-panel and program jumper P7 on the exciter circuit board in position 1-2.
transmitter RF output connection is located on the transmitter top-panel (refer to Figure
2-9). The AM-5E requires 7/8 inch transmission line with a 7/16 male DIN connector.
The AM-2.5E requires 1/2 inch transmission line with a 7/16 male DIN connector. To con
nect the RF transmission line to the transmitter, refer to Figure 2-9 and connect the 7/16
male DIN type connector to the RF OUT connector on the transmitter top-panel.
such as for a test load. The interlock will turn off the transmitter RF output when opened.
The interlock is located at J1-24 and J1-25 on the transmitter top-panel. Refer to
External Interlock Input and Interlock +5v in the REMOTE CONTROL section of the
preceding text and perform the procedures to connect equipment to the transmitter exter
nal interlock.
mitter top-panel. Refer to Figure 2-9 and connect the modulation monitor to the MOD
MONITOR SAMPLE OUTPUT receptacle.
2-20
2-21
COPYRIGHT
1999 BROADCAST ELECTRONICS, INC
597-1114-22
FIGURE 2-9. AM-2.5E/AM-5E RF OUTPUT CONNECTIONS
WARNING
WARNING
WARNING
WARNING
2-92.
of 196V to 252V ac, 50 Hz or 60 Hz at 75 Amperes. The AM-5E transmitter requires a
single-phase source of 196V to 252V ac, 50 Hz or 60 Hz at 125 amperes. For operating
safety, the power source must be routed to the transmitter through a fused power discon
nect (refer to Figures 2-10 and 2-11).
WARNING
2-94.
ENSURE AN EARTH GROUND CONDUCTOR IS SE
CURELY CONNECTED TO THE TRANSMITTER AC
GROUND LUG.
AC POWER CONNECTIONS. The AM-2.5E transmitter requires a single-phase source
WARNING
2-93.
ENSURE PRIMARY POWER IS DISCONNECTED BE
FORE PROCEEDING.
ENSURE PRIMARY POWER IS DISCONNECTED BE
FORE PROCEEDING.
Main ac Input -AM-2.5E. Refer to Figure 2-10 and connect the 75 Ampere service to ac
input/control device S1 through a fused service disconnect as shown. Ensure a utility com
pany ground conductor is securely connected to the transmitter common ground system
and the ac service ground wire is securely connected to the ac ground lug as shown.
Main ac Input - AM-5E. Refer to Figure 2-11 and connect the 125 ampere service to ac
input/control device S1 through a fused service disconnect as shown. Ensure a utility com
pany ground conductor is securely connected to the transmitter common ground system
and the ac service ground wire is securely connected to the ac ground lug as shown.
WARNING
WARNING
WARNING
WARNING
ENSURE PRIMARY POWER IS DISCONNECTED BE
FORE PROCEEDING.
ENSURE AN EARTH GROUND CONDUCTOR IS SE
CURELY CONNECTED TO THE TRANSMITTER
GROUND LUG.
2-95.
GROUND. The transmitter is equipped with a cabinet ground system for operating safety.
2-96.
TRANSMITTER SITE LIGHTNING PROTECTION SYSTEM CHECKOUT.
The ground system requires the connection of an earth ground. Refer to Figures 2-10 and
2-11 and connect an earth ground to the cabinet ground lug as shown using a 2 inch (5.08
cm) wide copper strap.
CAUTION
CAUTION
2-97.
THE TRANSMITTER SITE LIGHTNING PROTECTION
SYSTEM MUST BE INSPECTED AND IN PROPER
WORKING CONDITION FOR RELIABLE TRANSMIT
TER OPERATION.
For reliable transmitter operation, the transmitter site lightning protection system must
be inspected and in proper working condition. Due to the solid-state design of the trans
mitter, high voltage potentials from lightning activity can cause severe damage to the
transmitter circuitry. Therefore, perform the following procedures to inspect and improve
the lightning protection system at the transmitter site. Refer to the NAB Radio Handbook
for additional transmitter site lightning protection system information.
2-22
2-23
COPYRIGHT
1999 BROADCAST ELECTRONICS, INC
597-1114-10
FIGURE 2-10. AM-2.5E PRIMARY AC WIRING
2-24
COPYRIGHT
1999 BROADCAST ELECTRONICS, INC
597-1114-9
FIGURE 2-11. AM-5E PRIMARY AC WIRING
2-98.
ANTENNA BALL-GAP LIGHTNING ARRESTOR. Each tower in the antenna system must
2-99.
Ball-Gap Position. The antenna ball-gap lightning arrestor must be aligned horizontally.
Do not align the ball-gaps vertically. Vertical alignment allows rain water to collect on the
balls. This reduces the gap separation and results in arcing during rain activity.
2-100.
Ball-Gap Separation. The antenna ball-gap lightning arrestor must be adjusted for the
proper separation. If the ball-gap separation is too wide, the arrestor will not function. If
the ball-gap separation is too narrow, the arrestor will arc during normal transmitter op
eration. As a general rule: 1) a separation of approximately 0.020 in. for each peak kilo
volt at the transmitter tower is required or 2) 0.125 inch for each 9.4 peak kilovolt at the
transmitter tower is required.
2-101.
The recommended method for ball-gap separation adjustment is to adjust the gap to pre
vent arcing during peak modulation activity. To adjust the separation, proceed as follows:
be equipped with a ball-gap lightning arrestor (refer to Figure 2-12). The ball-gap
arrestor is designed to safely conduct lightning potentials to ground. Inspect the ball-gap
arrestors by performing the following procedures.
1. Adjust the ball-gap separation using the general rule presented in the preceding
text.
2. Operate the transmitter at peak modulation and check the ball-gap for arcing
activity.
WARNING
WARNING
DISCONNECT ALL TRANSMITTER PRIMARY POWER
BEFORE PROCEEDING.
3. Operate the transmitter to off.
4. Adjust the ball-gap separation as follows:
A. If no arcing activity is detected, reduce the ball-gap separation.
B. If arcing activity is detected, increase the ball-gap separation.
5. Repeat the procedure until the ball-gap separation is adjusted for the smallest gap
possible without arcing during peak modulation activity.
2-102.
ANTENNA-TUNING-UNIT SPARK-GAP LIGHTNING ARRESTOR. The
2-103.
TRANSMITTER SITE GROUNDING SYSTEM. The transmitter site grounding system must
be properly connected for reliable transmitter operation. A typical transmitter site ground
ing system is shown in Figure 2-12. Perform the following procedures to ensure the
grounding system connections are secure.
antenna-tuning-unit (ATU) must be equipped with a spark-gap lightning arrestor (refer
to Figure 2-12). The spark-gap arrestor can be: 1) a ball-gap type or 2) a horn type. Ad
just the spark-gap for the smallest possible gap without arcing during peak modulation
activity.
1. Ensure the antenna base ground strap is securely connected to the antenna ground
plane radials.
2. Ensure the antenna ball-gap lightning arrestor is securely connected to the
lightning ground rod system and to the antenna ground plane radials.
3. Ensure the ATU ground and the station RF ground is securely connected to the
antenna ground plane radials.
2-25
2-104.
CABLE PROTECTION. The ac line cable, audio/control cables, and the RF output trans
2-105.
Ferrite Core. The ac line cable, the audio/control cables, and the RF output transmission
line also require the placement of ferrite cores. The cores are designed to create a high
impedance for undesired current paths such as lightning. Ferrite cores for placement on ac
line audio/control and RF output transmission line cables are located in the accessory parts
kit. Locate the ferrite cores and install the cores by performing the following procedures.
2-106.
Modulation Monitor Core. One 375-0009-001 ferrite core is designed to be installed on
the modulation monitor cable. Install the core on the modulation monitor cable by:
1) routing the cable through the core and 2) wrapping the cable to create one cable loop
around the core. The core can be installed at any location on the cable.
2-107.
Audio/Remote Control/Status Core. A second 375-0009-001 ferrite core is designed to be
installed on the audio and remote control/status cables. Install the core on the audio and
remote control/status cables by: 1) routing the cables through the core and 2) if possible,
wrapping the cables to create one cable loop cable around the core. The core can be
installed at any location on the cables.
2-108.
Ac Input Core. A 375-0007-001 ferrite core is shipped with the unit for installation on
the transmitter ac input cable. Install the core by routing: 1) all ac line phase cables
through the core or 2) all ac line phase cables and ground cable through the core. Place the
core at any location between the wall mounted fused disconnect and the transmitter ac in
put switch.
2-109.
RF Output Core. A second 375-0007-001 ferrite core is designed to be installed on the
transmitter RF output transmission line cable. Install the core by routing the RF output
cable through the core. Place the core at any location between the transmitter RF output
connector and the next equipment connection in the RF output system such as the antenna
phasing system. It is recommended the core be placed outside the transmitter cabinet.
2-110.
ANTENNA RF FEED LINE. Check the antenna RF feed line between the ATU and the
2-111.
TRANSMISSION LINE AND ANTENNA CHECKOUT.
mission line require a combination of MOV and ferrite core protection to prevent the entry
of lightning potentials (refer to Figure 2-12). Refer to the following text to install MOV
and ferrite cores on the cables to prevent the conductance of lightning potentials. Ensure
MOVs are connected from the ac line and audio/control cable conductors to the station RF
ground as shown. The MOVs should be rated for 20,000 Ampere surges
(BE P/N 140-0032).
tower. Ensure the line contains one or more one foot diameter loops. The loops function as
a series inductance and increase the impedance of the line.
CAUTION
CAUTION
THE TRANSMISSION LINE AND ANTENNA MUST BE
INSPECTED AND IN PROPER WORKING CONDITION
FOR RELIABLE TRANSMITTER OPERATION.
2-112.
The transmission line and antenna must be inspected and in proper working condition for
reliable transmitter operation. Perform the following procedures to inspect the transmis
sion line and antenna.
2-113.
ANTENNA VSWR. The AM-2.5E/AM-5E are designed to operate into an antenna with a
2-114.
COAXIAL SWITCH CONTROLLER. To prevent damage to the transmitter, the transmit
maximum VSWR of 1.5 : 1. Check the antenna VSWR. If the VSWR is greater than
1.5 : 1, contact the Broadcast Electronics Customer Service Department. Typically, the an
tenna will require the installation of an additional tuning unit to reduce the antenna
VSWR.
ter must be muted during any antenna change sequence. Inspect the motorized coaxial
switch controller and ensure the unit outputs a +5 volt to +15 volt mute signal. Ensure the
mute signal is applied to the transmitter.
2-26
2-27
COPYRIGHT
FIGURE 2-12. ANTENNA LIGHTNING PROTECTION SYSTEM
1999 BROADCAST ELECTRONICS, INC
597-1111-36
2-115.
ATU AND PHASOR CHECKOUT. Inspect the ATU and the antenna phasor unit (if
installed in the system) for arcing activity during peak modulation periods. Repair or re
place any devices to prevent arcing during peak modulation periods.
2-116.
INITIAL CHECKOUT.
WARNING
WARNING
2-117.
ENSURE PRIMARY POWER IS DISCONNECTED BE
FORE PROCEEDING.
Prior to performing the preliminary operating procedures, the transmitter should be
checked to ensure all installation and connection procedures have been performed. To
check the transmitter, proceed as follows:
A. Ensure all ECU circuit boards, RF power modules, and power supply circuit boards
are installed.
B. Ensure the RF output transmission line is connected to the transmitter output
network.
C. Ensure the station earth ground is connected to the transmitter ground terminal.
D. Ensure all audio and control cables are connected to the transmitter.
E. Ensure the modulation monitor is connected to the transmitter.
F. Ensure all ac power connections are secure.
G. Ensure the station RF output transmission line system and antenna are in proper
working condition.
H. Ensure the antenna lightning protection system is in proper working condition.
2-118.
PRELIMINARY OPERATION AND ADJUSTMENT.
2-119.
Adjust the transmitter for operation with the equipment at the installation site as follows:
WARNING
WARNING
THE TRANSMITTER POWER SUPPLY OPERATES
FROM A HIGH FLOATING GROUND POTENTIAL.
NEVER OPERATE THE TRANSMITTER WITH THE
REARDOOR OPEN.
2-120.
TUNING. The transmitter must be adjusted to operate into the station antenna. To tune
2-121.
Operate the rear-door ac on/off switch to ON. The ECU and power module front-panel
indicators will illuminate.
2-122.
Depress the power level 1 switch/indicator to illuminate the switch/indicator.
2-123.
Operate the FORWARD POWER meter switch to LOW and observe the forward power
indication.
2-124.
Operate the REFLECTED POWER meter switch to LOW and observe the reflected power
indication.
2-125.
Tune the transmitter by adjusting the TUNING and LOADING controls as required for a
minimum reflected power indication on the REFLECTED POWER meter.
the transmitter, proceed as follows:
2-28
2-126.
POWER LEVEL AND MODULATION MONITOR CALIBRATION ADJUSTMENTS. The
transmitter power levels are adjusted to the levels specified in the sales order at the
factory. If no power levels are specified, the levels are adjusted as follows:
AM-2.5E
2-127.
AM-5E
Power level 1 = 500 watts
Power level 1 = 1000 watts
Power level 2 = 1000 watts
Power level 2 = 2000 watts
Power level 3 = 1500 watts
Power level 3 = 3000 watts
Power level 4 = 2000 watts
Power level 4 = 4000 watts
Power level 5 = 2500 watts
Power level 5 = 5000 watts
If desired, the transmitter power levels can be changed at any time. If the transmitter
power levels are adjusted, the modulation monitor output must also be re-calibrated. To
change the power level and re-calibrate the modulation monitor output, proceed as follows:
WARNING
WARNING
DISCONNECT ALL TRANSMITTER PRIMARY POWER
BEFORE PROCEEDING.
2-128.
Operate the transmitter rear-door ac on/off control switch to OFF and open the rear-door.
2-129.
Refer to Figure 2-13 and connect the test equipment to the transmitter modulation connec
tor as shown.
2-130.
Operate the transmitter rear-door ac on/off control switch to ON.
2-131.
Depress power level control 1 switch/indicator to illuminate the switch/indicator.
2-132.
Operate the FORWARD POWER meter switch to LOW or HIGH as required and observe
the forward power indication.
2-133.
Refer to Figure 2-7 and adjust the power level 1 control to obtain the desired indication on
the FORWARD POWER meter. The control range is from: 1) 250 watts to 1250 watts on
AM-2.5E models and 2) 500 watts to 2500 watts on AM-5E models.
2-134.
Refer to Figure 3-1 in SECTION III, OPERATION and adjust the power level 1 modula
tion monitor calibration control for a 5.7 volt peak-to-peak signal on the oscilloscope.
2-135.
Repeat the procedure for power levels 2 through 5. The power level control ranges are as
follows:
AM-2.5E
1. Power level 2 - 250 watts to 1250 watts.
2. Power level 3 - 250 watts to 1250 watts or 750 watts to 2800 watts as
programmed by a jumper on the controller circuit board.
3. Power level 4 - 750 watts to 2800 watts.
4. Power level 5 - 750 watts to 2800 watts.
AM-5E
1. Power level 2 - 500 watts to 2500 watts.
2. Power level 3 - 500 watts to 2500 watts or 1500 watts to 5600 watts as
programmed by a jumper on the controller circuit board.
3. Power level 4 - 1500 watts to 5600 watts.
4. Power level 5 - 1500 watts to 5600 watts.
2-29
COPYRIGHT 1999 BROADCAST ELECTRONICS, INC
597-1114-11
FIGURE 2-13. TEST EQUIPMENT CONNECTIONS, POWER LEVEL CALIBRATION
WARNING
WARNING
DISCONNECT ALL TRANSMITTER PRIMARY POWER
BEFORE PROCEEDING.
2-136.
Operate the transmitter rear-door ac on/off control switch to OFF.
2-137.
Disconnect the cable from the transmitter modulation monitor connector.
2-138.
STEREO ADJUSTMENT. If the transmitter is operated in the stereo mode, the transmitter
stereo circuitry must be adjusted to compensate for antenna system variances. The pri
mary objective in the adjustment of the transmitter is to configure the stereo circuitry to
minimize distortion and maximize separation across the entire audio band. A proof of per
formance sheet is provided at the end of this section to record performance measurements.
To adjust the stereo circuitry, perform the following procedures and record the measure
ments on the proof of performance sheet at the end of this section.
WARNING
WARNING
DISCONNECT ALL TRANSMITTER PRIMARY POWER
BEFORE PROCEEDING.
2-139.
Operate the transmitter rear-door ac on/off control switch to OFF.
2-140.
Refer to Figure 2-14 and connect the test equipment as shown.
2-30
COPYRIGHT 1999 BROADCAST ELECTRONICS, INC
597-1114-12
FIGURE 2-14. TEST EQUIPMENT CONNECTIONS, SEPARATION
2-141.
Operate the oscilloscope for: 1) 200 mV/div sensitivity and 2) dc coupled.
2-142.
Refer to Figure 2-8 and connect an audio generator to the audio input terminals.
2-143.
Operate the transmitter rear-door ac on/off control switch to ON.
2-144.
Select the antenna which is configured for equalization circuit 1 operation (refer to STE
REO CIRCUIT BOARD PROGRAMMING in the preceding text if required) and determine
a power level.
2-145.
Depress the desired power level switch/indicator to illuminate the switch/indicator.
2-146.
Refer to SECTION III, OPERATION and perform the following:
1. Operate the stereo circuit board mode control switch to illuminate the stereo
indicator. When power is applied to the transmitter, the stereo circuit board will
automatically be configured to the stereo mode.
2. Operate the stereo circuit board pilot switch to off.
3. Ensure the equalization circuit 1 indicator on the stereo circuit board is
illuminated.
2-147.
Adjust equalization circuit 1 as follows:
1. Adjust the audio generator for a 1 KHz left channel output at +10 dBm and
observe the lissajous pattern displayed on the oscilloscope.
2-31
2. Refer to Figure 2-6 and adjust the left channel level control to obtain a horizontal
lissajous pattern (refer to Figure 2-15).
3. Adjust the group delay as follows:
A. Configure the group delay circuitry for adjustment as follows:
1. Refer to Figure 2-6 and configure the left channel 4 microsecond and
8 microsecond sections to in.
2. Refer to Figure 2-6 and operate the left channel delay control fully counterclockwise.
B. Refer to Figure 2-6 and adjust the left channel delay control to close the oscilloscope display and obtain a straight-line lissajous display as shown in the maximum left channel separation lissajous pattern (refer to Figure 2-15). If the
display will not close, proceed as follows:
1. Refer to Figure 2-6 and: 1) configure only the 8 microsecond delay section
to in and 2) adjust the left channel delay control to close the oscilloscope
display.
2. If the display will not close refer to Figure 2-6 and: 1) configure only the 4
microsecond delay section to in and 2) adjust the left channel delay control to
close the oscilloscope display.
4. Adjust the separation at 7 kHz as follows:
A. Adjust the audio generator for a 7 kHz left channel output at +10 dBm.
B. Refer to Figure 2-6 and adjust the left channel cutoff and peak controls to
obtain a maximum left channel separation lissajous pattern as shown in
Figure 2-15.
C. If a maximum left channel lissajous pattern can not be obtained, refer to Figure
2-6 and adjust the left channel delay control to close the oscilloscope display
and obtain a straight-line lissajous pattern (refer to Figure 2-15).
5. Repeat the entire procedure for the right channel. Adjust the right channel level,
cutoff, peak, and delay controls as required to obtain optimum separation and
distortion from the right channel.
6. Repeat the entire procedure for equalization circuit 2. Adjust the equalization
circuit 2 using the equalization 2 left/right channel level, cutoff, peak, delay,
controls and the equalization 2 group delay sections to obtain optimum separation
and distortion.
2-148.
Once the stereo adjustment is complete: 1) refer to SECTION III, OPERATION and oper
ate the pilot switch on the stereo circuit board to ON and 2) remove the test equipment.
2-149.
SINGLE CHANNEL LEVEL. The transmitter is equipped with a single channel level con
trol. When the transmitter is operating in the stereo mode, the level control is designed to
boost a remaining audio channel level in the event of a failure in one channel. For trans
mitters operating in the stereo mode, adjust the single channel level control as follows:
2-32
COPYRIGHT
1999 BROADCAST ELECTRONICS, INC
597-0095-19
FIGURE 2-15. EQUALIZATION LISSAJOUS PATTERNS
(2-33/2-34)
WARNING
WARNING
DISCONNECT ALL TRANSMITTER PRIMARY POWER
BEFORE PROCEEDING.
2-150.
Operate the transmitter rear-door ac on/off control switch to OFF.
2-151.
If an audio processor is used with the transmitter, ensure the processor is connected as fol
lows:
1. Ensure normal program audio is connected to the processor input.
2. Ensure the audio processor output is connected to the transmitter audio input.
2-152.
Operate the transmitter rear-door ac on/off control switch to ON.
2-153.
Depress a desired power level switch/indicator to illuminate the switch/indicator.
2-154.
Refer to SECTION III, OPERATION and operate the stereo circuit board mode control
switch to illuminate the stereo indicator.
2-155.
Disable one channel applied to the transmitter.
2-156.
If an audio processor is used with the transmitter, refer to the audio processor manual and
adjust the processor single channel limiter as described in the procedure.
2-157.
Refer to SECTION III, OPERATION and operate the stereo circuit board mode control
switch to illuminate the mono left or mono right indicator as determined by the remaining
operating audio channel applied to the transmitter.
2-158.
Refer to Figure 2-5 and adjust the single channel level control on the exciter circuit board
as required to obtain an approximate 100% modulation indication on the modulation moni
tor.
2-35
SECTION III
OPERATION
3-1.
INTRODUCTION.
3-2.
This section identifies all controls and indicators associated with the AM-2.5E/AM-5E
transmitters and provides standard operating procedures.
3-3.
CONTROLS AND INDICATORS.
3-4.
Figures 3-1, 3-2, and 3-3 present the location of all controls and indicators associated with
normal operation of the AM-2.5E and AM-5E transmitters. Tables 3-1, 3-2, and 3-3
present the functions of each control or indicator. Refer to Figures 3-1 through 3-3 and
Tables 3-1 through 3-3 for a description of the controls and indicators associated with the
AM-2.5E/AM-5E transmitters.
TABLE 3-1. AM-2.5E/AM-5E CONTROLS AND INDICATORS
(Sheet 1 of 2)
INDEX
NO.
NOMENCLATURE
FUNCTION
FORWARD POWER
Meter
Displays the transmitter forward power output in
watts as selected by the FORWARD POWER Meter
LOW/HIGH/OFF switch.
FORWARD POWER
Meter HIGH/LOW/OFF
Switch
Configures the FORWARD POWER meter: 1) to
display forward power information on the HIGH
scale, 2) to display forward power information on the
LOW scale, or 3) to off. In the AM-2.5E: 1) the HIGH
scale is from 0 to 3000 watts and 2) the LOW scale is
from 0 to 750 watts. In the AM-5E: 1) the HIGH
scale is from 0 to 6000 watts and 2) the LOW scale is
from 0 to 1500 watts.
REFLECTED POWER
Meter
Displays the transmitter reflected power output in
watts or the ac input voltage in volts as selected by
the REFLECTED POWER HIGH/LOW/VAC
Switch.
REFLECTED POWER
Meter HIGH/LOW/VAC
Switch
Configures the REFLECTED POWER meter to
display: 1) reflected power information on the HIGH
scale, 2) reflected power information on the LOW
scale, or 3) the ac input voltage. In the AM-2.5E:
1) the HIGH scale is from 0 to 300 watts and 2) the
LOW scale is from 0 to 60 watts. In the AM-5E:
1) the HIGH scale is from 0 to 600 watts and 2) the
LOW scale is from 0 to 150 watts. The ac volts scale is
from 150 to 300 volts.
3-1
3-2
COPYRIGHT
1999 BROADCAST ELECTRONICS, INC
597-1114-13
FIGURE 3-1. AM-2.5E/AM-5E CONTROLS AND INDICATORS
TABLE 3-1. AM-2.5E/AM-5E CONTROLS AND INDICATORS
(Sheet 2 of 2)
INDEX
NO.
NOMENCLATURE
RF POWER MODULE
A modular plug-in assembly containing two RF
power amplifier circuit boards and one modulator
circuit board. The AM-2.5E is equipped with 2 power
modules. The AM-5E is equipped with 4 power
modules. Each power module is designed to output
1375 watts of RF power.
POWER BLOCK
An RF power amplifier assembly containing two RF
power modules and a combiner unit.
LOAD Control
Operates in association with the TUNE control to
match the transmitter output impedance to the
antenna.
TUNE Control
Operates in association with the LOAD control to
match the transmitter output impedance to the
antenna.
AC ON/OFF
Switch
Controls the application of ac power to the transmitter.
10
Modulation Monitor
Calibration Controls
Calibrates the modulation monitor sample to power
levels 1 through 5.
11
POWER SUPPLY 1-2
Fault Indicator
(AM-5E Only)
Illuminates to indicate a failure in the 1-2 power
supply. The supply provides power for RF power
modules 1-2.
12
POWER SUPPLY 3-4
Fault Indicator
(AM-5E Only)
Illuminates to indicate a failure in the 3-4 power supply. The supply provides power for RF power modules
3-4.
FUNCTION
TABLE 3-2. ECU CONTROLS AND INDICATORS
(Sheet 1 of 6)
INDEX
NO.
NOMENCLATURE
EXCITER Indicator
FUNCTION
Displays the operating status of the exciter.
GREEN Display - Indicates normal exciter
operation.
RED Display - Indicates an exciter fault.
3-3
TABLE 3-2. ECU CONTROLS AND INDICATORS
(Sheet 2 of 6)
INDEX
NO.
NOMENCLATURE
POWER MODULES
Indicator
FUNCTION
Displays the operating status of the transmitter
power modules.
GREEN Display - Indicates all power modules are
operating normally.
YELLOW Display - Indicates an RF power module is
removed from the transmitter.
RED Display - Indicates a fault in an RF power
module.
POWER SUPPLY
Indicator
Displays the operating status of the transmitter
power supply system.
GREEN Display - Indicates normal power supply
system operation.
YELLOW DISPLAY - Indicates one or more power
supplies are removed from the transmitter.
RED Display - Indicates a power supply system
fault.
ANTENNA VSWR
Indicator
Displays the condition of the antenna system.
GREEN Display - Indicates a normal antenna load.
YELLOW Display - Indicates a VSWR condition
of 1.2 : 1.
RED Display - Indicates a high reflected/forward
power indication. In the AM-2.5E, indicates a 100
watt reflected power condition or a condition which
results in a high forward power indication of greater
than 20%. In the AM-5E, indicates a 200 watt
reflected power condition or a condition which results
in a high forward power indication of greater than
20%.
FLASHING RED Display - Indicates a reflected
power emergency condition. In the AM-2.5E,
indicates a 500 watt reflected power condition. In
the AM-5E, indicates a 1000 watt reflected power
condition.
3-4
TABLE 3-2. ECU CONTROLS AND INDICATORS
(Sheet 3 of 6)
INDEX
NO.
NOMENCLATURE
POWER CONTROL
Switch/Indicators
FUNCTION
SWITCHES - A group of five switches designed to
select five customer adjustable transmitter operating
output power levels.
In the AM-2.5E, switches 1 and 2 can be adjusted to
obtain output power levels from 250 to 1250 watts.
Switches 4 and 5 can be adjusted to obtain output
power levels from 750 to 2800 watts. Switch 3 is
designed to be customer assigned to control power in
the 250 to 1250 watt range or the 750 to 2800 watt
range.
In the AM-5E, switches 1 and 2 can be adjusted to
obtain output power levels from 500 to 2500 watts.
Switches 4 and 5 can be adjusted to obtain output
power levels from 1500 to 5600 watts. Switch 3 is
designed to be customer assigned to control power in
the 500 to 2500 watt range or the 1500 to 5600 watt
range.
INDICATORS - Illuminates to indicate an associated
power control switch has been selected.
OFF Switch/Indicator
SWITCH - Deenergizes the transmitter RF output
power and configures the unit to off.
INDICATOR - Illuminates to indicate the OFF
switch has been selected.
POWER
Indicator
Switch/
SWITCH - Instructs the system controller to raise
the transmitter output power. The switch is designed
with the ability to raise power from 10% to 15% of the
selected output power level.
INDICATOR - During manual operating conditions,
illuminates to indicate the POWER switch is
selected. During automatic raise conditions, the indicator will illuminate to indicate the rate of automatic
power increase.
POWER
Indicator
Switch/
SWITCH - Instructs the system controller to lower
the transmitter output power. The switch is designed
with the ability to lower power from 10% to 15% of the
selected output power level.
INDICATOR - During manual operating conditions,
illuminates to indicate the POWER switch is
selected. During automatic lower conditions, the
indicator will illuminate to indicate the rate of automatic power decrease.
3-5
TABLE 3-2. ECU CONTROLS AND INDICATORS
(Sheet 4 of 6)
INDEX
NO.
NOMENCLATURE
RESET Switch/
Indicator
FUNCTION
SWITCH - Clears the transmitter fault circuitry
when: 1) the switch is depressed and 2) if the fault
condition is removed.
INDICATOR - Illuminates to indicate a fault has
been encountered.
10
EXCITER MONITOR
STEREO Indicator
Illuminates to indicate the exciter is configured
to the stereo mode.
11
EXCITER MONITOR
MODE Switch/
Indicator
SWITCH - Selects either left/right channel or
L-R/L+R information for presentation on the
EXCITER MONITOR LED bar-graph display.
INDICATOR - Indicates the type of information
selected for display on the exciter monitor. The L/R
indicator will illuminate to indicate the display of
left/right channel information. The L+R/L-R indicator will illuminate to indicate the display of L+R/
L-R information.
12
EXCITER MONITOR
+/- POLARITY
Switch/Indicator
SWITCH - Selects either positive or negative peak
audio for application to the EXCITER MONITOR
LED bar-graph display.
INDICATOR - Indicates the signal polarity selected
for display on the exciter monitor. The + indicator will
illuminate to indicate the display of positive information. The - indicator will illuminate to indicate the
display of negative information.
13
EXCITER MONITOR
LED Bar-Graph Display
Displays left, right, L+R, or L-R audio channel
peak levels as selected by the EXCITER MONITOR
MODE and POLARITY switches. Each indicator
will illuminate at the level indicated on the display.
In addition, the display is equipped with an autorange
feature to allow the monitoring of signals in the 0.5%
to 14.5% range. Indications of autorange operation are
provided by the R/L-R and L/L+R X10 indicators.
14
EXCITER MONITOR
MONO Indicator
Illuminates to indicate the exciter is configured to the
mono L, mono R, or mono L+R mode of operation.
15
R/L-R Display
X10 Indicator
Illuminates to indicate the autorange feature is
enabled to expand the R/L-R display by 10 to provide
the resolution required for low level audio monitoring.
3-6
COPYRIGHT
1999 BROADCAST ELECTRONICS, INC
597-1114-23
FIGURE 3-2. ECU CONTROLS AND INDICATORS
(3-7/3-8)
TABLE 3-2. ECU CONTROLS AND INDICATORS
(Sheet 5 of 6)
INDEX
NO.
NOMENCLATURE
FUNCTION
16
L/L+R Display
X10 Indicator
Illuminates to indicate the autorange feature is
enabled to expand the L/L+R display by 10 to provide
the resolution required for low level audio monitoring.
17
OVERTEMP Indicator
Illuminates to indicate when the transmitter
operating temperature exceeds 70° C (158° F).
18
FOLDBACK Indicator
Illuminates to indicate when the transmitter is in a
foldback condition. Foldback is when the transmitter
output power is automatically reduced in response to
one of the following fault conditions: 1) high reflected
power, 2) high forward power, 3) high temperature, or
4) detection of a lightning potential.
19
INTERLOCK
Indicator
Illuminates to indicate the internal interlock, external
interlock, and the remote fail-safe are closed. The
remote control fail-safe must be closed only when the
transmitter is configured for remote control operation.
20
REMOTE Indicator
Illuminates to indicate transmitter remote control
operations are enabled.
21
CONFLICT Indicator
Illuminates to indicate an incorrect power level is
selected for operation into the antenna connected to
the transmitter.
22
LIGHTNING Indicator
In the AM-2.5E, illuminates to indicate a 1500 volt or
greater potential is present at the transmitter output.
In the AM-5E, illuminates to indicate a 2100 volt or
greater potential is present at the transmitter output.
23
PWM Mute Indicator
Illuminates to indicate the power control PWM signal
is muted in response to a fault such as lightning, an
exciter fault, a reflected power emergency, an open
remote control fail-safe, or an external transmitter
mute.
24
Remote Fail-safe
Indicator
Illuminates to indicate the remote control unit is
enabled.
25
Remote/Local
Switch
Controls the transmitter remote control operations.
When the switch is operated to remote, remote control
operations are enabled. When the switch is operated
to local, remote control operations are disabled.
3-9
TABLE 3-2. ECU CONTROLS AND INDICATORS
(Sheet 6 of 6)
INDEX
NO.
NOMENCLATURE
FUNCTION
26
Battery OK Indicator
When the battery test switch is depressed, the indicator will: 1) illuminate to indicate the battery is
operational or 2) not illuminate to indicate the battery
is to be replaced.
27
Battery Test Switch
When depressed, evaluates the controller battery
status. The status is displayed by the battery OK
indicator.
28
Pilot On/Off Switch
Enables and disables the stereo pilot signal.
29
Stereo Indicator
Illuminates to indicate the exciter is configured to the
stereo mode.
30
Mono L+R Indicator
Illuminates to indicate the exciter is configured to the
mono L+R mode.
31
Mono Right Indicator
Illuminates to indicate the exciter is configured to the
mono right mode.
32
Mono Left Indicator
Illuminates to indicate the exciter is configured to the
mono left mode.
33
Exciter Mode
Control Switch
Configures the exciter for stereo, mono L+R, mono
left, or mono right operation. The switch is designed
to configure the exciter to a different mode of operation each time the switch is depressed. The switch
will advance to a mode of operation in the following
order: 1) mono left, 2) mono right, 3) mono L+R, and
4) stereo.
34
Stereo Equalization 1
Indicator
Illuminates to indicate the exciter stereo equalization
1 circuit is active.
35
Stereo Equalization 2
Indicator
Illuminates to indicate the exciter stereo equalization
2 circuit is active.
36
Lock Indicator
Illuminates to indicate the exciter is locked to the
programmed carrier frequency.
37
Exciter +5V Indicator
Illuminates to indicate the ECU +5V supply is
operational.
38
Exciter +15V Indicator
Illuminates to indicate the ECU +15V supply is
operational.
39
Exciter -15V Indicator
Illuminates to indicate the ECU -15V supply is
operational.
40
Negative Limiter
Indicator
Illuminates to indicate the negative limiter circuit is
enabled. Factory adjusted to illuminate at
approximately 94% negative modulation.
3-10
TABLE 3-3. POWER MODULE CONTROLS AND INDICATORS
(Sheet 1 of 2)
INDEX
NO.
NOMENCLATURE
FUNCTION
PA 1 RF DRIVE
Indicator
Illuminates to indicate RF drive is present at
power amplifier 1.
PA 1 FAULT
Indicator
Illuminates to indicate a fault has occurred
in power amplifier 1.
PA 2 RF DRIVE
Indicator
Illuminates to indicate RF drive is present at
power amplifier 2.
PA 2 FAULT
Indicator
Illuminates to indicate a fault has occurred in
power amplifier 2.
MOD PWM DRIVE
Indicator
Illuminates to indicate the exciter PWM drive
is present at the modulator circuit board.
MOD POWER
Indicator
Illuminates to indicate dc power is present at the
modulator circuit board.
COPYRIGHT 1999 BROADCAST ELECTRONICS, INC
597-1112-31
FIGURE 3-3. POWER MODULE CONTROLS AND INDICATORS
3-11
TABLE 3-3. POWER MODULE CONTROLS AND INDICATORS
(Sheet 2 of 2)
INDEX
NO.
3-5.
NOMENCLATURE
FUNCTION
MOD FAULT
Indicator
Illuminates to indicate a fault has occurred in the
modulator circuit board.
MOD FUSE
Indicator
Illuminates to indicate the modulator circuit
board fuse has blown.
MOD SAMPLE
Provides a dc voltage sample of the modulator circuit
board output. In the AM-2.5E, the sample will be
equal to approximately 5.6 volts dc at 2.5 kW (refer to
factory test data sheets). In the AM-5E, the sample
will be equal to approximately 5.6 volts dc at 5 kW
(refer to factory test data sheets).
OPERATION.
CAUTION
CAUTION
NOTE
NOTE
WHEN AC POWER IS APPLIED TO THE TRANSMIT
TER AND THE RF DRIVE AND PWM DRIVE INDICA
TORS ON RF POWER MODULES IN A POWER BLOCK
ARE EXTINGUISHED, THE RF POWER MODULES
MUST BE REMOVED FROM THE TRANSMITTER
CHASSIS TO PREVENT DAMAGE TO THE MODULES.
ENSURE THE TRANSMITTER IS COMPLETELY
INSTALLED PRIOR TO PERFORMING THE FOLLOW
ING PROCEDURES.
3-6.
TURN-ON.
3-7.
Operate the transmitter to ON by performing the following procedure.
3-8.
Ensure the transmitter rear-panel ac on/off switch is operated to ON. The ECU and RF
power module front-panel indicators will illuminate.
3-9.
Observe the ECU and RF power module indicators. Ensure normal operating conditions
are displayed by all indicators. If an indicator displays a fault condition, operate the ac
power switch to off and refer to SECTION V, MAINTENANCE to locate the problem.
3-10.
Select an output power level by depressing the desired power level switch/indicator. The
following events will occur:
1. The power level switch indicator will illuminate.
2. The transmitter flushing fans will begin operation.
3. The transmitter output power will be displayed on the FORWARD and
REFLECTED power meters.
3-12
3-11.
Operate the FORWARD and REFLECTED power meters to observe the transmitter for
ward and reflected power indications.
3-12.
Adjust the transmitter output power if required by performing the POWER ADJUST
procedure presented in the following text.
3-13.
If remote control operation is desired, operate the local/remote switch on the controller cir
cuit board to remote. This will enable both local and remote operation.
3-14.
TURN OFF.
3-15.
Operate the transmitter to OFF by depressing the OFF switch/indicator to illuminate the
switch/indicator. The transmitter will operate to off.
3-16.
METERING.
3-17.
FORWARD POWER. The forward power meter presents forward power indications. To
operate the meter, proceed as follows:
1. To monitor low forward power levels, operate the FORWARD POWER meter
switch to LOW. In the AM-2.5E, the LOW scale is from 0 to 300 watts. In the
AM-5E, the LOW scale is from 0 to 1500 watts.
2. To monitor high forward power levels, operate the FORWARD POWER meter
switch to HIGH. In the AM-2.5E, the HIGH scale is from 0 to 3000 watts. In the
AM-5E, the HIGH scale is from 0 to 6000 watts.
3. To configure the FORWARD POWER meter to off, operate FORWARD POWER
meter switch to OFF.
3-18.
REFLECTED POWER. The reflected power meter presents reflected power and ac input
indications. To operate the meter, proceed as follows:
1. To monitor low reflected power levels, operate the REFLECTED POWER meter
switch to LOW. In the AM-2.5E, the LOW scale is from 0 to 60 watts. In the
AM-5E, the LOW scale is from 0 to 150 watts.
2. To monitor high reflected power levels, operate the REFLECTED POWER meter
switch to HIGH. In the AM-2.5E, the HIGH scale is from 0 to 300 watts. In the
AM-5E, the HIGH scale is from 0 to 600 watts.
3. To monitor the ac input voltage, operate the REFLECTED POWER meter
switch to VAC.
3-19.
POWER ADJUST.
3-20.
The POWER
and
switches adjust the transmitter output power. To adjust the trans
mitter power, proceed as follows:
1. Depress the POWER
switch to increase the transmitter output power. Observe
the transmitter output power indications on the FORWARD and REFLECTED
power meters.
The switch will increase power from 10% to 15% of the selected power level.
OR
switch to decrease the transmitter output power. Observe
2. Depress the POWER
the transmitter output power indications on the FORWARD and REFLECTED
power meters.
The switch will decrease power from 10% to 15% of the selected power level.
3-13
3-21.
MONO/STEREO OPERATION.
3-22.
To configure the transmitter for monophonic or stereophonic operation, perform the follow
ing procedures.
3-23.
STEREO OPERATION. To configure the transmitter for stereo operations, depress the ex
3-24.
MONO OPERATION. The transmitter can be configured to the monophonic mode by:
3-25.
Mono Operation - Stereo Circuit Board. To configure the transmitter for mono operation
using the stereo circuit board, depress the exciter mode control switch to illuminate the
mono L+R, mono left, or mono right indicators on the stereo circuit board. In addition, the
ECU front-panel MONO indicator will illuminate.
3-26.
Mono Operation - No Stereo Circuit Board. In the event of a stereo circuit board failure,
the transmitter will automatically configure to the monophonic mode when the stereo cir
cuit board is removed from the ECU. To remove the stereo circuit board and configure the
transmitter for monophonic operation, proceed as follows:
citer mode control switch to illuminate the stereo indicator on the stereo circuit board. In
addition, the ECU front-panel stereo indicator will illuminate.
1) manually selecting the desired mono mode using the stereo circuit board or 2) automati
cally configuring the transmitter by removing the stereo circuit board. To configure the
transmitter for mono operations, proceed as follows:
CAUTION
CAUTION
TO PREVENT DAMAGE TO THE TRANSMITTER, EN
SURE THE TRANSMITTER PRIMARY POWER IS OPER
ATED TO OFF BEFORE REMOVING THE STEREO CIR
CUIT BOARD.
1. Operate the transmitter primary power to off.
2. Completely remove the stereo circuit board from the ECU. Do not leave the circuit
board in the ECU chassis.
3. Refer to Figure 2-5 in SECTION II, INSTALLATION and ensure the monophonic
audio channel select jumper is configured for the desired audio channel.
4. If required, adjust the single channel level by referring to SECTION II,
INSTALLATION and performing the SINGLE CHANNEL LEVEL procedure.
3-27.
PILOT CONTROL.
3-28.
The pilot switch on the stereo circuit board controls the pilot tone. Operate the pilot switch
to on to enable the pilot tone. Operate the pilot switch to off to disable the pilot tone.
3-29.
EXCITER MONITOR OPERATION.
3-30.
The following text presents procedures for specific exciter monitoring functions. Perform
the appropriate procedure for the type of monitor function desired.
3-31.
MONO/STEREO INDICATIONS. The MONO and STEREO indicators display the oper
3-32.
ating mode of the exciter. The MONO indicator will illuminate to indicate when the excit
er is configured for mono L+R, mono left, or mono right operation. The STEREO indicator
will illuminate to indicate when the exciter is configured for stereo operation.
INPUT SELECTION. Depress the L/R/L+R/L-R MODE switch/indicator to: 1) illuminate
the L/R indicator to select left and right channel information or 2) illuminate the L+R/L-R
indicator to select L+R and L-R information. The selected parameter will appear on the
EXCITER MONITOR display.
3-14
3-33.
POLARITY SELECTION. Depress the POLARITY switch/indicator to: 1) illuminate the +
3-34.
X10 AUTORANGE INDICATIONS. The EXCITER MONITOR display is designed with
3-35.
FAULT RESET.
3-36.
The transmitter monitors several parameters for fault conditions. The RESET indicator
will illuminate to indicate a fault when one of the following conditions occur:
1) over-temperature, 2) exciter fault, 3) power supply fault, 4) RF power module fault,
5) high reflected/forward power, 6) reflected power emergency, or 7) lightning. Once the
fault condition is removed, the fault circuitry must be reset. If a power supply fault is en
countered, the transmitter AC power must be disconnected to remove the fault condition
(refer to POWER SUPPLY FAULT RESET in the following text). To reset the fault cir
cuitry, depress the RESET switch. The fault circuitry will be reset.
3-37.
POWER SUPPLY FAULT RESET.
3-38.
If a power supply fault is encountered, ac power must be disconnected from the transmitter
to clear the fault. To reset a power supply fault, proceed as follows:
indicator to select positive peak audio or 2) illuminate the - indicator to select negative
peak audio. The selected parameter will appear on the EXCITER MONITOR display.
an autorange function to provide the appropriate resolution for the applied signal level.
The L/L+R display X10 indicator will illuminate to indicate the display is expanded by 10.
The R/L-R display X10 indicator will illuminate to indicate the display is expanded by 10.
1. Operate the rear-door ac ON/OFF switch to off.
2. Operate the rear-door ac on/off switch to on.
3. Depress the RESET switch.
3-39.
OVER-CYCLE OFF.
3-40.
The transmitter controller is equipped with an on/off cycle counter circuit. The circuit is
designed to monitor transmitter on/off cycles. If the transmitter is operated on/off seven
times within 15 seconds, the transmitter will automatically operate to OFF. The power
level or OFF switch/indicators will not respond. To operate the transmitter to ON, proceed
as follows:
1. Do not depress any power level switch/indicators or the OFF switch/indicator for
approximately 30 seconds. This allows the circuit to reset.
2. Depress the desired power level switch/indicator.
3-41.
OVER-MODULATION PWM MUTE.
3-42.
The transmitter is protected from modulation levels above 150% by an over-modulation
circuit. If the transmitter modulation increases to a level above 150%, the PWM signal
will be muted. This will mute the output power and prevent damage to the transmitter
power supply modules.
3-43.
TRANSMITTER MONITOR.
3-44.
The TRANSMITTER MONITOR is designed to present the operating status of: 1) the
exciter, 2) the RF power modules, 3) the power supply, 4) the antenna, 5) the remote con
trol, 6) antenna conflict conditions, 7) lightning conditions, 8) interlocks, 9) foldback condi
tions, and 10) over-temperature conditions. Use the information presented in Table 3-2 to
determine the status of the transmitter components and operating conditions.
3-45.
BATTERY TEST.
3-46.
The battery test and battery OK indicator check the ECU battery backup system. To check
the ECU battery, depress the battery test switch. The battery OK indicator will illuminate
to indicate an acceptable battery voltage. If the battery OK indicator does not illuminate,
replace the battery.
3-15
3-47.
CONTROLLER PWM MUTE INDICATOR.
3-48.
The PWM mute indicator illuminates to indicate when the power control PWM signal is
muted. The power control PWM signal is muted during: 1) lightning conditions, 2) an ex
citer fault, 3) reflected power emergency conditions, 4) an open remote control fail-safe, or
5) a transmitter mute control signal.
3-49.
CONTROLLER REMOTE FAIL-SAFE INDICATOR.
3-50.
The controller remote fail-safe indicator illuminates to indicate the remote control unit is
enabled. The indicator will extinguish when the remote control unit is disabled.
3-51.
EXCITER LOCK INDICATOR.
3-52.
The exciter circuit board lock indicator illuminates to indicate when the exciter is locked to
the programmed carrier frequency. The indicator will extinguish when the exciter is un
locked from the programmed carrier frequency.
3-53.
EXCITER +5V/+15V/-15V INDICATORS.
3-54.
The exciter circuit board +5V, +15V, and -15V indicators display the status of the operating
potentials from the ECU power supply. The +5V, +15V, and -15V indicators will illuminate
to indicate the +5 volt, +15 volt, and -15 supplies are operational.
3-55.
STEREO EQUALIZATION INDICATORS.
3-56.
The stereo circuit board equalization 1 indicator illuminates to indicate when equalization
circuit 1 is selected. The stereo circuit board equalization 2 indicator illuminates to indi
cate when equalization circuit 2 is selected.
3-57.
RF POWER MODULE INDICATORS.
3-58.
The RF power module indicators are designed to present the operating status of the power
amplifier circuit boards and the modulator circuit board. Use the information presented in
Table 3-3 to determine the status of the power amplifier circuit boards and the modulator
circuit board.
3-59.
POWER SUPPLY INDICATORS.
3-60.
On AM-5E models, the power supply indicators on the transmitter lower front-panel are
designed to present the operating status of the power supply circuit boards. The AM-5E
transmitter is equipped with power supply 1-2 and 3-4. The indicators illuminate to indi
cate a failure in a power supply.
3-61.
EXCITER NEGATIVE LIMITER INDICATOR.
3-62.
The exciter circuit board negative limiter indicator displays the status of the exciter nega
tive limiter circuit. The indicator will illuminate to indicate the negative limiter circuit is
enabled. The indicator is factory adjusted to illuminate at approximately 94% negative
modulation.
3-63.
HIGH/LOW AC LINE CONDITIONS.
3-64.
The transmitter is equipped with an ac line monitor. The monitor will deenergize the
transmitter in the event the ac power line is below 190 Volts or above 260 Volts. If this
condition occurs: 1) the transmitter output power will be disabled and 2) a no fault or
emergency condition will be generated. The transmitter will re-energize when the high/
low ac line condition is removed.
3-16
SECTION IV
THEORY OF OPERATION
4-1.
INTRODUCTION.
4-2.
This section presents the theory of operation for the Broadcast Electronics
AM-2.5E/AM-5E transmitters.
4-3.
The following text presents the AM-2.5E/AM-5E transmitter overall theory of operation.
The transmitter is divided into modular components for the discussion. The modular
components consist of the: 1) exciter/control unit (ECU), 2) output network, 3) RF power
module, 4) RF combiner, and 5) power supply. The ECU, RF power module, and power
supply are presented in further detail by the publication sections at the end of this
manual.
4-4.
Figures 4-1 and 4-2 present the AM-2.5E and AM-5E block diagrams. Figure 4-1
presents the AM-2.5E block diagram. Refer to Figure 4-1 and the AM-2.5E overall
schematic diagram in SECTION VII as required for the following discussion. Figure 4-2
presents the AM-5E block diagram. Refer to Figure 4-2 and the AM-5E overall
schematic diagram in SECTION VII as required for the following discussion.
4-5.
FUNCTIONAL DESCRIPTION.
4-6.
ECU.
4-7.
GENERAL. The transmitter ECU (exciter/control unit) is a modular assembly containing
4-8.
STEREO CIRCUIT BOARD. The ECU stereo circuit board consists of C-QUAM AM stereo
circuitry. C-QUAM AM stereo is a mode of AM stereo transmission utilizing amplitude
modulated (L+R) information and independently quadrature modulated stereo (L-R)
information. The results produce a stereo transmission system compatible with mono
receivers.
4-9.
The stereo circuit board is equipped with four modes of operation: 1) mono left, 2) mono
right, 3) mono L+R, and 4) stereo. Configuring the circuit board to monophonic operation
is accomplished by: 1) operating the circuit board to the mono left, mono right, or mono
L+R mode or 2) removing the stereo circuit board. The circuit board is equipped with two
equalization circuits. The circuits allow the transmitter to be configured for two different
antenna patterns such as for a day pattern and a night pattern.
4-10.
The stereo circuit board operates in association with the ECU exciter circuit board to
provide RF drive to the RF power modules. The stereo circuit board receives left and
right channel audio and an unmodulated TTL level RF signal at 4 times the carrier
frequency from the exciter circuit board. The stereo circuit board outputs a TTL level RF
signal to the exciter circuit board.
4-11.
EXCITER CIRCUIT BOARD. The ECU exciter circuit board is a modular plug-in exciter
plug-in stereo, exciter, controller, and extender circuit board assemblies. A forward
power meter is provided to monitor the transmitter forward output power. A reflected
power/primary ac power meter provides reflected power and primary ac voltage
indications. The ECU switch and display circuitry is contained on switch and display
circuit boards. Power for the ECU is provided by a modular switching power supply unit.
assembly. The circuit board operates in association with the stereo circuit board to
produce a C-QUAM AM stereo RF output. Instrumentation amplifiers provide balanced
left and right channel transformerless audio inputs.
4-1
4-12.
The exciter circuit board generates: 1) a PWM (pulse-width-modulation) signal and 2) an
RF carrier frequency signal. The 122 kHz to 135 kHz PWM signal is routed for
application to the modulator circuit boards in the RF power modules. The RF carrier
frequency signal is applied to the power amplifier circuit boards in the RF power modules.
The exciter carrier frequency is established by a digital frequency synthesizer. The
synthesizer is a phase-locked-loop circuit which provides extremely accurate and reliable
carrier frequency operation.
4-13.
CONTROLLER CIRCUIT BOARD. All transmitter control operations are directed by the
4-14.
The controller circuit board is designed with two interlock circuits. A transmitter
external interlock is provided such as for a test load. An antenna interlock circuit is
provided to prevent the transmitter from operating into an incorrect antenna.
4-15.
The transmitter power is controlled by a power control circuit. The circuit allows the
transmitter to be operated at five power levels. A power trim circuit allows the
transmitter power to be increased or decreased as required. A high reflected power
detection circuit, a high forward power detection circuit, and a high temperature
detection circuit operate in association with the power control circuit to foldback the
transmitter power during high reflected power, high forward power, and high
temperature conditions. In addition, a lightning detector circuit is provided to mute the
transmitter when lightning is present at the antenna.
4-16.
Several monitoring and display circuits provide information on transmitter operating
conditions. An RF power module status circuit displays: 1) if a module is removed for
maintenance or 2) if a power module fault has occurred. A power supply status circuit
displays: 1) if a power supply circuit board is removed for maintenance or 2) if a power
supply fault has occurred. An exciter status circuit indicates if a fault has occurred in the
exciter. An antenna status circuit displays: 1) 1.2 : 1 VSWR conditions, 2) high reflected
power conditions, and 3) emergency reflected power conditions.
4-17.
Additional display circuits include: 1) remote, 2) conflict, 3) lightning, 4) interlock,
5) over-temperature, and 6) reset. A remote indicator displays the status of the remote
control system. A conflict indicator illuminates to indicate an incorrect power level is
selected for operation into an antenna. A lightning indicator illuminates to indicate the
presence of lightning at the transmitter output. An interlock indicator displays the status
of the internal and external interlock. An over-temperature indicator illuminates to
indicate a transmitter temperature greater than 70 degrees C. A reset indicator
illuminates to indicate a transmitter fault has occurred. Transmitter faults include:
1) exciter failure, 2) power supply failure, 3) RF power module failure, 4) high reflected
power conditions, 5) reflected power emergency conditions, 6) over-temperature
conditions, 7) lightning conditions, and 8) 1.2:1 VSWR conditions.
4-18.
POWER SUPPLY. DC operating potentials for the ECU assembly is provided by a modular
4-19.
RF POWER MODULE.
4-20.
An RF power module is a plug-in assembly containing two RF amplifier circuit boards
and a modulator circuit board. Each RF power module is designed to produce 1375 watts
of RF power. Two RF power modules are contained in a power block. The AM-2.5E
transmitter is equipped with 1 power block. The AM-5E transmitter is equipped with 2
power blocks.
ECU controller circuit board. The controller circuit board is designed with CMOS control
and monitoring circuitry.
switching power supply unit. The unit provides +5V, +15V, and -15V dc operating
potentials for the ECU circuit boards. +5V, +15V, and -15V indicators are provided on the
exciter circuit board.
4-2
COPYRIGHT
1999 BROADCAST ELECTRONICS, INC
597-1114-5
FIGURE 4-1. AM-2.5E BLOCK DIAGRAM
(4-3/4-4)
COPYRIGHT
1999 BROADCAST ELECTRONICS, INC
597-1114-4
FIGURE 4-2. AM-5E BLOCK DIAGRAM
(4-5/4-6)
4-21.
The modular design of the RF power modules allow the modules to be removed from the
transmitter for maintenance. The remaining power modules will provide power to
maintain on-air operation.
4-22.
The PWM signal from the exciter circuit board is applied to the modulator circuit board.
The modulator circuit board is designed to amplify and convert the PWM signal to a dc
voltage which varies at an audio rate. The output of the modulator circuit board is
applied to the RF amplifier circuit boards. Four indicator circuits monitor and display the
status of the: 1) PWM drive signal, 2) B+ dc supply, 3) modulator fault conditions, and
4) blown fuse conditions.
4-23.
The RF amplifier circuit boards are designed with Class E amplifier technology and
MOSFET power transistors. The circuit board operates from: 1) the varying dc voltage
from the modulator circuit board and 2) the RF drive signal from the exciter circuit board.
The RF drive signal from the exciter circuit board and the varying dc voltage from the
modulator are applied to a push-pull power MOSFET transistor amplifier circuit. The
amplifier circuit is designed to output approximately 687.5 watts of RF power. A fault
detection circuit monitors amplifier operation for fault conditions.
4-24.
RF COMBINER.
4-25.
Power from each RF amplifier circuit board is applied to a star combiner network. The
combiner components are located on the rear panel of each power block. The star
combiner network consists of individual transformer and inductor networks for each
amplifier circuit board. The combiner accepts RF power from each RF power module to
produce the rated RF output power.
4-26.
In addition to combining the RF power from the RF power modules, the combiner design
allows one or more RF power modules to be removed from the transmitter for
maintenance. The remaining RF power modules will continue to operate to maintain
on-air operation. This is accomplished without the use of dummy modules or bypass
switches.
4-27.
OUTPUT NETWORK.
4-28.
The output network is a modular assembly designed to match the transmitter impedance
to the antenna. The assembly consists of a: 1) bandpass filter, 2) directional coupler
circuit board, 3) T-matching network, 4) lightning protection circuit board, and 5) a
lightning detection circuit board.
4-29.
The bandpass filter is an eight element LC filter designed to attenuate all harmonic
frequencies to FCC, DOC, and CCIR levels. The directional coupler circuit board consists
of a circuit designed to sample the transmitter RF output. The circuit board generates
both forward and reflected power samples for application to the controller circuit board.
The T" matching network consists of an LC network. The network is designed to match
the transmitter impedance to the antenna.
4-30.
A lightning protection circuit board is provided to protect the transmitter circuitry from
direct lightning potentials. The circuit protects the transmitter by shunting lightning
potentials to ground. The lightning detector circuit board is designed to mute the
transmitter RF output during the presence of a lightning potential. The lightning
detector circuit board is controlled by a spark gap. The circuit will respond to potentials
of 1500 volts in AM-2.5E models and 2100 volts in AM-5E models. This prevents the
transmitter from muting during near-by lightning activity.
4-7
4-31.
POWER SUPPLY.
4-32.
A single phase source of 196 to 252 volts ac 50/60 Hz is required to operate the
transmitter. The power source is routed through an RFI filter to prevent the coupling of
RFI components into or out-of the transmitter. A rear-door ac on/off switch provides ac
power control and disconnects all ac power to the transmitter when the door is opened.
The ac line is monitored for high/low conditions by an ac line voltage monitor. The
transmitter primary ac power will be interrupted if the ac line is above 260 volts or below
195 volts. Primary fuses protect the transmitter from over-current conditions. A power
factor corrector circuit modifies the ac line impedance to provide a power factor of
approximately 0.9.
4-33.
The ac line voltage is sampled at the ac sample circuit board. The sample circuit board
provides an ac line voltage sample for application to the meter switch circuit board.
4-34.
POWER SUPPLY CIRCUIT BOARD. DC operating potentials for the RF power modules
are provided by power supply circuit boards. One power supply circuit board provides dc
operating potentials for one power block. The AM-2.5E transmitter is equipped with 1
power supply circuit board. The AM-5E transmitter is equipped with 2 power supply
circuit boards.
4-35.
The power supply circuit board consists of a: 1) switching power supply circuit,
2) conventional bridge rectifier circuit, 3) fault detection circuit. The switching power
supply circuit operates directly from the ac power source. No primary ac power
transformer is included in the circuit. An SCR controlled bridge rectifier circuit and a
switching regulator circuit converts ac potentials to dc potentials at a desired voltage.
Control of the dc output voltage is provided by a power control PWM signal from the
controller.
4-36.
A transformer with five secondary windings provide low-voltage ac potentials to five
full-wave bridge rectifiers circuits. The circuits provide dc operating potentials for the
power supply circuit board and RF power module circuitry.
4-37.
The power supply design provides the RF power modules with a constant and stable dc
operating supply by not responding to fluctuations or surges in the ac line voltage. The
supply will produce a constant dc voltage during high/low ac line voltage or surge
conditions.
4-38.
The switching power supply output voltage is controlled by a power control PWM signal
from the controller circuit board. Current reduction at turn-on is controlled by a
soft-start circuit. The circuit is designed to generate start pulses synchronized to the ac
line phase to slowly bias the SCR bridge rectifier circuit on during initial turn-on
operations. The switching regulator circuitry is monitored for proper operation by an
overvoltage and loss-of-PWM signal circuitry. The switching regulator operation is
performed by IGBT (insulated-gate-bi-polar-transistors) transistors. The IGBTs are
designed to provide extremely reliable and efficient operation.
4-8
4-39.
METERING.
4-40.
The transmitter metering consists of the forward power meter, reflected power/primary ac
input voltage meter, and the exciter modulation meter. Forward power information is
presented on the forward power meter. Reflected power/primary ac input voltage
information is presented on the reflected power/primary ac input voltage meter. The
meters are controlled by three-position switches. Forward and reflected power samples
for the metering circuitry are provided by the directional coupler circuit board. An ac
sample for the reflected power/primary ac input voltage meter is provided by an ac sample
circuit board.
4-41.
Monitoring of exciter operations is provided by the exciter modulation monitor. Two 30
segment multi-color bar graph displays present L/L+R and R/L-R information. A X10
mode allows the monitoring of low level signals such as the pilot tone.
4-42.
COOLING FANS.
4-43.
The AM-2.5E/AM-5E transmitters are equipped with 2 cooling fans. The fans are
controlled by an optically-coupled-relay. In the fans provide 500 CFM of cooling air for
the transmitter. A temperature sensor circuit board monitors the transmitter air
temperature and provides status information to the controller.
4-44.
INTERFACE CIRCUIT BOARD (AM-5E ONLY).
4-45.
On AM-5E models, communication between the controller, RF power modules, and the
power supply circuit boards is provided by an interface circuit board. The circuit board:
1) routes status information from the RF power modules and power supply circuit boards
to the controller and 2) routes control signals from the controller to the RF power modules
and the power supply circuit boards.
4-46.
DETAILED DESCRIPTION.
4-47.
POWER SUPPLIES.
4-48.
The AM-2.5E/AM-5E transmitters require a 196V to 252V ac single phase power source
(refer to Figure 4-3). The following text presents ac power source required for each
transmitter.
TRANSMITTER
AC POWER SOURCE
AM-2.5E
196V to 252V ac 50/60 Hz single phase at 75 Amperes.
AM-5E
196V to 252V ac 50/60 Hz single phase at 125 Amperes.
4-49.
AC INPUT CIRCUITRY.
4-50.
When the transmitter fused disconnect is closed, single phase ac power is routed through
an RFI filter to rear-door ac input switch S1. The filter prevents the coupling of RFI
components into or out-of the transmitter. S1 is the transmitter primary ac power safety
device. S1 disconnects primary ac power when the transmitter rear door is opened.
4-51.
The ac line is monitored for high/low conditions by an ac line voltage monitor. The
monitor controls ac power contactor K2. The transmitter primary ac power will be
interrupted if the ac line is above 260 volts or below 190 volts. Overload protection for the
transmitter is provided by fuses F1 and F2.
4-9
4-52.
A power factor corrector circuit consisting of inductors L3/L4 and capacitor C1 modifies
the ac line impedance to provide a power factor of approximately 0.9. C1 is switched into
the circuit during soft-start by the power factor corrector relay circuit board. The relay
circuit board is controlled by a circuit on the power supply circuit board.
Metal-Oxide-Varistors MOV1, MOV2, and MOV3 protect the transmitter power supply
circuitry from ac line voltage surge potentials. AC power from the MOVs is applied to
the following circuits: 1) the ECU power supply assembly, 2) the transmitter flushing
fans, 3) low voltage power supply transformer T1, 4) the power supply circuit board, and
5) the ac sample circuit board.
4-53.
ECU POWER SUPPLY ASSEMBLY.
4-54.
The ECU power supply is a 40W modular switching power supply unit. The power supply
assembly provides regulated +5V, +15V, and -15V operating potentials for the ECU circuit
boards.
4-55.
The power supply for the ECU controller circuit board is backed-up by a 9V battery.
During an ac power failure, the battery will maintain the transmitter operating
configuration stored in the controller logic circuitry. Once power is returned to the
transmitter, the transmitter will automatically resume operation in the configuration
appearing prior to the ac failure. If an extended ac power failure occurs, the transmitter
will be operated to off by an ac loss/auto shutdown circuit.
4-56.
The battery back-up system requires a standard 9V battery. The battery will maintain
the controller logic for several months. Replace the battery approximately once a year to
ensure proper transmitter operation during ac power failure conditions.
4-57.
TRANSMITTER FLUSHING FANS.
4-58.
Cooling air for the transmitter circuitry is provided by flushing fans B1 and B2. Control
of the fans is provided by optically-coupled-relay (OCR) K1.
4-59.
The flushing fans are controlled by a signal from the ECU controller circuit board. When
a power level switch/indicator is depressed, the controller circuit board will enable
optically-coupled relay (OCR) K1 to energize the fans. The fans will operate during
transmitter operation.
4-60.
LOW-VOLTAGE POWER SUPPLY TRANSFORMER.
4-61.
Low-voltage operating potentials for the transmitter power supply circuit board and RF
power modules are provided by ac power transformer T1. Transformer T1 consists of:
1) one primary winding and 2) five secondary windings. The secondary windings provide
low-voltage ac potentials for application to five rectifier circuits on the power supply
circuit board. The circuitry provides dc operating potentials for the power supply and the
RF power modules.
4-62.
POWER SUPPLY CIRCUIT BOARD.
4-63.
Low and high voltage dc operating potentials for the RF power modules are provided by
the power supply circuit board. The AM-2.5E is equipped with 1 power supply circuit
board. The AM-5E is equipped with 2 power supply circuit boards. Each power supply
circuit board provides dc operating potentials for two RF power modules.
4-64.
The power supply circuit board is equipped with: 1) a switching power supply circuit
designed to produce high-voltage operating potentials and 2) conventional rectifier
circuitry designed to produce low-voltage operating potentials. The following text
describes the circuitry.
4-10
COPYRIGHT
1999 BROADCAST ELECTRONICS, INC
597-1114-6
FIGURE 4-3.
AM-2.5E/AM-5E POWER SUPPLY
SIMPLIFIED SCHEMATIC
(4-11/4-12)
4-65.
CONVENTIONAL RECTIFIER CIRCUITRY. +30V and +20V dc operating potentials for the
RF power modules are provided by four conventional rectifier circuits. AC power from a
winding of ac power transformer T1 is applied to bridge rectifier D9. D9 rectifies the ac
potential into an unregulated +20 volt ac supply for application to: 1) the modulator
circuit board and 2) to regulator U3. U3 is a +15 volt dc regulator. The output of U3
routed for application to the components on the power supply circuit board.
4-66.
AC power from a second winding of transformer T1 is applied to bridge rectifier D10. D10
rectifies the ac potential into an unregulated +20V dc supply for application to the RF
power module power amplifier circuit boards. AC power from a third winding of power
transformer T1 is applied to bridge rectifier D11. D11 rectifies the ac potential into an
unregulated +30V dc supply for application to the RF power module power amplifier
circuit boards. AC power from a fourth winding of power transformer T1 is applied to
bridge rectifier D12. D12 rectifies the ac potential into an unregulated +15V dc supply for
application to: 1) the power supply circuit board and 2) regulator U4. U4 is a +12 volt dc
regulator. The output of U4 routed for application to the components on the power supply
circuit board.
4-67.
An ac sample from a winding of T1 is also routed to a soft-start circuit. The soft-start
circuit is designed to generate control pulses synchronized with the ac line phase. A
complete description of the soft-start circuit is presented in Rectifier/Soft-Start Circuit
(refer to the following text).
4-68.
SWITCHING POWER SUPPLY CIRCUIT. AC power from the power factor corrector
4-69.
Rectifier/Soft-Start Circuit. The ac line is full-wave rectified by an isolated SCR
controlled bridge rectifier circuit. The SCR bridge rectifier consists of diodes D15 through
D17 and SCRs D13 and D14. The rectifier is controlled by a soft-start circuit. The
soft-start circuit is designed to: 1) determine when the ac line waveform crosses the 0
volt axis and 2) generate short duration pulses in synchronization with the ac line 0 volt
crossings. The pulses are amplified and applied to the gates of the rectifier circuit SCR
components to slowly bias the components on during initial start operations. This
operation eliminates the component stress at power-on by limiting the supply in-rush
current. The rectifier will output an unregulated and unfiltered dc supply at
approximately 300V to an inductor and capacitor filter network.
4-70.
The output of the rectifier circuit is applied to afilter consisting of capacitors C24 through
C27. The output of the LC filter generates a 300V main operating supply for the RF
power modules. The positive leg of the dc supply is the common for the dc voltages
contained in the switching regulator circuitry and the RF power modules. The negative
leg of the supply is regulated and controlled to generate the required operating potentials
for the RF power modules.
4-71.
Switching Regulator Circuit. The main operating supply is regulated by a buck-type
switching regulator circuit. The switching regulator circuit generates the negative leg of
the B supply. The regulator circuit consists of: 1) a power supply mute circuit, 2) a
switching regulator power control PWM circuit, 3) optical coupler U17 4) inverting buffer
U19, and 5) switching regulator transistors Q21 and Q22.
circuitry is applied to fuses F1 and F2 on the power supply circuit board. The fuses
protects the power supply circuitry from overload conditions. Metal-Oxide-Varistor
MOV1 prevents damage to the switching power supply circuit from ac line voltage surge
potentials.
4-13
4-72.
A dc operating supply for optical coupler U17 and buffer U19 is generated by bridge
rectifier D25. D25 full-wave rectifies an ac potential from ac transformer T1 into an
unregulated +20V supply. The supply is applied to +18V regulator U16. U16 outputs a
+18V supply which is further regulated to a 5V operating potential by a resistive divider
and a zener diode. The 5V supply is applied to optical couplers U17 and buffer U19.
4-73.
Control of the regulator circuit is provided by the switching regulator power control PWM
circuit, a current sampling circuit, and a voltage and current feedback correction circuit.
Together, the circuits function in a closed-loop to control regulator operation. The
switching regulator power control PWM circuit is designed to produce two out-of-phase
square wave signals with varying duty cycles. The duty cycle is varied in response to the
signal from the correction circuit. The output of the control circuit is applied to optical
coupler U17. U17 provides isolation between two different ground circuits. The output of
the coupler is applied to gate drive inverting buffer U19. The output of U19 is applied to
the gates of IGBT switching regulator transistors Q21 and Q22. Q21 and Q22 are
operated to on for a specific time duration to regulate the output voltage for varying load
conditions.
4-74.
The regulator circuit output voltage is directed by a 1 kHz power control PWM signal
from the controller. The signal is applied to the correction circuit on the power supply
circuit board. In addition to the 1 kHz PWM signal, a voltage and current sample from
the regulator output is routed to the voltage and current feedback correction circuit. The
correction circuit responds by evaluating the output samples and the power control signal
and generating a correction voltage. The voltage is applied to the switching regulator
power control PWM circuit to adjust the output of the regulator.
4-75.
The output of the transistor switching regulator circuit is applied to filter inductor L2.
Protection of the transistors from switching transients during turn on/off operation is
provided by clamp diode D32. Clamp diode D32 protects the transistors by limiting
positive peak voltages. The output of the regulator circuit is applied to circuitry on RF
power module modulator circuit boards.
4-76.
MODULATOR CIRCUIT BOARD.
4-77.
The B- leg from the power supply circuit board is routed to circuitry on the RF power
module modulator circuit board. The B- leg is applied to relay K1 on the modulator
circuit board. K1 is controlled by a fault detector circuit. The relay is designed to
immediately remove the supply from the forward converter circuit during a fault
condition. The output of the relay is applied to the converter circuit.
4-78.
Transistors Q1 and Q2 are the switching devices in the forward converter circuit. The
circuit is controlled by the audio PWM signal from the driver circuit board. The circuit
operates by switching the applied B- leg at a 122 kHz to 135 kHz rate. The duty cycle of
the PWM signal is 40% with no modulation. The output of the forward converter circuit
is applied to an LC PWM low-pass filter network. Protection of the transistors from
switching transients is provided by clamp diodes D2 and D3. D2 and D3 limit the positive
peak transients appearing on the output.
4-79.
A sample of the modulator circuit output is routed to a fault detector circuit. The circuit
will respond to a fault by: 1) routing a control signal to relay K1 to disconnect the
amplifier circuit from the B- supply and 2) route a control signal to the power supply
circuit board to momentarily mute the power supply. After a short delay, a control signal
is routed to the power supply to enable the supply to provide power to RF module 2.
4-80.
The B+ leg of the supply is also routed to the modulator circuit board. The B+ leg is
applied to fuse F1 and is the common for the dc voltages contained in the power supply
circuit board switching regulator circuit and the RF power modules. F1 is provided to
protect clamp diodes D2 and D3 from overcurrent conditions.
4-14
4-81.
POWER AMPLIFIER CIRCUIT BOARDS.
4-82.
The power amplifier circuit board circuitry is configured in a Class E switching amplifier
design. A Class E design is recognized by: 1) the application of the B+ power supply
through an RF choke to combining transformers and 2) the use of only two MOSFET
power transistors in a push-pull configuration per amplifier. The circuitry on each
amplifier circuit board is identical, therefore only amplifier circuit board 1 will be
discussed.
4-83.
The dc voltage output of the modulator circuit board is routed to the power amplifier 1
circuitry through fuse F1. F1 protects the amplifier circuitry from over-current
conditions. The supply is applied to a switching amplifier circuit consisting of transistors
Q1 and Q2. The B+ leg of the main dc supply from the power supply circuit board is
applied to Q1 and Q2 through choke L4 to a primary center tap of combiner transformer
T4. RF choke L4: 1) prevents RF signals from entering the dc supply and 2) functions as
the last series inductor for the PWM low-pass filter on the modulator circuit board.
4-84.
The amplifier circuit is driven by the RF drive signal from the exciter circuit board. The
RF drive signal consists of a square-wave signal at the carrier frequency. The signal is
amplified prior to application to Q1 and Q2 by a driver circuit.
4-85.
The amplifier circuit functions by switching the dc voltage from the modulator circuit
board at an RF rate to produce a monophonic or a C-QUAM AM stereo signal at the
programmed carrier frequency. The signal appears at the primary of combiner
transformer T4. The RF signal is transferred to the secondary of T4 and routed to power
amplifier 2 circuit board combiner transformer T3. The RF output signal from T4 is
combined with the RF output signal from transformer T3 to generate a C-QUAM signal
at approximately 1375 watts of carrier.
4-86.
SEQUENCE OF OPERATION.
4-87.
When transmitter switch S1 is closed, ac power is routed to contactor K2 and the ac line
monitor. If the ac power line is between 190 and 260 volts, power from K2 is applied to: 1)
the power factor corrector circuitry, 2) the ECU power supply, 3) fan control relay K1, 4)
low-voltage ac power transformer T1, and 5) the ac sample circuit board. If the ac line
voltage is not between 190 and 260 volts, the ac line monitor will open K2 and deenergize
the transmitter. When ac power is applied to T1, a soft start circuit will detect the ac
waveform. When this occurs, the power factor corrector control circuit will energize the
relays on the power factor corrector circuit board to switch capacitor C1 in the circuit.
This enables the power factor corrector circuitry to change the power factor to
approximately 0.9. In response to the application of ac power with no error conditions,
the following controller and RF power module indicators will illuminate green:
CONTROLLER INDICATORS
RF POWER MODULE INDICATORS
1. Exciter
1. PA 1 RF Drive
2. Power Modules
2. PA 2 RF Drive
3. Power Supply
3. PWM Drive
4. Antenna
5. Mono or Stereo (depending on
exciter mode of operation)
6. Exciter Circuit Board: 1) +15V, 2) -15V
3) Lock, and 4) +5V
4-15
7. Stereo Circuit Board: 1) Mono L+R/Stereo/
Mono L/Mono R (depending on exciter mode
of operation), 2) Equalization 1 or Equalization 2
(depending on antenna configuration)
4-88.
A start sequence is initiated when a power level switch/indicator is depressed. Logic from
the controller will enable optically-coupled-relay K1 to enable the flushing fans.
4-89.
Logic from the controller will also enable the SCR controlled bridge rectifier circuit on the
power supply circuit board. The B+ dc potential from the rectifier is applied to the
inductor and capacitor filter networks on the power supply panel. Generation of the Bleg is provided by the IGBT switching regulator circuit.
4-90.
Power output of the regulator is controlled by the PWM signal from the controller. The
regulator will increase or decrease power as determined by the PWM signal. The output
of the regulator is routed to the modulator circuit board. The modulator POWER
indicator will illuminate if the B+ supply from the power supply circuit board is present.
The modulated output from the modulator circuit board is routed to the power amplifier 1
and power amplifier 2 circuit board for amplification.
4-91.
RF CIRCUITRY.
4-92.
EXCITER CIRCUIT BOARD. Audio for application to the AM-2.5E/AM-5E transmitter is
4-93.
Left channel audio is applied to an RFI filter and a defeatable 10 Hz high-pass filter. The
10 Hz high-pass filter is provided to remove low frequency residual products from specific
audio processing units. Balanced-to-unbalanced signal conversion is provided by an
instrumentation amplifier. The output of the instrumentation amplifier is applied to a
defeatable high frequency boost circuit. The high frequency boost circuit is provided to
increase high frequency response to compensate for a Bessel filter in the PWM modulator.
The output of the high frequency boost circuit is applied to an active PWM filter/equalizer
and a mode switching circuit. The output of the PWM filter is routed for application to
the stereo circuit board.
4-94.
The mode switching circuit is designed to select the left or right channel for mono left or
mono right operation. A summing amplifier is provided as a mono support circuit to
increase the gain of the circuit 6 dB during mono operations. The output of the summing
amplifier is applied to a 24 uS delay and limiter circuit. The delay circuit is provided for
stereo equalization. The negative limiter is provided to limit negative modulation from
90% to 100%.
4-95.
The output of the 24 uS delay and negative limiter is applied to: 1) a PWM circuit and
2) an IPM comparator and corrector circuit. The PWM circuit is designed to output a
square wave signal in which the duty cycle changes in response to the applied audio level.
The output of the PWM circuit is applied to a PWM driver circuit. The PWM driver
circuit consists of parallel transistor drivers to lower the impedance and improve
reliability.
applied to the exciter circuit board (refer to Figure 4-4). The exciter circuit board is
designed to: 1) process left/right channel or monaural audio to generate a
Pulse-Width-Modulated (PWM) signal at 122 kHz to 135 kHz and 2) generate an RF
signal using a frequency synthesizer, a phase modulator for IPM correction, and an RF
driver network.
4-16
4-96.
The transmitter carrier frequency is generated by digitally programmed frequency
synthesizer circuit. The frequency synthesizer is designed to output: 1) the carrier
frequency to a mono/stereo select circuit, 2) a FcX4 (carrier frequency times four) signal
for application to the stereo circuit board, and 3) a 25 Hz pilot signal for application to the
stereo circuit board. A mono/stereo select circuit functions as an automatic mono/stereo
select switch. If a stereo signal from the internal stereo circuit board or an external
stereo generator is present, the exciter will be configured for stereo operation. If the
stereo signal is not present, the circuit will configure the exciter for mono operation. The
output of the mono/stereo select circuit is applied to the IPM (Incidental Phase
Modulation) signal generator and modulator. The IPM signal generator is designed to
produce a waveform similar to the signal produced by the RF amplifier circuitry. The
IPM generator signal is out-of-phase with the signal generated by the RF power
modules. The signal is applied to a modulator circuit which will generate a phase
compensated RF signal at the carrier frequency. The phase compensation will effectively
cancel the IPM generated in the RF circuitry.
4-97.
The output of the IPM circuitry is applied to an RF driver network. The network consists
of a high/low side driver and output drive transistors.
4-98.
STEREO CIRCUIT BOARD. Left/right channel audio and an RF signal at FcX4 (carrier
4-99.
Left channel audio from the exciter circuit board is applied to the left channel
equalization 1 circuit. The equalization circuit consists of 1) a state variable low-pass
filter, 2) an 8 uS group delay section, and 3) a 4 uS group delay section. The circuit is
designed to equalize frequencies to produce maximum separation.
4-100.
The output of each equalization circuit is routed to an equalization and mono/stereo select
circuit. The equalization circuit selects equalization 1 or equalization 2 as determined by
the selected antenna pattern. The mono/stereo circuit selects the required signals for
stereo, mono left, mono right, or mono L+R operation.
4-101.
The output of the equalization and mono/stereo select circuits is applied to a summing
amplifier network. The network functions as a matrix to generate the L+R and L-R
stereo signals. The output of the summing amplifier network is applied to a digital
switching modulator. The modulator accepts: 1) the L+R and L-R signals and 2) four RF
out-of-phase signals at the carrier frequency. The modulator outputs two signals: 1) an
AM modulated signal containing the L+R information and 2) a double-sidebandsuppressed-carrier signal referenced to a 90 degree carrier. The signals are summed and
amplified at U37 to produce a quadrature signal. The output of U37 is applied to a fourth
order linear phase bandpass filter. The output of the filter is applied to an amplitude
limiter circuit. The limiting operation produces the phase modulation (L-R information)
component of the C-QUAM signal. The output of the limiter circuit is routed to the
exciter circuit board.
4-102.
RF POWER MODULE. The PWM and RF drive signals from the exciter circuit board are
frequency times four) from the exciter circuit board is applied to the stereo circuit board.
The stereo circuit board is designed to generate a TTL level RF signal. The circuit board
contains identical left/right channel and equalization 1/2 circuitry. Therefore, only the
left channel equalization 1 circuit will be discussed.
routed to the RF power modules. The RF power modules consist of a modulator circuit
board and two RF amplifier circuit boards.
4-17
4-18
COPYRIGHT
1999 BROADCAST ELECTRONICS, INC
FIGURE 4-4. AM-2.5E/AM-5E RF CIRCUITRY SIMPLIFIED SCHEMATIC (SHEET 1 OF 2)
597-1113-18
COPYRIGHT
1999 BROADCAST ELECTRONICS, INC
597-1113-18A
FIGURE 4-4. AM-2.5E/AM-5E RF CIRCUITRY
SIMPLIFIED SCHEMATIC (SHEET 2 OF 2)
(4-19/4-20)
4-103.
Modulator Circuit Board. The modulator circuit board consists of a MOSFET forward
converter circuit and a filter network. The forward converter circuit consists of MOSFET
transistors Q1 and Q2. The filter network consists of inductors L1 through L3 and
capacitors C13 through C16. A dc operating voltage for transistors Q1 and Q2 is provided
by the power supply circuit board. The B- leg of the supply is routed through relay K1 to
the transistors. K1 is provided to immediately terminate the supply during a modulator
fault condition.
4-104.
The PWM signal at a 15 volt level from the exciter circuit board is applied to the gates of
MOSFET transistors Q1 and Q2. Q1/Q2 function to switch the B- leg at a 122 kHz to 135
kHz rate. The output from Q1/Q2 is applied to the LC low-pass filter network to convert
the square-wave PWM signal to a dc voltage. The output from the filter will produce a 50
volt dc signal with: 1) a nominal PWM duty cycle of 40% and 2) no audio modulation.
The dc voltage will vary from 0 to 125 volts with -100% to +150% modulation. The output
of the filter network is applied to the drains of MOSFET amplifier transistors on the
power amplifier circuit boards.
4-105.
Power Amplifier Circuit Boards. The RF circuitry on the power amplifier circuit boards
consists of a Class E MOSFET power amplifier circuit. Each power amplifier circuit
board is designed to output approximately 350 watts. The power amplifier circuit boards
are identical. Therefore, only power amplifier 1 will be discussed.
4-106.
The MOSFET amplifier circuit is designed in a push-pull design Class E configuration.
Class E power amplifier characteristics consist of: 1) the transistor drain-to-source
voltage must be nominally zero immediately prior to the turn-on of the transistor and
2) the time slope of the drain-to-source voltage waveform must be nominally zero prior to
the turn-on of the transistor. The Class E circuit results in: 1) lower device dissipation
resulting in reduced transistor operating temperature which greatly increases component
life, 2) an operating efficiency of 95% or greater, and 3) increased reliability when
operated into VSWR conditions.
4-107.
Additional characteristics of a Class E amplifier design is the application of dc power to
the amplifier transistors. The B+ leg of the B supply is applied to RF choke L1. The
choke is connected to the primary center tap winding of combiner transformer T1. The
transistors are connected to the primary winding of the transformers.
4-108.
Two signals are applied to the power amplifier 1 circuit board: 1) an RF square-wave
signal from the driver circuit board and 2) a dc voltage from the modulator circuit board
which varies at an audio rate. The RF square-wave signal at the carrier frequency is
applied to the gates of MOSFETs Q1 and Q2. The varying dc voltage from the modulator
circuit board is applied to the source of MOSFETs Q1 and Q2. Q1/Q2 operate in a
push-pull configuration to develop approximately 350 watts of RF power at combiner
transformer T1. The power at transformer T1 is combined with the 687.5 watts of RF
power from power amplifier circuit board 2 to generate 1375 watts of RF power from the
RF power module.
4-109.
RF COMBINER. The RF combiner components are located on the rear-panel of each
power block assembly. The combiner consists of a star combiner design. The star
combiner contains an individual transformer, an RF choke, and an impedance matching
circuit for each power amplifier circuit board. The impedance matching circuit consists of
star inductors. The circuit presents the correct impedance when a module is removed
from the chassis. This allows the transmitter to operate at an output power which is
proportional to the modules removed from the power block chassis.
4-21
4-110.
HARMONIC BAND-PASS FILTER. The output signal harmonic and spur frequencies are
4-111.
DIRECTIONAL COUPLER CIRCUIT BOARD. Transmitter forward and reflected power
4-112.
Forward And Reflected Power Sample Circuit. A voltage sample from the RF output is
obtained by transformer T203. A current sample of the RF output is obtained by
transformers T201 and T202. The current sample is converted to a voltage by a resistor
network and applied to transformer T203. A voltage proportional to the square root of the
forward power is obtained by summing the voltage from the secondary of T203 with the
voltage sample from T201. A voltage proportional to the square root of the reflected
power is obtained by summing the voltage from the secondary of T203 and with the
voltage sample from T202. The forward power sample voltage is half-wave rectified by
diode D202. The reflected power sample voltage is half-wave rectified by diode D201.
Diodes D205 through D208 and zener diodes D209 and D210 protect the rectifier diodes
from overvoltage conditions. The rectified forward and reflected power samples are
routed for application to the controller circuit board. Programmable header J206 is
provided to increase the adjustment range of the directional coupler circuitry. The header
is programmed at the factory for the adjustment range required by the transmitter.
4-113.
Modulation Monitor Calibration Circuit. A voltage sample for application to the
modulation monitor calibration circuit is provided by the lightning detection circuit board.
A sample from the RF output is obtained by a capacitor circuit and applied to a relay
circuit on the directional coupler circuit board. The relay circuit is designed to select a
voltage sample from a calibration potentiometer for application to the modulation monitor
receptacle. The relays are controlled by power level 1 through 5 commands from the
controller circuit board. Each relay circuit operates in an identical manner, therefore only
the circuit for power level 5 will be explained.
4-114.
A voltage is applied to the modulation monitor receptacle when the power level 5
command energizes relay K201. K201 applies a sample voltage to power level 5
modulation monitor calibration control R201. R201 is provided to obtain a 2 volt RMS
sample to the modulation monitor receptacle. Frequency programming switch S201 is
provided to compensate the RF sample for frequencies within the AM band for power
levels 1 through 3. Power level programming switch P203 is provided to program the
power level 3 circuit for low power range or high power range operation. The calibrated
sample from potentiometer R201 is applied to the modulation monitor receptacle.
4-115.
T-MATCHING NETWORK. Output matching to antenna loads for up to a VSWR
4-116.
LIGHTNING PROTECTION CIRCUIT BOARD. The transmitter is protected from
lightning potentials present at the output network by the lightning protection circuit
board. The circuit board consists of series connected transzorbs. The AM-2.5E
transmitter is equipped with transzorbs D1 through D6. The AM-5E transmitter is
equipped with transzorbs D1 through D7. The transzorbs are designed to conduct the
lightning potentials to ground prior to the operation of the lightning detection circuit
spark-gap.
reduced to FCC, DOC, and CCIR levels by a band-pass filter. The filter consists of a
fourth order LC network consisting of inductors L1 through L3 and capacitors C1 through
C4. The components are located in the output network assembly and are frequency
dependent. The output of the filter is routed to the directional coupler circuit board.
are sampled by a directional coupler circuit board. The directional coupler circuit board is
designed to: 1) process the forward and reflected power samples for application to the
controller circuit board and 2) calibrate the RF modulation monitor sample.
condition of 1.4:1 at any phase angle relative to the 50 Ohm load is provided by a
T-matching network. The T-matching network consists of tune control L4, load control
L6, inductor L5 and capacitor C5/C5A. Inductor L5 and capacitor C5/C5A are frequency
dependent components. The tune and load controls are designed to be adjusted to present
the optimum impedance for the power amplifier modules.
4-22
4-117.
LIGHTNING DETECTION CIRCUIT BOARD. Lightning potentials present at the
4-118.
The RF sampling circuit consists of a parallel capacitor circuit. The circuit is designed to
provide a constant RF voltage sample for application to the directional coupler circuit
board. The optically operated transistor circuit is designed to detect lightning potentials
present at the transmitter output. The circuit operates in association with the lightning
detector spark-gap. When lightning is present at the transmitter RF output, the
spark-gap will: 1) be biased on to conduct the potential to ground and 2) emit a light
pulse to optically operated transistor Q401. Q401 will be biased on to output a lightning
detect signal to the controller circuit board.
4-119.
RF OUTPUT POWER CONTROL CIRCUITRY. The transmitter output power is controlled
4-120.
RF Output Power Control - Controller Circuit Board. A transmitter RF output power level
is selected by the power control 1 through power control 5 switch/indicators. The power
control switch/indicators route a LOW control signal to a priority encoder circuit. The
priority encoder circuit determines which control pulse is routed to the power control
circuitry. The circuit allows transmitter off commands to be assigned a high priority.
With no transmitter off commands present, the power control signal is applied to
multiplexer U39. U39 selects a reference voltage from the power control potentiometers
on the controller circuit board. The potentiometers are designed to establish a preset
transmitter power level such as 1 kW. The voltage is used as the reference for
digital-to-analog converter U42. With no fault conditions present, the voltage is applied
without change to power trim digital-to-analog converter U43. With no power trim
commands present, the reference voltage is applied to a driver circuit which converts the
dc control voltage to a power control PWM signal. The power control PWM duty cycle
responds to the changes in the voltage reference level. When the voltage reference
increases, the power control PWM signal duty-cycle increases. When the voltage
reference decreases, the power control PWM signal duty-cycle decreases. The power
control PWM signal is routed for application to the power supply circuit board(s).
4-121.
The transmitter output power level is trimmed to a precise level by the power up and
down switches. The switches output a LOW control signal to a control logic circuit. The
control logic circuit generates the required control signals to drive an up/down counter
circuit. The circuit is designed to: 1) count up if power is required to be increased or
2) count down if power is required to be decreased. The up/down counter circuit output is
converted to a dc potential by digital-to-analog converter U43. The output of U43 is
summed with the dc potential from power control switch digital-to-analog converter U42
to generate a dc power control signal. The power control signal is applied to the driver
circuit which converts the signal to a power control PWM signal.
4-122.
Automatic Power Control Circuitry. The transmitter power control circuitry is equipped
with several monitor circuits designed to determine if power control correction is required
during adverse operating conditions. Circuitry on the controller circuit board monitors
the transmitter components and the RF output for: 1) lightning, 2) high forward power,
3) high reflected power, and 4) over-temperature. If a lightning, high forward power,
high reflected power, or over-temperature, condition occurs, a signal is routed to the
fault detection circuit.
transmitter output are detected by the lightning detection circuit board. The circuit
board is equipped with an RF sampling circuit and an optically operated transistor
circuit.
by circuitry on the controller and power supply circuit boards. The transmitter power
level is controlled by a Pulse-Width-Modulated (PWM) signal generated by the controller
circuit board. The power control PWM signal is routed for application to the power
supply circuit board(s). The power supply circuit board(s) respond by routing the
required dc voltage to the modulator circuit boards and the RF amplifier circuit boards.
The following text presents a description of the RF power control circuitry.
4-23
4-123.
The fault detection circuit: 1) processes lightning and over-temperature signals and
2) analyzes forward and reflected power signals. As determined by the the fault
condition, the fault detection circuit will generate a fast or slow control signal to the
up/down counter circuit. The counter circuit will respond by decreasing the power control
voltage at digital-to-analog converter U42. U42 will respond by decreasing the output
power to an acceptable level. Once the condition which caused the fault to occur is
removed, the fault detection circuitry will automatically output a control signal to
increase power to a normal level.
4-124.
Forward/Reflected Power Circuitry. Samples of the transmitter forward and reflected
power are processed by forward and reflected power circuits on the controller circuit
board. Forward power samples from the directional coupler circuit board are applied to
the forward power circuit. The forward power circuit converts the sample into a dc signal
for application to the fault detection circuitry and to the meter switch circuit board.
Reflected power samples from the directional coupler circuit board are applied to the
reflected power circuit. The reflected power circuit converts the sample into a dc signal
for application to the fault detection circuit and the meter switch circuit board.
4-125.
Meter Switch Circuit Board. Forward and Reflected power samples from the controller
circuit board are applied to the meter switch circuit board. The circuit board allows the
selection of forward power, reflected power, and ac input samples for display on forward
power meter M1 and reflected power meter M2.
4-126.
RF Output Power Control - Power Supply Circuit Board/RF Power Modules. The power
control PWM signal from the controller circuit board is applied to a correction circuit on
the power supply circuit board. The PWM signal is converted to a dc signal and combined
with a dc feedback signal to generate a power control signal for application to the switch
regulator power control PWM circuit. The circuit converts the dc signal into two PWM
180 degree out-of-phase square-wave drive signals. The square-wave drive signals are
applied to a driver circuit. The driver circuit outputs the out-of-phase square-wave
signals to an IGBT transistor regulator circuit. The regulator circuit transistors are
operated to on for a specific time duration to generate a specific B- supply voltage. The
B- supply voltage is filtered by capacitor C55 and applied to the forward power converter
on the modulator circuit boards.
4-127.
The main operating supply B+ leg is created by a SCR controlled bridge rectifier circuit.
AC power from an ac input filter is applied to the SCR controlled bridge rectifier. The
rectifier is controlled by a soft-start circuit. The full-wave rectified dc potential is filtered
by capacitors C24 through C27. The output of the filter generates the positive leg of a B
supply. The B+ line of the power supply is applied to the forward power converter circuit
on modulator circuit boards and the RF amplifier transistors on RF amplifier circuit
boards.
4-128.
To provide an example of output power control operation, a 10 kW output level is required
from the transmitter. The controller power control PWM duty-cycle will be
approximately 85%. The power supply will respond by generating a 120 volt B- supply
for application to the forward power converter on the modulator circuit boards. The
modulator circuit boards will output a dc voltage which varies at an audio rate to the
amplifier circuit boards. The amplifier circuit boards will respond by using the modulator
circuit board dc voltage and the B+ leg of the main supply to amplify the RF drive signal
from the exciter circuit board.
4-24
SECTION V
MAINTENANCE
5-1.
INTRODUCTION.
5-2.
This section provides maintenance information, electrical adjustment procedures, and
troubleshooting information for the Broadcast Electronics AM-2.5E and AM-5E
transmitters.
5-3.
SAFETY CONSIDERATIONS.
WARNING
WARNING
WARNING
WARNING
THE TRANSMITTER CONTAINS MULTIPLE CIRCUIT
GROUNDS WITH HIGH AC AND DC POTENTIALS
WITH RESPECT TO THE CABINET WHICH IS AT
EARTH POTENTIAL. DO NOT ENERGIZE THE
TRANSMITTER WITH TEST EQUIPMENT CON
NECTED TO THE TRANSMITTER OUTPUT
NETWORK, RF POWER MODULE, RF COMBINER, OR
POWER SUPPLY COMPONENTS.
5-4.
The AM-2.5E/AM-5E 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 transmitter is equipped with many built-in safety features,
however good judgement, care, and common sense must be practiced to prevent accidents.
5-5.
In addition to high voltages and currents, the transmitter contains 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 transmitter 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. The
maintenance procedures presented in this section should be performed only by trained
and experienced maintenance personnel.
5-6.
FIRST LEVEL MAINTENANCE.
5-7.
First level maintenance consists of procedures applied to the equipment to prevent future
failures. The procedures are performed on a regular basis and the results recorded in a
maintenance log. Preventive maintenance of the transmitter consists of good
housekeeping and checking performance levels using the meters and various indicators
built into the equipment.
5-8.
ROUTINE MAINTENANCE.
5-1
WARNING: DISCONNECT POWER PRIOR TO SERVICING
WARNING
WARNING
NEVER OPEN THE EQUIPMENT UNLESS ALL TRANS
MITTER PRIMARY POWER IS DISCONNECTED. EN
SURE ALL TRANSMITTER PRIMARY POWER IS DIS
CONNECTED BEFORE ATTEMPTING MAINTENANCE
ON ANY AREA WITHIN THE TRANSMITTER.
5-9.
INSPECTION AND CLEANING. On a regular basis, clean the equipment of accumulated
dust using a brush and vacuum cleaner. Inspect the modulator circuit boards, RF
amplifier circuit boards, and the power supply circuit boards for damage caused by
components overheating. Overheated components are identified by circuit board
discoloration near the component leads. Inspect the circuit boards for loose hardware as
required.
5-10.
CONTROLLER BATTERY. Periodically, the controller battery in the ECU assembly should
5-11.
AIR FILTERS. The AM-2.5E/AM-5E transmitters are equipped with a single screen-type
be checked by depressing the battery test switch on the controller circuit board. The
battery test indicator will illuminate to indicate the battery is operational. If the battery
test indicator fails to illuminate, the battery must be replaced. A good-quality Alkaline
battery is recommended for replacement. Typically, it is recommended the controller
battery be replaced annually.
air filter. The screen filter is designed to be removed and cleaned using a brush and
vacuum. A dirty filter results in restricted air flow and increased operating temperatures
for the transmitter solid-state components. Check the filter approximately once a week.
The filter is designed to be removed during transmitter operation. To remove the filter,
proceed as follows:
1. Refer to Figure 5-1 and remove the six filter housing screws.
2. Using the handles, lift the filter housing off of the rear door.
3. Remove the filter.
5-12.
FLUSHING FANS. Inspect the transmitter flushing fans for dust accumulation and
5-13.
It is recommended the flushing fan mounting hardware be periodically checked. The
flushing fans are equipped with sealed bearings which do not permit lubrication. If a
bearing fails, the motor must be replaced.
5-14.
SPARK GAP. The output network is equipped with a spark gap. The spark gap is
5-15.
SECOND LEVEL MAINTENANCE.
5-16.
Second level maintenance consists of procedures required to adjust the transmitter
circuitry or restore the transmitter to operation after a fault has occurred. The
procedures consist of electrical adjustments, troubleshooting, and component replacement
procedures.
periodically clean the fans using a brush and vacuum cleaner. Do not use compressed air
and an air gun. The fans are cooled by air passing around each motor. If dust is allowed
to accumulate on the motors, the ambient air temperature will increase due to restricted
air flow. When the ambient air temperature increases, the fan motor bearing lubricant
will gradually vaporize and bearing failure will occur.
provided to safely conduct lightning potentials appearing at the transmitter output to
ground. Inspect the spark gap annually to ensure the gap is operational.
5-2
WARNING: DISCONNECT POWER PRIOR TO SERVICING
COPYRIGHT 1999 BROADCAST ELECTRONICS, INC
597-1114-15
FIGURE 5-1. REMOVING THE AIR FILTER
5-3
WARNING: DISCONNECT POWER PRIOR TO SERVICING
WARNING
WARNING
NEVER OPEN THE EQUIPMENT UNLESS ALL TRANS
MITTER PRIMARY POWER IS DISCONNECTED. EN
SURE ALL TRANSMITTER PRIMARY POWER IS DIS
CONNECTED BEFORE ATTEMPTING MAINTENANCE
ON ANY AREA WITHIN THE TRANSMITTER.
5-17.
The maintenance philosophy for the AM-2.5E/AM-5E transmitters consists of isolating a
problem to a specific area. Once the specific area is located, subsequent troubleshooting
using the information in the following text and the modular sections in PART II of this
manual will assist in problem isolation to a replaceable assembly or component. If
required, the assembly may be: 1) returned to the factory for repair or exchange or
2) repaired locally.
5-18.
ELECTRICAL ADJUSTMENTS.
WARNING
WARNING
NEVER OPEN THE EQUIPMENT UNLESS ALL TRANS
MITTER PRIMARY POWER IS DISCONNECTED. EN
SURE ALL TRANSMITTER PRIMARY POWER IS DIS
CONNECTED BEFORE ATTEMPTING MAINTENANCE
ON ANY AREA WITHIN THE TRANSMITTER.
5-19.
Adjustment procedures for controls associated with the transmitter circuitry is presented
in the ECU, output network, RF power module, and power supply module sections of this
manual. Determine the transmitter modular component requiring adjustment and refer
to the appropriate section of this manual for the adjustment procedures.
5-20.
TRANSMITTER FREQUENCY RE-PROGRAMMING.
5-21.
The AM-2.5E/AM-5E transmitters are configured for a specific frequency when shipped
from the factory. The transmitters are equipped with several frequency dependent parts
and circuits. Due to the frequency dependent parts, frequency dependent circuits, and
specialized procedures, the transmitters can not be reprogrammed for a different
frequency in the field. If a transmitter is required to be programmed for a different
frequency, contact the Broadcast Electronics Customer Service department.
5-22.
TROUBLESHOOTING.
5-4
WARNING: DISCONNECT POWER PRIOR TO SERVICING
THE TRANSMITTER CONTAINS MULTIPLE CIRCUIT
GROUNDS WITH HIGH AC AND DC POTENTIALS
WITH RESPECT TO THE CABINET WHICH IS AT
EARTH POTENTIAL. DO NOT ENERGIZE THE
TRANSMITTER WITH TEST EQUIPMENT CON
NECTED TO THE TRANSMITTER OUTPUT
NETWORK, RF POWER MODULE, RF COMBINER, OR
POWER SUPPLY COMPONENTS.
WARNING
WARNING
WARNING
WARNING
5-23.
The AM-2.5E/AM-5E transmitters are equipped with extensive indicator and meter
circuitry to allow the operator to isolate problems to a specific area within the transmitter.
Due to the hazardous voltages and currents contained in the equipment, 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. 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.
Therefore, the transmitter indicators and meters must be used to isolate a problem to a
specific area.
5-24.
TRANSMITTER INDICATORS. The following text presents a description of the transmitter
indicators and typical meter indications. Refer to the following text as required to
determine the function of a specific indicator.
TABLE 5-1. AM-2.5E/AM-5E INDICATORS
(Sheet 1 of 4)
ASSEMBLY
INDICATOR FUNCTION
ECU ASSEMBLY
TRANSMITTER MONITOR
EXCITER
GREEN DISPLAY - Indicates normal exciter
operation.
RED DISPLAY - Indicates no exciter RF drive or
PWM output.
POWER MODULES
GREEN DISPLAY - Indicates all RF power modules
are operating normally.
YELLOW DISPLAY - Indicates one or more RF power
modules are removed from the transmitter for
maintenance.
RED DISPLAY - Indicates a modulator or power
amplifier circuit board fault in one or more RF power
modules.
POWER SUPPLY
GREEN DISPLAY - Indicates normal power supply
operation.
RED DISPLAY - Indicates an open loop or overvoltage fault in one or more power supply modules.
YELLOW Display - Indicates one or more power
supplies are removed from the transmitter.
5-5
WARNING: DISCONNECT POWER PRIOR TO SERVICING
TABLE 5-1. AM-2.5E/AM-5E INDICATORS
(Sheet 2 of 4)
ASSEMBLY
INDICATOR FUNCTION
ANTENNA VSWR
GREEN DISPLAY - Indicates a normal antenna load.
YELLOW DISPLAY - Indicates a VSWR condition of
1.2:1.
RED Display - Indicates a high reflected/forward
power condition. In the AM-2.5E, indicates a 100 watt
reflected power condition or a condition which results
in a high forward power indication of greater than 20%.
In the AM-5E, indicates a 200 watt reflected power
condition or a condition which results in a high forward
power indication of greater than 20%.
FLASHING RED Display - Indicates a reflected power
emergency condition. In the AM-2.5E, indicates a 500
watt reflected power condition. In the AM-5E,
indicates a 1000 watt reflected power condition.
REMOTE
Illuminates to indicate transmitter remote control
operations are enabled. Extinguishes to indicate
transmitter remote control operations are disabled:
1) using the remote/local switch on the controller
circuit board or 2) due to a fault in the remote control
unit.
CONFLICT
Illuminates to indicate an incorrect power level is
selected for operation into the antenna connected to the
transmitter.
LIGHTNING
In the AM-2.5E, Illuminates to indicate a 1500 volt
or greater potential is present at the transmitter
output. In the AM-5E, illuminates to indicate a 2100
volt or greater potential is present at the transmitter
output.
INTERLOCK
Illuminates to indicate all internal and external
interlocks are closed.
FOLDBACK
Illuminates to indicate when the transmitter is in a
foldback condition. Foldback is when the transmitter
output power is automatically reduced in response to
one of the following fault conditions: 1) high reflected
power, 2) high forward power, 3) high temperature, or
4) detection of a lightning potential.
OVERTEMP
Illuminates to indicate when the transmitter operating
temperature exceeds 70 °C (158 °F).
RESET
Illuminates to indicate one or more of the following
transmitter faults have occurred: 1) over-temperature,
2) exciter fault, 3) power supply fault, 4) RF power
module fault, 5) high reflected power, 6) reflected power
emergency, or 7) lightning. Once the fault condition is
removed, the fault circuitry must be reset.
5-6
WARNING: DISCONNECT POWER PRIOR TO SERVICING
TABLE 5-1. AM2.5E/AM-5E INDICATORS
(Sheet 3 of 4)
ASSEMBLY
INDICATOR FUNCTION
CONTROLLER CIRCUIT BOARD
PWM Mute
Illuminates to indicate the power control PWM signal is
muted in response to a fault such as lightning, an exciter
fault, a reflected power emergency, an open remote
control failsafe, an external transmitter mute, lightning,
or high reflected or forward power.
Remote Failsafe
Illuminates to indicate the remote control unit is
enabled.
Battery OK
When the battery test switch is depressed, the indicator
will: 1) illuminate to indicate the battery is operational
or 2) not illuminate to indicate the battery is to be
replaced.
STEREO CIRCUIT BOARD
Stereo Equalization 1
Illuminates to indicate stereo equalization circuit 1 is
active.
Stereo Equalization 2
Illuminates to indicate stereo equalization circuit 2 is
active.
EXCITER CIRCUIT BOARD
Exciter Lock
Illuminates to indicate the exciter is locked to the
programmed carrier frequency.
Exciter +5V
Illuminates to indicate the ECU +5V supply is
operational.
Exciter +15V
Illuminates to indicate the ECU +15V supply is
operational.
Exciter -15V
Illuminates to indicate the ECU -15V supply is
operational.
RF POWER MODULE
PA 1 RF DRIVE
Illuminates to indicate RF drive from the exciter circuit
board is present at power amplifier 1.
PA 1 FAULT
Illuminates to indicate a fault has occurred in power
amplifier 1.
PA 2 RF DRIVE
Illuminates to indicate RF drive from the exciter circuit
board is present at power amplifier 2.
PA 2 FAULT
Illuminates to indicate a fault has occurred in power
amplifier 2.
5-7
WARNING: DISCONNECT POWER PRIOR TO SERVICING
TABLE 5-1. AM-2.5E/AM-5E INDICATORS
(Sheet 4 of 4)
ASSEMBLY
INDICATOR FUNCTION
MOD PWM DRIVE
Illuminates to indicate the PWM drive signal from the
exciter is present at the modulator circuit board.
MOD POWER
Illuminates to indicate dc power from the power supply
circuit board is present at the modulator circuit board.
MOD FAULT
Illuminates to indicate a modulator, fuse, or power
supply fault has occurred in the modulator circuit board.
MOD FUSE
Illuminates to indicate the modulator circuit board fuse
has blown.
POWER SUPPLY 1-2
Illuminates to indicate an open loop, over-current,
or over-voltage fault in the 1-2 power supply. The
supply provides power for modules 1-2.
POWER SUPPLY 3-4
(AM-5E Only)
Illuminates to indicate an open loop, over-current,
or over-voltage fault in the 3-4 power supply. The
supply provides power for modules 3-4.
Exciter -15V
Illuminates to indicate the ECU -15V supply is
operational.
CAUTION
CAUTION
WHEN AC POWER IS APPLIED TO THE TRANSMIT
TER AND THE RF DRIVE AND PWM DRIVE INDICA
TORS ON RF POWER MODULES IN A POWER BLOCK
ARE EXTINGUISHED, THE RF POWER MODULES
MUST BE REMOVED FROM THE TRANSMITTER
CHASSIS TO PREVENT DAMAGE TO THE MODULES.
5-25.
RF POWER MODULE REMOVAL. When ac power is applied to the transmitter, check the
5-26.
TRANSMITTER TROUBLESHOOTING PROCEDURES. Table 5-2 presents troubleshooting
information for the AM-2.5E/AM-5E transmitters. Refer to Table 5-2 to isolate the
problem to a specific assembly. Once the trouble is isolated, refer to the applicable
modular section of this manual for the theory of operation and schematic diagrams to
assist in problem resolution.
5-27.
TRANSMITTER COMPONENT LOCATIONS. Figures 5-2 through 5-4 present
RF DRIVE and PWM DRIVE indicators on the RF power modules. If the RF DRIVE
and PWM DRIVE indicators on RF power modules in a power block are extinguished, the
RF power modules must be removed from the transmitter to prevent damage to the
modules.
transmitter component locations. Refer to Figures 5-2 to 5-4 as required during the
troubleshooting procedures to locate components within the transmitter.
5-8
WARNING: DISCONNECT POWER PRIOR TO SERVICING
TABLE 5-2. AM-2.5E/AM-5E TROUBLESHOOTING
(Sheet 1 of 5)
SYMPTOM
NO OUTPUT POWER
NO NORMAL/FAULT
INDICATIONS
CIRCUITRY TO CHECK
1. Check the ac line voltage using the reflected power/
ac voltage meter. If no line voltage is present, check
fuses F1 and F2.
2. Check the ±15 volt and +5 volt indicators on the
exciter circuit board. If no indicators are
illuminated, check the ECU power supply.
NO OUTPUT POWER
NORMAL INDICATIONS
NO CONTROL OPERATIONS
1. Transmitter operated to off due to 7 on/off cycles
within 15 seconds. Operate the transmitter to on
as follows: 1) do not depress any controller
switch/indicators for approximately 30 seconds and
2) depress the desired power level switch/indicator.
2. Refer to the POWER SUPPLY section and
troubleshoot the power supply circuit board for no
120 Hz signal output.
RED EXCITER INDICATION
1. Check the lock indicator on the exciter circuit
board. If the lock indicator is not illuminated, refer
to the ECU section and troubleshoot the exciter
circuit board for lock indicator extinguished.
2. Remove the stereo circuit board and perform the
following: 1) depress the RESET switch and
2) initiate transmitter operation. If the transmitter
will not operate, refer to the ECU section and
troubleshoot the exciter circuit board. If the
transmitter operates, refer to the ECU section and
troubleshoot the stereo circuit board.
YELLOW POWER MODULE
INDICATION
1. Indicates one or more RF power modules are
removed from the transmitter.
RED POWER MODULE
INDICATION RED FAULT
INDICATION ON A MODULE
1. Refer to the RF POWER MODULE section and
troubleshoot the RF power module.
2. Visually inspect the RF power module combiner
panel for discolored components.
YELLOW POWER SUPPLY
INDICATION
1. Indicates one or more power supply modules are
removed from the transmitter.
RED POWER SUPPLY
INDICATION
1. Check for an over-temperature condition by
inspecting the fans and filter.
2. If the fans and filter are normal, use the power supply
fault display circuit boards in each cabinet to
determine the defective power supply module. When
the defective power supply is located, refer to the
POWER SUPPLY MODULE section and troubleshoot
the power supply module.
5-9
WARNING: DISCONNECT POWER PRIOR TO SERVICING
TABLE 5-2. AM-2.5E/AM-5E TROUBLESHOOTING
(Sheet 2 of 5)
SYMPTOM
CIRCUITRY TO CHECK
YELLOW ANTENNA INDICATION
1. Check the antenna and phasor equipment.
2. Visually inspect the T-matching network for
discolored components.
3. Refer to the OUTPUT NETWORK section and
troubleshoot the directional coupler circuit board.
RED ANTENNA INDICATION
1. Check the antenna and phasor equipment.
2. Visually inspect the T-matching network for
discolored components.
3. Refer to the OUTPUT NETWORK section of this
manual and troubleshoot the directional coupler
circuit board.
FLASHING RED ANTENNA
INDICATION
1. Check the antenna and phasor equipment.
2. Visually inspect the spark gap in the output network
assembly for a short circuit condition.
3. Check the antenna shorting switch on the output
network assembly.
4. Visually inspect the T-matching network capacitors
in the output network assembly for a short circuit
condition.
5. Check the lightning protection circuit board in the
output network assembly for a short circuit
condition.
INTERLOCK INDICATOR
EXTINGUISHED WHEN IN THE
REMOTE CONTROL MODE
1. Operate remote/local switch to local.
A. If the interlock indicator illuminates, ensure
a +5 volt signal is applied to remote failsafe
input J1-23 on the ECU rear-panel when the
remote control unit is enabled.
1. If the +5 volt signal is not present, troubleshoot
the remote control unit.
2. If the +5 volt signal is present, check Q48 and
U56 on the controller circuit board.
B. If the interlock indicator is extinguished,
check the cabinet and the external interlocks.
CONFLICT INDICATION
1. Ensure a +5 volt status signal from the selected
antenna is applied to the antenna A, B, or C input
on the ECU rear-panel.
2. Ensure the correct transmitter power level is
selected for operation into the antenna.
3. Check the antenna interlock circuit programming on
the controller circuit board.
4. Refer to the ECU section and troubleshoot the
controller circuit board for a conflict indication.
5-10
WARNING: DISCONNECT POWER PRIOR TO SERVICING
TABLE 5-2. AM-2.5E/AM-5E TROUBLESHOOTING
(Sheet 3 of 5)
SYMPTOM
CIRCUITRY TO CHECK
NO OUTPUT POWER
LIGHTNING INDICATOR
ILLUMINATED
1. Transmitter operated to off due to 7 on/off cycles
within 15 seconds. Operate the transmitter to
on as follows: 1) do not depress any controller
switch/indicators for approximately 30 seconds
and 2) depress the desired power level
switch/indicator.
2. Ensure J1 on output network is connected.
3. Check Q401 on the lightning detection circuit board.
NORMAL OUTPUT POWER
LIGHTNING INDICATOR
ILLUMINATED
1. Indicates the presence of lightning at the output of
transmitter. Depress the RESET switch to reset the
indicator.
INTERLOCK INDICATOR
EXTINGUISHED
1. Ensure a +5 volt signal is applied to external
interlock input J1-23 on the ECU rear panel.
OVERTEMP INDICATOR
ILLUMINATED
1. Ensure the transmitter air filter is clean.
2. Check the transmitter fans in each cabinet. If the
fans are not operating, check optical-coupled-relay
(OCR) K1.
3. Ensure the transmitter exhaust area is clear of
obstructions.
MISSING NORMAL/FAULT
INDICATIONS FOR A POWER
BLOCK
1. Check the fuses for the power supply: 1) power
supply 1-2 = F6 and F7, 2) power supply 3-4 =
F8 and F9 (AM-5E only).
2. Check power transformer T1 on the power supply
panel.
NO L+R MODULATION ACTIVITY
DURING MONO OPERATION
1. Ensure audio is present at J3-1/J3-2/J3-4/J3-5
on the ECU rear panel.
2. Check for audio at J101-29 through J101-31 and
J101-36/J101-37 on the ECU motherboard. If no
audio is present, check the filter components on the
ECU motherboard.
3. Refer to the ECU section and troubleshoot the
exciter circuit board.
NO L+R MODULATION ACTIVITY
DURING STEREO OPERATION
1. Ensure audio is present at J3-1/J3-2/J3-4/J3-5 on
the ECU rear panel.
2. Check for audio at J101-29 through J101-31 and
J101-36/J101-37 on the ECU motherboard. If no
audio is present, check the filter components on the
ECU motherboard.
3. Refer to the ECU section and troubleshoot the
exciter circuit board.
5-11
WARNING: DISCONNECT POWER PRIOR TO SERVICING
TABLE 5-2. AM-2.5E/AM-5E TROUBLESHOOTING
(Sheet 4 of 5)
SYMPTOM
CIRCUITRY TO CHECK
RF DRIVE INDICATORS
EXTINGUISHED FOR A
POWER BLOCK
1. Check the RF drive output on the ECU motherboard
as follows: 1) output 1 -P101-7 and 2) output 2 P101-47 (AM-5E only).
1. If no RF drive is present, refer to the ECU
section and troubleshoot the exciter circuit board.
2. If RF drive is present at the exciter circuit board,
check bridge rectifiers D10 and D11 on the power
supply module for the power block.
2. Refer to the RF POWER MODULE section and
troubleshoot each RF power module.
LOW DEMODULATOR LEFT
CHANNEL MODULATION LEVEL
WITH LOW EXCITER
MONITOR LEFT CHANNEL
MODULATION LEVEL
1. Refer to the ECU section and troubleshoot the
exciter circuit board.
LOW DEMODULATOR RIGHT
CHANNEL MODULATION LEVEL
WITH LOW EXCITER
MONITOR RIGHT CHANNEL
MODULATION LEVEL
1. Refer to the ECU section and troubleshoot the
exciter circuit board.
LOW DEMODULATOR LEFT
CHANNEL MODULATION LEVEL
WITH NORMAL EXCITER
MONITOR LEFT CHANNEL
MODULATION LEVEL
1. Refer to the ECU section and troubleshoot the
stereo circuit board.
LOW DEMODULATOR RIGHT
CHANNEL MODULATION LEVEL
WITH NORMAL EXCITER
MONITOR RIGHT CHANNEL
MODULATION LEVEL
1. Refer to the ECU section and troubleshoot the
stereo circuit board.
PWM DRIVE INDICATOR
EXTINGUISHED ON A POWER
BLOCK
1. Refer to the ECU section and troubleshoot the
exciter circuit board.
PWM DRIVE AND RF DRIVE
INDICATORS EXTINGUISHED
ON ALL POWER BLOCKS
1. Refer to the ECU section and troubleshoot the exciter
circuit board.
5-12
WARNING: DISCONNECT POWER PRIOR TO SERVICING
TABLE 5-2. AM-2.5E/AM-5E TROUBLESHOOTING
(Sheet 5 of 5)
SYMPTOM
MOD PWR INDICATORS
EXTINGUISHED ON A POWER
BLOCK
CIRCUITRY TO CHECK
1. Check for a power control PWM signal at the
drain of Q22 on the controller circuit board.
A. If the PWM signal is not present, refer to the
ECU section and troubleshoot the controller
circuit board for no power control PWM signal.
B. If the PWM output is present, check for a LOW at
Q13 on the controller circuit board.
1. If the LOW at Q13 is not present, refer to the
ECU section and troubleshoot the controller
circuit board for no transmitter on signal.
2. If the LOW at Q13 is present, refer to the
POWER SUPPLY section and troubleshoot the
power supply for no MOD POWER indicator on
a power block.
REFLECTED POWER METER
1. Narrow-band antenna. Contact the Broadcast
FLUCTUATES WITH MODULATION
Electronics Customer Service Department.
FORWARD POWER METER
1. Enable the high-pass filter on the exciter circuit
FLUCTUATES WITH MODULATION
board.
5-28.
COMPONENT REPLACEMENT PROCEDURE. Component replacement on printed
5-29.
On all circuit boards, the adhesive securing the copper trace to the board melts at almost
the same temperature at which solder melts. A circuit board trace can be destroyed by
excessive heat or lateral movement during soldering. Use of a small iron with steady
pressure is required for circuit board repairs.
5-30.
To remove a component from a circuit board, cut the leads from the body of the defective
component while the device is still soldered to the board.
5-31.
Grip each component lead, one at a time, with long-nose pliers. Rotate the circuit board
and touch a soldering iron to the lead at the solder connection. When the solder begins to
melt, push the lead through the back side of the board. Each lead may now be heated
independently and pulled out of each hole. The holes may be cleared of solder by carefully
re-heating each hole with a low wattage iron and removing the residual solder with a
soldering vacuum tool.
circuit boards requires extreme care to avoid damage to the circuit board traces. The
following text describes the procedure to replace components on the circuit boards.
5-13
WARNING: DISCONNECT POWER PRIOR TO SERVICING
WARNING
WARNING
WARNING
WARNING
MOST SOLVENTS WHICH WILL REMOVE ROSIN FLUX
ARE VOLATILE AND TOXIC BY THEIR NATURE AND
SHOULD BE USED ONLY IN SMALL AMOUNTS IN A
WELL VENTILATED AREA, AWAY FROM FLAME SUCH
AS FROM A SOLDERING IRON OR SMOKING MATERI
ALS. OBSERVE THE MANUFACTURER'S CAU
TIONARY INSTRUCTIONS.
5-32.
Install the new component and apply solder from the bottom side of the circuit board.
After soldering, remove flux with a cotton swab moistened with a suitable solvent.
Rubbing alcohol is highly diluted and is not effective.
5-33.
The board should be checked to ensure the flux has been removed and not just smeared.
Rosin flux is not normally corrosive, but rosin will absorb enough moisture in time to
become conductive and cause problems.
5-34.
INTEGRATED CIRCUITS. Special care should be exercised with integrated circuits. Each
integrated circuit must be installed by matching the integrated circuit notch with the
notch on the socket. Do not attempt to remove an integrated circuit from a socket with
your fingers. Use an integrated circuit puller to lightly pry the component from the
socket.
5-14
WARNING: DISCONNECT POWER PRIOR TO SERVICING
5-15
WARNING: DISCONNECT POWER PRIOR TO SERVICING
COPYRIGHT
1999 BROADCAST ELECTRONICS, INC
597-1114-18
FIGURE 5-2. AM-2.5E COMPONENT LOCATOR (SHEET 1 OF 3)
COPYRIGHT 1999 BROADCAST ELECTRONICS, INC
597-1114-16
FIGURE 5-2. AM-2.5E COMPONENT LOCATOR (SHEET 2 OF 3)
5-16
WARNING: DISCONNECT POWER PRIOR TO SERVICING
COPYRIGHT 1999 BROADCAST ELECTRONICS, INC
597-1114-16A
FIGURE 5-2. AM-2.5E COMPONENT LOCATOR (SHEET 3 OF 3)
5-17
WARNING: DISCONNECT POWER PRIOR TO SERVICING
5-18
WARNING: DISCONNECT POWER PRIOR TO SERVICING
COPYRIGHT
1999 BROADCAST ELECTRONICS, INC
597-1114-19
FIGURE 5-3. AM-5E COMPONENT LOCATOR (SHEET 1 OF 3)
COPYRIGHT 1999 BROADCAST ELECTRONICS, INC
597-1114-24
FIGURE 5-3. AM-5E COMPONENT LOCATOR (SHEET 2 OF 3)
5-19
WARNING: DISCONNECT POWER PRIOR TO SERVICING
COPYRIGHT 1999 BROADCAST ELECTRONICS, INC
597-1114-17
FIGURE 5-3. AM-5E COMPONENT LOCATOR (SHEET 3 OF 3)
5-20
WARNING: DISCONNECT POWER PRIOR TO SERVICING
ECU COMPONENT LOCATOR
COPYRIGHT 1999 BROADCAST ELECTRONICS, INC
POWER BLOCK COMPONENT LOCATOR
FIGURE 5-4. AM-2.5E/AM-5E ECU/POWER BLOCK/OUTPUT NETWORK
ASSEMBLY COMPONENT LOCATOR (SHT 1 OF 2)
5-21
WARNING: DISCONNECT POWER PRIOR TO SERVICING
597-1114-20
5-22
WARNING: DISCONNECT POWER PRIOR TO SERVICING
AM-2.5E/AM-5E OUTPUT NETWORK ASSEMBLY COMPONENT LOCATOR
COPYRIGHT
FIGURE 5-4. AM-2.5E/AM-5E ECU/POWER BLOCK/OUTPUT NETWORK
ASSEMBLY COMPONENT LOCATOR (SHT 2 OF 2)
1999 BROADCAST ELECTRONICS, INC
597-1114-21
SECTION VI
PARTS LIST
6-1.
INTRODUCTION.
6-2.
This section provides parts lists for the AM-2.5E/AM-5E transmitter. The parts lists pro
vide descriptions and part numbers of electrical components, assemblies, and selected me
chanical parts required for maintenance. Each parts list entry in this section is indexed
by reference designators appearing on the applicable schematic diagrams.
TABLE 6-1. AM-2.5E/AM-5E REPLACEABLE PARTS LIST INDEX (Sheet 1 of 2)
TABLE
6-2
6-3
6-4
6-5
6-6
6-7
6-8
6-9
6-10
6-11
6-12
6-13
6-14
6-15
6-16
6-17
6-18
6-19
6-20
6-21
6-22
6-23
6-24
6-25
6-26
6-27
6-28
6-29
6-30
6-31
6-32
6-33
DESCRIPTION
AM-2.5E Transmitter
AM-5E Transmitter
AC Sample Circuit Board Assembly
Temperature Sensor Circuit Board Assembly
PFC Relay Board Circuit Board Assembly
Optically Coupled Relay Circuit Board Assembly
Optically Coupled Relay Circuit Board Assembly
Harness Assembly
Power Block Assembly, AM-2.5E
Power Block Assembly, AM-5E
Power Block Motherboard Circuit Board Assembly
Combiner Circuit Board Assembly, AM-2.5E
Combiner Circuit Board Assembly, AM-5E
Accessory Parts Kit, AM-2.5E
Accessory Parts Kit, AM-5E
Frequency Dependant Kit, AM-2.5E, 522 - 650 KHZ
Frequency Dependant Kit, AM-2.5E, 651 - 770 KHZ
Frequency Dependant Kit, AM-2.5E, 771 - 920 KHZ
Frequency Dependant Kit, AM-2.5E, 921 - 1080 KHZ
Frequency Dependant Kit, AM-2.5E, 1081 - 1300 KHZ
Frequency Dependant Kit, AM-2.5E, 1301 - 1580 KHZ
Frequency Dependant Kit, AM-2.5E, 1581 - 1700 KHZ
Frequency Dependant Kit, AM-5E, 522 - 650 KHZ
Frequency Dependant Kit, AM-5E, 651 - 770 KHZ
Frequency Dependant Kit, AM-5E, 771 - 920 KHZ
Frequency Dependant Kit, AM-5E, 921 - 1080 KHZ
Frequency Dependant Kit, AM-5E, 1081 - 1300 KHZ
Frequency Dependant Kit, AM-5E, 1301 - 1580 KHZ
Frequency Dependant Kit, AM-5E, 1581 - 1700 KHZ
Power Block Frequency Dependant Kit, 522 - 650 KHZ
Power Block Frequency Dependant Kit, 651 - 770 KHZ
Power Block Frequency Dependant Kit, 771 - 920 KHZ
6-1
PART NO.
907-2500-100
907-5000-100
917-0306-007
917-0306-009
917-0330
919-0096-001
919-0096
947-0210
957-0022-021
957-0022-051
917-0303
917-0321-002
917-0321-005
957-0069
957-0071
957-0015-121
957-0015-122
957-0015-123
957-0015-124
957-0015-125
957-0015-126
957-0015-127
957-0015-151
957-0015-152
957-0015-153
957-0015-154
957-0015-155
957-0015-156
957-0015-157
957-1025-061
957-1025-062
957-1025-063
PAGE
6-3
6-3
6-4
6-5
6-5
6-5
6-5
6-6
6-7
6-7
6-7
6-7
6-7
6-8
6-8
6-9
6-9
6-9
6-9
6-9
6-10
6-10
6-10
6-10
6-10
6-11
6-11
6-11
6-11
6-11
6-12
6-12
TABLE 6-1. AM-2.5E/AM-5E REPLACEABLE PARTS LIST INDEX (Sheet 2 of 2)
TABLE
6-34
6-35
6-36
6-37
DESCRIPTION
Power Block Frequency Dependant Kit, 921 - 1080 KHZ
Power Block Frequency Dependant Kit, 1081 - 1300 KHZ
Power Block Frequency Dependant Kit, 1301 - 1580 KHZ
Power Block Frequency Dependant Kit, 1581 - 1700 KHZ
6-2
PART NO.
957-1025-064
957-1025-065
957-1025-066
957-1025-067
PAGE
6-12
6-12
6-12
6-12
TABLE 6-2. AM-2.5E TRANSMITTER - 907-2500-100
REF. DES.
B1, B2
C1
F1, F2
F7, F8
K2
L3, L4
MOV1
MOV2
MOV3
S1
TB1
TB2
----------------------------------------------------------
DESCRIPTION
Fan, Patriot, 230 Vac
Capacitor, 50 uF, 370 Vac, Motor Run
Fuse, 50 Amperes, Dual Element, Time Delay
Fuse, 3AG, 250V, 2 Amperes
Contactor, 40 Amperes, 220/240 Vac, 50/60 Hz
Inductor, 5.8 mH, 30 Amperes
Metal-Oxide Varistor, B40K275, 275V, 1680 Joules
Metal-Oxide Varistor, B40K275, 275V, 1680 Joules
Metal-Oxide Varistor, B40K275, 275V, 1680 Joules
Switch, Disconnect, Safety Interlock, 60 Amperes
Barrier Strip, 9 Terminal
Terminal Block, GOULD 63133
Meter, 3.5 Inch (8.89 cm), Taut Band Type, FS = 1 mA dc
±1%, 35 Ohm Resistance (REFLECTED POWER Meter)
Meter, 3.5 Inch (8.89 cm), Taut Band Type, FS = 1 mA dc
±1%, 35 Ohm Resistance (FORWARD POWER Meter)
Filter, RFI, 30 Amperes
Fuseholder, 60 Amperes, 250V, Reject Type
Fuse Holder, AGC
Connector, 7/16 DIN,Panel Jack, Solder
Cable, L5PDF-BH, L5PDR ,17.5", LDF5
Cable, L5PDM, L5PDR, 11.8", LDF5
AC Sample Circuit Board Assembly
Temperature Sensor Circuit Board Assembly
PFC Relay Board Circuit Board Assembly
Optically Coupled Relay Circuit Board Assembly
Harness, AM-2.5E
Exciter/Controller Assembly
Power Module Assembly
Power Block Assembly
Output Network Assembly
Accessory Parts Kit
Power Supply Panel Assembly
PART NO.
QTY.
380-9001
047-5063-370
334-2501
330-0200
341-0076
370-2366
140-0021
140-0021
140-0021
341-0061
412-0090
412-0050
310-0068
310-0069
339-0030
415-0019
415-2012
417-0716
610-0009
610-0010
917-0306-007
917-0306-009
917-0330
919-0096-001
947-0210
957-0009-100
957-0010-001
957-0022-021
957-0068
957-0069
957-0315-100
TABLE 6-3. AM-5E TRANSMITTER - 907-5000-100
(Sheet 1 of 2)
REF. DES.
B1, B2
C1, C2
F1, F2
F7 thru F10
K2
DESCRIPTION
Fan, Patriot, 230 Vac
Capacitor, 50 uF, 370 Vac, Motor Run
Fuse, 100 Amperes, Dual Element, Time Delay
Fuse, 3AG, 250V, 2 Amperes
Contactor, 80 Amperes, 220/240Vac, 50/60 Hz
6-3
PART NO.
380-9001
047-5063-370
334-0002
330-0200
341-0074
QTY.
TABLE 6-3. AM-5E TRANSMITTER - 907-5000-100
(Sheet 2 of 2)
REF. DES.
DESCRIPTION
PART NO.
QTY.
L3 thru L6
Inductor, 5.8 mH, 30 Amperes
370-2366
MOV1 thru
Metal-Oxide Varistor, B40K275, 275V, 1680 Joules
140-0021
S1
Switch, Disconnect, Safety Interlock, 60 Amperes
341-0061
TB1
Barrier Strip, 9 Terminal
412-0090
TB2
Terminal Block, GOULD 63133
412-0050
----
Meter, 3.5 Inch (8.89 cm), Taut Band Type, FS = 1 mA dc
±1%, 35 Ohm Resistance (REFLECTED POWER Meter)
310-0064
----
Meter, 3.5 Inch (8.89 cm), Taut Band Type, FS = 1 mA dc
±1%, 35 Ohm Resistance (FORWARD POWER Meter)
310-0065
----
Filter., RFI, 55 Amperes
339-0055
----
Fuseholder, 100 Amperes, 250V, Reject Type
415-0020
----
Fuse Holder, AGC
415-2012
----
Connector, 7/16 DIN,Panel Jack, Solder
417-0716
----
Cable, L5PDF-BH, L5PDR ,17.5", LDF5
610-0009
----
Cable, L5PDM, L5PDR, 11.8", LDF5
610-0010
----
AC Sample Circuit Board Assembly
917-0306-007
----
Temperature Sensor Circuit Board Assembly
917-0306-009
----
PFC Relay Board Circuit Board Assembly
917-0330
----
Optically Coupled Relay Circuit Board Assembly
919-0096-001
----
Exciter/Controller Assembly
957-0009-100
----
Power Module Assembly
957-0010-001
----
Power Block Assembly
957-0022-051
----
Output Network Assembly
957-0070
----
Accessory Parts Kit
957-0071
----
Power Supply Panel Assembly
957-0315-100
----
Harness, AM-5E
947-0212
MOV3
TABLE 6-4. AC SAMPLE CIRCUIT BOARD ASSEMBLY - 917-0306-007
REF. DES.
C701
D701 thru
D704
E701, E702
J701
R701 thru
R706
R707
----
DESCRIPTION
PART NO.
QTY.
Capacitor, Polypropylene Film, .47 uF ±10%, 600V
Diode, 1N4005, Silicon, 600V @ 1 Ampere
033-4763
203-4005
Terminal, Male Disconnect
Connector, 2-Pin
Resistor, 150 k Ohm±1%, 1/4W
410-0025
417-0700
103-1561
Resistor, 3.3 Meg Ohm ±5%, 1/4W
Blank, AC Sample Circuit Board
100-3373
517-0306-007
6-4
TABLE 6-5. TEMPERATURE SENSOR CIRCUIT BOARD ASSEMBLY - 917-0306-009
REF. DES.
C902
C906
C907
J901
R901
R902
R903
TP901,
TP902
U901
----
DESCRIPTION
PART NO.
QTY.
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Ceramic, 0.001 uF, 1 kV
Socket, 4-Pin
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 2.21 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Terminal, Turret, Double Shoulder
003-1066
003-1066
002-1034
418-0255
100-1051
103-2241
100-1051
413-1597
Integrated Circuit, LM35DZ, Celsius Temperature Sensor,
TO-92 Case
Blank, Temperature Sensor, Circuit Board
220-0035
517-0306-009
TABLE 6-6. PFC RELAY BOARD CIRCUIT BOARD ASSEMBLY - 917-0330
REF. DES.
J1
J2, J3
K1, K2
R1
----
DESCRIPTION
Socket, 4-Pin
Stud, PEM, KFH-832-5ET, PCB Mount
Relay, SPST, 30 Amperes
Resistor, 100k Ohm, 2W, ±5%
Blank, PFC Relay Board Circuit Board
PART NO.
418-0255
426-8008
270-1213
130-1062
517-0330
QTY.
TABLE 6-7. OPTICALLY COUPLED RELAY CIRCUIT BOARD ASSEMBLY - 919-0096-001
REF. DES.
DESCRIPTION
PART NO.
QTY.
----
Optically Coupled Relay Circuit Board Assembly
919-0096
C3
R2
Capacitor, Ceramic Disc, 0.1 uF, 600V
Resistor, 560 Ohm ±5%, 1/2W
000-1051
110-5633
DELETE PARTS
TABLE 6-8. OPTICALLY COUPLED RELAY CIRCUIT BOARD ASSEMBLY - 919-0096
(Sheet 1 of 2)
REF. DES.
C1
C2
C3
C4
D1
DESCRIPTION
Capacitor, Ceramic, 0.001 uF, 1 kV
Capacitor, Electrolytic, 47 uF, 35V
Capacitor, Ceramic Disc, 0.1 uF, 600V
Capacitor, Ceramic, 0.001 uF, 1 kV
Diode, 1N4005, Silicon, 600V @ 1 Ampere
6-5
PART NO.
002-1034
020-4773
000-1051
002-1034
203-4005
QTY.
TABLE 6-8. OPTICALLY COUPLED RELAY CIRCUIT BOARD ASSEMBLY - 919-0096
(Sheet 2 of 2)
REF. DES.
D2
D4
D5
E1 thru E5
F1, F2
K1
MOV1
R1
R2
R3
R4
R5
U1
XU1
----
DESCRIPTION
Diode, Zener, 1N5359, 24V ±10%, 5W
Diode, 1N4005, Silicon, 600V @ 1 Ampere
Bridge Rectifier, MDA970A3, 4 Amperes, 50-200V
Terminal, Male Disconnect
Fuse, 3 Amperes, 250V, Printed Circuit Board Mount
Relay, Printed Circuit Board Mount
Coil: 24V dc, 660 Ohm ±10%
Contacts: SPST-NO, 0.5 to 15A @ 12 to 240V ac Resistance
Varistor, 27V, V27ZA60
Resistor, 2 k Ohm ±3%, 10W, W/W
Resistor, 560 Ohm ±5%, 1/2W
Resistor, 820 Ohm ±5%, 1/2W
Resistor, 51.1 Ohm ±1%, 1/4W
Resistor, 2 k Ohm ±3%, 10W, W/W
Integrated Circuit, 4N33, Optical Isolator, NPN Photo
Transistor/Infared Emitting Diode Type, 1500V Isolation,
Response: 30 kHz Maximum, Current: 50 mA Maximum,
6-Pin DIP
Socket, 6-Pin DIP
Blank, Optically Coupled Relay Circuit Board
PART NO.
QTY.
200-5359
203-4005
239-0003
410-0025
330-0055
270-0054
140-0023
130-2032
110-5633
110-8233
103-5112
130-2032
229-0033
417-0600
519-0096
TABLE 6-9. HARNESS ASSEMBLY - 947-0210
REF. DES.
-------------------------------------------------
DESCRIPTION
Pins, Connector
Pins, Connector
Pins, Connector
Pins, Socket
Connector Plug, 25-Pin
Receptacle, 15-Pin, D-Type
Kit, Housing, 15-Pin, D-Type
Housing, Wire, MR, Female, 24-Pin, Amp
Kit, Housing, 25-Pin
Plug and Cord ET, AM-500 FAN
3 Circuit-Commoning Bar, AMP MR
Housing, Connector, 4-Pin
Plug, Housing, 4-Pin
Connector Housing, 6-Pin
Connector Housing, 2-Pin, Female
AC Line Cord, N.E.M.A. 3-Wire North American Plug
6-6
PART NO.
417-0036
417-0053
417-0142
417-0143
417-0251
417-1504
417-1510
417-2402
417-2510
417-8500
418-0054
418-0233
418-0240
418-0670
418-0701
682-0001
QTY.
51
42
13
TABLE 6-10. POWER BLOCK ASSEMBLY, AM-2.5E- 957-0022-021
REF. DES.
-------
DESCRIPTION
Power Block Motherboard Circuit Board Assembly
Combiner Circuit Board Assembly
PART NO.
QTY.
917-0303
917-0321-002
TABLE 6-11. POWER BLOCK ASSEMBLY, AM-5E - 957-0022-051
REF. DES.
-------
DESCRIPTION
Power Block Motherboard Circuit Board Assembly
Combiner Circuit Board Assembly
PART NO.
QTY.
917-0303
917-0321-005
TABLE 6-12. POWER BLOCK MOTHERBOARD CIRCUIT BOARD ASSEMBLY - 917-0303
REF. DES.
C1, C2
C3, C4
E1, E2,
E5 thru E8
E11 thru E16
E22, E23
J3
J1A thru J1F
J2A thru J2F
T1, T2
----
DESCRIPTION
PART NO.
QTY.
Capacitor, Ceramic, Monolythic, .1 uF ±10%, 50V
Capacitor, Polypropylene Film, 2.2 uF, 400V
Stud, PEM, KFH-832-8ET, PCB Mount
003-1066
030-2256
426-8007
14
Connector, Male, 24-Pin
Socket, Card Edge, AMP 531353-6
Connector, 15-Pin SUB-D, Female
Transformer, P.A. Drive, AM-1/5
Blank, Power Block Motherboard Circuit Board
417-2401
417-0300
417-0375
370-0037
517-0303
TABLE 6-13. COMBINER CIRCUIT BOARD ASSEMBLY, AM-2.5E - 917-0321-002
REF. DES.
DESCRIPTION
E1 thru E9
Stud, PEM, KFH-832-8ET, Printed Circuit Board Mount
L1 thru L4
RF Choke Assembly
T1 thru T4
Combiner Transformer Assembly
TP1 thru TP10 Terminal Test Point, Oval Red
---Blank, Combiner Circuit Board Assembly
PART NO.
426-8007
360-0107
370-0060
413-0106
517-0321
QTY.
10
TABLE 6-14. COMBINER CIRCUIT BOARD ASSEMBLY, AM-5E - 917-0321-005
(Sheet 1 of 2)
REF. DES.
E1 thru E9
L1 thru L4
DESCRIPTION
Stud, PEM, KFH-832-8ET, Printed Circuit Board Mount
RF Choke Assembly
6-7
PART NO.
426-8007
360-0107
QTY.
TABLE 6-14. COMBINER CIRCUIT BOARD ASSEMBLY, AM-5E - 917-0321-005
(Sheet 2 of 2)
REF. DES.
DESCRIPTION
T1 thru T4
Combiner Transformer Assembly
TP1 thru TP10 Terminal, Test Point, Oval, Red
---Blank, Combiner Circuit Board
PART NO.
370-0061
413-0106
517-0321
QTY.
10
TABLE 6-15. ACCESSORY PARTS KIT, AM-2.5E - 957-0069
REF. DES.
----------------------------------
DESCRIPTION
Fuse, 3AG, 250V, 2 Amperes
Fuse, 3AB, 15 Amperes, 65V, Very Fast
Fuse, 3AB, 250V, 20 Amperes
Fuse, 30 Amperes, 125V, 1/4x1-1/5850P Lead
Fuse, AGC, 1A, 250V, Slow-Blow (for 115 Volt operation)
Fuse, 5 X 20MM, 1.5 Amperes, Slow-Blow
Battery, 9 Volt, Alkaline
Ferrite Core Large AM Transmitter
Core, 1.102 OD X .63 ID X .512 THK
Adjustment Tool, Extended and Recessed Flat Blades
Kit, Instruction Manual AM-2.5E/5E
PART NO.
330-0200
330-1502
330-2000
334-0030-001
334-0100
334-1150
350-0002
375-0007-001
375-0009
407-0186
977-1114
QTY.
TABLE 6-16. ACCESSORY PARTS KIT, AM-5E - 957-0071
REF. DES.
----------------------------------
DESCRIPTION
Fuse, 3AG, 250V, 2 Amperes
Fuse, 3AB, 15 Amperes, 65V, Very Fast
Fuse, 3AB, 250V, 20 Amperes
Fuse, 30 Amperes, 125V, 1/4x1-1/5850P Lead
Fuse, AGC, 1 Ampere, 250V, Slow-Blow (For 115 Volt Operation)
Fuse, 5 X 20MM, 1.5 Ampere, Slow-Blow
Battery, 9 Volt, Alkaline
Ferrite Core Large AM Transmitter
Core, 1.102 OD X .63 ID X .512 THK
Adjustment Tool, extended and recessed flat blades
Kit, Instruction Manual, AM-2.5E/5E
6-8
PART NO.
330-0200
330-1502
330-2000
334-0030-001
334-0100
334-1150
350-0002
375-0007-001
375-0009
407-0186
977-1114
QTY.
TABLE 6-17. FREQUENCY DEPENDANT KIT, AM-2.5E, 522 - 650 KHZ - 957-0015-121
REF. DES.
----------
DESCRIPTION
PART NO.
Kit, Frequency Dependent Parts, Power Amplifier Modulator Circuit, 957-1015-001
Board, 522 - 650 KHZ
Kit, Frequency Dependent Parts, Power Block, 522 - 650 KHZ
957-1025-061
Kit, Frequency Dependent Parts, Output Network, 522 - 650 KHZ
957-1035-121
QTY.
TABLE 6-18. FREQUENCY DEPENDANT KIT, AM-2.5E, 651 - 770 KHZ - 957-0015-122
REF. DES.
----------
DESCRIPTION
PART NO.
Kit, Frequency Dependent Parts, Power Amplifier Modulator Circuit, 957-1015-002
Board, 651 - 770 KHZ
Kit, Frequency Dependent Parts, Power Block, 651 - 770 KHZ
957-1025-062
Kit, Frequency Dependent Parts, Output Network, 651 - 770 KHZ
957-1035-122
QTY.
TABLE 6-19. FREQUENCY DEPENDANT KIT, AM-2.5E, 771 - 920 KHZ - 957-0015-123
REF. DES.
----------
DESCRIPTION
PART NO.
Kit, Frequency Dependent Parts, Power Amplifier Modulator Circuit, 957-1015-003
Board, 771 - 920 KHZ
Kit, Frequency Dependent Parts, Power Block, 771 - 920 KHZ
957-1025-063
Kit, Frequency Dependent Parts, Output Network, 771 - 920 KHZ
957-1035-123
QTY.
TABLE 6-20. FREQUENCY DEPENDANT KIT, AM-2.5E, 921 - 1080 KHZ - 957-0015-124
REF. DES.
----------
DESCRIPTION
PART NO.
Kit, Frequency Dependent Parts, Power Amplifier Modulator Circuit, 957-1015-004
Board, 921 - 1080 KHZ
Kit, Frequency Dependent Parts, Power Block, 921 - 1080 KHZ
957-1025-064
Kit, Frequency Dependent Parts, Output Network, 921 - 1080 KHZ 957-1035-124
QTY.
TABLE 6-21. FREQUENCY DEPENDANT KIT, AM-2.5E, 1081 - 1300 KHZ - 957-0015-125
REF. DES.
----------
DESCRIPTION
PART NO.
Kit, Frequency Dependent Parts, Power Amplifier Modulator Circuit, 957-1015-005
Board, 1081 - 1300 KHZ
Kit, Frequency Dependent Parts, Power Block, 1081 - 1300 KHZ
957-1025-065
Kit, Frequency Dependent Parts, Output Network, 1081 - 1300 KHZ 957-1035-125
6-9
QTY.
TABLE 6-22. FREQUENCY DEPENDANT KIT, AM-2.5E, 1301 - 1580 KHZ - 957-0015-126
REF. DES.
----------
DESCRIPTION
PART NO.
Kit, Frequency Dependent Parts, Power Amplifier Modulator Circuit, 957-1015-006
Board, 1301 - 1580 KHZ
Kit, Frequency Dependent Parts, Power Block, 1301 - 1580 KHZ
957-1025-066
Kit, Frequency Dependent Parts, Output Network, 1301 - 1580 KHZ 957-1035-126
QTY.
TABLE 6-23. FREQUENCY DEPENDANT KIT, AM-2.5E, 1581 - 1700 KHZ - 957-0015-127
REF. DES.
----------
DESCRIPTION
PART NO.
Kit, Frequency Dependent Parts, Power Amplifier Modulator Circuit, 957-1015-007
Board, 1581 - 1700 KHZ
Kit, Frequency Dependent Parts, Power Block, 1581 - 1700 KHZ
957-1025-067
Kit, Frequency Dependent Parts, Output Network, 1581 - 1700 KHZ 957-1035-127
QTY.
TABLE 6-24. FREQUENCY DEPENDANT KIT, AM-5E, 522 - 650 KHZ - 957-0015-151
REF. DES.
----------
DESCRIPTION
PART NO.
Kit, Frequency Dependent Parts, Power Amplifier Modulator Circuit, 957-1015-001
Board, 522 - 650 KHZ
Kit, Frequency Dependent Parts, Power Block, 522 - 650 KHZ
957-1025-061
Kit, Frequency Dependent Parts, Output Network, 522 - 650 KHZ
957-1035-151
QTY.
TABLE 6-25. FREQUENCY DEPENDANT KIT, AM-5E, 651 - 770 KHZ - 957-0015-152
REF. DES.
----------
DESCRIPTION
PART NO.
Kit, Frequency Dependent Parts, Power Amplifier Modulator Circuit, 957-1015-002
Board, 651 - 770 KHZ
Kit, Frequency Dependent Parts, Power Block, 651 - 770 KHZ
957-1025-062
Kit, Frequency Dependent Parts, Output Network, 651 - 770 KHZ
957-1035-152
QTY.
TABLE 6-26. FREQUENCY DEPENDANT KIT, AM-5E, 771 - 920 KHZ - 957-0015-153
REF. DES.
----------
DESCRIPTION
PART NO.
Kit, Frequency Dependent Parts, Power Amplifier Modulator Circuit, 957-1015-003
Board, 771 - 920 KHZ
Kit, Frequency Dependent Parts, Power Block, 771 - 920 KHZ
957-1025-063
Kit, Frequency Dependent Parts, Output Network, 771 - 920 KHZ
957-1035-153
6-10
QTY.
TABLE 6-27. FREQUENCY DEPENDANT KIT, AM-5E, 921 - 1080 KHZ - 957-0015-154
REF. DES.
----
DESCRIPTION
PART NO.
Kit, Frequency Dependent Parts, Power Amplifier Modulator Circuit, 957-1015-004
Board, 921 - 1080 KHZ
Kit, Frequency Dependent Parts, Power Block, 921 - 1080 KHZ
957-1025-064
Kit, Frequency Dependent Parts, Output Network, 921 - 1080 KHZ 957-1035-154
-------
QTY.
TABLE 6-28. FREQUENCY DEPENDANT KIT, AM-5E, 1081 - 1300 KHZ - 957-0015-155
REF. DES.
----
DESCRIPTION
PART NO.
Kit, Frequency Dependent Parts, Power Amplifier Modulator Circuit, 957-1015-005
Board, 1081 - 1300 KHZ
Kit, Frequency Dependent Parts, Power Block, 1081 - 1300 KHZ
957-1025-065
Kit, Frequency Dependent Parts, Output Network, 1081 - 1300 KHZ 957-1035-155
-------
QTY.
TABLE 6-29. FREQUENCY DEPENDANT KIT, AM-5E, 1301 - 1580 KHZ - 957-0015-156
REF. DES.
----
DESCRIPTION
PART NO.
Kit, Frequency Dependent Parts, Power Amplifier Modulator Circuit, 957-1015-006
Board, 1301 - 1580 KHZ
Kit, Frequency Dependent Parts, Power Block, 1301 - 1580 KHZ
957-1025-066
Kit, Frequency Dependent Parts, Output Network, 1301 - 1580 KHZ 957-1035-156
-------
QTY.
TABLE 6-30. FREQUENCY DEPENDANT KIT, AM-5E, 1581 - 1700 KHZ - 957-0015-157
REF. DES.
----
DESCRIPTION
PART NO.
Kit, Frequency Dependent Parts, Power Amplifier Modulator Circuit, 957-1015-007
Board, 1581 - 1700 KHZ
Kit, Frequency Dependent Parts, Power Block, 1581 - 1700 KHZ
957-1025-067
Kit, Frequency Dependent Parts, Output Network, 1581 - 1700 KHZ 957-1035-157
-------
QTY.
TABLE 6-31. POWER BLOCK FREQUENCY DEPENDANT KIT, 522 - 650 KHZ 957-1025-061
REF. DES.
L5 thru
L8
DESCRIPTION
Coil, 522 - 650 kHz
PART NO.
360-0114-XXX
6-11
QTY.
TABLE 6-32. POWER BLOCK FREQUENCY DEPENDANT KIT, 651 - 770 KHZ 957-1025-062
REF. DES.
L5 thru
L8
DESCRIPTION
Coil, 651 - 770 kHz
PART NO.
QTY.
360-0114-XXX
TABLE 6-33. POWER BLOCK FREQUENCY DEPENDANT KIT, 771 - 920 KHZ 957-1025-063
REF. DES.
L5 thru
L8
DESCRIPTION
Coil, 771 - 920 kHz
PART NO.
QTY.
360-0114-XXX
TABLE 6-34. POWER BLOCK FREQUENCY DEPENDANT KIT, 921 - 1080 KHZ 957-1025-064
REF. DES.
L5 thru
L8
DESCRIPTION
Coil, 921 - 1080 kHz
PART NO.
QTY.
360-0114-XXX
TABLE 6-35. POWER BLOCK FREQUENCY DEPENDANT KIT, 1081 - 1300 KHZ 957-1025-065
REF. DES.
L5 thru
L8
DESCRIPTION
Coil, 1081 - 1300 kHz
PART NO.
QTY.
360-0114-XXX
TABLE 6-36. POWER BLOCK FREQUENCY DEPENDANT KIT, 1301 - 1580 KHZ 957-1025-066
REF. DES.
L5 thru
L8
L9
DESCRIPTION
PART NO.
QTY.
Coil, 1301 - 1580 kHz
360-0114-XXX
Inductor, 120 uH, 1.5 Amperes ±10%
360-1824
TABLE 6-37. POWER BLOCK FREQUENCY DEPENDANT KIT, 1581 - 1700 KHZ 957-1025-067
REF. DES.
L5 thru
L8
L9
DESCRIPTION
PART NO.
QTY.
Coil, 1581 - 1700 kHz
360-0114-XXX
Inductor, 100 uH, 1.5 Amperes ±10%
360-1823
6-12
SECTION VII
DRAWINGS
7-1.
INTRODUCTION.
7-2.
This section provides schematic diagrams and assembly diagrams as indexed below for the
Broadcast Electronics AM-2.5E/AM-5E transmitters.
FIGURE
7-1
7-2
7-3
7-4
TITLE
NUMBER
OVERALL SCHEMATIC DIAGRAM, AM-2.5E
SCHEMATIC DIAGRAM, TEMPERATURE SENSOR
CIRCUIT BOARD
SCHEMATIC DIAGRAM, AC SAMPLE CIRCUIT BOARD
ASSEMBLY DIAGRAM, ECU DISPLAY CIRCUIT
BOARD
7-5
7-6
7-7
SCHEMATIC DIAGRAM, POWER BLOCK MOTHERBOARD
ASSEMBLY DIAGRAM, POWER BLOCK MOTHERBOARD
ASSEMBLY DIAGRAM, COMBINER
7-8
7-9
SCHEMATIC DIAGRAM, OPTICALLY COUPLED RELAY
ASSEMBLY DIAGRAM, OPTICALLY COUPLED
RELAY (OCR)
SCHEMATIC DIAGRAM, CUSTOMER INTERFACE PRINTED
CIRCUIT BOARD
ASSEMBLY DIAGRAM, CUSTOMER INTERFACE PRINTED
CIRCUIT BOARD
SCHEMATIC DIAGRAM, POWER FACTOR CORRECTOR BOARD
ASSEMBLY DIAGRAM, POWER FACTOR CORRECTOR BOARD
SCHEMATIC DIAGRAM, INTERFACE CIRCUIT BOARD, AM-5E
SCHEMATIC DIAGRAM, POWER SUPPLY STATUS
CIRCUIT BOARD, AM-5E
7-10
7-11
7-12
7-13
7-14
7-15
7-1
SB907-2500-100
SA917-0306-009
SA917-0306-007
AD917-0306-001/
-002/-003/-004/
-005/-006/-007/
-009/-014
SB917-0303
AC917-0303
AC917-0321/-001
-006
SB919-0096/-001
AB919-0096/-001
SD917-0410
AB917-0410
SB917-0330
AB917-0330
SB917-0306-003
SA917-0306-006
TABLE OF CONTENTS
PARAGRAPH
SECTION I
1-1
1-3
1-6
1-8
1-10
1-12
1-16
1-18
1-20
1-23
1-25
1-28
1-30
1-31
1-33
1-34
1-38
1-43
1-47
SECTION II
2-1
2-3
2-6
2-8
2-10
2-12
2-13
2-14
2-17
2-18
SECTION III
3-1
SECTION IV
4-1
PAGE NO.
POWER SUPPLY THEORY OF OPERATION
Introduction
General Description
AC Input
Conventional Rectifier Circuitry
Soft-Start Circuit
AC Line Detection/Synchronization
Soft-Start Control Circuit
Power Factor Corrector Circuit Board Control Circuit
SCR Controlled Rectifier Circuit
Filter Circuit
Power Supply Enable Circuit
Switching Regulator Circuit
Low Voltage Power Supply
Switching Regulator Control Circuit
Switching Regulator Circuit Operation
Power Control/Correction Circuit
Fault Detection
Crowbar Circuit
Power Supply Circuit Grounds
1-1
1-1
1-1
1-1
1-1
1-2
1-2
1-2
1-5
1-5
1-5
1-5
1-6
1-6
1-6
1-6
1-7
1-7
1-8
POWER SUPPLY CIRCUIT BOARD MAINTENANCE
Introduction
Safety Considerations
First Level Maintenance
Cleaning and Inspection
Second Level Maintenance
Troubleshooting
Safety Considerations
Removing/Installing a Power Supply Circuit Board
Troubleshooting Procedures
Component Replacement Procedure
2-1
2-1
2-1
2-1
2-2
2-2
2-2
2-2
2-3
2-4
POWER SUPPLY CIRCUIT BOARD PARTS LIST
Introduction
3-1
POWER SUPPLY CIRCUIT BOARD DRAWINGS
Introduction
4-1
LIST OF ILLUSTRATIONS
FIGURE
1-1
TITLE
PAGE NO.
POWER SUPPLY CIRCUIT BOARD
SIMPLIFIED SCHEMATIC
1-3
LIST OF TABLES
TABLE
2-1
3-1
TITLE
POWER SUPPLY MODULE TROUBLESHOOTING
REPLACEABLE PARTS LIST INDEX
PAGE NO.
2-3
3-1
SECTION I
POWER SUPPLY THEORY OF OPERATION
1-1.
INTRODUCTION.
1-2.
This section presents a general description of the Broadcast Electronics AM-2.5E/AM-5E
transmitter power supply assembly.
1-3.
GENERAL DESCRIPTION.
1-4.
DC operating potentials for the RF power modules are provided by power supply assem
blies (refer to Figure 1-1). The power supply assembly consists of: 1) a power supply cir
cuit board and 2) filter and transformer components located on a power supply panel.
One power supply assembly provides dc operating potentials for one power block. The
AM-2.5E transmitter is equipped with 1 power supply assembly. The AM-5E transmitter
is equipped with 2 power supply assemblies.
1-5.
The modular design of the power supply assembly allows the power supply circuit board
to be removed from the transmitter for maintenance. The following text presents a de
scription of the power supply circuit board and the components located on the power supply panel assembly.
1-6.
AC INPUT.
1-7.
AC power from the ac input switch is applied through fuses F6 and F7 to power transformer T1. Fuses F6 and F7 protect the circuitry from over-current conditions. Trans
former T1 consists of: 1) a single primary winding and 2) five secondary windings. The
transformer is designed to provide low-voltage ac samples for application to five conven
tional bridge rectifier circuits.
1-8.
CONVENTIONAL RECTIFIER CIRCUITRY.
1-9.
AC power from a winding of power transformer T1 is applied to bridge rectifier D11. D11
rectifies the ac potential into an unregulated 30V dc supply for application to the RF power module power amplifier circuit boards. Capacitor C21 provides filtering for the supply.
AC power from a second winding of transformer T1 is applied to bridge rectifier D10. D10
rectifies the ac potential into an unregulated +20V dc supply for the power supply circuit
board circuitry. Capacitor C20 provides filtering for the supply. AC power from a third
winding of ac power transformer T1 is applied to bridge rectifier D9. D9 rectifies the ac
potential into an unregulated +20 volt dc supply for application to: 1) the modulator circuit board and 2) to regulator U3. U3 is a +15 volt dc regulator. The output of U3 routed
for application to the components on the power supply circuit board. AC power from a
fourth winding of power transformer T1 is applied to bridge rectifier D12. D12 rectifies
the ac potential into an unregulated +15V dc supply for application to: 1) the power supply circuit board and 2) regulator U4. U4 is a +12 volt dc regulator. The output of U4
routed for application to the components on the power supply circuit board. An ac sample
from the winding is routed for application to a soft-start circuit. Capacitor C15 provides
filtering for the supply.
1-10.
SOFT-START CIRCUIT.
1-11.
An ac sample from the winding of T1 is also routed to a soft-start circuit. The soft-start
circuit is designed to eliminate component stress during turn-on by limiting the current
in-rush. The circuit consists of an ac line detection/synchronization and soft-start control
circuits.
1-1
1-12.
AC LINE DETECTION/SYNCHRONIZATION. An ac sample from a winding of transform
er T1 is rectified by diodes D7 and D8 and applied to integrated circuit U6B. U6B func
tions as a zero phase detector. As the ac line phase approaches zero degrees, U6B will
output a HIGH pulse. The HIGH pulse is applied to: 1) transistor Q2, 2) transistor Q7 of
the soft-start circuit, and 3) ac line detector U5A/U5B. The pulse biases transistor Q2
and optical coupler U2 on. Q2 and U2 will output a pulse each time the ac line phase is
zero. As a result, U2 will output a 120 Hz signal to the controller circuit board.
1-13.
U5A and U5B function as an ac line voltage detector. When ac line voltage is present,
U5A will output a LOW. The LOW allows transistor Q3 to be biased on. With Q3 on, a
+12 volt dc signal is applied to optical coupler U1. When a power supply enable and a
PWM OK signal is applied to U1, U1 will output a reference voltage to a soft-start control
circuit for power supply operation. When ac line voltage is not present, U5A will output a
HIGH, the HIGH biases transistor Q3 off to terminate power supply operation. When ac
power is re-applied, U5B will maintain a HIGH for 100 milliseconds to allow the circuit to
stabilize during turn-on operations.
1-14.
In addition to the ac line voltage detection circuit, integrated circuit U6A functions as a
low line voltage detector. When the dc supply is above the threshold at U6A, U6A will
output a LOW to bias transistor Q1 off. As a result, a HIGH ac OK signal indicating ac
ceptable ac line voltage is applied to optical coupler U9. When the dc supply is below 185
volts, U6A will output a HIGH to bias transistor Q1 on. As a result, a LOW ac OK signal
indicating low ac line voltage is applied to optical coupler U9. When the voltage increases
to approximately 190 volts, the output of U6A will go LOW to enable the power supply.
1-15.
This circuit is also used to detect high ac line voltage potentials. If the ac line voltage is
above approximately 270 volts, transistor Q28 will be biased on. With Q28 on, the input
to U6A will be muted. When the input is muted: 1) the transmitter output power will be
muted and 2) no transmitter fault or emergency condition will be generated.
1-16.
SOFT-START CONTROL CIRCUIT. The soft-start control circuit consists of: 1) transistors
1-17.
The circuit generates the soft-start pulses from two signals: 1) a ramp signal and 2) a
triangle signal. The ramp signal is generated by transistors Q4 and Q5. When ac line
voltage is detected, a +12 volt signal from U1 is applied to transistor Q4. Q4 operates in
association with capacitor C16 and transistor Q5 to generate a ramp voltage. The
triangle signal is generated by transistors Q6 and Q7. Pulses from U6B are applied to
transistor Q7. Q7 operates in association with capacitor C17 and transistor Q6 to generate a triangle signal. The triangle signal and the ramp signal are applied to comparator
U7. U7 responds by generating a square-wave signal with a short duty cycle when the ac
line phase is zero. The square-wave signal from U7 is applied to soft-start driver transis
tors Q8 and Q9. Q8 and Q9 will slowly bias the rectifier circuit on to limit the current
in-rush.
1-18.
POWER FACTOR CORRECTOR CIRCUIT BOARD CONTROL CIRCUIT.
1-19.
Transistors Q26 and Q27 control a power factor corrector circuit board. During soft-start
operation, ramp voltage will drop below approximately 3V. When this occurs, the output
of transistor Q26 will go LOW. This LOW biases transistor Q27 on. With Q27 on, a LOW
energizes two relays on the power factor corrector circuit board. With the relays energized, a capacitor is inserted into the circuit to enable power factor correction.
Q4 through Q9 and 2) integrated circuit U7. The circuit is designed to generate short
duration pulses in each time the ac line waveform crosses the 0 volt axis. The pulses are
applied to an SCR controlled rectifier to slowly bias the components on during initial start
operations. This operation eliminates the component stress at power-on by limiting the
supply in-rush current.
1-2
COPYRIGHT
1999 BROADCAST ELECTRONICS, INC
597-1112-28A
FIGURE 1-1. POWER SUPPLY CIRCUIT BOARD
SIMPLIFIED SCHEMATIC
(1-3/1-4)
1-20.
SCR CONTROLLED RECTIFIER CIRCUIT.
1-21.
The ac line voltage is rectified into a main dc supply for the modulator and amplifier cir
cuitry by an SCR controlled bridge rectifier circuit. Primary ac power for the main dc
supply is applied to fuses F1 and F2. The fuses protect the power supply circuitry from
over-current conditions. Metal-Oxide-Varistor MOV1 prevents damage to the rectifier
circuitry from ac line voltage surge potentials.
1-22.
The SCR controlled rectifier circuit consists of diodes D15 through D17 and SCRs D13
and D14. The rectifier circuit is controlled by the soft-start control circuit. When power
is required from the circuit, the soft-start circuit will output synchronized ac line pulses
to SCRs D13 and D14. The SCRs will respond by slowly biasing the rectifier circuit on.
The rectifier will output an unregulated and unfiltered dc supply at a maximum of 300V
to an inductor and capacitor filter network located on the power supply panel.
1-23.
FILTER CIRCUIT.
1-24.
The output of the rectifier circuit is applied to a filter network consisting of capacitors C24
through C27. The filter is designed to remove the ripple in the supply. The output of the
capacitor network generates the positive leg of the B supply. The B supply is the main
operating supply for the RF power modules. The negative leg of the B supply is generated
by a switching regulator circuit (refer to the following text).
1-25.
POWER SUPPLY ENABLE CIRCUIT.
1-26.
The power supply is controlled by a: 1) power supply enable signal from the controller
and 2) power supply mute signal from the modulator circuit boards. When power supply
operation is required, the controller will output a LOW power supply enable signal to opti
cal coupler U8. With no mute signals present, U8 will output a HIGH to AND gate U12A.
With a HIGH ac OK signal from U9 indicating the presence of ac power and no power
supply faults, U12A will output a HIGH to U12B. With a HIGH from U21A/U21B, U12B
will output a HIGH to U12C and to Q12. With a HIGH from U14 indicating the crowbar
circuit is off, U12C will output a HIGH after a one second delay to: 1) transistor Q10,
2) AND gate U12D, and 3) NAND gate U21C. The HIGH biases Q12 and U15 on to disable the crowbar circuit. Q10 will respond by routing a HIGH power supply enable signal
to optical coupler U1. U1 will output a dc voltage to enable the power supply soft-start
circuit. AND gate U12D will output a HIGH to transistor Q11. The HIGH biases Q11 on
to enable regulator controller U13 and bias Q13 off.
1-27.
When a power supply mute operation is required, an RF power module modulator circuit
board will output a mute signal to optical coupler U8. U8 will output a LOW to AND gate
U12A. With a HIGH ac OK signal from U9, U12A will output a LOW to U12B. U12B will
output a LOW to U12C and to Q12. The LOW biases Q12 and U15 off to enable the crow
bar circuit. U12C will output a LOW to: 1) transistor Q10, 2) AND gate U12D. Q10 will
be biased off to terminate power supply operation by disabling the drive to the SCR rectifier circuit. U12D will disable Q11 which allows a HIGH to disable regulator controller
U13 and bias Q13 on. Q13 will output a LOW to disable the fault detection circuit to pre
vent erroneous fault indications during mute conditions.
1-28.
SWITCHING REGULATOR CIRCUIT.
1-29.
The B supply is regulated and controlled by a switching regulator circuit. The switching
regulator circuit generates the - leg of the B supply and consists of: 1) a low voltage power supply circuit, 2) a power control network, 3) optical coupler U17, 4) inverting buffer
U19, and 5) switching regulator transistors Q21 and Q22.
1-5
1-30.
LOW VOLTAGE POWER SUPPLY. A dc operating supply for the optical couplers and the
1-31.
SWITCHING REGULATOR CONTROL CIRCUIT. The switching regulator circuit is con
1-32.
Integrated circuit U13 functions as the switching regulator controller. U13 is a PWM out
put device designed to produce two out-of-phase square wave signals with varying duty
cycles. The duty cycle is varied in response to the signal from the voltage correction cir
cuit. With a correction voltage present at U13, U13 will output a PWM square wave signal to optical coupler U17. U17 provides isolation for the transition of the signal from two
different circuit ground potentials. The output of coupler U17 is inverted by inverting
buffer U19.
1-33.
SWITCHING REGULATOR CIRCUIT OPERATION. The PWM output of U19 is applied to
1-34.
POWER CONTROL/CORRECTION CIRCUIT.
1-35.
The switching regulator output voltage is controlled by a PWM (pulse-width-modulated)
signal from the controller. The PWM signal is a 1 kHz square-wave signal with a duty
cycle which varies in response to different power levels. The PWM signal from the controller is applied to optical coupler U22. With a +5 volt signal from the motherboard, U22
will output the PWM signal to transistors Q17 and Q18. Q17 will discharge capacitor C63
when a 1 kHz control signal is present. C63 will output a LOW PWM OK signal to optical
coupler U1. Q18 inverts the power control PWM signal. The output of Q18 is applied
through buffer U24C to a low-pass filter consisting of: 1) resistors R115, R116, and R117
and 2) capacitors C75, C76, and C77. The filter converts the power control PWM squarewave signal into a dc control voltage. The voltage is routed through buffer U24A to U24B.
1-36.
U24B functions as a current feedback loop filter. U24B differentially amplifies the dc con
trol voltage and a current sample from the switching regulator output filter capacitor. As
a result, U24B produces a dc control voltage for application to U24D.
1-37.
U24D functions as a voltage feedback loop filter. U24D differentially amplifies the control
voltage from U24B and a voltage sample from the B+ leg of the supply. As a result,
U24D produces a dc control voltage for application to: 1) switching regulator controller
U13 and 2) a fault detection circuit. U13 will respond to the correction voltage by changing the duty cycle of the PWM drive signal to optical coupler U17. The switching regulator circuit will respond by changing the output voltage to a level required by the power
control PWM signal.
inverting buffers is generated by bridge rectifier D25. D25 full-wave rectifies an ac potential from ac transformer T1 into an unregulated +20V supply. The supply is applied to
+18V regulator U16. The output of U16 is further regulated to a 5V operating potential
by a resistive divider and a zener diode. The 5V supply is applied to optical coupler U17
and buffer U19.
trolled by: 1) regulator controller U13 and 2) a power control/correction circuit. The cir
cuits function in a closed-loop to control the operation of the switching regulator. As a
result, the regulator outputs a precision dc operating voltage at the appropriate level for
application to the RF power modules.
the gates of IGBT (insulated-gate-bipolar-transistor) switching regulator transistors Q21
and Q22. The transistors function to regulate the negative leg of the B supply. The output of the transistor switching regulator circuit is applied to filter inductor L2. Protection
of the transistors from switching transients during turn on/off operation is provided by
clamp diode D32. Capacitor C55 provides filtering for the negative leg of the B supply.
The output of the regulator circuit (B- leg) is applied to circuitry on the modulator circuit
board.
1-6
1-38.
FAULT DETECTION.
1-39.
A fault detection circuit monitors the regulator for four conditions: 1) over-voltage,
2) open-loop, 3) over-current, and 4) over temperature. Over-voltage conditions are
monitored by U23A. U23A compares a sample of the B+ leg to a reference voltage. When
the B+ sample exceeds the reference voltage, the output of U23A will go LOW. The LOW
is routed to fault detector latch U21A/U21B. Open-loop conditions are monitored by
U23B. U23B compares a correction voltage sample to a reference voltage. When the
correction voltage sample exceeds the reference, the output of U23B will go LOW. The
LOW is inverted at U21D and applied to NAND gate U21C. With a HIGH power supply
enable signal from U12C, U21C will output a LOW to fault detector latch U21A/U21B.
1-40.
Over-current conditions are monitored by transistors Q19 and Q20. When an over-cur
rent condition occurs, Q19 and Q20 will output a LOW. The LOW is routed to fault detec
tor latch U21A/U21B. Over-temperature conditions are monitored by temperature sensor
U25. When the power supply temperature exceeds 72 degrees C, U25 will output a LOW
through transistor Q25 to U21D. The LOW is inverted at U21D and applied to NAND
gate U21C.
1-41.
With a LOW from U21C or U23A, latch U21A/U21B will: 1) output a HIGH to transistor
Q16 and 2) output a LOW to transistor Q15 and to U12B. Transistor Q16 will be biased
on and will output a LOW to enable optical coupler U11. U11 will respond by generating
a power supply fault signal. AND gate U12B will output a LOW to: 1) disable regulator
controller U13, 2) disable the SCR controlled rectifier circuit, and 3) initiate a logic se
quence to enable the crowbar circuit (refer to the following text). Transistor Q15 will be
biased off and will disable optical coupler U10. The output of U10 will open.
1-42.
The output of U10 is connected in parallel with U10 on each power supply circuit board.
When the output of U10 on each power supply circuit board is open, a HIGH power supply emergency signal to be applied to the controller. The power supply emergency signal
indicates all power supply modules contain fault conditions.
1-43.
CROWBAR CIRCUIT.
1-44.
The power supply circuit board is equipped with a crowbar circuit to discharge the B sup
ply during power supply off, ac off, and power supply mute conditions. The crowbar circuit consists of: 1) crowbar MOSFET Q23 and 2) resistor R72. Control of the circuit is
provided by logic gates which monitor power supply off, ac off, and power supply mute
conditions.
1-45.
During a power supply off, ac off, or power supply mute condition, AND gate U12A will
output a LOW to U12B. With a HIGH from U21A/U21B, U12B will output a LOW to
transistor Q12. The LOW biases Q12 and optical coupler U15 off. As a result, a HIGH is
applied to the gate of crowbar MOSFET Q23. The HIGH biases Q23 on to short the B
supply and discharge capacitors C24, C25, C26, C27 and C55. Resistor R72 limits the cur
rent during shorting operations.
1-46.
When U15 is biased off, optical coupler U14 will also be disabled. With U14 disabled, a
LOW is applied to U12C. U12C will output a LOW to disable the PWM drive to the
switching regulator circuit.
1-7
1-47.
POWER SUPPLY CIRCUIT GROUNDS.
1-48.
The power supply circuit board is equipped with three isolated circuit grounds: 1) 0VS,
2) 0VP, and 3) 0VI. The circuit grounds are at different potentials and are not referenced
to earth ground. The 0VS ground is the circuit ground for the: 1) SCR controlled bridge
rectifier circuit, 2) soft-start control circuit, 3) ac line voltage detector circuit, and 4) lowvoltage detection circuit. The 0VP circuit ground is used to create the negative leg of the
B supply. The 0VI ground is the circuit ground for the: 1) crowbar circuit, 2) switching
regulator circuit, 3) inverting drive buffers, and 4) switching regulator transistors. The
circuit grounds are used in association with the circuitry to generate the operating voltages for the RF power modules.
1-8
SECTION II
POWER SUPPLY CIRCUIT BOARD MAINTENANCE
2-1.
INTRODUCTION.
2-2.
This section provides maintenance information for the AM-2.5E/AM-5E transmitter
power supply circuit board assembly.
2-3.
SAFETY CONSIDERATIONS.
WARNING
WARNING
WARNING
WARNING
THE TRANSMITTER CONTAINS MULTIPLE CIRCUIT
GROUNDS WITH HIGH AC AND DC POTENTIALS
WITH RESPECT TO THE CABINET WHICH IS AT
EARTH POTENTIAL. DO NOT ENERGIZE THE
TRANSMITTER WITH TEST EQUIPMENT CON
NECTED TO THE TRANSMITTER OUTPUT
NETWORK, RF POWER MODULE, RF COMBINER, OR
POWER SUPPLY COMPONENTS.
2-4.
The AM-2.5E/AM-5E 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 transmitter is equipped with many built-in safety features,
however good judgement, care, and common sense must be practiced to prevent accidents.
2-5.
In addition to high voltages and currents, the 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 transmitter 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. The
maintenance procedures presented in this section should be performed only by trained
and experienced maintenance personnel.
2-6.
FIRST LEVEL MAINTENANCE.
2-7.
First level maintenance consists of precautionary procedures applied to the equipment to
prevent future failures. The procedures are performed on a regular basis and the results
recorded in a performance log.
2-8.
CLEANING AND INSPECTION.
2-1
WARNING: DISCONNECT POWER PRIOR TO SERVICING
WARNING
WARNING
DISCONNECT ALL TRANSMITTER PRIMARY POWER
BEFORE PROCEEDING.
2-9.
Ensure all transmitter primary power is disconnected and clean a circuit board of
accumulated dust as required using a nylon bristle brush and vacuum cleaner. Inspect
the circuit board for improperly seated semiconductors and components damage by
overheating. In addition, inspect the circuit board for loose hardware. Repeat the
procedure for each power supply circuit board in the transmitter.
2-10.
SECOND LEVEL MAINTENANCE.
2-11.
Second level maintenance is the performance of procedures required to restore a power
supply circuit board to operation after a fault has occurred. The power supply circuit
board contains no adjustments. Therefore, the following text presents only
troubleshooting procedures.
2-12.
TROUBLESHOOTING.
WARNING
WARNING
WARNING
WARNING
THE TRANSMITTER CONTAINS MULTIPLE CIRCUIT
GROUNDS WITH HIGH AC AND DC POTENTIALS
WITH RESPECT TO THE CABINET WHICH IS AT
EARTH POTENTIAL. DO NOT ENERGIZE THE
TRANSMITTER WITH TEST EQUIPMENT CON
NECTED TO THE TRANSMITTER OUTPUT
NETWORK, RF POWER MODULE, RF COMBINER, OR
POWER SUPPLY COMPONENTS.
2-13.
SAFETY CONSIDERATIONS. The AM-2.5E/AM-5E transmitters are equipped with
2-14.
REMOVING/INSTALLING A POWER SUPPLY CIRCUIT BOARD. A power supply circuit
extensive indicator and meter circuitry to allow the operator to isolate problems to a
specific area within the transmitter. Due to the hazardous voltages and currents
contained in the equipment, 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. 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. The maintenance procedures presented in
this section should be performed only by trained and experienced maintenance personnel.
board is removed by disconnecting three connectors, loosening the mounting hardware,
and sliding the circuit board from the mounting pins. To remove or install a power supply
circuit board, proceed as follows:
WARNING
WARNING
DISCONNECT ALL TRANSMITTER PRIMARY POWER
BEFORE PROCEEDING.
2-15.
Disconnect all transmitter primary power.
2-16.
To remove a power supply circuit board, proceed as follows:
1. Refer to Figure 5-2/5-3 in SECTION V, MAINTENANCE and locate the desired
power supply circuit board to be removed.
2-2
WARNING: DISCONNECT POWER PRIOR TO SERVICING
2. Disconnect connectors P1, P2, and P3 on the circuit board assembly.
3. Loosen the power supply circuit board mounting hardware.
4. Lift the circuit board from the mounting pins and remove the circuit board from
the cabinet.
2-17.
TROUBLESHOOTING PROCEDURES. The power supply module troubleshooting
procedures are presented in Table 2-1. During the execution of the troubleshooting
information, perform all the procedures for a symptom. The symptom may contain
multiple component failures. Once the trouble is isolated, refer to the circuit board
theory of operation and schematic diagrams to assist in problem resolution.
TABLE 2-1. POWER SUPPLY MODULE TROUBLESHOOTING
(Sheet 1 of 2)
SYMPTOM
1. RED POWER SUPPLY
INDICATION
CIRCUITRY TO CHECK
1. Check for an over-temperature condition by
inspecting the fans and filter.
2.. Check transistors Q21 and Q22 as follows:
A. Using a digital voltmeter, operate the voltmeter
to diode check. On Q21, place the negative lead on
the drain (center pin) and the positive lead on the
source.
1. If the voltmeter indicates a non-shorted
condition, check transistor Q23.
2. If the voltmeter indicates a shorted condition,
proceed as follows:
a. On Q21, place the negative lead on the drain
(center pin) and the positive lead on the gate
and record the voltmeter indication.
b. On Q22, place the negative lead on the drain
and the positive lead on the gate and
record the voltmeter indication.
c. The transistor with the lowest voltage is
defective.
2. Place the negative lead on the drain of Q21
and the positive lead on the source and
determine if a short circuit condition is
present.
3. If a short circuit condition is present,
defective Q21.
B. Repeat the procedure for transistor Q22.
3. Check transistor Q23 as follows:
A. Using a digital voltmeter, operate the
voltmeter to diode check and troubleshoot
transistor Q23 as follows:
1. Place the negative lead on the drain
and the positive lead on the gate and
determine if a short circuit condition is
present.
2-3
WARNING: DISCONNECT POWER PRIOR TO SERVICING
TABLE 2-1. POWER SUPPLY MODULE TROUBLESHOOTING
(Sheet 2 of 2)
SYMPTOM
CIRCUITRY TO CHECK
RED POWER SUPPLY
INDICATION (CONT'D)
2. Place the negative lead on the drain
and the positive lead on the source and
determine if a short circuit condition is
present.
3. If a short circuit condition is present,
defective Q23.
3. Visually inspect crowbar resistor R72.
4. Check SCRs D13/D14 and diodes D15, D16, and D17
for a short circuit condition.
5. Replace all blown fuses on the circuit board.
NO 120 Hz SIGNAL OUTPUT
1. Check for a 120 Hz square-wave pulse at the
source of transistor Q55 on the controller circuit
board.
A. If a 120 Hz signal is present, defective Q55 on
the controller circuit board.
B. If a 120 Hz signal is not present, defective U3
on the power supply circuit board.
2. Re-install the power supply circuit board and
operate the transmitter. If the circuit board
remains defective, contact the Broadcast
Electronics Customer Service Department.
MOD PWR INDICATORS
EXTINGUISHED ON A
POWER BLOCK
1. Check U7, U9A, U9B, U9C, U9D, Q9 and Q21.
2-18.
COMPONENT REPLACEMENT PROCEDURE. Component replacement procedures for
the power supply circuit board are presented in PART I SECTION V. Refer to
COMPONENT REPLACEMENT in SECTION V as required for the replacement
procedures.
2-4
WARNING: DISCONNECT POWER PRIOR TO SERVICING
SECTION III
POWER SUPPLY CIRCUIT BOARD
PARTS LIST
3-1.
INTRODUCTION.
3-2.
This section provides descriptions and part numbers of electrical components, assemblies,
and selected mechanical parts required for maintenance of the power supply circuit board.
Each table entry in this section is indexed by reference designators appearing on the applicable schematic.
TABLE 3-1. REPLACEABLE PARTS LIST INDEX
TABLE
3-2
3-3
3-4
3-5
3-6
DESCRIPTION
Power Supply Panel Assembly
Power Supply Circuit Board Assembly
Power Supply Bulk Capacitor Circuit Board Assembly
Power Supply Capacitor Circuit Board Assembly
Power Supply Panel Harness
3-1
PART NO.
957-0315-100
917-0315-001
917-0315-002
917-0315-004
947-0208
PAGE
3-2
3-2
3-9
3-9
3-9
TABLE 3-2. POWER SUPPLY PANEL ASSEMBLY - 957-0315-100
REF. DES.
L2
T1
----------------------------
DESCRIPTION
Choke, 1.04 mH, AM Transmitter
Transformer, AM Transmitter Power Supply
Pin Connector
Pins, Connector
Connector Housing, 2-Pin, Male
Plug, Connector Housing, 12-Pin
Power Supply Circuit Board Assembly
Power Supply Bulk Capacitor Circuit Board Assembly
Power Supply Capacitor Circuit Board Assembly
Power Supply Harness Assembly
Blank, Power Supply AC Input Circuit Board
PART NO.
370-2364
376-0047
417-0036
417-0053
418-0702
418-1271
917-0315-001
917-0315-002
917-0315-004
947-0208
517-0315-006
QTY.
10
TABLE 3-3. POWER SUPPLY CIRCUIT BOARD ASSEMBLY - 917-0315-001
(Sheet 1 of 8)
REF. DES.
C1
C2
C3
C4
C5, C6
C7, C8
C9
C10
C11
C12
C13, C14
C15
C16
C17
C18, C19
C20
C21
C22
C23
C29
C30, C31
C32
C33
C34
C35
C36
C37
DESCRIPTION
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Monolythic Ceramic, 0.01 uF ±5%, 100V
Capacitor, Ceramic, 0.001 uF ±10%, 200V
Capacitor, Electrolytic, 2200 uF, 35V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Monolythic Ceramic, 0.1 uF, ±10%, 50V
Capacitor, Electrolytic, 10 uF, 50V
Capacitor, Monolythic Ceramic, 0.01 uF ±5%, 100V
Capacitor, Ceramic, 0.001 uF ±10%, 200V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Electrolytic, 10 uF, 50V
Capacitor, Electrolytic, 470 uF, 50V
Capacitor, Electrolytic, 100 uF, 35V
Capacitor, Monolythic Ceramic, .47 uF ±10%, 50V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Electrolytic, 2200 uF, 35V
Capacitor, Electrolytic, 27000 uF ±20%, 50V
Capacitor, Polyester, .15 uF ±10%, 600WV dc
Capacitor, Polypropylene Film, .47 uF ±10%, 600V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Ceramic, 0.001 uF ±10%, 200V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Electrolytic, 10 uF, 50V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Monolythic Ceramic, .47 uF ±10%, 50V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Monolythic Ceramic, .0027 uF ±5%, 100V
3-2
PART NO.
003-1066
003-1013
030-1033
014-2293
003-1066
003-1066
023-1076
003-1013
030-1033
003-1066
023-1076
024-4783
023-1084
003-4743
003-1066
014-2293
020-2795-500
030-1523
033-4763
003-1066
030-1033
003-1066
023-1076
003-1066
003-4743
003-1066
003-2723
QTY.
TABLE 3-3. POWER SUPPLY CIRCUIT BOARD ASSEMBLY - 917-0315-001
(Sheet 2 of 8)
REF. DES.
DESCRIPTION
PART NO.
QTY.
C38
C39
C40
C41
C42
C43
C44
C45
C46
C47
C49
C50
C52
C56, C57
C58
C59, C60
C61
C62
C63
C64
C65, C66
C67
C68
C69
C70
C71
C72
C73
C74
C75 thru C77
C78
C79
C80
C81
C82
C83
C84
C85
Capacitor, Silvered Mica, 100 pF ±5%, 500V
Capacitor, Electrolytic, 10 uF, 50V
Capacitor, Silvered Mica, 100 pF ±5%, 500V
Capacitor, Monolythic Ceramic, .47 uF ±10%, 50V
Capacitor, Monolythic Ceramic, 0.01 uF ±5%, 100V
Capacitor, Electrolytic, 10 uF, 50V
Capacitor, Electrolytic, 100 uF, 35V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Electrolytic, 10 uF, 50V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Electrolytic, 10 uF, 50V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Polyester, 2.2 uF, 400V
Capacitor, Ceramic, 0.001 uF ±10%, 200V
Capacitor, Monolythic Ceramic, 0.1 uF, ±10%, 50V
Capacitor, Monolythic Ceramic, 0.01 uF ±5%, 100V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Electrolytic, 10 uF, 35V
Capacitor, Electrolytic, 10 uF, 50V
Capacitor, Monolythic Ceramic, 0.01 uF ±5%, 100V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Monolythic Ceramic, .47 uF ±10%, 50V
Capacitor, Silvered Mica, 100 pF ±5%, 500V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Ceramic, 0.001 uF ±10%, 200V
Capacitor, Silvered Mica, 100 pF ±5%, 500V
Capacitor, Monolythic Ceramic, 0.0047 uF ±5%, 100V
Capacitor, Monolythic Ceramic, 0.01 uF ±5%, 100V
Capacitor, Monolythic Ceramic, .47 uF ±10%, 50V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Monolythic Ceramic, .47 uF ±10%, 50V
Capacitor, Electrolytic, 10 uF, 50V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Electrolytic, 100 uF, 35V
Capacitor, Monolythic Ceramic, .47 uF ±10% 50V
Capacitor, Ceramic, 0.001 uF ±10%, 200V
Capacitor, Electrolytic, 10 uF, 50V
040-1022
023-1076
040-1022
003-4743
003-1013
023-1076
023-1084
003-1066
023-1076
003-1066
023-1076
003-1066
030-2256
030-1033
003-1066
003-1013
003-1066
023-1075
023-1076
003-1013
003-1066
003-1066
003-4743
040-1022
003-1066
030-1033
040-1022
003-4723
003-1013
003-4743
003-1066
003-4743
023-1076
003-1066
023-1084
003-4743
030-1033
023-1076
C86
C91 thru C94
C95
C96
C98
C99
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Electrolytic, 10 uF, 50V
Capacitor, Monolythic Ceramic, 0.0047 uF ±5%, 100V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Electrolytic, 10 uF, 50V
003-1066
003-1066
023-1076
003-4723
003-1066
023-1076
3-3
TABLE 3-3. POWER SUPPLY CIRCUIT BOARD ASSEMBLY - 917-0315-001
(Sheet 3 of 8)
REF. DES.
DESCRIPTION
D1
Diode, HP5082-2800, High Voltage, Schottky Barrier Type,
70V, 15 mA
D2, D3
Diode, 1N4148, Silicon, 75V @ 0.3 Amperes
D4
Diode, HP5082-2800, High Voltage, Schottky Barrier Type,
70V, 15 mA
D5 ,D6
Diode, Zener, 1N4733A, 5.1V ±5%, 1W
D7, D8
Diode, 1N4005, Silicon, 600V @ 1 Ampere
D9
Bridge Rectifier, NAE 3060A, 1 Ampere, 200V
D10
Bridge Rectifier, MDA970A3, 4 Amperes, 50-200V
D11
Bridge Rectifier, MDA970A3, 4 Amperes, 50-200V
D12
Bridge Rectifier, NAE 3060A, 1 Ampere, 200V
D13, D14
Silicon Controlled Rectifiers, 2N6508, 25 Amperes, 600V
D15
Rectifier, MR2406, 24 Amperes, 600V
D16
Power Rectifier, Switchmode, MUR4100E, 4 Amperes, 1000V
D17
Rectifier, MR2406, 24 Amperes, 600V
D18
Diode, Zener, 1N4733A, 5.1V ±5%, 1W
D19
Diode, 1N4005, Silicon, 600V @ 1 Ampere
D21, D22
Diode, 1N4148, Silicon, 75V @ 0.3 Amperes
D23
Diode, 1N4005, Silicon, 600V @ 1 Ampere
D24
Diode, 1N4148, Silicon, 75V @ 0.3 Amperes
D25
Bridge Rectifier, NAE 3060A, 1 Ampere, 200V
D26
Diode, Zener, 1N4733A, 5.1V ±5%, 1W
D27
Diode, Zener, 1N4746, 18V ±10%, 1W
D28
Diode, 1N4005, Silicon, 600V @ 1 Ampere
D29
Diode, 1N4148, Silicon, 75V @ 0.3 Amperes
D30, D31
Diode, 1N4005, Silicon, 600V @ 1 Ampere
D32
Rectifier, Fast Recovery, FEN30JP, 30 Amperes, 600V
D34
Power Rectifier, Switchmode, MUR4100E, 4 Amperes, 1000V
D37
Diode, 1N4148, Silicon, 75V @ 0.3 Amperes
D39
Diode, 1N4148, Silicon, 75V @ 0.3 Amperes
D40
Diode, 1N4005, Silicon, 600V @ 1 Ampere
D41, D42
Diode, 1N4148, Silicon, 75V @ 0.3 Amperes
D43, D44
Diode, 1N4005, Silicon, 600V @ 1 Ampere
D45
Diode, 1N4148, Silicon, 75V @ 0.3 Amperes
F1, F2
Fuse, 30 Amperes, 125V, 1/4x1-1/4, Lead Type
J1
Connector, Male, Printed Circuit Board Mount, PLB16M3N0A1
J2
Receptacle, 12-Pin
J3
Connector, AMP 6405051-1, MR Printed Circuit Board, Male
24-Pin
J4
Receptacle, Male, 8-Pin In-Line, Right Angle
J5 thru J7
Connector, Header, 2-Pin
J9, J10
Receptacle, Male, 2-Pin In-line
MOV1
Varistor, V320LA40B
MOV2
Varistor, V320LA20AGE
P4 thru P7, P9 Jumper, Programmable, 2-Pin
3-4
PART NO.
QTY.
201-2800
203-4148
201-2800
200-4733
203-4005
239-0001
239-0003
239-0003
239-0001
237-6508
230-0015
230-0017
230-0015
200-4733
203-4005
203-4148
203-4005
203-4148
239-0001
200-4733
200-4746
203-4005
203-4148
203-4005
230-0013
230-0017
203-4148
203-4148
203-4005
203-4148
203-4005
203-4148
334-0030-001
417-0376
417-1276
417-2401
417-0080-001
417-4004
417-4004
140-0039
140-0038
340-0004
TABLE 3-3. POWER SUPPLY CIRCUIT BOARD ASSEMBLY - 917-0315-001
(Sheet 4 of 8)
REF. DES.
Q1
Q2
Q3, Q4
Q5
Q6
Q7
Q8, Q9
Q10 thru
Q13
Q14
Q15 thru
Q18
Q19, Q20
Q21, Q22
Q23
Q24
Q25
Q26, Q27
Q28
R1
R2
R3, R4
R5
R6
R7
R8
R9
R10 thru
R12
R13
R14
R15
R16
R17
R18
R19
R20
R22, R23
R24
R25
R26
R27
R28
R29, R30
R31
DESCRIPTION
PART NO.
QTY.
Transistor, 2N3904, NPN, Silicon, TO-92 Case
Transistor, 2N27000, FET, N-Channel, TO-92 Case
Transistor, 2N3906, PNP, Silicon, TO-92 Case
Transistor, 2N3904, NPN, Silicon, TO-92 Case
Transistor, 2N3906, PNP, Silicon, TO-92 Case
Transistor, 2N27000, FET, N-Channel, TO-92 Case
Transistor, 2N2222A, TO-18 Case
Transistor, 2N7000, FET, N-Channel, TO-92 Case
211-3904
210-7000
210-3906
211-3904
210-3906
210-7000
210-2222
210-7000
Transistor, 2N7000, FET, N-Channel, TO-92 Case
Transistor, 2N7000, FET, N-Channel, TO-92 Case
210-7000
210-7000
Transistor, 2N3904, NPN, Silicon, TO-92 Case
Transistor, Insulated Gate Bipolar, IRGPC50U, TO-247 Case
RF FET APT6018, 600V
Transistor, 2N27000, FET, N-Channel, TO-92 Case
Field Effect Transistor, J3100, RF, N-Channel, TO-92 Case
Transistor, 2N27000, FET, N-Channel, TO-92 Case
Transistor, 2N3904, NPN, Silicon, TO-92 Case
Resistor, 1.33 k Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 150 k Ohm ±1%, 1/4W
Resistor, 21 k Ohm ±1%, 1/4W
Resistor, 6.34 k Ohm ±1%, 1/4W
Resistor, 499 k Ohm ±1%, 1/4W
Resistor, 2.21 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
211-3904
210-4060
210-6018
210-7000
212-0310
210-7000
211-3904
103-1331
103-1062
100-1051
103-1561
103-2105
103-6344
103-4996
103-2241
100-1051
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 20.0 k Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 3.3 Meg Ohm ±5%, 1/4W
Resistor, 100 Ohm ±1%, 1/4W
Resistor, 1.10 k Ohm ±1%, 1/4W
Resistor, 51.1 Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 5.11 k Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 1.33 k Ohm ±1%, 1/4W
Resistor, 3.32 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
100-1041
103-2051
103-1062
100-1051
103-1062
100-1051
100-3373
100-1031
103-1104
103-5112
100-1051
103-5141
100-1041
103-1331
103-3324
100-1051
3-5
TABLE 3-3. POWER SUPPLY CIRCUIT BOARD ASSEMBLY - 917-0315-001
(Sheet 5 of 8)
REF. DES.
R32
R33
R34
R35
R36
R37, R38
R39, R40
R41, R42
R43
R44
R45
R46
R47
R48, R49
R52
R53
R54
R55
R56
R57
R58
R59
R60, R61
R62
R63
R64
R65
R66
R67, R68
R69
R70
R71
R72
R73
R74
R75
R76
R77 thru R79
R80
R81
R82, R83
R84
R85
R86
R87
DESCRIPTION
Resistor, 51.1 Ohm ±1%, 1/4W
Resistor, 665 Ohm ±1%, 1/4W
Resistor, 499 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 82 Ohm ±5%, 2W
Resistor, 270 Ohm ±5%, 1/2W
Resistor, 47 Ohm ±5%, 2W
Resistor, 1.33 k Ohm ±1%, 1/4W
Resistor, 2.21 k Ohm ±1%, 1/4W
Resistor, 3.3 Meg Ohm ±5%, 1/4W
Resistor, 100 Ohm ±1%, 1/4W
Resistor, 1.10 k Ohm ±1%, 1/4W
Resistor, 47 Ohm ±5%, 2W
Resistor, 2.21 k Ohm ±1%, 1/4W
Resistor, 3.3 Meg Ohm ±5%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 3.3 Meg Ohm ±5%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 1.33 k Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 1.33 k Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 1.33 k Ohm ±1%, 1/4W
Resistor, 3.3 Meg Ohm ±5%, 1/4W
Resistor, 1.33 k Ohm ±1%, 1/4W
Resistor, 3.3 Meg Ohm ±5%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 100 Ohm ±1%, 1/4W
Resistor, 866 Ohm ±1%, 1/4W
Resistor, 100k Ohm ±5%, 2W
Resistor, 12 Ohm ±20%, 30W
Resistor, 34.8 k Ohm ±1%, 1/4W
Resistor, 39.2 k Ohm ±1%, 1/4W
Resistor, 39.2 k Ohm ±1%, 1/4W
Resistor, 1.10 k Ohm ±1%, 1/4W
Resistor, 1.33 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 393 Ohm ±5%, 1/2W
Resistor, 100 Ohm ±1%, 1/4W
Resistor, 1.33 k Ohm ±1%, 1/4W
Resistor, 3.3 Meg Ohm ±5%, 1/4W
Resistor, 1.33 k Ohm ±1%, 1/4W
Resistor, 3.3 Meg Ohm ±5%, 1/4W
PART NO.
103-5112
103-6653
103-4996
100-1051
100-1051
130-8223
110-2733
130-4723
103-1331
103-2241
100-3373
100-1031
103-1104
130-4723
103-2241
100-3373
100-1051
100-3373
100-1051
103-1331
103-1062
103-1331
103-1062
100-1051
103-1331
100-3373
103-1331
100-3373
100-1041
100-1031
103-8663
130-1062
130-1225
103-3485
100-3951
100-3951
103-1104
103-1331
100-1051
110-3933
100-1031
103-1331
100-3373
103-1331
100-3373
3-6
QTY.
TABLE 3-3. POWER SUPPLY CIRCUIT BOARD ASSEMBLY - 917-0315-001
(Sheet 6 of 8)
REF. DES.
R88
R89
R90
R91
R92
R93, R94
R95
R96
R97
R98
R99
R100, R101
R102, R103
R104
R105 thru
R107
R108
R109
R110
R111 thru
R117
R118
R119
R120, R121
R122
R123
R124
R125
R126
R127
R130
R134, R135
R137, R138
R140
R141
R143
R144
R146
R147
R148
R149, R150
R151
R152
R153
R154
DESCRIPTION
PART NO.
QTY.
Resistor, 1.33 k Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 1.33 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 88.7 Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 13 k Ohm ±1%, 1/4W
Resistor, 3.32 k Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 33.2 k Ohm ±1%, 1/4W
Resistor, 5.11 k Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 3.32 k Ohm ±1%, 1/4W
Resistor, 0.1 Ohm ±1%, 10W, WW
103-1331
103-1062
103-1331
100-1051
103-8872
103-1062
103-1305
103-3324
103-1062
100-1051
103-3325
103-5141
103-1062
103-3324
130-1010
Resistor, 475 Ohm ±1%, 1/4W
Resistor, 162 Ohm ±1%, 1/4W
Resistor, 51.1 Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
103-4753
100-1631
103-5112
100-1051
Resistor, 39.2 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 150 Ohm ±1%, 1/4W
Resistor, 82.5 Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 249 k Ohm ±1%, 1/4W
Resistor, 1 Meg Ohm ±1%, 1/4W
Resistor, 1.33 k Ohm ±1%, 1/4W
Resistor, 6.8 k Ohm ±5%, 1/2W,
Resistor, 0.1 Ohm ±1%, 10W, WW
Resistor, 82 Ohm ±5%, 2W
Resistor, 3.3 Meg Ohm ±5%, 1/4W
Resistor, 48.7 k Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 5.11 k Ohm ±1%, 1/4W
Resistor, 39.2 k Ohm ±1%, 1/4W
Resistor, 150 k Ohm ±1%, 1/4W
Resistor, 1 Meg Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W,
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 249 Ohm ±1%, 1/4W
100-3951
100-1051
100-1041
100-1531
103-8251
100-1051
103-2496
103-1007
103-1331
110-6843
130-1010
130-8223
100-3373
103-4875
103-1062
103-5141
100-3951
100-1531
103-1007
100-1041
100-1051
103-1062
100-1051
103-2493
3-7
TABLE 3-3. POWER SUPPLY CIRCUIT BOARD ASSEMBLY - 917-0315-001
(Sheet 7 of 8)
REF. DES.
RT1
TP1 thru
TP12, TP14
U1, U2
U3, U4
U5
U6
U7
U8 thru U11
U12
U13
U14, U15
U16
U17
U19
U21
U22
U23
U24
U25
XU1, XU2
XU5
XU6, XU7
XU8 thru
XU11
XU12
XU13
XU14, XU15
XU17
XU21
XU22, XU23
XU24
DESCRIPTION
Thermistor, 100 Ohms ±20%
Terminal, Test Point, Oval, Red
PART NO.
140-0030
413-0106
Integrated Circuit, 4N33, Optical Isolator, NPN Photo
229-0033
Transistor/Infared Emitting Diode Type, 1500V Isolation,
Response: 30 kHz Maximum, Current: 50 mA Maximum, 6-Pin DIP
Integrated Circuit, LM317T, Adjustable Positive Voltage
227-0317
Regulator, 1.2V to 37V, 1.5 Ampere, TO-220 Case
Integrated Circuit, MC14538B, Dual Retriggerable, Resettable
228-4538
Monostable Multivibrator, CMOS, 16-Pin DIP
Voltage Comparator, LM393N, 8-Pin DIP
221-0393
Integrated Circuit, TL311P, JFET-Input Differential Comparator,
220-0311
8-Pin DIP
Integrated Circuit, 4N33, Optical Isolator, NPN Photo
229-0033
Transistor/Infared Emitting Diode Type, 1500V Isolation,
Response: 30 kHz Maximum, Current: 50 mA Maximum, 6-Pin DIP
Integrated Circuit, CD4081B, Quad 2-Input AND Gate, CMOS,
225-0008
14-Pin DIP
Integrated Circuit, SG3525AN, PWM Control
228-3525
Integrated Circuit, 4N33, Optical Isolator, NPN Photo
229-0033
Transistor/Infared Emitting Diode Type, 1500V Isolation,
Response: 30 kHz Maximum, Current: 50 mA Maximum, 6-Pin DIP
Integrated Circuit, LM317T, Adjustable Positive Voltage
227-0317
Regulator, 1.2V to 37V, 1.5 Ampere, TO-220 Case
Integrated Circuit, Opto-Isolator, 6N137, 8-Pin DIP
220-6137
Integrated Circuit, Driver, Mosfet, TSC4429CAT, 5-Pin, TO-220
220-4429
Case, Inverting
Integrated Circuit, MC14093B, Quad 2-Input NAND Schmitt Trigger, 220-4093
CMOS, 14-Pin DIP
Integrated Circuit, Opto-Isolator, 6N137, 8-Pin DIP
220-6137
Voltage Comparator, LM393N, 8-Pin DIP
221-0393
Integrated Circuit, TLO74CN, Quad JFET-Input Operational
221-0074
Amplifier, 14-Pin DIP
Temperature Sensor Chip, TMP01FP, 8-Pin DIP
229-1750
Socket, 6-Pin DIP
417-0600
Socket, 16-Pin DIP
417-1604
Socket, 8-Pin DIP
417-0804
Socket, 6-Pin DIP
417-0600
Socket, 14-Pin DIP
Socket, 16-Pin DIP
Socket, 6-Pin DIP
Socket, 8-Pin DIP
Socket, 14-Pin DIP
Socket, 8-Pin DIP
Socket, 14-Pin DIP
417-1404
417-1604
417-0600
417-0804
417-1404
417-0804
417-1404
3-8
QTY.
13
TABLE 3-3. POWER SUPPLY CIRCUIT BOARD ASSEMBLY - 917-0315-001
(Sheet 8 of 8)
REF. DES.
XU25
----
DESCRIPTION
Socket, 8-Pin DIP
Blank, Power Supply Circuit Board
PART NO.
QTY.
417-0804
517-0315-001
TABLE 3-4. POWER SUPPLY BULK CAPACITOR CIRCUIT BOARD ASSEMBLY 917-0315-002
REF. DES.
C24 thru C27
C28
R50
R51
R129
----
DESCRIPTION
Capacitor, Electrolytic, 1500 uF, 450Vdc
Capacitor, Polypropylene Film, .47 uF, 600V
Resistor, 100k Ohm ±5%, 2W
Resistor, 36 Ohm ±5%, 2W
Resistor, 470k Ohm ±5%, 1/2W
Blank, Power Supply Bulk Capacitor Circuit Board
PART NO.
013-1500
033-4763
130-1062
130-3623
110-4763
517-0315-002
QTY.
TABLE 3-5. POWER SUPPLY CAPACITOR CIRCUIT BOARD ASSEMBLY - 917-0315-004
REF. DES.
DESCRIPTION
C87 thru C90 Capacitor, Electrolytic, 7200 uF, 200 WVDC
MOV3
Metal Oxide Varistor, V130LA10A, 130V ac RMS, 10 Joules
---Blank, Power Supply Capacitor Circuit Board
PART NO.
014-7200
140-0006
517-0315-004
QTY.
TABLE 3-6. POWER SUPPLY HARNESS ASSEMBLY - 947-0208
REF. DES.
-------
DESCRIPTION
Connector, FC112N2, Crimp Contact
Connector, Female, PLB16F0000, Positronic
3-9
PART NO.
417-0372
417-0377
QTY.
16
SECTION IV
POWER SUPPLY CIRCUIT BOARD DRAWINGS
4-1.
INTRODUCTION.
4-2.
This section provides assembly drawings, wiring diagrams, and schematic diagrams as
listed below for the Broadcast Electronics AM-2.5E/AM-5E power supply circuit board.
FIGURE
TITLE
NUMBER
4-1
SCHEMATIC DIAGRAM, POWER SUPPLY CIRCUIT BOARD
4-2
ASSEMBLY DIAGRAM, POWER SUPPLY CIRCUIT BOARD
4-3
SCHEMATIC DIAGRAM, OVERALL POWER SUPPLY
4–1
SB917-0315-001/
-002/
-003/
-004/
-005
AC917-0315-001/
-002/
-003/
-004/
-005
SC957-0315-100
TABLE OF CONTENTS
PARAGRAPH
SECTION I
1-1
1-3
1-5
1-6
1-9
1-16
1-18
1-20
1-22
1-23
1-26
1-27
1-29
SECTION II
2-1
2-3
2-6
2-8
2-10
2-12
2-13
2-15
2-16
2-17
2-18
SECTION III
3-1
SECTION IV
4-1
PAGE NO.
RF POWER MODULE THEORY OF OPERATION
Introduction
General Description
Modulator Circuit Board
Modulator Circuit
Fault Detection Circuits
Power Supply
RF Amplifier Circuit Board
Pre-Driver Circuit
Driver Circuit
RF Amplifier Circuit
RF Drive Status Circuit
Fault Detector Circuit
Power Supply Circuit
1-1
1-1
1-1
1-1
1-1
1-2
1-5
1-5
1-5
1-5
1-6
1-6
1-6
RF POWER MODULE MAINTENANCE
Introduction
Safety Considerations
First Level Maintenance
Cleaning and Inspection
Second Level Maintenance
Troubleshooting
Safety Considerations
RF Power Module Assembly Procedure
RF Power Module Exchange Program
Troubleshooting Procedures
Component Replacement Procedure
2-1
2-1
2-1
2-1
2-2
2-2
2-2
2-3
2-3
2-3
2-3
RF POWER MODULE PARTS LIST
Introduction
3-1
RF POWER MODULE DRAWINGS
Introduction
4-1
LIST OF ILLUSTRATIONS
FIGURE
1-1
1-2
TITLE
PAGE NO.
MODULATOR CIRCUIT BOARD
SIMPLIFIED SCHEMATIC
POWER AMPLIFIER CIRCUIT BOARD
SIMPLIFIED SCHEMATIC
1-3
1-7
LIST OF TABLES
TABLE
2-1
3-1
TITLE
RF POWER MODULE TROUBLESHOOTING
REPLACEABLE PARTS LIST INDEX
PAGE NO.
2-4
3-1
SECTION I
RF POWER MODULE THEORY OF OPERATION
1-1.
INTRODUCTION.
1-2.
This section presents a general description of the Broadcast Electronics AM-2.5E/AM-5E
transmitter RF power module.
1-3.
GENERAL DESCRIPTION.
1-4.
An RF power module is a plug-in assembly containing two RF amplifier circuit boards
and a modulator circuit board. Each RF power module is designed to produce 1375 watts
of RF power. The modular design of the RF power assemblies allow the modules to be re
moved from the transmitter for maintenance. The remaining power modules will provide
power to maintain on-air operation. The following text presents a description of the RF
power modules.
1-5.
MODULATOR CIRCUIT BOARD.
1-6.
MODULATOR CIRCUIT. The modulator circuit board is designed to convert the CMOS
1-7.
Integrated circuits U2 and U13 are MOSFET driver stages. The outputs switch to: 1) a
logic 1 at 2 volts and 2) a logic 0 at 0.8 volts. The output of U2 is applied to the gate of
forward converter transistor Q1. The output of U13 is applied to the gate of forward con
verter transistor Q2. Q1 and Q2 are switched on/off by the PWM signal. The transistors
convert the 125 volt B- supply to approximately 50 volts with a nominal PWM duty cycle
of 40%. Catch diodes D2 and D3 clamps inductors L1 and L2 to prevent transistor damage from high switching voltages during transistor turn-off operations. A dc operating
potential for Q1 and Q2 is provided by the B- supply from the power supply circuit board.
Control of the B- leg is provided by relay K1. K1 immediately terminates the power sup
ply during a power supply or modulator failure.
1-8.
The output of transistors Q1 and Q2 are applied to an LC low-pass filter network consist
ing of: 1) inductor L1/L3 and capacitor C13 and 2) inductor L2/L3 and capacitor C14. The
LC networks function with inductor L4 and capacitors C15/C16/C49 as a fifth-order
Bessel low-pass filter designed to remove the 125 kHz frequency from the output signal.
The output from L4/C15/C16/C49 is routed: 1) to a monitor circuit and 2) for application
to the power amplifier circuit boards.
1-9.
FAULT DETECTION CIRCUITS. The modulator circuitry is monitored for proper operation
level PWM signal from the exciter circuit board into a dc voltage which varies at the audio modulation rate (refer to Figure 1-1). The duty cycle of the 122 kHz to 135 kHz PWM
signal is 40% with no audio modulation. The duty cycle varies to allow modulation of the
transmitter from -100% to +150%. The PWM signal from the exciter circuit board is ap
plied to integrated circuit U1. U1 is a high-speed optical coupler designed to provide
isolation for the transition of the signal from the exciter circuit board ground system to
the modulator circuit board ground system. The output of U1 is applied to level converter
U11A. U11A converts the 5 volt signal to a 15 volt peak-to-peak signal. The output of
U11A is applied to two MOSFET driver stages. A 9.7 volt dc bias signal is incorporated
into the PWM signal by resistor R10, and zener diodes D17/D18.
by four fault detection circuits. The fault detection circuits consist of: 1) a PWM drive
detector, 2) a modulator fault detector, 3) a B+ supply fuse fault detector, and 4) a +20 volt
power supply fault detector.
1-1
1-10.
PWM Drive Fault Detector. A sample of the PWM drive signal from integrated circuit U2
is applied to comparator U3A. U3A compares the signal to a reference. When the PWM
drive signal is present, the output of U3A will go HIGH. The HIGH is inverted at U5F.
U5F will output a LOW to illuminate PWM drive indicator DS1. When the PWM drive
signal is not present, the output of U3A will go LOW. The LOW is inverted at U5F. U5F
will output a HIGH to extinguish PWM drive indicator DS1.
1-11.
Modulator Fault Detector. A sample of the modulator circuit output is applied to
comparator U3D. U3D compares the signal to a reference generated by a divider consist
ing of resistors R43 and R44. When the output signal from the modulator circuit is not
present, the output of U3D will go LOW. The LOW is applied to a modulator status circuit (refer to the following text).
1-12.
B+ Supply Fuse Fault Detector. The B+ supply is protected from over-current conditions
on the modulator circuit board by fuse F1. The status of F1 is monitored by a B+ supply
fuse fault detector circuit. The circuit consists of optical couplers U4/U12 and comparator
U3B. When the fuse has blown, the output of couplers U4/U12 will go HIGH. The HIGH
is applied to comparator U3B. U3B compares the signal to a reference. The output of
U3B will go HIGH. The HIGH is inverted at U5C. U5C will output a LOW: 1) to illumi
nate fuse indicator DS2 and 2) to a modulator status circuit.
1-13.
B+ Power Supply Fault Detector. The status of the B+ supply is monitored by a B+ power
supply fault detector circuit. The circuit consists of B+ power supply fault detector
comparator U3C. U3C compares the power supply sample to a reference. When the B+
power supply sample is present, the output of U3C will be HIGH. The HIGH is applied to
inverter U5E and NAND gate U6B of the modulator status circuit. U5E will output a
LOW to enable power supply indicator DS3. When the B+ power supply sample is not
present, the output of U3C will be LOW. The LOW is applied to inverter U5E and NAND
gate U6B of the modulator status circuit. U5E will output a HIGH to disable power supply indicator DS3.
1-14.
Modulator Status Circuit. The modulator status circuit consists of: 1) NAND gates U6A,
U6B, U6C, and U6D, 2) latches U7A, U7B, and U7C, 3) inverters U5B, U5D and U5G,
and 4) optical couplers U8 and U9. When a LOW from the modulator fault detector or the
B+ supply fuse fault detector is applied to NAND gate U6A, U6A will output a HIGH to
U6B. With a HIGH from power supply fault detector U3C, U6B will output a LOW to
latches U7B, U7C, and U7A. Latch U7C will output a HIGH to inverter U5G. U5G will
output a LOW to enable power supply mute optical coupler U9. U9 will output a LOW
power supply mute command to the power supply circuit board. When the supply is
muted, comparator U3C will respond by routing a LOW to U5E. U5E will output a HIGH
to: 1) disable power supply indicator DS3 and 2) NAND gate U6C.
1-15.
Latch U7B will output a HIGH to inverter U5D. U5D will output a LOW to: 1) illuminate modulator fault indicator DS4, 2) enable modulator fault detector optical coupler U8,
and 3) NAND gate U6D. U6D will output a HIGH to latch U7D. Latch U7A will output a
HIGH to NAND gate U6C. With a HIGH from U5E, U6C will output a LOW to latch
U7D. U7D will output a LOW to U5B. U5B will respond by routing a HIGH to bias relay
K1 on. Relay K1 is provided to immediately disconnect the forward converter transistors
from the power supply during a modulator fault or high B+ supply conditions.
1-16.
POWER SUPPLY. A +20 volt operating potential for the modulator circuit board is pro-
1-17.
U10 is a three-terminal adjustable positive regulator containing internal thermal overload protection and short-circuit current limiting features. Further protection for U10 is
provided by diodes D8 and D9. D8 protects the regulator from a short circuit on the regu
lator input. D9 protects the regulator from a reverse polarity potential applied to the out
put. Capacitor C25 provides filtering for the +15 volt supply. A sample of the +15 supply
is regulated into a +5 volt supply by zener diode D1.
vided by the applicable power supply circuit board. The +20 volt supply is applied
through fuse F2 to +15 volt regulator U10. Fuse F2 protects the +20 volt supply from
over-current conditions.
1-2
COPYRIGHT
1999 BROADCAST ELECTRONICS, INC
597-1112-26
FIGURE 1-1. MODULATION CIRCUIT BOARD
SIMPLIFIED SCHEMATIC
(1-3/1-4)
1-18.
RF AMPLIFIER CIRCUIT BOARD.
1-19.
Each RF power module is equipped with two RF amplifier circuit boards: 1) power amplifi
er 1 and 2) power amplifier 2. The circuit boards are designed with Class E power amplifier circuitry. Each circuit board is designed to produce approximately 687.5 watts of
RF power. Figure 1-2 presents the RF amplifier circuit board circuitry. The RF amplifier
circuit boards are identical, therefore only power amplifier 1 will be explained.
1-20.
PRE-DRIVER CIRCUIT. A +15 volt peak-to-peak square-wave signal at the carrier fre
1-21.
The output from U5A is applied through inverters U5B/U5C to high/low side driver U7
and U8. U7/U8 output high and low drive signals to driver circuit transistors Q3/Q5 and
Q4/Q6.
1-22.
DRIVER CIRCUIT. The driver circuit consists of: 1) transistors Q3 and Q5 and 2) Q4 and
1-23.
RF AMPLIFIER CIRCUIT. The RF amplifier circuit consists of switching MOSFET transis
1-24.
Additional characteristics of a Class E amplifier design is the application of dc power to
the amplifier transistors. The B+ and B- supplies are applied to RF choke L1 on the com
biner assembly. The choke is connected to the primary center tap winding of combiner
transformer T1. The transistors are connected to the primary winding of the transformers. The B- supply for the power amplifier is provided by the modulator circuit board.
The modulator outputs a dc voltage which varies with audio modulation and functions as
the RF ground for transistors Q1 and Q2. The RF ground potential will change in response to the applied audio. Fuse F1 protects the power amplifiers from over-current
conditions.
1-25.
Transistors Q1 and Q2 operate together to generate approximately 687.5 watts of RF pow
er. Q1 operates 180 degrees out-of phase with transistor Q2. Inductors L1 through L7
improve the efficiency of the drive circuit by storing the energy required to charge the
input capacitance of the transistors. Transzorbs D9/D10 prevent the gates of Q1/Q2 from
damage by transients during power on and off. Capacitors C 44 through C50 and C51
through C57 provide shaping for the Class E waveform. The RF power from power amplifier 1 is combined with the 687.5 watts of RF power from power amplifier circuit board 2
at a combiner transformer on the power block motherboard assembly to generate 1375
watts of RF power.
quency is applied to a transformer on the power block motherboard assembly. The trans
former outputs two signals to inverter U5A.
Q6. Q3/Q5 and Q4/Q6 are MOSFET transistors configured as a push-pull driver circuit.
The outputs of Q3/Q5 and Q4/Q6 are applied to MOSFET power transistors Q1 and Q2.
Operating potentials for the driver circuitry is provided by the RF driver +30 volt supply.
The supply is protected from over-voltage conditions by a regulator Q7. The regulator
limits the voltage to approximately 47 volts dc. Fuse F2 protects the +30 volt supply from
over-current conditions. Fuse F3 protects the driver circuit components from
over-current conditions.
tors Q1 and Q2. Q1 and Q2 are configured as a Class E switching amplifier network.
Class E power amplifier characteristics consist of: 1) the transistor drain-to-source volt
age must be nominally zero immediately prior to the turn-on of the transistor and 2) the
time slope of the drain-to-source voltage waveform must be nominally zero prior to the
turn-on of the transistor. The Class E circuit results in: 1) reduced device dissipation
and lowers the transistor operating temperature which greatly increases the life of the
components, 2) an operating efficiency of 95% or greater, and 3) increased reliability when
operated into VSWR conditions.
1-5
1-26.
RF DRIVE STATUS CIRCUIT. The RF drive signal is monitored by an RF drive status cir
1-27.
FAULT DETECTOR CIRCUIT. The power amplifier circuit board circuitry is monitored for
1-28.
The fault detector functions by monitoring fuses F1 and F2. When fuse F2 is blown, tran
sistor Q11 will output +20 volts to silicon-controlled-rectifier (SCR) Q13. When fuse F1 is
blown, optical coupler U3 will output +20 volts to SCR Q13. When either voltage is pres
ent, the voltage will bias Q13 on to illuminate PA fault indicator DS2 and bias optical cou
pler U4 on. U4 will respond by routing a PA fault signal to the controller circuit board.
1-29.
POWER SUPPLY CIRCUIT. An operating potential for the amplifier circuit board circuitry
is provided by the +30 volt supply from the power supply circuit board. The supply is pro
tected from over-current conditions by fuse F2. The +30 supply is regulated into a:
1) +15 volt supply by U1 and 2) +20 volt supply by R29. U1 is a three-terminal adjustable
regulator containing internal thermal and short-circuit current limiting features. Fuse
F2 protects the +30 volt supply from over-current conditions. Fuse F1 protects the power
amplifier components from over-current conditions. Fuse F3 protects the driver circuit
components from over-current conditions.
cuit. When an RF drive signal is present, a sample of the RF drive signal is rectified by
diodes D5/D6. The voltage from D5/D6 is applied to optical coupler U2. The output of U2
will go HIGH and bias transistor Q12 on. The output of Q12 will go LOW to illuminate
RF drive status indicator DS1.
fault conditions by a fault detector circuit. The circuit is designed to monitor two opera
tions: 1) the +30 volt supply and 2) the modulator output voltage (RF ground). The modulator output is monitored by optical coupler U3. The +20 volt supply is monitored by
transistor Q11. The power amplifier is protected from over-current conditions by fuse F1.
The +30 volt supply is protected from over-current conditions by fuse F2.
1-6
COPYRIGHT
1999 BROADCAST ELECTRONICS, INC
597-1112-27
FIGURE 1-2. POWER AMPLIFIER
CIRCUIT BOARD
SIMPLIFIED SCHEMATIC
(1-7/1-8)
SECTION II
RF POWER MODULE MAINTENANCE
2-1.
INTRODUCTION.
2-2.
This section provides maintenance information for the AM-2.5E/AM-5E transmitter RF
power modules.
2-3.
SAFETY CONSIDERATIONS.
WARNING
WARNING
WARNING
WARNING
THE TRANSMITTER CONTAINS MULTIPLE CIRCUIT
GROUNDS WITH HIGH AC AND DC POTENTIALS
WITH RESPECT TO THE CABINET WHICH IS AT
EARTH POTENTIAL. DO NOT ENERGIZE THE
TRANSMITTER WITH TEST EQUIPMENT CON
NECTED TO THE TRANSMITTER OUTPUT
NETWORK, RF POWER MODULE, RF COMBINER, OR
POWER SUPPLY COMPONENTS.
2-4.
The AM-2.5E/AM-5E 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 transmitter is equipped with many built-in safety features,
however good judgement, care, and common sense must be practiced to prevent accidents.
2-5.
In addition to high voltages and currents, the 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 transmitter 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. The
maintenance procedures presented in this section should be performed only by trained and
experienced maintenance personnel.
2-6.
FIRST LEVEL MAINTENANCE.
2-7.
First level maintenance consists of precautionary procedures applied to the equipment to
prevent future failures. The procedures are performed on a regular basis and the results
recorded in a performance log.
2-8.
CLEANING AND INSPECTION.
2-1
WARNING: DISCONNECT POWER PRIOR TO SERVICING
WARNING
WARNING
CAUTION
CAUTION
DISCONNECT ALL TRANSMITTER PRIMARY POWER
BEFORE ATTEMPTING ANY EQUIPMENT MAINTE
NANCE.
REMOVING OR INSTALLING AN RF POWER MODULE
WITH THE TRANSMITTER ENERGIZED MAY RESULT
IN DAMAGE TO THE MODULE. DO NOT REMOVE THE
RF POWER MODULES WITH THE TRANSMITTER EN
ERGIZED.
2-9.
Ensure all transmitter primary power is disconnected and remove an RF power module.
Clean the module of accumulated dust as required using a nylon bristle brush and vacuum
cleaner. Inspect the circuit boards for improperly seated semiconductors and components
damage by overheating. In addition, inspect the module for loose hardware. Repeat the
procedure for each module in the transmitter.
2-10.
SECOND LEVEL MAINTENANCE.
2-11.
Second level maintenance is the performance of procedures required to restore an RF
power module to operation after a fault has occurred. The RF power modules contain no
electrical adjustments. Therefore, the following text presents only troubleshooting
procedures.
2-12.
TROUBLESHOOTING.
WARNING
WARNING
WARNING
WARNING
CAUTION
CAUTION
THE TRANSMITTER CONTAINS MULTIPLE CIRCUIT
GROUNDS WITH HIGH AC AND DC POTENTIALS
WITH RESPECT TO THE CABINET WHICH IS AT
EARTH POTENTIAL. DO NOT ENERGIZE THE
TRANSMITTER WITH TEST EQUIPMENT CON
NECTED TO THE TRANSMITTER OUTPUT
NETWORK, RF POWER MODULE, RF COMBINER, OR
POWER SUPPLY COMPONENTS.
REMOVING OR INSTALLING AN RF POWER MODULE
WITH THE TRANSMITTER ENERGIZED MAY RESULT
IN DAMAGE TO THE MODULE. DO NOT REMOVE THE
RF POWER MODULES WITH THE TRANSMITTER EN
ERGIZED.
2-13.
SAFETY CONSIDERATIONS. The AM-2.5E/AM-5E transmitters are equipped with
2-14.
The RF power modules are not designed to be removed from the cabinet with the power
energized. Therefore, operate the transmitter to off before removing an RF power module
from the cabinet for maintenance procedures.
extensive indicator and meter circuitry to allow the operator to isolate problems to a
specific area within the transmitter. Due to the hazardous voltages and currents contained
in the equipment, 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. 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. The maintenance procedures presented in this section
should be performed only by trained and experienced maintenance personnel.
2-2
WARNING: DISCONNECT POWER PRIOR TO SERVICING
2-15.
RF POWER MODULE ASSEMBLY PROCEDURE. In the event of a failure in an RF power
module, the module will be required to be disassembled. The module must be properly
re-assembled to prevent circuit board and connector mis-alignment. To re-assemble an
RF power module, proceed as follows:
1. Locate the PA 2 circuit board and install the hex standoffs in the four locations at
the rear of the circuit board.
2. Locate the PA 1 circuit board and install the front panel mounting bracket using
the four Phillips-head screws. Do not secure the screws at this time. Repeat the
procedure for the PA2 circuit board and the modulator circuit board.
3. Install the PA 1 circuit board in the PA 1 location on the RF power module front
panel. Secure the circuit board bracket to the front panel using the hex nuts.
Repeat the procedure for the PA 2 and modulator circuit boards.
4. Place the RF power module on a square and flat surface such as a table with the
top of the module facing up.
5. Place the module front panel flush with the edge of the table and align the circuit
boards as follows:
A. Move the PA 1 circuit board until the front of the circuit board is flush with the
RF module front panel and the top edge of the circuit board is straight.
B. Secure the two Phillips-head screws which mount the circuit board to the
bracket.
C. Repeat the procedure for the PA 2 and modulator circuit boards.
6. Rotate the module and repeat the alignment procedure for the bottom circuit board
bracket screws. Secure the two Phillips-head screws mounting the circuit board
to the bracket when each circuit board is properly aligned.
7. Install the hardware securing the PA 1 circuit board and the modulator circuit
board to the standoffs.
2-16.
RF POWER MODULE EXCHANGE PROGRAM. If an RF power module is determined to
2-17.
TROUBLESHOOTING PROCEDURES. The RF power module troubleshooting procedures
are presented in Table 2-1. During the execution of the procedures, perform all
troubleshooting procedures for a symptom. The symptom may contain multiple component
failures. Once the trouble is isolated, refer to the circuit board theory of operation and
schematic diagrams to assist in problem resolution.
2-18.
COMPONENT REPLACEMENT PROCEDURE. Component replacement procedures for
be defective, Broadcast Electronics has established an RF power module exchange
program. The program allows the customer to exchange a defective module for a
re-conditioned module. Terms of the program are available from the Broadcast Electronics
Customer Service Department. If an RF power module is determined to be defective,
troubleshoot the module or contact the Broadcast Electronics Customer Service
department for terms of the module exchange program.
the RF power modules are presented in PART I SECTION V. Refer to COMPONENT
REPLACEMENT in SECTION V as required for the replacement procedures.
2-3
WARNING: DISCONNECT POWER PRIOR TO SERVICING
TABLE 2-1. RF POWER MODULE TROUBLESHOOTING
(Sheet 1 of 3)
SYMPTOM
RF DRIVE INDICATOR
EXTINGUISHED OR FLICKERING
OR FAULT INDICATOR
ILLUMINATED
CIRCUITRY TO CHECK
1. Determine transistor reference voltages of a
power amplifier with no faults as follows:
A. Remove an operational power amplifier with no
faults from an RF power module.
B. Using a digital voltmeter, operate the
voltmeter to diode check and determine a
reference voltage for the transistors on the
circuit board as follows:
1. Place the negative lead on the drain of Q1
(center pin) and the positive lead on the gate
and determine the voltage. The voltage using a
Fluke 77 meter = .45.
2. Place the negative lead on the drain of Q1
and the positive lead on the source and
determine the voltage. The voltage using a
Fluke 77 meter = .45.
2. Using the voltmeter as described in the preceding
step, measure the drain-to-gate and
drain-to-source voltage of transistor Q1 on the
defective power amplifier circuit board.
A. If the voltage is greater than ±0.1 volt of
the reference, defective Q1, Q3, and Q5.
B. If the voltage is equal to the reference, repeat
the preceding step for transistor Q2 on
the defective power amplifier circuit board.
3. Using a digital voltmeter, operate the voltmeter
to diode check and troubleshoot transistor Q3 as
follows:
A. Place the negative lead on the drain of Q3
(center pin) and the positive lead on the gate
and determine if a short circuit condition is
present.
B. Place the negative lead on the drain of Q3
and the positive lead on the source and
determine if a short circuit condition is
present.
C. If a short circuit condition is present, defective
Q3.
4. Repeat the procedure for transistors Q4, Q5, and
Q6.
5. Visually inspect regulator U1 for broken leads.
6. Check and replace all blown fuses on the circuit
board.
2-4
WARNING: DISCONNECT POWER PRIOR TO SERVICING
TABLE 2-1. RF POWER MODULE TROUBLESHOOTING
(Sheet 2 of 3)
SYMPTOM
CIRCUITRY TO CHECK
MOD PWM DRIVE INDICATOR
EXTINGUISHED AND FAULT
OR FUSE INDICATOR
ILLUMINATED
1. Refer to RF DRIVE INDICATOR
EXTINGUISHED OR FLICKERING OR FAULT
INDICATOR ILLUMINATED in the preceding
text and troubleshoot the power amplifier circuit
board.
2. If no defective circuitry is located on the power
amplifier circuit board, refer to FAULT OR FUSE
INDICATOR ILLUMINATED in the following
text and troubleshoot the modulator circuit
board.
MOD PWM DRIVE INDICATOR
EXTINGUISHED
1. Defective U2 or U13 on the modulator circuit board.
FAULT OR FUSE INDICATOR
ILLUMINATED
1. Visually inspect regulator U10 for broken leads.
2. Determine transistor reference voltages of a
modulator circuit board with no faults as
follows:
A. Remove a modulator with no faults from
an RF power module.
B. Using a digital voltmeter, operate the
voltmeter to diode check and determine a
reference voltage for the transistors on the
circuit board as follows:
1. Place the negative lead on the drain of Q1
(center pin) and the positive lead on the gate
and determine the voltage. The voltage using a
Fluke 77 meter = 1.2V.
2. Place the negative lead on the drain of Q1
and the positive lead on the source and
determine the voltage. The voltage using a
Fluke 77 meter = .46V.
3. Using the voltmeter as described in the preceding
step, measure the drain-to-gate and
drain-to-source voltage of transistor Q1 on the
defective modulator circuit board.
A. If the voltage is greater than ±0.1 volt of
the reference, proceed as follows:
1. Remove the wire from terminal E1.
2. Using the voltmeter as described in the
preceding text, measure the drain-to-gate and
drain-to-source voltage of transistor Q1 on
the defective modulator circuit board.
B. If the voltage at Q1 is greater than ± 0.1V of
the reference, defective Q1.
C. If the voltage at Q1 is equal to the reference,
defective Q2.
2-5
WARNING: DISCONNECT POWER PRIOR TO SERVICING
TABLE 2-1. RF POWER MODULE TROUBLESHOOTING
(Sheet 3 of 3)
SYMPTOM
FAULT OR FUSE INDICATOR
ILLUMINATED (CONT'D)
CIRCUITRY TO CHECK
4. Replace all blown fuses on the circuit board.
5. Re-install the modulator circuit board and install
the RF module in the transmitter. If the
modulator remains defective, replace U2 and U13.
6. If the modulator remains defective, contact the
Broadcast Electronics Customer Service
Department.
2-6
WARNING: DISCONNECT POWER PRIOR TO SERVICING
SECTION III
RF POWER MODULE
PARTS LIST
3-1.
INTRODUCTION.
3-2.
This section provides descriptions and part numbers of electrical components, assemblies,
and selected mechanical parts required for maintenance of the RF Power Module. Each
table entry in this section is indexed by reference designators appearing on the applicable
schematic.
TABLE 3-1. REPLACEABLE PARTS LIST INDEX
TABLE
3-2
3-3
3-4
3-5
3-6
3-7
3-8
3-9
3-10
3-11
DESCRIPTION
Power Module Assembly
Modulator Circuit Board Assembly
Power Amplifier Circuit Board Assembly
Power Module Frequency Dependant Kit, 522 - 650 kHz
Power Module Frequency Dependant Kit, 651 - 770 kHz
Power Module Frequency Dependant Kit, 771 - 920 kHz
Power Module Frequency Dependant Kit, 921 - 1080 kHz
Power Module Frequency Dependant Kit 1081 - 1300 kHz
Power Module Frequency Dependant Kit 1301 - 1580 kHz
Power Module Frequency Dependant Kit, 1581 - 1700 kHz
3-1
PART NO.
957-0010-001
917-0302
917-0304
957-1015-001
957-1015-002
957-1015-003
957-1015-004
957-1015-005
957-1015-006
957-1015-007
PAGE
3-2
3-2
3-5
3-8
3-8
3-8
3-8
3-9
3-9
3-9
TABLE 3-2. POWER MODULE ASSEMBLY - 957-0010-001
REF. DES.
-------
DESCRIPTION
Modulator Circuit Board Assembly
Power Amplifier Circuit Board Assembly
PART NO.
917-0302
917-0304
QTY.
TABLE 3-3. MODULATOR CIRCUIT BOARD ASSEMBLY- 917-0302
(Sheet 1 of 4)
REF. DES.
C1
C2
C3
C4
C5
C6
C7
C8
C9
C10
C11, C12
C13, C14
C15, C16
C17
C18, C19
C20
C21
C22
C23
C24
C25
C26, C27
C28 thru C32
C33
C34
C35
C36, C37
C38, C39
C40
C41
C42
C43
C44
C45
C46, C47
C48
DESCRIPTION
Capacitor, Electrolytic, 10 uF, 50V
Capacitor, Monolythic Ceramic, .1 uF ±10%, 100V
Capacitor, Electrolytic, 22 uF, 50V
Capacitor, Monolythic Ceramic 1 uF ±10%, 100V
Capacitor, Electrolytic, 330 uF, 200V dc
Capacitor, Polypropylene Film, .47 uF, 250V, Oval
Capacitor, Mica, 1000 pF ±10%, 350V
Capacitor, Electrolytic, 330 uF, 200V dc
Capacitor, Polypropylene Film, .47 uF, 250V, Oval
Capacitor, Mica, 1000 pF ±10%, 350V
Capacitor, Monolythic Ceramic, .1 uF ±10%, 100V
Capacitor, Polypropylene Film, 2.2 uF, 400V
Capacitor, Metallized Polypropylene Film, .068 uF ±10%, 250V
Capacitor, Monolythic Ceramic, .1 uF ±10%, 100V
Capacitor, Electrolytic, 10 uF, 50V
Capacitor, Monolythic Ceramic, .1 uF ±10%, 100V
Capacitor, Ceramic, 0.001 uF ±10%, 200V
Capacitor, Electrolytic, 10 uF, 50V
Capacitor, Electrolytic, 22 uF, 50V
Capacitor, Electrolytic, 10 uF, 50V
Capacitor, Electrolytic, 22 uF, 50V
Capacitor, Monolythic Ceramic, .1 uF ±10%, 100V
Capacitor, Electrolytic, 10 uF, 50V
Capacitor, Monolythic Ceramic, .1 uF ±10%, 100V
Capacitor, Electrolytic, 47 uF, 35V
Capacitor, Electrolytic, 10 uF, 50V
Capacitor, Ceramic, 0.001 uF ±10%, 200V
Capacitor, Monolythic Ceramic, .1 uF ±10%, 100V
Capacitor, Electrolytic, 10 uF, 50V
Capacitor, Electrolytic, 33 uF, 25V
Capacitor, Polypropylene Film, 2.2 uF, 400V
Capacitor, Polypropylene Film, .47 uF, 250V, Oval
Capacitor, Polypropylene Film, .033 uF, ±10%, 200V
Capacitor, Mica, 820 pF ±5%, 300V
Capacitor, Monolythic Ceramic, .1 uF ±10%, 100V
Capacitor, Metallized Polypropylene Film, .068 uF ±10%, 250V
3-2
PART NO.
023-1076
003-1041
024-2274
003-1041
013-3385-201
033-4743
046-0002
013-3385-201
033-4743
046-0002
003-1041
030-2256
030-6843
003-1041
023-1076
003-1041
030-1033
023-1076
024-2274
023-1076
024-2274
003-1041
023-1076
003-1041
020-4773
023-1076
030-1033
003-1041
023-1076
020-3374
030-2256
033-4743
030-3353
042-8222
003-1041
030-6843
QTY.
TABLE 3-3. MODULATOR CIRCUIT BOARD ASSEMBLY - 917-0302
(Sheet 2 of 4)
REF. DES.
DESCRIPTION
Capacitor, Polypropylene Film, .033 uF ±10%, 200V
Capacitor, Mylar, 0.01 uF ±10%, 100V
Diode, Zener, 1N4733A, 5.1V ±5%, 1W
Diode, Fast Recovery, 16JPF20
Diode, 1N4005, Silicon, 600V @ 1 Ampere
Diode, 1N4148, Silicon, 75V @ 0.3 Amperes
Diode, 1N4005, Silicon, 600V @ 1 Ampere
Diode, Zener, 1N4739A, 9.1V ±5%, 1W
Diode, 1N4005, Silicon, 600V @ 1 Ampere
Diode, 1N6276A, Silicon, Transient Voltage Suppressor,
16V ±0.05% Breakdown
D11
Switchmode Power Rectifier, MUR460
D12, D13
Diode, 1N4148, Silicon, 75V @ 0.3 Amperes
D14, D15
Diode, 1N4005, Silicon, 600V @ 1 Ampere
D16
Diode, 1N4148, Silicon, 75V @ 0.3 Amperes
D17
Diode, Zener, 1N4739A, 9.1V ±5%, 1W
D18
Diode, Zener, 1N4728, 3.3V ±5%, 1W
D19
Diode, 1N4005, Silicon, 600V @ 1 Ampere
D20 thru D23 Diode, 1N4148, Silicon, 75V @ 0.3 Amperes
D24, D25
Diode, Schottky, 20V, 1 Amp, 1N5817
DS1
Indicator, LED, Green, 521-9175, 3V @ 40 mA Maximum
DS2
Indicator, LED, Red, 521-9212, 1.7V @ 50 mA Maximum
DS3
Indicator, LED, Green, 521-9175, 3V @ 40 mA Maximum
DS4
Indicator, LED, Red, 521-9212, 1.7V @ 50 mA Maximum
F1
Fuse, 3AG, 20 Amperes, 250V
F2
Fuse, MDL, 1 Ampere, 250V, Slow-Blow
J3, J4
Jumper, Programmable, 2-Pin
K1
Relay, SPST, 30 Amperes
P2
Connector, 15-Pin, SUB-D, Male, Right Angle
P3
Receptacle, Male, 3-Pin In-line
P4
Receptacle, Male, 2-Pin In-line
Q1, Q2
Modulator, FET MTY55N20E, 200V, 55 Amperes
R1
Resistor, 1.33 k Ohm ±1%, 1/4W
R2
Resistor, 470 Ohm ±5%, 1/2W
R3
Resistor, 332 Ohm ±1%, 1/4W
R4
Resistor, 1 Ohm ±5%, 1/4W
R5
Resistor, 10 k Ohm ±1%, 1/4W
R7
Resistor, 12k Ohm, 2W, ±5%
R8
Resistor, 3.3 Meg Ohm ±5%, 1/4W
R9
Resistor, 1 Ohm ±5%, 1/4W
R10
Resistor, 3.65 k Ohm ±1%, 1/4W
R11
Resistor, 1 Ohm ±5%, 1/4W
R12
Resistor, 453 k Ohm ±1%, 1/4W
R13
Resistor, 130 k Ohm ±1%, 1/4W
R14
Resistor, 1 k Ohm ±1%, 1/4W
C49
C50
D1
D2, D3
D4
D5
D6
D7
D8, D9
D10
3-3
PART NO.
QTY.
030-3353
031-1043
200-4733
200-1620
203-4005
203-4148
203-4005
200-0009
203-4005
206-6276
230-0014
203-4148
203-4005
203-4148
200-0009
201-4728
203-4005
203-4148
200-0019
323-9224
323-9217
323-9224
323-9217
330-2000
334-0100
340-0004
270-1213
417-0374
417-0003
417-4004
210-0550
103-1331
110-4733
103-3323
100-1013
100-1051
130-1253
100-3373
103-1021
103-3641
100-1021
100-4561
103-1306
100-1041
TABLE 3-3. MODULATOR CIRCUIT BOARD ASSEMBLY - 917-0302
(Sheet 3 of 4)
REF. DES.
R15
R16
R17
R18
R19
R20
R21
R22
R23
R24
R25
R26
R27
R28
R29
R30
R31
R32
R33
R34
R35
R38
R39
R40
R41
R42
R43
R44
R45
R46
R47 thru R49
R51
R52
R53
R54, R55
R56, R57
R58
TP1 thru TP4
TP5, TP6
U1
U2
U3
U4
DESCRIPTION
PART NO.
Resistor, 332 k Ohm ±1%, 1/4W
103-3326
Resistor, 69.8 k Ohm ±1%, 1/4W
103-6985
Resistor, 2.21 k Ohm ±1%, 1/4W
103-2241
Resistor, 10 k Ohm ±1%, 1/4W
100-1051
Resistor, 3.65 k Ohm ±1%, 1/4W
103-3641
Resistor, 1 k Ohm ±1%, 1/4W
100-1041
Resistor, 27 k Ohm ±5%, 1W
120-2753
Resistor, 22.1 k Ohm ±1%, 1/4W
103-2211
Resistor, 10 k Ohm ±1%, 1/4W
100-1051
Resistor, 332 k Ohm ±1%, 1/4W
103-3326
Resistor, 2.21 k Ohm ±1%, 1/4W
103-2241
Resistor, 1 k Ohm ±1%, 1/4W
100-1041
Resistor, 100 k Ohm ±1%, 1/4W
103-1062
Resistor, 69.8 k Ohm ±1%, 1/4W
103-6985
Resistor, 3.65 k Ohm ±1%, 1/4W
103-3641
Resistor, 10 k Ohm ±1%, 1/4W
100-1051
Resistor, 332 k Ohm ±1%, 1/4W
103-3326
Resistor, 2.21 k Ohm ±1%, 1/4W
103-2241
Resistor, 1 k Ohm ±1%, 1/4W
100-1041
Resistor, 121 Ohm ±1%, 1/4W
100-1231
Resistor, 1.33 k Ohm ±1%, 1/4W
103-1331
Resistor, 47.5 k Ohm ±1%, 1/4W
103-4755
Resistor, 1 k Ohm ±1%, 1/4W
100-1041
Resistor, 1 k Ohm ±1%, 1/4W
100-1041
Resistor, 100 k Ohm ±1%, 1/4W
103-1062
Resistor, 8.66 k Ohm ±1%, 1/4W
100-8641
Resistor, 499 k Ohm ±1%, 1/4W
103-4996
Resistor, 8.25 k Ohm ±1%, 1/4W
103-8254
Resistor, 1 k Ohm ±1%, 1/4W
100-1041
Resistor, 1 Meg Ohm ±1%, 1/4W
103-1007
Resistor, 10 k Ohm ±1%, 1/4W
100-1051
Resistor, 15.4 k Ohm ±1%, 1/4W
103-1551
Resistor, 39 Ohm ±5%, 1/2W
110-3923
Resistor, 3.3 Meg Ohm ±5%, 1/4W
100-3373
Resistor, 100 Ohm ±1%, 1/4W
100-1031
Resistor, 3.3 Meg Ohm ±5%, 1/4W
100-3373
Resistor, 453 k Ohm ±1%, 1/4W
100-4561
Terminal, Test Point, Oval, Red
413-0106
Jack, Test, Right Angle Printed Circuit Board Mount
417-0004
Integrated Circuit, Opto-Isolator, 6N137
220-6137
Driver, TC4421CAT, 2 Ampere, 5-Pin, TO-220 Case
220-4421
Integrated Circuit, LM339AN, Quad Comparator, 14-Pin DIP
221-0339
Integrated Circuit, 4N33, Optical Isolator, NPN Photo
229-0033
Transistor/Infared Emitting Diode Type, 1500V Isolation,
Response: 30 kHz Maximum, Current: 50 mA Maximum, 6-Pin DIP
3-4
QTY.
TABLE 3-3. MODULATOR CIRCUIT BOARD ASSEMBLY - 917-0302
(Sheet 4 of 4)
REF. DES.
U5
U6
U7
U8, U9
U10
U11
U12
U13
XF1, XF2
XU1
XU3
XU4
XU5
XU6
XU7
XU8, XU9
XU11
XU13
-------------
DESCRIPTION
PART NO.
Integrated Circuit, ULN2004, 7 NPN Darlington Driver Pack,
226-2004
16-Pin DIP
Integrated Circuit, MC14093B, Quad 2-Input NAND Schmitt Trigger, 220-4093
CMOS, 14-Pin DIP
Integrated Circuit, MC14044BP, Quad NAND R-S Latch, CMOS,
228-4044
16-Pin DIP
Integrated Circuit, 4N33, Optical Isolator, NPN Photo
229-0033
Transistor/Infared Emitting Diode Type, 1500V Isolation,
Response: 30 kHz Maximum, Current: 50 mA Maximum, 6-Pin DIP
Integrated Circuit, LM317T, Adjustable Positive Voltage
227-0317
Regulator, 1.2V to 37V, 1.5 Ampere, TO-220 Case
Integrated Circuit, 14505, Hex Level Shifter, TTL to CMOS,
228-4504
16-Pin DIP
Integrated Circuit, 4N33, Optical Isolator, NPN Photo
229-0033
Transistor/Infared Emitting Diode Type, 1500V Isolation,
Response: 30 kHz Maximum, Current: 50 mA Maximum, 6-Pin DIP
Driver, TC4421CAT, 2 Ampere, 5-Pin, TO-220 Case
220-4421
Fuse Clips, AGC
415-2068
Socket, 8-Pin DIP
417-0804
Socket, 14-Pin DIP
417-1404
Socket, 6-Pin DIP
417-0600
Socket, 16-Pin DIP
417-1604
Socket, 14-Pin DIP
417-1404
Socket, 16-Pin DIP
417-1604
Socket, 6-Pin DIP
417-0600
Socket, 16-Pin DIP
417-1604
Socket, 6-Pin DIP
417-0600
Coil, 36 uH, MOD PWM
360-0108
Coil, 9.2 uH, MOD PWM
360-0109
Coil, 14 uH, MOD PWM
360-0110
Blank, Modulator Circuit Board
517-0302
QTY.
TABLE 3-4. POWER AMPLIFIER CIRCUIT BOARD ASSEMBLY - 917-0304
(Sheet 1 of 3)
REF. DES.
C2
C3 thru C6
C8
C10
C11
C12
DESCRIPTION
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 100V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Electrolytic, 100 uF, 35V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 100V
3-5
PART NO.
003-1066
003-1041
003-1066
023-1084
003-1066
003-1041
QTY.
TABLE 3-4. POWER AMPLIFIER CIRCUIT BOARD ASSEMBLY - 917-0304
(Sheet 2 of 3)
REF. DES.
C13
C15
C16 thru C18
C19 thru C21
C23
C24
C25
C26
C27, C28
C29 thru
C32
C33
C34
C36 ,C37
C38, C39
C40 thru C43
C45 thru C55
C58
C59
D1 thru D6
D9, D10
D11
D16
D17
D18
D19
D20, D21
D22, D23
D25 thru D28
D29, D30
D31
D32 thru D35
DS1
DS2
F1
F2, F3
FC1, FC2
FC3 thru FC6
L1, L2
L3 thru L7
P2
Q1, Q2
Q3 thru Q6
Q7
DESCRIPTION
Capacitor, Electrolytic, 100 uF, 63V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Ceramic, 0.001 uF ±10%, 200V
Capacitor, Monolytic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Mylar Film, 0.01 uF ±10%, 200V
Capacitor, Electrolytic, 10 uF, 50V
Capacitor, Electrolytic, 10 uF, 50V
Capacitor, Ceramic, 0.001 uF, 1 kV
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 200V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 100V
PART NO.
015-1084
003-1066
030-1033
003-1066
030-1043
023-1076
023-1076
002-1034
003-1065
003-1041
Capacitor, Electrolytic, 10 uF, 50V
023-1076
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 100V
003-1041
Capacitor, Mica, 39 pF ±5%, 500V
042-3912
Capacitor, Monolythic Ceramic, .47 uF ±10%, 50V
003-4743
Capacitor, Electrolytic, 1 uF, 50V
024-1064
Refer to Frequency Dependant Parts - Power Amplifier Table at the end of this section.
Capacitor, Monolythic Ceramic, .47 uF ±10%, 50V
003-4743
Capacitor, Electrolytic, 10 uF, 50V
023-1076
Diode, 1N4148, Silicon, 75V @ 0.3 Amperes
203-4148
Transzorb Diode, 27 Volt, 1.5KE27CA
206-0027
Diode, Zener 1N5229, 4.3V, 0.5W
201-0035
Diode, Transzorb, Diode, 300BV, 1.5FE300CA
206-0300
Transzorb Diode, 250BV, 1.5KE250CA
206-0250
Diode, Transzorb, Diode, 300BV, 1.5FE300CA
206-0300
Transzorb Diode, 250BV, 1.5KE250CA
206-0250
Diode, Zener, 1N4749, 24V, 10.5 Amperes
200-0024
Diode, 1N4005, Silicon, 600V @ 1 Ampere
203-4005
Diode, 1N4148, Silicon, 75V @ 0.3 Amperes
203-4148
Diode, Zener, 1N4742A, 12V ±5%, 1W
200-4742
Diode, Zener, 1N4737A, 7.5V, 1W, 34 mA
200-4737
Diode, 1N4148, Silicon, 75V @ 0.3 Amperes
203-4148
Indicator, LED, Green, 521-9175, 3V @ 40 mA Maximum
323-9224
Indicator, LED, Red, 521-9212, 1.7V @ 50 mA Maximum
323-9217
Fuse, 3AB, 15 Amperes, 65V, Very Fast
330-1502
Fuse, 5 X 20MM, 1.5 Ampere, Slow-Blow
334-1150
Fuse Clips, AGC
415-2068
Fuse Clips, Littlefuse, 111501
415-2069
Coil, 4uH
360-0112
Refer to Frequency Dependant Parts - Power Amplifier Table at the end of this section.
Connector, 15-Pin Sub-D, Male, Right Angle
417-0374
RF FET, APT6018, 600V
210-6018
Hexfet Power Mosfet, IRFI520G, TO-220 Fullpak
210-0520
Transistor, TIP120, NPN Darlington-Connected Silicon
210-0120
Power, 65W @ 25#C Case
3-6
QTY.
TABLE 3-4. POWER AMPLIFIER CIRCUIT BOARD ASSEMBLY - 917-0304
(Sheet 3 of 3)
REF. DES.
DESCRIPTION
Q11
Q12
Q13
R1
R2, R3
R4
R5
R6, R7
R8 thru R11
R12
R13
R14
R15
R16
R18
R20
R21, R22
R23
R24
R25
R26
R27, R28
R29
R30, R31
R32, R33
R34, R35
R36, R37
R38
R39, R40
U1
PART NO.
Transistor, 2N3906, PNP, Silicon, TO-92 Case
210-3906
Transistor, 2N3904, NPN, Silicon, TO-92 Case
211-3904
Silicon Controlled Rectifier, GE6CA, 100V @ 1.6 Ampere
237-0006
Resistor, 1 k Ohm ±5%,1W
120-1043
Resistor, 10 k Ohm ±1%, 1/4W
100-1051
Resistor, 100 Ohm ±1%, 1/4W
100-1031
Resistor, 1.10 k Ohm ±1%, 1/4W
103-1104
Resistor, 10 k Ohm ±1%, 1/4W
100-1051
Resistor, 27 Ohm ±5%, 1/4W
100-2723
Resistor, 15k Ohm ±5%, 2W
130-1553
Resistor, 3.3 Meg Ohm ±5%, 1/4W
100-3373
Resistor, 1.10 k Ohm ±1%, 1/4W
103-1104
Resistor, 1 k Ohm ±5%, 1W
120-1043
Resistor, 3.3 Meg Ohm ±5%, 1/4W
100-3373
Resistor, 1.10 k Ohm ±1%, 1/4W
103-1104
Resistor, 1.96 k Ohm ±1%, 1/4W
103-1964
Resistor, 10 k Ohm ±1%, 1/4W
100-1051
Resistor, 10 Meg Ohm ±5%, 1/4W
100-1083
Resistor, 1.96 k Ohm ±1%, 1/4W
103-1964
Resistor, 680 Ohm ±5%, 1/2W
110-6833
Resistor, 10 k Ohm ±1%, 1/4W
100-1051
Resistor, 332 Ohm ±1%, 1/4W
103-3323
Resistor, 300 Ohm ±5%, 2W, W/W
130-3004
Resistor, 2.67 k Ohm ±1%, 1/4W
103-2674
Resistor, 100 Ohm ±1%, 1/4W
100-1031
Resistor, 10 k Ohm ±1%, 1/4W
100-1051
Resistor, 300 Ohm ±5%, 2W, W/W
130-3004
Resistor, 562 Ohm ±1%, 1/4W
103-5623
Resistor, 10 k Ohm ±1%, 1/4W
100-1051
Integrated Circuit, LM317T, Adjustable Positive Voltage
227-0317
Regulator, 1.2V to 37V, 1.5 Ampere, TO-220 Case
U2 thru U4
Integrated Circuit, 4N33, Optical Isolator, NPN Photo
229-0033
Transistor/Infared Emitting Diode Type, 1500V Isolation,
Response: 30 kHz Maximum, Current: 50 mA Maximum, 6-Pin DIP
U5
Integrated Circuit, MC14584, 14-Pin Schmitt
228-4584
U7, U8
Driver High and Low Side, IR2110
227-2110
XU2 thru XU4 Socket, 6-Pin DIP
417-0600
XU5, XU7,
Socket, 14-Pin DIP
417-1404
XU8
---Blank, Power Amplifier Circuit Board Assembly
517-0304
3-7
QTY.
TABLE 3-5. POWER MODULE FREQUENCY DEPENDANT KIT, 522 - 650 KHZ 957-1015-001
REF. DES.
C45, C56
DESCRIPTION
PART NO.
QTY.
Capacitor, Mica, 1600 pF, 1 kV
042-1622
C46 thru C55 Capacitor, Mica, 1800 pF, 1 kV
042-1832
20
L3, L4
Inductor, PA Drive
360-0113-XXX
----
Blank, PA Capacitor Board Circuit Board
517-0318-001
----
Blank, PA Inductor Board Circuit Board
517-0319-001
TABLE 3-6. POWER MODULE FREQUENCY DEPENDANT KIT, 651 - 770 KHZ 957-1015-002
REF. DES.
C46, C55
DESCRIPTION
Capacitor, Mica, 1600 pF, 1 kV
PART NO.
QTY.
042-1622
C47 thru C54 Capacitor, Mica, 1800 pF, 1 kV
042-1832
16
L3, L4
Inductor, PA Drive
360-0113-XXX
----
Blank, PA Capacitor Board Circuit Board
517-0318-001
----
Blank, PA Inductor Board Circuit Board
517-0319-001
TABLE 3-7. POWER MODULE FREQUENCY DEPENDANT KIT, 771 - 920 KHZ 957-1015-003
REF. DES.
DESCRIPTION
C47 thru C54 Capacitor, Mica, 1800 pF, 1 kV
PART NO.
QTY.
042-1832
16
L3, L4
Inductor, PA Drive
360-0113-XXX
----
Blank, PA Capacitor Board Circuit Board
517-0318-001
----
Blank, PA Inductor Board Circuit Board
517-0319-001
TABLE 3-8. POWER MODULE FREQUENCY DEPENDANT KIT, 921 - 1080 KHZ 957-1015-004
REF. DES.
C48, C53
DESCRIPTION
PART NO.
QTY.
Capacitor, Mica, 1600 pF, 1 kV
042-1622
C49 thru C52 Capacitor, Mica, 1800 pF, 1 kV
042-1832
C47, C54
042-9122
Capacitor, Mica, 910 pF, 1 kV
L5, L7
Inductor, PA Drive
360-0113-XXX
----
Blank, PA Capacitor Board Circuit Board
517-0318-001
----
Blank, PA Inductor Board Circuit Board
517-0319-001
3-8
TABLE 3-9. POWER MODULE FREQUENCY DEPENDANT KIT, 1081 - 1300 KHZ 957-1015-005
REF. DES.
C48, C53
C49 thru C52
L5, L7
-------
DESCRIPTION
Capacitor, Mica, 1600 pF, 1 kV
Capacitor, Mica, 1800 pF, 1 kV
Inductor, PA Drive
Blank, PA Capacitor Board Circuit Board
Blank, PA Inductor Board Circuit Board
PART NO.
042-1622
042-1832
360-0113-XXX
517-0318-001
517-0319-001
QTY.
TABLE 3-10. POWER MODULE FREQUENCY DEPENDANT KIT, 1301 - 1580 KHZ 957-1015-006
REF. DES.
C48, C53
C49 thru C52
L5, L6, L7
-------
DESCRIPTION
Capacitor, Mica, 910 pF, 1 kV
Capacitor, Mica, 1600 pF, 1 kV
Inductor, PA Drive
Blank, PA Capacitor Board Circuit Board
Blank, PA Inductor Board Circuit Board
PART NO.
042-9122
042-1622
360-0113-XXX
517-0318-001
517-0319-001
QTY.
TABLE 6-11. POWER MODULE FREQUENCY DEPENDANT KIT, 1581 - 1700 KHZ 957-1015-007
REF. DES.
C49, C52
C50, C51
L5, L6, L7
-------
DESCRIPTION
Capacitor, Mica, 1600 pF, 1 kV
Capacitor, Mica, 1800 pF, 1 kV
Inductor, PA Drive
Blank, PA Capacitor Board Circuit Board
Blank, PA Inductor Board Circuit Board
3-9
PART NO.
042-1622
042-1832
360-0113-XXX
517-0318-001
517-0319-001
QTY.
SECTION IV
RF POWER MODULE DRAWINGS
4-1.
INTRODUCTION.
4-2.
This section provides assembly drawings, wiring diagrams, and schematic diagrams as
listed below for the Broadcast Electronics AM-2.5E/AM-5E transmitter RF power module.
FIGURE
4-1
4-2
4-3
4-4
TITLE
NUMBER
SCHEMATIC DIAGRAM, MODULATOR CIRCUIT BOARD
ASSEMBLY DIAGRAM, MODULATOR CIRCUIT BOARD
SCHEMATIC DIAGRAM, POWER AMPLIFIER CIRCUIT
BOARD
ASSEMBLY DIAGRAM, POWER AMPLIFIER CIRCUIT
BOARD
4–1
SB917-0302/-001
AD917-0302/-001
SB917-0304
AD917-0304
TABLE OF CONTENTS
PARAGRAPH
SECTION I
1-1
1-3
SECTION II
2-1
2-3
2-6
2-8
2-10
2-12
2-13
2-14
2-15
2-16
2-17
2-18
2-19
SECTION III
3-1
SECTION IV
4-1
PAGE NO.
OUTPUT NETWORK THEORY OF OPERATION
Introduction
Functional Description
1-1
1-1
OUTPUT NETWORK MAINTENANCE
Introduction
Safety Considerations
First Level Maintenance
Cleaning and Inspection
Second Level Maintenance
Electrical Adjustments
Modulation Calibration Controls
Directional Coupler Null Controls
Troubleshooting
Safety Considerations
Output Network Assembly Component Locations
Troubleshooting Procedures
Component Replacement Procedure
2-1
2-1
2-1
2-1
2-2
2-2
2-2
2-2
2-2
2-2
2-2
2-3
2-3
OUTPUT NETWORK ASSSEMBLY PARTS LIST
Introduction
3-1
OUTPUT NETWORK ASSEMBLY DRAWINGS
Introduction
4-1
LIST OF TABLES
TABLE
2-1
2-2
2-3
3-1
TITLE
DIRECTIONAL COUPLER CIRCUIT BOARD
TROUBLESHOOTING
LIGHTNING DETECTION CIRCUIT BOARD/
SPARK GAP TROUBLESHOOTING
LIGHTNING PROTECTION CIRCUIT BOARD
TROUBLESHOOTING
REPLACEABLE PARTS LIST INDEX
PAGE NO.
2-3
2-3
2-3
3-1
SECTION I
OUTPUT NETWORK THEORY OF OPERATION
1-1.
INTRODUCTION.
1-2.
This section presents the theory of operation for the AM-2.5E/AM-5E output network
assembly.
1-3.
FUNCTIONAL DESCRIPTION.
1-4.
The output network assembly contains the: 1) harmonic band-pass filter, 2) directional
coupler circuit board, 3) lightning protection circuit board, 4) T-matching network,
5) lightning detection circuit board, and 6) spark gap. The theory of operation for the out
put network assembly components is presented in PART I SECTION IV, THEORY OF OP
ERATION. Refer to SECTION IV as required for a description of the output network as
sembly components.
1-1
SECTION II
OUTPUT NETWORK MAINTENANCE
2-1.
INTRODUCTION.
2-2.
This section provides maintenance information for the AM-2.5E/AM-5E transmitter
output network assembly.
2-3.
SAFETY CONSIDERATIONS.
WARNING
WARNING
WARNING
WARNING
THE TRANSMITTER CONTAINS MULTIPLE CIRCUIT
GROUNDS WITH HIGH AC AND DC POTENTIALS
WITH RESPECT TO THE CABINET WHICH IS AT
EARTH POTENTIAL. DO NOT ENERGIZE THE
TRANSMITTER WITH TEST EQUIPMENT CON
NECTED TO THE TRANSMITTER OUTPUT
NETWORK, RF POWER MODULE, RF COMBINER, OR
POWER SUPPLY COMPONENTS.
2-4.
The AM-2.5E/AM-5E 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 transmitter is equipped with many built-in safety features,
however good judgement, care, and common sense must be practiced to prevent accidents.
2-5.
In addition to high voltages and currents, the 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 transmitter 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. The
maintenance procedures presented in this section should be performed only by trained
and experienced maintenance personnel.
2-6.
FIRST LEVEL MAINTENANCE.
2-7.
First level maintenance consists of precautionary procedures applied to the equipment to
prevent future failures. The procedures are performed on a regular basis and the results
recorded in a performance log.
2-8.
CLEANING AND INSPECTION.
2-1
WARNING: DISCONNECT POWER PRIOR TO SERVICING
WARNING
WARNING
DISCONNECT ALL TRANSMITTER PRIMARY POWER
BEFORE ATTEMPTING ANY EQUIPMENT MAINTE
NANCE.
2-9.
Ensure all transmitter primary power is disconnected and clean the output network
assembly of accumulated dust using a nylon bristle brush and vacuum cleaner. Inspect
the components for damage by overheating and arcing. In addition, check the
components for loose hardware.
2-10.
SECOND LEVEL MAINTENANCE.
2-11.
Second level maintenance is the performance of procedures required to restore the ECU to
operation after a fault has occurred. The procedures are divided into electrical
adjustments procedures and troubleshooting.
2-12.
ELECTRICAL ADJUSTMENTS.
2-13.
MODULATION CALIBRATION CONTROLS. Modulation calibration controls R201
2-14.
DIRECTIONAL COUPLER NULL CONTROLS. Directional coupler null controls R223,
2-15.
TROUBLESHOOTING.
through R205 calibrate the modulation sample for each power level. A complete
description of the procedure to adjust the power level controls is presented in SECTION
II, INSTALLATION. Refer to POWER LEVEL AND MODULATION CALIBRATION
ADJUSTMENT in SECTION II for the adjustment procedure.
R224, R234, and R235 null the directional coupler sampling circuit. Due to the critical
nature of the directional coupler null controls, the controls are not considered field
adjustable. If the controls are required to be adjusted, contact the Broadcast Electronics
Customer Service Department for information and instructions to adjust the directional
coupler null controls.
WARNING
WARNING
WARNING
WARNING
THE TRANSMITTER CONTAINS MULTIPLE CIRCUIT
GROUNDS WITH HIGH AC AND DC POTENTIALS
WITH RESPECT TO THE CABINET WHICH IS AT
EARTH POTENTIAL. DO NOT ENERGIZE THE
TRANSMITTER WITH TEST EQUIPMENT CON
NECTED TO THE TRANSMITTER OUTPUT
NETWORK, RF POWER MODULE, RF COMBINER, OR
POWER SUPPLY COMPONENTS.
2-16.
SAFETY CONSIDERATIONS. The AM-2.5E/AM-5E transmitters are equipped with
2-17.
OUTPUT NETWORK ASSEMBLY COMPONENT LOCATIONS. Component locations for
the output network assembly are presented in PART I SECTION V, MAINTENANCE.
Refer to TRANSMITTER COMPONENT LOCATIONS in SECTION V to locate
components within the output network assembly.
extensive indicator and meter circuitry to allow the operator to isolate problems to a
specific area within the transmitter. Due to the hazardous voltages and currents
contained in the equipment, 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. 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. The maintenance procedures presented in
this section should be performed only by trained and experienced maintenance personnel.
2-2
WARNING: DISCONNECT POWER PRIOR TO SERVICING
2-18.
TROUBLESHOOTING PROCEDURES. The output network assembly troubleshooting
procedures are presented in Tables 2-1 through 2-3. Table 2-1 presents the directional
coupler circuit board troubleshooting. Table 2-2 presents the lightning detection circuit
board and spark gap troubleshooting. Table 2-3 presents the lightning protection circuit
board troubleshooting. Refer to Tables 2-1 through 2-3 to isolate the problem to a specific
circuit. Once the trouble is isolated, refer to the circuit board theory of operation
presented in PART I SECTION IV and the schematic diagrams presented in this section
to assist in problem resolution.
TABLE 2-1. DIRECTIONAL COUPLER CIRCUIT BOARD TROUBLESHOOTING
SYMPTOM
HIGH REFLECTED POWER
METER INDICATION WHEN
ACTUAL REFLECTED POWER
IS LOW
CIRCUITRY TO CHECK
1. Check diode D201 through D210.
TABLE 2-2. LIGHTNING DETECTION CIRCUIT BOARD/SPARK GAP TROUBLESHOOT
ING
SYMPTOM
CIRCUITRY TO CHECK
HIGH REFLECTED POWER
CONDITION
1. Check the lightning detection circuit board for a
short circuit condition.
NO LIGHTNING DETECTION
OPERATION
1. Check the spark gap.
2. Check optically operated transistor Q401 on the
lightning detection circuit board.
TABLE 2-3. LIGHTNING PROTECTION CIRCUIT BOARD TROUBLESHOOTING
SYMPTOM
HIGH REFLECTED POWER
OR SHORTED OUTPUT
CONDITION
2-19.
CIRCUITRY TO CHECK
1. Check the circuit board for a short circuit condition.
COMPONENT REPLACEMENT PROCEDURE. Component replacement procedures for
the output network assembly are presented in PART I SECTION V. Refer to
COMPONENT REPLACEMENT in SECTION V as required for the replacement
procedures.
2-3
WARNING: DISCONNECT POWER PRIOR TO SERVICING
SECTION III
OUTPUT NETWORK ASSEMBLY
PARTS LIST
3-1.
INTRODUCTION.
3-2.
This section provides descriptions and part numbers of electrical components, assemblies,
and selected mechanical parts required for maintenance of the output network assembly.
Each table entry in this section is indexed by reference designators appearing on the applicable schematic.
TABLE 3-1. REPLACEABLE PARTS LIST INDEX (Sheet 1 of 2)
TABLE
3-2
3-3
3-4
3-5
3-6
3-7
3-8
3-9
3-10
3-11
3-12
3-13
3-14
3-15
3-16
3-17
3-18
3-19
3-20
DESCRIPTION
Output Network Assembly, AM-2.5E
Output Network Assembly, AM-5E
Lightning Protection Circuit Board, AM-2.5E
Lightning Protection Circuit Board, AM-5E
Directional Coupler Circuit Board
Assembly
Lightning Detection Circuit Board Assembly
Harness Output Network Assembly
Output Network Frequency Dependant Parts, AM-2.5E
522 - 650 KHZ
Output Network Frequency Dependant Parts, AM-2.5E
651 - 770 KHZ
Output Network Frequency Dependant Parts, AM-2.5E
771 - 920 KHZ
Output Network Frequency Dependant Parts, AM-2.5E
921 - 1080 KHZ
Output Network Frequency Dependant Parts, AM-2.5E
1081 - 1300 KHZ
Output Network Frequency Dependant Parts, AM-2.5E
1301 - 1580 KHZ
Output Network Frequency Dependant Parts, AM-2.5E
1581 - 1700KHZ
Output Network Frequency Dependant Parts, AM-5E
522 - 650 KHZ
Output Network Frequency Dependant Parts, AM-5E
651 - 770 KHZ
Output Network Frequency Dependant Parts, AM-5E
771 - 920 KHZ
Output Network Frequency Dependant Parts, AM-5E
921 - 1080 KHZ
Output Network Frequency Dependant Parts, AM-5E
1081 - 1300 KHZ
3-1
PART NO.
PAGE
957-0068
957-0070
917-0216-003
917-0216-001
917-0306-002
3-3
3-3
3-3
3-3
3-4
917-0306-004
947-0211
957-1035-121
3-5
3-5
3-6
957-1035-122
3-6
957-1035-123
3-6
957-1035-124
3-7
957-1035-125
3-7
957-1035-126
3-7
957-1035-127
3-8
957-1035-151
3-8
957-1035-152
3-8
957-1035-153
3-9
957-1035-154
3-9
957-1035-155
3-9
TABLE 3-1. REPLACEABLE PARTS LIST INDEX (Sheet 2 of 2)
TABLE
3-21
3-22
DESCRIPTION
Output Network Frequency Dependant Parts, AM-5E
1301 - 1580 KHZ
Output Network Frequency Dependant Parts, AM-5E
1581 - 1700KHZ
3-2
PART NO.
PAGE
957-1035-156
3-10
957-1035-157
3-10
TABLE 3-2. OUTPUT NETWORK ASSEMBLY, AM-2.5E- 957-0068
REF. DES.
DESCRIPTION
C1 thru
C5
L1 thru L3,
L5
----------------------
Refer to Frequency Dependant Parts, Output Network Table
in the following text.
Refer to Frequency Dependant Parts, Output Network, AM-1 Table
in the following text.
Spark Gap, 1.5KV
Coil, Variable, 16 uH, 20 Amps, AM Transmitter
BNC Receptacle, Bulkhead, UG492A/U
Lightning Protection Circuit Board Assembly
Directional Coupler Circuit Board Assembly
Lightning Detector Circuit Board Assembly
Output Network Harness
PART NO.
QTY.
----
----
140-0031
360-0088
417-0017
917-0216-003
917-0306-002
917-0306-004
947-0211
TABLE 3-3. OUTPUT NETWORK ASSEMBLY, AM-5E - 957-0070
REF. DES.
-------------------------
DESCRIPTION
Spark Gap, 2.1 kV
Coil, Variable, 16 uH, 20 Amperes, AM Transmitter
BNC Receptacle, Bulkhead, UG492A/U
Connector, 7/16 DIN, Panel Jack, Solder
Lightning Protection Circuit Board Assembly
Directional Coupler Circuit Board Assembly
Lightning Detector Circuit Board Assembly
Output Network Harness
PART NO.
QTY.
140-0024
360-0088
417-0017
417-0716
917-0216-001
917-0306-002
917-0306-004
947-0211
TABLE 3-4. LIGHTNING PROTECTION CIRCUIT BOARD ASSEMBLY, AM-2.5E 917-0216-003
REF. DES.
D1, D2
D3 thru
D5
D6
----
DESCRIPTION
PART NO.
QTY.
Transzorb, 1.5KE300CA, 300BV
Transzorb, 1.5KE250CA, 250BV
206-0300
206-0250
Transzorb, 1.5KE250CA, 300BV
Blank, Lightning Protection Circuit Board
206-0300
517-0216
TABLE 3-5. LIGHTNING PROTECTION CIRCUIT BOARD ASSEMBLY, AM-5E 917-0216-001 (Sheet 1 of 2)
REF. DES.
D1
----
DESCRIPTION
Transzorb, 1.5KE400CA, 400BV
Blank, Lightning Protection Circuit Board
3-3
PART NO.
206-0400
517-0216
QTY.
TABLE 3-5. LIGHTNING PROTECTION CIRCUIT BOARD ASSEMBLY, AM-5E 917-0216-001 (Sheet 2 of 2)
REF. DES.
D2, D3 thru
D6
D7
DESCRIPTION
PART NO.
QTY.
Transzorb, 1.5KE300CA, 300BV
206-0300
Transzorb, 1.5KE400CA, 400BV,
206-0400
TABLE 3-6. DIRECTIONAL COUPLER CIRCUIT BOARD ASSEMBLY - 917-0306-002
(Sheet 1 of 2)
REF. DES.
C201
C202 thru
C217
C218
C219, C220
D201 thru
D204
D205 thru
D208
D209, D210
D211, D212
D213, D214
D215, D216
E202 thru
E208
E209 thru
E211
E212 thru
E217
E219 thru
E221
J201
J202, J203
J204 thru
J206
K201 thru
K205
L201
L202
L203, L204
P203, P204A
P204B, P205A
P205B, P206
R201 thru
R205
R206
R207 thru
R209
R210 thru
R214
DESCRIPTION
PART NO.
QTY.
Capacitor, Mylar Film, 0.01 uF ±10%, 200V
Capacitor, Ceramic, Monolythic, .1 uF ±10%, 50V
030-1043
003-1066
16
Capacitor, Mica, 500 pF ±1%, 500V
Capacitor, Polyester, 0.0022 uF ±10%, 100V
Diode, HP5082-2800, High Voltage, Schottky Barrier Type,
70V, 15 mA
Diode, 1N4148, Silicon, 75V @ 0.3 Amperes
042-5021
031-2033
201-2800
203-4148
Diode, Zener, 1N4749, 24V, 10.5 Amperes
Diode, 1N4148, Silicon, 75V @ 0.3 Amperes
Diode, Zener, 1N4749, 24V, 10.5 Amperes
Diode, 1N4148, Silicon, 75V @ 0.3 Amperes
Turret, Double Shoulder
200-0024
203-4148
200-0024
203-4148
413-0025
Terminal, Male Disconnect
410-0025
Turret, Double Shoulder
413-0025
Turret, Double Shoulder
413-0025
Receptacle, Male, 20-Pin In-Line
Receptacle, Male, 8-Pin In-Line, Right Angle
Receptacle, Male, 20-Pin In-Line
417-0200
417-0080-001
417-0200
Relay, SPST, 5V dc, 500 Ohm, Reed
270-0062
Coil, Molded, Shielded, 5.6 uH
Coil, Molded, Shielded, 56 uH
RF Choke, 10 mH ±10%, 6.3 Ohms DC Resistance, 220 mA Maximum
Jumper, Programmable, 2-Pin
Jumper, Programmable, 2-Pin
Jumper, Programmable, 2-Pin
Potentiometer, 250 Ohm, 2W, Double, 1-Turn
364-0056
360-0093
364-0670
340-0004
340-0004
340-0004
192-2533
Resistor, 30.1 Ohm ±1%, 1/4W
Resistor, 18 Ohm ±1%, 3W
103-3011
130-1821
Resistor, 30.1 Ohm ±1%, 1/4W
103-3011
3-4
TABLE 3-6. DIRECTIONAL COUPLER CIRCUIT BOARD ASSEMBLY - 917-0306-002
(Sheet 2 of 2)
REF. DES.
R215 thru
R222
R223, R224
R226 thru
R229
R230 thru
R233
R234, R235
R236 thru
R239
S201
T201, T202
T203
----
DESCRIPTION
PART NO.
QTY.
Resistor, 200 Ohm ±1%, 1W
120-2031
Potentiometer, 20 k ±10%, 1W, Horizontal, 22 Turn
Resistor, 10 Ohm ±1%, 1/4W
178-2056
103-1021
Resistor, 150 Ohm ±1%, 1W
120-1531
Potentiometer, 20 k ±10%, 1W, Horizontal, 22 Turn
Resistor, 200 Ohm ±1%, 1W
178-2056
120-2031
Switch, SPST, 4- Position, 8-Pin DIP Dual In-line
Transformer, Current, AM-1/5
Transformer, Voltage, AM-1/5
Blank, Directional Coupler Circuit Board
340-0002
370-0040
370-0041
517-0306-002
TABLE 3-7. LIGHTNING DETECTOR CIRCUIT BOARD ASSEMBLY - 917-0306-004
REF. DES.
C401 thru
C420
E201, E202
E403
J401, J402
J403 thru
J405
P403 thru
P405
Q401
S401
----
DESCRIPTION
PART NO.
QTY.
Capacitor, Mica, 1000 pF ±5%, 500V
042-3913
20
Terminal, Male Disconnect
Terminal, Male Disconnect
Receptacle, Male, 20-Pin In-Line
Receptacle, Male, 2-Pin In-line
410-0025
410-0025
417-0200
417-4004
Jumper, Programmable, 2-Pin
340-0004
Phototransistor, 1.8 mA, IC AT 5V
Finger Contact Strip
Blank, Lightning Detector Circuit Board
215-0001
469-0369
517-0306-004
TABLE 3-8. HARNESS OUTPUT NETWORK ASSEMBLY - 947-0211
REF. DES.
----------------------
DESCRIPTION
Contact Housing, 4-Pin In-line
Pins, Connector
Plug, Housing, 2-Pin
Plug, Housing, 14-Pin
Connector, 15-Pin, D-Type
Pins, Crimp Type
Plug, BNC, Dual Crimp
PART NO.
417-0138
417-0142
417-0499
417-1401
417-1500
417-8766
418-0034
3-5
QTY.
13
21
TABLE 3-9. OUTPUT NETWORK FREQUENCY DEPENDANT PARTS, 522-650 KHZ,
AM-2.5E - 957-1035-121
REF. DES.
DESCRIPTION
PART NO.
QTY.
C1
Capacitor, Mica, 5100 pF, 6kV, 20 Amperes, ±5%
044-5123-292
C2
Capacitor, Mica, 3300 pF, 8kV, 16 Amperes, ±5%
044-3323-292
C3
Capacitor, Mica, 5100 pF, 6kV, 20 Amperes, ±5%
044-5123-292
C4
Capacitor, Mica, 8200 pF, 4kV, 20 Amperes, ±5%
044-8223-291
C5
Capacitor, Mica, 3900 pF, 8kV, 18 Amperes, ±5%
044-3923-292
L1
Coil, All Frequency
360-1251-XXX
L2
Coil, All Frequency
360-1252-XXX
L3
Coil, All Frequency
360-1253-XXX
L5
Coil, All Frequency
360-1255-XXX
TABLE 3-10. OUTPUT NETWORK FREQUENCY DEPENDANT PARTS, 651-770 KHZ,
AM-2.5E - 957-1035-122
REF. DES.
DESCRIPTION
PART NO.
QTY.
C1
Capacitor, Mica, 4300 pF, 8kV, 18 Amperes, ±5%
044-4323-292
C2
Capacitor, Mica, 2700 pF, 8kV, 15 Amperes, ±5%
044-2723-292
C3
Capacitor, Mica, 4300 pF, 8kV, 18 Amperes, ±5%
044-4323-292
C4
Capacitor, Mica, 6800 pF, 4kV, 18 Amperes, ±5%
044-6823-291
C5
Capacitor, Mica, 3300 pF, 8kV, 16 Amperes, ±5%
044-3323-292
L1
Coil, All Frequency
360-1251-XXX
L2
Coil, All Frequency
360-1252-XXX
L3
Coil, All Frequency
360-1253-XXX
L5
Coil, All Frequency
360-1255-XXX
TABLE 3-11. OUTPUT NETWORK FREQUENCY DEPENDANT PARTS, 771-920 KHZ,
AM-2.5E - 957-1035-123
REF. DES.
DESCRIPTION
PART NO.
QTY.
C1
Capacitor, Mica, 3600 pF, 8kV, 18 Amperes, ±5%
044-3623-292
C2
Capacitor, Mica, 2200 pF, 8kV, 13 Amperes, ±5%
044-2223-292
C3
Capacitor, Mica, 3600 pF, 8kV, 18 Amperes, ±5%
044-3623-292
C4
Capacitor, Mica, 5600 pF, 4kV, 18 Amperes, ±5%
044-5623-291
C5
Capacitor, Mica, 2700 pF, 8kV, 15 Amperes, ±5%
044-2723-292
L1
Coil, All Frequency
360-1251-XXX
L2
Coil, All Frequency
360-1252-XXX
L3
Coil, All Frequency
360-1253-XXX
L5
Coil, All Frequency
360-1255-XXX
3-6
TABLE 3-12. OUTPUT NETWORK FREQUENCY DEPENDANT PARTS, 921-1080 KHZ,
AM-2.5E - 957-1035-124
REF. DES.
DESCRIPTION
PART NO.
QTY.
C1
Capacitor, Mica, 3300 pF, 8kV, 16 Amperes, ±5%
044-3323-292
C2
Capacitor, Mica, 2000 pF, 10kV, 12 Amperes, ±5%
044-2023-292
C3
Capacitor, Mica, 3300 pF, 8kV, 16 Amperes, ±5%
044-3323-292
C4
Capacitor, Mica, 4700 pF, 6kV, 16 Amperes, ±5%
044-4723-291
C5
Capacitor, Mica, 2200 pF, 8kV, 13 Amperes, ±5%
044-2223-292
L1
Coil, All Frequency
360-1251-XXX
L2
Coil, All Frequency
360-1252-XXX
L3
Coil, All Frequency
360-1253-XXX
L5
Coil, All Frequency
360-1255-XXX
TABLE 3-13. OUTPUT NETWORK FREQUENCY DEPENDANT PARTS, 1081-1300 KHZ,
AM-2.5E - 957-1035-125
REF. DES.
DESCRIPTION
PART NO.
QTY.
C1
Capacitor, Mica, 2700 pF, 8kV, 15 Amperes, ±5%
044-2723-292
C2
Capacitor, Mica, 1600 pF, 10kV, 12 Amperes, ±5%
044-1623-292
C3
Capacitor, Mica, 2700 pF, 8kV, 15 Amperes, ±5%
044-2723-292
C4
Capacitor, Mica, 3900 pF, 6kV, 15 Amperes, ±5%
044-3923-291
C5
Capacitor, Mica, 1800 pF, 10kV, 13 Amperes, ±5%
044-1823-292
L1
Coil, All Frequency
360-1251-XXX
L2
Coil, All Frequency
360-1252-XXX
L3
Coil, All Frequency
360-1253-XXX
L5
Coil, All Frequency
360-1255-XXX
TABLE 3-14. OUTPUT NETWORK FREQUENCY DEPENDANT PARTS, 1301-1580 KHZ,
AM-2.5E - 957-1035-126
REF. DES.
DESCRIPTION
PART NO.
QTY.
C1
Capacitor, Mica, 2200 pF, 8kV, 13 Amperes, ±5%
044-2223-292
C2
Capacitor, Mica, 1300 pF, 10kV, 11.0 Amperes, ±5%
044-1323-292
C3
Capacitor, Mica, 2200 pF, 8kV, 13 Amperes, ±5%
044-2223-292
C4
Capacitor, Mica, 3300 pF, 6kV, 15 Amperes, ±5%
044-3323-291
C5
Capacitor, Mica, 1600 pF, 10kV, 12 Amperes, ±5%
044-1623-292
L1
Coil, All Frequency
360-1251-XXX
L2
Coil, All Frequency
360-1252-XXX
L3
Coil, All Frequency
360-1253-XXX
L5
Coil, All Frequency
360-1255-XXX
3-7
TABLE 3-15. OUTPUT NETWORK FREQUENCY DEPENDANT PARTS, 1581-1700 KHZ,
AM-2.5E - 957-1035-127
REF. DES.
DESCRIPTION
Capacitor, Mica, 1800 pF, 10kV, 13 Amperes, ±5%
Capacitor, Mica, 1100 pF, 10kV, 10 Amperes, ±5%
Capacitor, Mica, 1800 pF, 10kV, 13 Amperes, ±5%
Capacitor, Mica, 2700 pF, 6kV, 13 Amperes, ±5%
Capacitor, Mica, 1300 pF, 10kV, 11 Amperes, ±5%
Coil, All Frequency
Coil, All Frequency
Coil, All Frequency
Coil, All Frequency
C1
C2
C3
C4
C5
L1
L2
L3
L5
PART NO.
044-1823-292
044-1123-292
044-1823-292
044-2723-291
044-1323-292
360-1251-XXX
360-1252-XXX
360-1253-XXX
360-1255-XXX
QTY.
TABLE 3-16. OUTPUT NETWORK FREQUENCY DEPENDANT PARTS, 522-650 KHZ,
AM-5E - 957-1035-151
REF. DES.
DESCRIPTION
PART NO.
QTY.
C1A, C1B
C2
C3A, C3B
C4
Capacitor, Mica, 2700 pF, 8kV, 15 Amperes, ±5%
Capacitor, Mica, 3300 pF, 12kV, 24 Amperes, ±5%
Capacitor, Mica, 2700 pF, 8kV, 15 Amperes, ±5%
Capacitor, Mica, 8200 pF, 4kV, 20 Amperes, ±5%
044-2723-292
044-3323-293
044-2723-292
044-8223-291
C5A
C5B
L1
L2
L3
L5
Capacitor, Mica, 2400 pF, 6kV, 13 Amperes, ±5%
Capacitor, Mica, 1500 pF, 6kV, 9.1 Amperes, ±5%
Coil, All Frequency
Coil, All Frequency
Coil, All Frequency
Coil, All Frequency
044-2423-291
044-1523-291
360-1501-XXX
360-1502-XXX
360-1503-XXX
360-1505-XXX
TABLE 3-17. OUTPUT NETWORK FREQUENCY DEPENDANT PARTS, 651-770 KHZ,
AM-5E - 957-1035-152
REF. DES.
DESCRIPTION
PART NO.
QTY.
C1A, C1B
C2
C3A, C3B
C4
C5A
C5B
L1
L2
L3
Capacitor, Mica, 2200 pF, 8kV, 13 Amperes, ±5%
Capacitor, Mica, 2700 pF, 12kV, 22 Amperes, ±5%
Capacitor, Mica, 2200 pF, 8kV, 13 Amperes, ±5%
Capacitor, Mica, 6800 pF, 4kV, 18 Amperes, ±5%
Capacitor, Mica, 1500 pF, 6kV, 9.1 Amperes, ±5%
Capacitor, Mica, 1800 pF, 6kV, 11 Amperes, ±5%
Coil, All Frequency
Coil, All Frequency
Coil, All Frequency
044-2223-292
044-2723-293
044-2223-292
044-6823-291
044-1523-291
044-1823-291
360-1501-XXX
360-1502-XXX
360-1503-XXX
L5
Coil, All Frequency
360-1505-XXX
3-8
TABLE 3-18. OUTPUT NETWORK FREQUENCY DEPENDANT PARTS, 771-920 KHZ,
AM-5E - 957-1035-153
REF. DES.
DESCRIPTION
PART NO.
QTY.
C1A, C1B
C2
C3A, C3B
C4
C5A
C5B
L1
L2
L3
Capacitor, Mica, 1800 pF, 10kV, 13 Amperes, ±5%
Capacitor, Mica, 2200 pF, 12kV, 20 Amperes, ±5%
Capacitor, Mica, 1800 pF, 10kV, 13 Amperes, ±5%
Capacitor, Mica, 5600 pF, 4kV, 18 Amperes, ±5%
Capacitor, Mica, 1500 pF, 6kV, 9.1 Amperes, ±5%
Capacitor, Mica, 1200 pF, 6kV, 8.2 Amperes, ±5%
Coil, All Frequency
Coil, All Frequency
Coil, All Frequency
044-1823-292
044-2223-293
044-1823-292
044-5623-291
044-1523-291
044-1223-291
360-1501-XXX
360-1502-XXX
360-1503-XXX
L5
Coil, All Frequency
360-1505-XXX
TABLE 3-19. OUTPUT NETWORK FREQUENCY DEPENDANT PARTS, 921-1080 KHZ,
AM-5E - 957-1035-154
REF. DES.
DESCRIPTION
PART NO.
QTY.
C1A, C1B
C2
Capacitor, Mica, 1600 pF, 10kV, 12 Amperes, ±5%
Capacitor, Mica, 2000 pF, 15kV, 20 Amperes, ±5%
044-1623-292
044-2023-293
C3A, C3B
C4
C5A, C5B
L1
L2
L3
L5
Capacitor, Mica, 1600 pF, 10kV, 12 Amperes, ±5%
Capacitor, Mica, 4700 pF, 6kV, 16 Amperes, ±5%
Capacitor, Mica, 1100 pF, 6kV, 8.2 Amperes, ±5%
Coil, All Frequency
Coil, All Frequency
Coil, All Frequency
Coil, All Frequency
044-1623-292
044-4723-291
044-1123-291
360-1501-XXX
360-1502-XXX
360-1503-XXX
360-1505-XXX
TABLE 3-20. OUTPUT NETWORK FREQUENCY DEPENDANT PARTS, 1081-1300 KHZ,
AM-5E - 957-1035-155
REF. DES.
DESCRIPTION
PART NO.
QTY.
C1A, C1B
C2
C3A, C3B
C4
C5A, C5B
L1
L2
L3
Capacitor, Mica, 1300 pF, 10kV, 11 Amperes, ±5%
Capacitor, Mica, 1600 pF, 15kV, 18 Amperes, ±5%
Capacitor, Mica, 1300 pF, 10kV, 11 Amperes, ±5%
Capacitor, Mica, 3900 pF, 6kV, 15 Amperes, ±5%
Capacitor, Mica, 910 pF, 6kV, 7.5 Amperes, ±5%
Coil, All Frequency
Coil, All Frequency
Coil, All Frequency
044-1323-292
044-1623-293
044-1323-292
044-3923-291
044-9113-291
360-1501-XXX
360-1502-XXX
360-1503-XXX
L5
Coil, All Frequency
360-1505-XXX
3-9
TABLE 3-21. OUTPUT NETWORK FREQUENCY DEPENDANT PARTS, 1301-1580 KHZ,
AM-5E - 957-1035-156
REF. DES.
C1A, C1B
C2
C3A, C3B
C4
C5A, C5B
L1
L2
L3
L5
DESCRIPTION
Capacitor, Mica, 1100 pF, 10kV, 10 Amperes, ±5%
Capacitor, Mica, 1200 pF, 15kV, 15 Amperes, ±5%
Capacitor, Mica, 1100 pF, 10kV, 10 Amperes, ±5%
Capacitor, Mica, 3300 pF, 6kV, 15 Amperes, ±5%
Capacitor, Mica, 820 pF, 6kV, 6.8 Amperes, ±5%
Coil, All Frequency
Coil, All Frequency
Coil, All Frequency
Coil, All Frequency
PART NO.
044-1123-292
044-1223-293
044-1123-292
044-3323-291
044-8213-291
360-1501-XXX
360-1502-XXX
360-1503-XXX
360-1505-XXX
QTY.
TABLE 3-22. OUTPUT NETWORK FREQUENCY DEPENDANT PARTS, 1581-1700 KHZ,
AM-5E - 957-1035-157
REF. DES.
C1A, C1B
C2
C3A, C3B
C4
C5A, C5B
L1
L2
L3
L5
DESCRIPTION
Capacitor, Mica, 910 pF, 10kV, 9.1 Amperes, ±5%
Capacitor, Mica, 1100 pF, 20kV, 15 Amperes, ±5%
Capacitor, Mica, 910 pF, 10kV, 9.1 Amperes, ±5%
Capacitor, Mica, 2700 pF, 6kV, 13 Amperes, ±5%
Capacitor, Mica, 620 pF, 6kV, 6.2 Amperes, ±5%
Coil, All Frequency
Coil, All Frequency
Coil, All Frequency
Coil, All Frequency
3-10
PART NO.
044-9113-292
044-1123-293
044-9113-292
044-2723-291
044-6213-291
360-1501-XXX
360-1502-XXX
360-1503-XXX
360-1505-XXX
QTY.
SECTION IV
OUTPUT NETWORK ASSEMBLY DRAWINGS
4-1.
INTRODUCTION.
4-2.
This section provides assembly drawings, wiring diagrams, and schematic diagrams as
listed below for the Broadcast Electronics AM-2.5E/AM-5E transmitter output network
assembly.
FIGURE
4-1
4-2
4-3
----
4-4
TITLE
NUMBER
SCHEMATIC DIAGRAM, OUTPUT NETWORK AM-2.5E
ASSEMBLY
SCHEMATIC DIAGRAM, DIRECTIONAL COUPLER
CIRCUIT BOARD
SCHEMATIC DIAGRAM, LIGHTNING DETECTOR
CIRCUIT BOARD
REFER TO PART I, SECTION VII FOR THE ECU
DISPLAY CIRCUIT BOARD ASSEMBLY
ASSEMBLY DIAGRAM, LIGHTNING PROTECTION BOARD
4–1
SB957-0068
SB917-0306-002
SB917-0306-004
AD917-0306-001/
-002/-003/-004/-005
/-006/-007/-009/-014
AB917-0216-003
TABLE OF CONTENTS
PARAGRAPH
SECTION I
1-1
1-3
1-5
1-6
1-9
1-10
1-11
1-12
1-13
1-14
1-16
1-17
1-19
1-21
1-24
1-26
1-31
1-33
1-36
1-38
1-43
1-46
1-50
1-51
1-55
1-57
1-71
1-73
1-74
1-82
1-84
1-88
1-91
1-93
1-95
1-97
1-99
1-100
1-104
1-105
1-106
1-107
1-109
1-110
1-111
1-117
1-118
PAGE NO.
ECU THEORY OF OPERATION
Introduction
General Description
Functional Description
ECU Display Circuit Board
Exciter Monitor Mode Control Circuit
Autorange Circuit
Polarity Control Circuit
Half-Wave Rectifier Circuit
Meter Circuitry
Indicator Circuitry
Reset Switch
ECU Switch Circuit Board
ECU Meter Switch Circuit Board
Motherboard
Controller Circuit Board
Cabinet/External Interlock and Remote Control
Fail-Safe
External Mute
Antenna Interlock
Remote Control
Power On
Power Control Circuit
Power Control Trim Circuit
Transmitter Off
AC Power Interruptions
Forward and Reflected Power Circuitry
Foldback Protection
Attack Signal Operation
1.2: 1 VSWR Conditions
Foldback Recovery
Exciter Monitoring
Power Supply Monitoring
RF Power Module Monitoring
Fault Circuit
Oscillator Circuit
Over-Cycle Off Circuit
Power Supply Circuit
Exciter Circuit Board
Left/Right Channel Input Circuit
Mono Mode Switching
24 uS Delay Circuit
Negative Limiter
IPM Correction Circuit
PWM Circuit
PWM Driver Circuit
Frequency Synthesizer
PWM Reference Circuit
Lock Detector Circuit
1-1
1-1
1-1
1-1
1-1
1-2
1-2
1-2
1-2
1-2
1-2
1-2
1-3
1-3
1-3
1-3
1-4
1-4
1-9
1-9
1-10
1-11
1-11
1-12
1-12
1-13
1-16
1-16
1-16
1-17
1-18
1-18
1-19
1-19
1-19
1-19
1-20
1-20
1-23
1-23
1-23
1-23
1-23
1-24
1-24
1-24
1-25
PARAGRAPH
1-120
1-124
1-125
1-128
1-129
1-130
1-131
1-132
1-134
1-135
1-136
1-137
1-138
1-142
1-146
1-147
1-148
1-149
1-150
1-155
1-158
1-160
1-161
SECTION II
2-1
2-3
2-6
2-9
2-11
2-13
2-15
2-17
2-19
2-20
2-21
2-22
2-23
2-24
2-25
2-26
2-27
2-28
2-29
2-30
2-31
2-32
2-33
2-34
2-35
2-48
PAGE NO.
Stereo Detection Circuit
IPM Wave Shape Circuit
Phase Modulator Circuit
RF Drive Circuit
Exciter Failure Detector Circuit
Power Supply Circuits
Stereo Circuit Board
Equalization Circuitry
8 Microsecond Delay Circuit
4 Microsecond Delay Circuit
All-Pass Filter
Equalization Selection Circuit
L+R and L-R Matrix Circuit
Phase Modulator Circuit
Band-Pass Filter
Transistor Amplifier Circuit
Amplitude Limiter Circuit
Output Network
Operating Mode Selection and Indication Circuit
Equalization Selection
Pilot Signal
Power Supply Filter Network
ECU Power Supply Assembly
1-25
1-25
1-25
1-26
1-26
1-26
1-26
1-26
1-29
1-29
1-29
1-29
1-29
1-30
1-31
1-31
1-31
1-31
1-31
1-32
1-32
1-32
1-32
TRANSMITTER ECU MAINTENANCE
Introduction
Safety Considerations
ECU Circuit Board Installation/Removal
First Level Maintenance
Cleaning and Inspection
Second Level Maintenance
Electrical Adjustments
ECU Extender Circuit Board Operation
Controller Circuit Board Adjustments
P1 Set - P5 Set Controls
FWD and RFL Calibrations
ECU Meter Switch Circuit Board Adjustments
Forward Power Meter Low and High Scale
Calibrations
Reflected Power Meter Low and High Scale
Calibrations
FWD and RFL Calibrations
Stereo Circuit Board Adjustments
Stereo Adjustment
Exciter Circuit Board Adjustments
Modulation Calibration
Phase Modulator Calibration
Symmetry Control
IPM Correction Circuit Controls
Single Chan Mono Level Control
Average Modulation Limit Control
Neg Limit Control
Frequency Calibration Control
2-1
2-1
2-1
2-2
2-2
2-2
2-2
2-3
2-3
2-3
2-3
2-3
2-3
2-3
2-4
2-4
2-4
2-4
2-4
2-4
2-4
2-4
2-4
2-4
2-4
2-5
PARAGRAPH
2-58
2-59
2-66
2-67
2-68
2-69
SECTION III
3-1
SECTION IV
4-1
PAGE NO.
Display Circuit Board Adjustments
L/L+R and R/L-R Display Calibration Control
Troubleshooting
Safety Considerations
Troubleshooting Procedures
Component Replacement Procedure
2-6
2-6
2-6
2-6
2-7
2-11
ECU ASSEMBLY PARTS LIST
Introduction
3-1
ECU ASSEMBLY DRAWINGS
Introduction
4-1
LIST OF ILLUSTRATIONS
FIGURE
1-1
1-2
1-3
TITLE
PAGE NO.
CONTROLLER CIRCUIT BOARD
SIMPLIFIED SCHEMATIC
EXCITER CIRCUIT BOARD
SIMPLIFIED SCHEMATIC
STEREO CIRCUIT BOARD
SIMPLIFIED SCHEMATIC
1-5
1-21
1-27
LIST OF TABLES
TABLE
2-1
2-2
2-3
2-4
3-1
TITLE
EXCITER CIRCUIT BOARD TROUBLESHOOTING
STEREO CIRCUIT BOARD TROUBLESHOOTING
CONTROLLER CIRCUIT BOARD
TROUBLESHOOTING
ECU POWER SUPPLY TROUBLESHOOTING
REPLACEABLE PARTS LIST INDEX
PAGE NO.
2-7
2-9
2-10
2-11
3-1
SECTION I
ECU THEORY OF OPERATION
1-1.
INTRODUCTION.
1-2.
This section presents a general description of the Broadcast Electronics AM-2.5E/AM-5E
transmitter ECU (Exciter/Controller unit).
1-3.
GENERAL DESCRIPTION.
1-4.
The AM-2.5E/AM-5E transmitter control, status/monitoring circuitry, audio/power PWM
generation, stereo generation circuitry, and meter display circuitry is contained in the
ECU (Exciter/Controller unit) assembly. The ECU is a modular control center designed
for the installation of the: 1) controller circuit board assembly, 2) ECU display and switch
circuit boards, 3) transmitter forward/reflected power meter displays, 4) exciter circuit
board assembly, 5) stereo generator circuit board assembly, and 6) ECU power supply
assembly.
1-5.
FUNCTIONAL DESCRIPTION.
1-6.
ECU DISPLAY CIRCUIT BOARD.
1-7.
The ECU display circuit board contains the controller status display indicators, the power
control switch/indicators, and meter display circuitry (refer to schematic diagram
SD917-0206-001/-008). The circuit board is equipped with the following display
indicators: 1) exciter, 2) power supply, 3) power module, 4) antenna, 5) interlock,
6) remote control, 7) lightning, 8) antenna interlock, 9) foldback, and
10) over-temperature. Control switches include power level 1, power level 2, power level
3, power level 4, power level 5, raise power, and lower power switch/indicators. The meter
display circuitry consists of a driver circuit and a stereo 30-segment LED bar-graph
display.
1-8.
The ECU display circuit board also contains left/L+R and right/L-R audio metering
circuits. The left/L+R and right/L-R metering circuits are identical. Therefore, only the
left/L+R metering circuit will be discussed in the following text.
1-9.
EXCITER MONITOR MODE CONTROL CIRCUIT. Left, right, and L+R metering samples
from the exciter circuit board and an L-R meter sample from the stereo circuit board are
applied to integrated circuit U1. U1 is controlled by latch U5A and mode switch S1.
When S1 is depressed, a LOW is applied to inverter U4B. U4B outputs a HIGH to clock
latch U5A. The Q output of U5A will respond by routing a HIGH to: 1) U1 and 2) bias Q3
on to illuminate the L+R/L-R switch LED. U1 will select L+R/L-R information for
application to the autorange circuitry. When S1 is depressed again, a HIGH from U4B
will clock latch U5A. The Q output of U5A will respond by routing a HIGH to: 1) U1 and
2) bias Q4 on to illuminate the left/right switch LED. U1 will select left/right channel
audio for application to the autorange circuit.
1-1
1-10.
AUTORANGE CIRCUIT. The autorange circuit consists of integrated circuits U2A, U3A,
1-11.
POLARITY CONTROL CIRCUIT. Positive or negative signal monitoring is controlled by
1-12.
HALF-WAVE RECTIFIER CIRCUIT. Integrated circuit U8A and U8B function as a
1-13.
METER CIRCUITRY. The output of the half-wave rectifier circuit is applied to a meter
circuit consisting of: 1) integrated circuits U9, U10, and U11, and 2) 10-segment LEDs
DS7, DS8, and DS9. The output from U8B is applied to meter drivers U9, U10, and U11.
U9/U10/U11 control 10-segment LED sections DS7, DS8 and DS9. Drivers U9/U10/U11
function to illuminate the required segments of DS7/DS8/DS9 to display the left/L+R
levels. One-shot U12 is provided to identify short modulation peaks.
1-14.
INDICATOR CIRCUITRY. The display circuit board is equipped with several indicators.
1-15.
Indicators DS15 through DS20 provide status indications for over-temperature, foldback,
antenna conflict, lightning, remote control, and interlock conditions. The indicators are
controlled by drivers on the controller circuit board. When activated, the drivers will
output a LOW to illuminate the indicators.
1-16.
RESET SWITCH. The reset of fault conditions is provided by switch S3. When S3 is
1-17.
ECU SWITCH CIRCUIT BOARD.
1-18.
ECU power level switches S803 through S807, raise switch S801, lower switch S802, and
off switch S808 are located on the controller switch circuit board (refer to schematic
diagram SD917-0206-001/-008). The switches output +15 volts to activate a function.
and U3B. An output of U1 is routed to integrated circuit U2A and U3A. U3A is
configured as an amplifier stage. U2A is configured as an amplifier/buffer stage. When
audio is applied to the circuit, U3A amplifies the audio. The output of U3A is half-wave
rectified by diode D1. The output of D1 is applied to integrated circuit U3B. U3B is
configured as a comparator. When the audio level is above the threshold at U3B, U3B
will output a HIGH to transistor Q1. The HIGH biases Q1 off to configure U2A as a
buffer. When the audio level is below the threshold at U3B, U3B will output a LOW to:
1) bias Q1 on to configure U2A as an amplifier with a gain of 10 and 2) illuminate X10
indicator DS1. The output of U2A is routed for application to the polarity control circuit.
polarity switch S2. Audio from the mode control circuit is applied to integrated circuit
U6A and U7. U6A is configured as an inverting buffer. When S1 is depressed, a LOW is
applied to inverter U4C. U4C outputs a HIGH to clock latch U5B. The Q output of U5B
will respond by routing a HIGH to: 1) U7 and 2) bias Q6 on to illuminate the negative
switch LED. U7 will select inverted audio from U6A for application to a rectifier circuit.
When S1 is depressed again, a HIGH from U4C will clock latch U5B. U5B will respond
by routing a HIGH to: 1) U7 and 2) bias Q5 on to illuminate the positive switch LED. U7
will select non-inverted audio for application to a rectifier circuit.
half-wave rectifier circuit. Audio from integrated circuit U7 is applied to U8A/U8B.
U8A/U8B half-wave rectify the audio for application to the meter display circuitry.
Resistor R38 and capacitor C21 establish the meter ballistics.
DS22, DS23, DS24, and DS25 are bi-color LEDs providing status indications for the
exciter, power supply, RF power modules, and antenna. The indicators are controlled by
drivers on the controller circuit board. When activated, the drivers will output a HIGH to
illuminate the indicators. A yellow display is generated when the red and green LEDs
are illuminated simultaneously.
depressed, a HIGH is routed to the controller circuit board to reset the fault conditions.
The switch LED will illuminate when one of the following fault condition occurs:
1) over-temperature, 2) exciter, 3) power supply, 4) RF power module, 5) reflected power
high, 6) reflected power emergency, 7) lightning conditions, or 8) 1.2 : 1 VSWR.
1-2
1-19.
ECU METER SWITCH CIRCUIT BOARD.
1-20.
ECU meter switches S501 and S502 are located on the ECU meter switch circuit board
(refer to schematic diagram SD917-0206-005). The switches control the signals applied
to the forward and reflected power meters. Low scale control R501 and high scale control
R503 calibrate the forward power meter. Low scale control R505, high scale control 506,
and ac sample control R511 calibrate the reflected power meter.
1-21.
MOTHERBOARD.
1-22.
The interfacing of transmitter status signals, audio, PWM/RF drive signals, and operating
commands to/from the ECU circuit boards is provided by the ECU motherboard assembly
(refer to schematic diagram SB917-0201). Connectors J4, J5, and J6 route status inputs
and control commands to/from the ECU assembly. 80-pin connector J101 is provided for
the exciter circuit board. 50-pin connector J201 is provided for the stereo exciter circuit
board. 80-pin connector J302 and 50-pin connector J301 are provided for the controller
circuit board. Connector J8 routes status signals to/from the display circuit board.
Connector J10 routes control and status signals to/from the switch circuit board.
1-23.
The motherboard also contains RFI filters for the ECU remote inputs and outputs. The
filter circuitry consists of single PI-section low-pass RC and LC networks. The networks
prevent RFI from entering the exciter and controller circuitry.
1-24.
CONTROLLER CIRCUIT BOARD.
1-25.
All transmitter operations are directed by the controller circuit board (refer to Figure
1-1). The controller circuit board is a digital CMOS logic assembly containing control and
parameter monitoring/display circuitry. The control circuitry includes an antenna
interlock circuit, a power control network, and a foldback control circuit. The
monitor/display circuitry includes exciter, power supply, power module, antenna,
interlock, remote control, lightning, antenna interlock, foldback, and over-temperature
networks. The circuitry determines the transmitter output power control operating
characteristics and responses to fault conditions such as an ac power failure, load failure,
power supply failure, or remote control unit failure.
1-26.
CABINET/EXTERNAL INTERLOCK AND REMOTE CONTROL FAIL-SAFE. The controller
circuit board monitors: 1) an external interlock and 2) a remote control failsafe interlock.
The external interlock is any interlock external to the transmitter such as a test load
interlock. The remote control failsafe is an input requiring a +5 to +15 volt signal to
indicate the remote control unit is operational. If the external interlock and the remote
control failsafe are closed, the ECU interlock indicator will illuminate and the
transmitter may be energized. If the external interlock opens or the remote control
failsafe signal is removed, the transmitter will immediately de-energize and the interlock
indicator will extinguish.
1-27.
External Interlock. The transmitter external interlock is an optically coupled input
designed to accept the output of a series interlock switch circuit external to the
transmitter. The circuit accepts a +5 volt to +15 volt output of an interlock circuit
external to the transmitter such as from a test load. Optical coupling of the external
interlock input to the controller circuitry is provided by U11. Diode D17 protects the
circuit from a reverse polarity potential applied to the input.
1-3
1-28.
A HIGH is required at the input of coupler U11 when the external interlock is closed.
U11 will output a HIGH to OR gate U69B in the transmitter enable circuit. The HIGH
will configure U69B to output a HIGH to AND gate U71B. U71B will output a HIGH
cabinet command to allow the transmitter to be energized. U71B also outputs a HIGH to
NAND gate U71D. With a HIGH failsafe command, U71D will output a HIGH to
illuminate the interlock indicator. When the external interlock is opened, a LOW is
applied to U11. The output of U11 will go LOW. OR gate U69B will respond by
outputting a LOW to AND gate U71B. U71B will output a LOW cabinet command. A
LOW cabinet command configures a power control circuit to operate the transmitter to
off. U71D will output a LOW to: 1) extinguish the interlock indicator and 2) generate a
LOW operate command. A LOW operate command mutes: 1) the exciter PWM signal and
2) the power supply circuit board(s).
1-29.
Remote Control Fail-safe. The remote control failsafe input is designed to accept a +5 to
+15 volt output from the remote control unit failsafe connection. The signal is optically
coupled to the controller circuitry by integrated circuit U56. Diode D23 protects the
circuit from a reverse polarity potential applied to the input.
1-30.
A HIGH is required at the input of U56 to indicate when the remote control unit is
operational. The output of coupler U56 will go HIGH. The HIGH will configure OR gate
U45C to output a HIGH failsafe signal. The failsafe signal is applied to AND gate
U71D. With a HIGH cabinet signal, U71D will output a HIGH to illuminate the interlock
indicator. The HIGH will also bias driver transistor Q48 on to illuminate remote failsafe
indicator DS2. When the remote control failsafe signal is removed, a LOW is applied to
U56. The output of U56 will go LOW. The LOW generates a LOW transmitter operate
command to mute: 1) the exciter PWM signal, 2) the power supply circuit board(s), and
3) extinguish remote failsafe indicator DS2. The LOW from U56 will generate a LOW
failsafe command. The LOW is applied to U71D. U71D will output a LOW to extinguish
the interlock indicator.
1-31.
EXTERNAL MUTE. The controller circuit board monitors the transmitter mute signal.
The external mute input is designed to accept a +5 to +15 volt output from an antenna
switch controller RF mute circuit. The signal is optically coupled to the controller
circuitry by U10. Diode D16 protects the circuit from a reverse polarity potential applied
to the input.
1-32.
A HIGH is required at the input of coupler U10 when the external mute circuit is
required to mute the transmitter RF power output. U10 will output a HIGH to OR gate
U13C and NOR gate U24A. U13C will output a HIGH to inverter U25A. U25A will
output a LOW to U22B. The LOW will configure U22B to output a LOW operate
command to mute: 1) the exciter PWM signal and 2) the power supply circuit board(s).
U24A will output a LOW to disable the antenna conflict indicator operations.
1-33.
ANTENNA INTERLOCK. The controller circuit board is equipped with an antenna
interlock circuit. The circuit accepts: 1) control signals from power levels 2 through 5,
and 2) status inputs from three antenna systems. The antenna interlock circuit consists
of: 1) programming switches S1 through S3, 2) OR gates U12A/B and U21A/B, and
3) NAND gates U20A through U20D. The circuit analyzes the information and
determines if a correct antenna system and power level is selected for operation.
1-4
COPYRIGHT
1999 BROADCAST ELECTRONICS, INC
597-1112-29
FIGURE 1-1. CONTROLLER CIRCUIT BOARD
SIMPLIFIED SCHEMATIC
(SHEET 1 OF 2)
(1-5/1-6)
COPYRIGHT
1999 BROADCAST ELECTRONICS, INC
597-1112-29B
FIGURE 1-1. CONTROLLER CIRCUIT BOARD
SIMPLIFIED SCHEMATIC
(SHEET 2 OF 2)
(1-7/1-8)
1-34.
To provide an operational example, antenna 1 is designed to operate with power level 2.
When antenna 1 is connected to the transmitter, a HIGH status signal is applied to
optical coupler U7. U7 outputs a HIGH to switch S1. S1 is a four-section SPST switch.
The S1 switch sections are assigned the following power levels: 1) power level 2, 2) power
level 3, 3) power level 4, and 4) power level 5. The switch is programmed by closing the
switch sections for the power levels which are acceptable for the antenna 1 system. The
outputs of programming switch S1 are applied to a control network consisting of: 1) a
power level 2 circuit, 2) a power level 3 circuit, 3) a power level 4 circuit, and 4) a power
level 5 circuit. Each power level control circuit contains an OR gate to monitor the status
of the antenna systems and an AND gate to monitor the status of the selected power level.
1-35.
With S1 programmed to operate with power level 2, the HIGH from U7 is applied to OR
gate U12A. U12A will output a HIGH to NAND gate U20A. With power level 2 selected,
a HIGH from BCD-to-decimal decoder U18 will be applied to U20A. U20A will respond
by routing a HIGH to OR gate U21C. U21C will output a HIGH to OR gate U13B.
Programmable jumper J1 is provided to disable the antenna interlock circuit. With the
antenna interlock circuit enabled, U13B will output a HIGH to NOR gate U24A and AND
gate U22B. With no mute or off commands present, U24A will output a LOW to disable
antenna conflict indicator driver Q16. With a closed interlock system and no ac failures
or failsafe conditions present, U22B will output a HIGH operate command to enable the
transmitter.
1-36.
REMOTE CONTROL. The transmitter control functions, status indications, and metering
1-37.
Remote control of the transmitter is enabled or disabled by remote/local switch S4. S4
enables remote control operation by applying a positive voltage to optical couplers U1
through U6, U32/U33, and U53. S4 disables remote control operation by applying a
ground to the couplers. The remote position allows both local and remote transmitter
control. The local position allows only local control of the transmitter. The remote control
inputs and outputs are RFI filtered on the motherboard for maximum reliability.
1-38.
POWER ON. A transmitter power on operation initiates a sequence to determine if all
1-39.
Transmitter power is enabled when a power level switch/indicator is activated. For
example, when the ECU power level 2 switch/indicator is depressed, a HIGH is applied to
priority encoder U14. When a remote power level 2 command activated, a HIGH is
applied to optical coupler U4. U4 will output a HIGH to U14. U14 analyzes power level
and off commands to determine priorities when two switches are operated simultaneously.
The off command is assigned the highest priority. When the power level 2 command is
received, U14 will output a binary number to latch U15. U15 outputs the binary number
to latch U17. U15 and U17 operate in association to provide the appropriate output
timing of the binary number to the antenna interlock circuit and to the power control
circuit.
signals are designed for remote operation. Control functions require a +5 volt to +15 volt
dc signal to activate the function. Status indications will output a LOW (0 volts) when
active. The remote meter indications can be programmed for +5 volt or +2.5 volt
full-scale meter operations. The circuitry may be interfaced to any type of remote control
unit.
the interlocks are closed and the remote control unit is operational. RF output power
from the transmitter is enabled by commands from the power level 1 through power level
5 switch/indicators. Each power level switch/indicator provides a one-button power on
start command and configures the transmitter for a specific power output level. Each
switch/indicator will illuminate as selected to indicate the command has been received
and stored by the controller power control circuit.
1-9
1-40.
The binary power level 2 command from latch U17 is routed to: 1) BCD-to-decimal
decoder U18 and 2) multiplexer U39. U18 is designed to decode the binary number from
U17 and output a HIGH on the appropriate control line to indicate the selected power
level. With the power level 2 selected, a HIGH from BCD-to-decimal decoder U18 is
applied to AND gate U20A. With antenna 1 switch S1 programmed to operate with power
level 2, a HIGH from OR gate U12A is also applied to U20A. U20A will respond by
routing a HIGH to OR gate U21C. U21C will output a HIGH to OR gate U13B. U13B
will output a HIGH to U22B.
1-41.
AND gates U69B, U71B, and U71D monitor the status of the external interlock, the
remote control failsafe input, and the external/exciter mute commands. The circuit
functions to determine if all the interlocks are closed, the remote control unit is
operational, and the exciter is operational. If the external interlock is closed and the
remote control unit is operational, U71D will output a HIGH to U22B. If no external or
exciter mute commands are present, U13C will output a LOW to inverter U25A. U25A
will output a HIGH to U22B. With a HIGH antenna interlock signal from U13B
indicating a proper antenna/power level selection, U22B will output a HIGH operate
command to the power control circuit, an exciter/power supply mute circuit, and a high
reflected power circuit.
1-42.
The HIGH operate signal is routed to the power control circuit to allow the transmitter to
be energized. If the remote control unit fails, or the external or exciter mute signal is
activated, U22B will output a LOW operate command. The LOW operate command
mutes: 1) the exciter PWM signal and 2) the power supply circuit board(s). If the cabinet
or external interlock is opened, AND gate U71B will output a LOW cabinet command. A
LOW cabinet command configures the power control circuit to operate the transmitter to
off. U71D will output a LOW to: 1) extinguish the interlock indicator and 2) generate a
LOW operate command. A LOW operate command mutes: 1) the exciter PWM signal and
2) the power supply circuit board(s).
1-43.
POWER CONTROL CIRCUIT. Binary power level information from latch U17 is applied
1-44.
U42 is designed to output a reference voltage to a power control driver circuit. U42 is
controlled by up/down counters U30 and U31, multiplexer U27, priority encoder U28, and
divider U26. The up/down counters, multiplexer, and priority encoder function to output
clock signals to U42 in response to fault conditions. U42 will respond by
increasing/decreasing the power reference voltage in response to foldback and release
commands from U27. With no foldback or release signals, U42 will output the power
level 2 reference voltage without change to a power control driver circuit.
to multiplexer U39. U39 decodes the power level number and selects a reference voltage
from a potentiometer network. Potentiometers R2 through R6 provide a voltage reference
proportional to output power for power levels 1 through 5. For example, power level 2
selected for operation. With power level 2 selected, U39 will select a reference voltage
from potentiometer R5. The voltage is routed through buffer U40B to digital-to-analog
converter U42.
1-10
1-45.
Power Control Driver Circuit. The power control driver circuit consists of: 1) operational
amplifiers U40B and U44A, 2) switch U41A, and 3) AND gate U36C. The power level
reference voltage from U42 is applied to integrated circuit U40B. U40B is configured as
an inverting amplifier. The output of U40B is applied to comparator U44A and switch
U41A. U41A is controlled by the sample from the output of U44A. U41A is a feedback
control network designed to convert the reference voltage from U40B to a voltage
proportional to power. U44A compares the power level reference to a ramp signal
generated by integrated circuit U40C. U44A produces a square-wave PWM
(pulse-width-modulated) signal which varies in response to the power level. The signal
is ANDed at U36C with the operate signal from U22B. With a HIGH operate signal from
U22B, the PWM signal is routed through carrier control driver Q22 to the power supply
circuit board.
1-46.
POWER CONTROL TRIM CIRCUIT. The transmitter RF output power level can be
trimmed to a desired level by the raise/lower switch/indicators. When a raise or lower
switch/indicator is depressed, a HIGH is applied to the raise/lower power adjust circuit.
The circuit consists of: 1) logic gates U24B, U31D, U16B, U23C, and U19C, 2) up/down
counters U34 and U35, and 3) digital-to-analog converter U43. The circuit is designed to
increase or decrease RF output power by increasing/decreasing the reference voltage.
1-47.
Logic gates U24B, U31D, U16B, U23C, and U19C control up/down counters U34 and U35.
NOR gate U24B and OR gate U31D monitor raise, lower, and foldback signals. NOR gate
U24B is designed to configure counters U34/U35 to count up or down. U24B will output a
HIGH to configure U34/U35 to count up. U24B will output a LOW to configure U34/U35
to count down. For example, when the raise switch/indicator is depressed, a HIGH is
applied to U34/U35. The HIGH configures U34/U35 to count up. U34/U35 will output
binary numbers to digital-to-analog converter U43. U43 decodes the numbers from
U34/U35 and increases the power control reference voltage generated from power control
D-to-A converter U42. U42 outputs the increased reference voltage to the power control
driver circuit to increase the RF output power.
1-48.
Logic gates U16B, U23C, and U19C control the loading of counters U34/U35. The logic
gates monitor: 1) high reflected power conditions, 2) reset conditions, and 3) trim reset
operations. Trim reset is when the power control trim is reset to mid-range when a
power level switch/indicator is depressed. If a trim reset condition, a reset condition, or a
high reflected power condition occurs, U19C will output a HIGH to counters U34/U35.
The HIGH resets counters U34/U35 to mid-range.
1-49.
Trim Reset. Trim reset is a function which resets the power control trim function to
mid-range when a power level switch/indicator is depressed. When a power level switch
is depressed, a HIGH trim reset command from U14 is applied through jumper P12 to OR
gate U19C. U19C will output a HIGH to up/down counters U34/U35. The HIGH
configures U34/U35 to mid-range. With U34/U35 at mid-range, the power trim circuit
can be raised or lowered an equal amount. Jumper P12 allows the trim reset function to
be disabled if required.
1-50.
TRANSMITTER OFF. RF output power is immediately terminated when the ECU off
switch is depressed. When the off switch/indicator is depressed, a HIGH is applied to OR
gate U13A. U13A will output a HIGH to priority encoder U14. U14 will output a binary
number through latches U15/U17 to BCD-to-decimal decoder U18 and to multiplexer
U39. U18 will output a HIGH to NOR gate U23A. U23A will output a HIGH to bias
power contactor driver Q13 off to disable the fans and the power supplies. U39 will
respond by terminating the power control reference voltage to terminate the power
control PWM signal
1-11
1-51.
AC POWER INTERRUPTIONS. The AM-2.5E/AM-5E transmitters are designed to
respond to two different types of ac power interruptions: 1) momentary and 2) extended.
The transmitter will respond to a momentary power interruption by automatically
returning to on-air operation immediately after power is returned to the transmitter.
Automatic return of the transmitter to on-air operation is provided by the controller
circuit board battery backup circuit which maintains the transmitter configuration
information. In the event of an extended ac power interruption, the controller circuit
board is equipped with a programmable ac loss/auto-off circuit. The circuit is designed to
output an off command once power is returned to the transmitter. The ac loss circuit may
be programmed to output an off command after a 1 minute, 4.5 minute, 17 minute, or 68
minute ac power interruption. The circuit primarily designed to be used to prevent the
transmitter from automatically returning to an incorrect antenna or power level after a
power failure.
1-52.
The ac loss detection/auto-off circuit consists of: 1) one-shots U57A/U68B, 2) divider U58,
3) OR gate U62C, 4) NOR gate U52A, and inverter U54C. When ac power is applied to
the unit, 120 Hz pulses from an ac detection circuit on the power supply circuit board are
applied to integrated circuit U68B. U68B will respond by routing a LOW pulse to:
1) one-shot U57A, 2) OR gate U62C, and 3) inverter U54C. One-shot U57A responds by
providing a one second delay to allow the circuitry to stabilize. U54C responds by
inverting the LOW to provide a HIGH reset pulse to counter U58. The HIGH disables
counter U58 and prevents the counter from generating an ac fail command.
1-53.
When ac power interruption is detected, U68B: 1) routes a HIGH pulse to one-shot
U57A, OR gate U62C, and inverter U54C and 2) outputs a LOW ac fail command. U57A
will output a HIGH to U62C. U62C will output a a HIGH ac fail command. U54C inverts
HIGH to output a LOW to counter U58. U58 will begin a count operation. 0.5 Hz clock
pulses for U58 are provided by U52A and an battery backed-up oscillator. Programmable
jumper P6 programs the counter to provide a 1, 4.5, 17, or 68 minute shutdown command.
When the programmed time has elapsed, U58 will output a HIGH shutdown command to
OR gate U37A. The HIGH is routed through U37A and U31A to priority encoder U14 to
automatically operate the transmitter to off.
1-54.
The shutdown signal is also applied to AND gate U71C. If fault conditions have occurred,
U71C will AND a LOW from NOR gate U55 to output a LOW to latch U49D. U49D will
output a LOW to bias transistor Q52 on to maintain the battery supply and the fault
indication circuitry. If no fault conditions exist, U71C will AND a HIGH from NOR gate
U55. U71C will output a HIGH to latch U49D. U49D will output a HIGH to bias
transistor Q52 off to terminate battery operation.
1-55.
FORWARD AND REFLECTED POWER CIRCUITRY. Transmitter forward and reflected
power voltage samples are processed by forward and reflected power monitoring circuits.
The circuits are identical therefore, only the forward power circuit will be described.
1-12
1-56.
A voltage sample of the forward power is applied through potentiometer R56 and resistor
R183 to integrated circuit U63D. Potentiometer R56 allows the forward power circuit to
be calibrated. U63D operates in association with diodes D35/D36 as a full-wave rectifier.
The full-wave rectified output from U63D is applied to a third order high-pass filter
consisting of U63A, R60, R61, R67, C63, C64, and C88. The dc output of the filter is
applied to comparator U61D. U61D compares the forward power sample to a ramp
voltage generated by integrated circuit U40C. U61D will output a square-wave signal
equal to the forward power voltage sample. The output of U63D is applied to switch
U41B. U41B functions as a feedback control device designed to convert the forward
power voltage sample into a signal proportional to power. The square-wave output from
U41B is applied to a low-pass filter consisting of resistor R70 and capacitor C89. The
output of the low-pass filter generates a dc voltage which is proportional to the forward
power. The voltage is amplified by operational amplifier U64A. The output of U64A is
applied to: 1) the fault detection circuitry, 2) a +5 volt full-scale meter output, and 3)
buffer U64B. Buffer U64B operates in association with programmable jumper P2 to
provide a +2.5 volt full-scale meter output. Jumper P2 enables or disables the +2.5 volt
full-scale meter output.
1-57.
FOLDBACK PROTECTION. The controller circuit board is designed to monitor several
1-58.
If the controller detects a high reflected/forward power, a high VSWR, lightning, or an
over-temperature condition, the foldback circuit will automatically reduce the transmitter
RF output power to an acceptable operating level to prevent damage to the transmitter. If
the controller detects a high reflected power or VSWR condition, the antenna status
indicator will illuminate as described below to indicate the problem.
operating parameters for problem conditions. Several of the monitored conditions are
routed to a foldback circuit. The foldback circuit will automatically reduce the
transmitter RF output power to an acceptable operating level to prevent damage to the
transmitter. The controller monitors: 1) the cabinet temperature for over-temperature
conditions, 2) reflected power for a high reflected power condition, 3) forward power for
high forward power conditions, and 4) lightning detector for lightning conditions. When
an over-temperature, high reflected power, or a high VSWR condition occurs, the foldback
indicator will illuminate to indicate the transmitter is in a foldback condition.
ANTENNA STATUS INDICATOR
1-59.
CONDITION
YELLOW
1.2 : 1 VSWR or greater.
RED
High reflected power condition. A reflected
power condition equal to 100 watts for AM-2.5E
models or 200 watts for AM-5E models.
FLASHING RED
Reflected power emergency condition. A
reflected power condition equal to 500 watts for
AM-2.5E models or 1000 watts for AM-5E
models.
High Forward Power Circuitry. High forward power conditions are monitored by a high
forward power fault detection circuit. Integrated circuits U66A and U66B are configured
as comparators designed to monitor forward power conditions. U66B functions as an
output power monitor. Integrated circuit U66B compares a forward power sample from
U64A to a power control sample. U66A compares a forward power sample from U41B to a
voltage reference.
1-13
1-60.
Comparators U66A/U66B operate in association to monitor high forward power
conditions. U66A/U66B use the high reflected power attack circuitry to reduce the
transmitter power when a high forward power condition occurs. When the transmitter
power is greater than 90%, U66B will output a HIGH. When a high forward power
conditions results in the forward power sample to increase above the voltage reference by
approximately 20%, the output of U66A will go HIGH. The HIGH is applied to AND gate
U47B. With a HIGH from U66B, U47B will output a HIGH to OR gate U62A. U62A will
output a HIGH to AND gate U47A. With a HIGH enable failure signal, U47A will output:
1) a HIGH reflected power high attack signal to priority encoder U28 and 2) a HIGH to
latch U67A. The HIGH reflected power attack signal is used by U28 to initiate an attack
sequence to reduce the transmitter output power. The HIGH to U67A will configure
U67A to output a HIGH reflected power signal to enable latch U48D. U48D will output a
HIGH to bias: 1) alarm status indicator driver transistors Q34 and Q35 on and
2) antenna indicator driver Q28 on. When the transmitter power is reduced to
approximately 90%, the output of U66B will go LOW. The LOW is applied to U47B.
U47B will output a LOW through U62A to U47A. U47A will respond by routing a LOW to
terminate the high reflected power attack signal. The indicators will remain illuminated
until the alarm reset switch is depressed.
1-61.
High Reflected Power Circuitry. Integrated circuit U65C monitors reflected power
conditions. U65C compares a reflected power sample from U64C to a voltage reference.
When the reflected power sample increases above the voltage reference, the output of
U65C will go HIGH. The HIGH is applied through OR gate U62A to AND gate U47A.
With a HIGH enable failure signal, U47A will output: 1) a HIGH reflected power high
attack signal to priority encoder U28 and 2) a HIGH to latch U67A. The HIGH reflected
power attack signal is used by U28 to initiate an attack sequence to reduce the
transmitter output power. The HIGH to U67A will configure U67A to output a HIGH
reflected power signal to enable latch U48D. U48D will output a to HIGH to bias:
1) alarm status indicator driver transistors Q34 and Q35 on and 2) antenna mismatch
indicator driver Q28 on.
1-62.
Over-temperature Circuitry. Over-temperature conditions are monitored by an
over-temperature fault detection circuit. A dc voltage representing the transmitter
temperature is applied to: 1) integrated circuits U65A/U65B and 2) integrated circuit
U61A. When the temperature voltage increase above a reference voltage, the output of
U65A will go HIGH. The HIGH is routed to AND gate U51D. With a HIGH enable
failure signal, U51D will output: 1) a HIGH over-temperature attack signal to priority
encoder U28 and 2) a HIGH to latch U67C. The HIGH over temperature attack signal is
used by U28 to initiate an attack sequence to reduce the transmitter output power. The
HIGH to U67C will configure U67C to output a HIGH: 1) over-temperature signal to
latch U49B and 2) to AND gate U47D. The output of U49B will go HIGH to bias:
1) alarm status indicator driver transistors Q34 and Q35 on and 2) over-temperature
indicator drivers Q32 and Q36 on. When the transmitter temperature is reduced to 70
degrees C, the output of U65A will go LOW and the output of U65B will go HIGH. The
LOW is applied to U51D. U51D will output a LOW to terminate the over-temperature
attack signal. The indicators will remain illuminated until the alarm reset switch is
depressed. The from HIGH from U65B is also applied to U47D. With the HIGH from
U67C, U47D will output a over temperature release signal to encoder U28.
1-63.
U61A is configured as a comparator designed to monitor extreme temperature conditions.
When the temperature voltage increases above the reference voltage, the output of U61A
will go HIGH. U61A will output a HIGH temperature shutdown command to U13A of the
transmitter off control circuit.
1-14
1-64.
Reflected Power Emergency. Reflected power emergency conditions are monitored by
comparator U66D. U66D compares a reflected power sample to a fast voltage reference
from U63C. When a reflected power emergency causes the sample to increase above the
reference, the output of U66D will go LOW. The LOW is applied to OR gate U62B. U62B
will output a LOW reflected power emergency attack signal to NAND gate U60D. With a
HIGH lightning detector signal indicating no lightning activity, U60D will output a HIGH
to latch U59A and OR gate U45B. U45B will output a HIGH: 1) to AND gate U47C, 2) to
OR gate U19A, and 3) emergency mute command. With a HIGH enable failure signal,
U47C will output a HIGH fast foldback attack signal to priority encoder U28. U19A will
output a HIGH to: 1) bias driver transistor Q50 on to illuminate PWM mute indicator
DS3 and 2) inverter U54A. U54A will output a LOW to bias driver transistor Q51 off to
mute the PWM signal.
1-65.
A LOW reflected power emergency attack signal is also applied to inverter U60C. U60C
will output a HIGH to OR gate U69C. U69C is designed as a latching gate. When a
reflected power emergency attack signal is present, a LOW foldback reset command will
bias transistor Q56 off. This allows the output of U69C to be latched HIGH to maintain
the indicator circuitry when the condition is removed.
1-66.
The HIGH from U69C is applied to reflected power emergency latch U49A. The output of
U49A will go HIGH. The HIGH is applied to: 1) OR gate U50B, 2) NOR gate U55,
3) AND gate U51A, and 4) transistor Q29. OR gate U50B will output a HIGH to bias Q39
off to disable the green antenna status indicator. NOR gate U55 will output a LOW which
is inverted at U54F. U54F will output a HIGH to bias Q34 and Q35 on to enable the
alarm indicator. U51A ANDs a 2 Hz signal with the HIGH from U49A to generate a
flashing signal to OR gate U50C. U50C will output the signal through U51 and U50 to
transistor Q38. The output of Q38 will flash to generate a flashing red antenna status
indicator. Transistor Q29 will be biased on to provide a LOW remote reflected power
emergency signal.
1-67.
Lightning Conditions. Lightning conditions are monitored by NAND gate U60D. When
lightning is detected at the transmitter output, the lightning detector status input will go
LOW. The LOW is applied to NAND gate U60D and inverter U46B. U60D will output a
HIGH to latch U59A and to OR gate U45B. With a HIGH from U60D, U45B will output a
HIGH: 1) to AND gate U47C, 2) to OR gate U19A, and 3) emergency mute command.
With a HIGH enable failure signal, U47C will output a HIGH fast foldback attack signal
to priority encoder U28. U19A will output a HIGH to: 1) bias driver transistor Q50 on to
illuminate PWM mute indicator DS3 and 2) inverter U54A. U54A will output a LOW to
bias driver transistor Q51 off to mute the PWM signal.
1-68.
Inverter U46B will respond by routing a HIGH to latch U49C. The output of U49C will
go HIGH. The HIGH is applied to NOR gate U55 and to transistors Q33 and Q37. The
HIGH will bias Q33 and Q37 on to illuminate the lightning status indicators. NOR gate
U55 will output a LOW which is inverted at U54F. U54F will output a HIGH to bias Q34
and Q35 on to enable the alarm indicator.
1-69.
Foldback Indication. Two circuit functions are monitored to indicate when the
transmitter is in a foldback condition: 1) when the Q2 output of U28 is HIGH and
2) when the carryout signal of U31 is HIGH. When priority encoder U28 outputs a binary
number in response to an attack signal, the Q2 output of U28 will be HIGH. The HIGH is
applied to latch U67D. The Q output of U67D will go HIGH. The HIGH is inverted at
U25C and applied to NAND gate U16C.
1-15
1-70.
When a foldback condition, counter U31 will not be clocked to a maximum number
resulting in a HIGH carryout signal. The HIGH is inverted at U25B. U25B will output a
LOW to U16C. With a LOW from U25B or U25C, U16C will output a HIGH to foldback
indicator driver transistors Q20 and Q21. The transistors will be biased on to indicate the
transmitter is in a foldback condition.
1-71.
ATTACK SIGNAL OPERATION. During high reflected/forward power, reflected power
1-72.
The signal from U27 is applied to up/down counters U30/U31. U30/U31 will respond by
counting down and routing binary numbers to digital-to-analog converter U42. U42 will
respond by routing a reduced voltage reference to U43. U43 will output a reduced
reference voltage to reduce the transmitter output power.
1-73.
1.2 : 1 VSWR CONDITIONS. 1.2 : 1 VSWR conditions are monitored by a VSWR
detection circuit. The detection circuit consists of comparator U66C. U66C compares a
forward power sample to a reflected power sample. When the reflected power sample
increases above a forward power sample at approximately 1.2: 1, the output of U66C will
go LOW. The LOW is inverted at U54E. U54E will output a HIGH 1.2 : 1 VSWR signal to
OR gate U50C. U50C will output a HIGH to AND gate U51B and NAND gate U52C.
With a LOW reflected power emergency signal from U51A, U51B will output a LOW to
AND gate U50D. With a HIGH from U50C and a LOW from U51A, AND gate U52C will
output a LOW to U50D. U50D will respond by routing a LOW to antenna status red
indicator driver Q38. The output of Q38 will go LOW to bias the red antenna indicator
on. With no reflected power conditions, the output of OR gate U50B will be LOW. The
LOW biases the green antenna indicator on. This will result in a yellow antenna LED
indication.
1-74.
FOLDBACK RECOVERY. When the foldback circuit is activated in response to a problem,
the controller will initiate a recovery sequence. The following text describes the reflected
power recovery, over temperature recovery, and reflected power emergency/lightning
recovery.
1-75.
High Reflected Power Recovery. When the reflected power is reduced to a level below
the reference at U65C, U65C will output a LOW to U62A. With a LOW from U47B, U62A
will output a LOW to U47A. U47A will output a LOW reflected power high attack signal
to terminate foldback operation. Once the problem which caused the high reflected power
condition is removed, the transmitter will output a high reflected power release signal
(refer to the following text).
1-76.
High Forward Power Recovery. High forward power conditions use the high reflected
power circuitry to reduce/recover the transmitter output power. When the transmitter
power is reduced to approximately 90%, the output of comparator U66B will go LOW. The
LOW is applied to AND gate U47B. U47B will output a LOW through U62A to AND gate
U47A. U47A will respond by routing a LOW to terminate the high reflected power attack
signal. Once the problem which caused the high forward power condition is removed, the
transmitter will output a high reflected power release signal (refer to the following text).
emergency, over-temperature, or lightning conditions, an attack signal is applied to
priority encoder U28. U28 is designed to determine priorities if two attack signals occur
simultaneously. U28 will respond by routing a binary number to multiplexer U27. U27
will respond by selecting a clock signal from integrated circuit U26. U26 is a divider
designed to generate several clock signals. The clock signals are used to drive the power
control circuit up/down counters up or down as determined by the type of attack or
release signal applied to U28. For example, a high reflected power condition selects a 4
Hz clock signal. An over-temperature signal will select a 1/16th Hz clock signal.
1-16
1-77.
High Reflected Power Release Signal. A reflected power release signal is controlled by
AND gate U38A. When condition causing the high forward/reflected power condition is
removed, a HIGH operate signal, a HIGH 1.2 : 1 VSWR signal from comparator U66C,
and a HIGH from latch U67A will be ANDed at U38A. U38A will respond by routing a
HIGH reflected power release signal to priority encoder U28. U28 will respond by
routing a binary number to multiplexer U27. U27 will respond by selecting a clock signal
from integrated circuit U26. U26 is a divider designed to generate several clock signals.
The clock signals are used to drive the power control circuit up/down counters up as
determined by the type of release signal applied to U28. For example, a high reflected
power release condition selects a 2 Hz clock signal. The 2 Hz clock signal from U27 is
applied to up/down counters U30/U31. U30/U31 will respond by counting up and routing
binary numbers to digital-to-analog converter U42. U42 will respond by routing an
increased voltage reference to U43. U43 will output an increased reference voltage to
increase the transmitter output power.
1-78.
Over-Temperature Recovery. When the condition which caused the over-temperature
problem is removed, the transmitter will initiate a recovery sequence. The output of
comparator U65A will go LOW. The LOW is applied to AND gate U51D. With a HIGH
enable failure signal, U51D will output a LOW to terminate the over-temperature attack
signal.
1-79.
When the temperature is reduced to approximately 55 degrees C, the output of
comparator U65B will go HIGH. The HIGH is applied to AND gate U47D. With the
HIGH from latch U67C, U47D will output a HIGH over-temperature release signal to
priority encoder U28. U28 will respond by routing a binary number to multiplexer U27.
U27 will respond by selecting a 1/16 Hz clock signal from integrated circuit U26. The
1/16 Hz clock signal from U27 is applied to up/down counters U30/U31. U30/U31 will
respond by counting up and routing binary numbers to digital-to-analog converter U42.
U42 will respond by routing an increased voltage reference to U43. U43 will output an
increased reference voltage to increase the transmitter output power.
1-80.
Reflected Power Emergency/Lightning Recovery. When the condition which caused the
reflected power emergency/lightning problem is removed, the transmitter will initiate a
recovery sequence. The sequence is initiated by comparator U65D. U65D compares a fast
reflected power voltage sample to a reference voltage. When the sample voltage is below
the reference, the output of U65D will go HIGH. The HIGH is applied to AND gate
U71A. With a HIGH from latch U67B, U71A will output a fast foldback release signal to
priority encoder U28. U28 will respond by routing a binary number to multiplexer U27.
U27 will respond by selecting a 512 Hz clock signal from integrated circuit U26. The 512
Hz clock signal from U27 is applied to up/down counters U30/U31. U30/U31 will respond
by counting up and routing binary numbers to digital-to-analog converter U42. U42 will
respond by routing an increased voltage reference to U43. U43 will output an increased
reference voltage to increase the transmitter output power.
1-81.
In addition to the sequence initiated by U65D, a HIGH foldback reset command is applied
to transistor Q56. The HIGH biases Q56 on to unlatch OR gate U69C. U69C will output
a LOW to latch U49A to allow the latch to be reset.
1-82.
EXCITER MONITORING. The operating condition of the exciter is monitored by a exciter
status circuit. During an exciter fault condition, the exciter fault status input will go
HIGH. The HIGH is applied to AND gate U36D. With a HIGH enable failure signal,
U36D will output a HIGH to latch U48A. U48A will output a HIGH to: 1) bias driver
transistor Q45 off to extinguish the exciter indicator green LED and 2) inverter U46A.
U46A will output a LOW to bias driver transistor Q44 on. This will illuminate the
exciter indicator red LED.
1-17
1-83.
A HIGH exciter fault signal is also applied to OR gate U13C. U13C will output a HIGH to
inverter U25A. U25A will output a LOW to AND gate U22B. U22B will output a LOW
transmitter operate command to mute: 1) the exciter PWM signal and 2) the power
supply circuit board(s).
1-84.
POWER SUPPLY MONITORING. The power supply(s) operating condition is monitored
by a power supply status circuit. The following text presents the power supply
monitoring operations.
1-85.
Power Supply Fault. During a power supply fault condition, the power supply fault status
input will go LOW. The LOW is applied to OR gate U45A. With a LOW ac fail signal
present, U45A will output a LOW to NAND gate U60A. With a HIGH power supply
emergency signal present from U46D, U60A will output a HIGH to latch U48B. U48B
will output a HIGH to: 1) bias driver transistor Q43 off to extinguish the power supply
indicator green LED and 2) NOR gate U52D. U52D will output a LOW to bias driver
transistor Q42 on. This will illuminate the power supply indicator red LED.
1-86.
Power Supply Emergency Condition. During a power supply emergency condition, the
power supply emergency fault status input will go HIGH. The HIGH is applied to AND
gate U36B. With a HIGH enable failure signal present, U36B will output a HIGH to:
1) inverter U46D and 2) OR gate U37B. U46D will output a LOW to NAND gate U60A.
U60A will output a HIGH to latch U48B. U48B will output a HIGH to: 1) bias driver
transistor Q43 off to extinguish the power supply indicator green LED and 2) NOR gate
U52D. U52D will output a LOW to bias driver transistor Q42 on to illuminate the power
supply indicator red LED. With a HIGH from U36B applied to U37B, U37B will output a
HIGH emergency off signal to OR gate U37A. This configures U37A and OR gate U13A
to generate a transmitter off signal.
1-87.
Power Supply Maintenance Condition. During a power supply maintenance condition,
the power supply maintenance fault status input will go HIGH. The HIGH is applied to
NOR gate U52D. U52D will output a LOW to bias transistor Q42 on. This will illuminate
the power supply indicator red LED. With no power supply fault indications, the output
of U48B will be LOW. The LOW bias driver transistor Q43 on to illuminate the power
supply indicator green LED. The simultaneous illumination of the indicator green and
red LEDs will produce a yellow maintenance indication.
1-88.
RF POWER MODULE MONITORING. The RF power module operating condition is
monitored by an RF power module status circuit. The following text presents the RF
power module monitoring operations.
1-89.
RF Power Module Fault. During an RF power module fault, the power supply fault status
input will go LOW. The LOW is applied to inverter U46F. U46F will output a HIGH to
latch U48C. U48C will output a HIGH to: 1) bias driver transistor Q41 off to extinguish
the RF power module indicator green LED and 2) NOR gate U52B. U52B will output a
LOW to bias driver transistor Q40 on. This will illuminate the RF power module
indicator red LED.
1-90.
RF Power Module Maintenance Condition. During an RF power module maintenance
condition, the RF power module maintenance fault status input will go HIGH. The HIGH
is applied to NOR gate U52B. U52B will output a LOW to bias transistor Q40 on. This
will illuminate the RF power module indicator red LED. With no RF power module fault
indications, the output of U48C will be LOW. The LOW will bias driver transistor Q41 on
to illuminate the RF power module indicator green LED. This simultaneous illumination
the indicator green and red LEDs will produce a yellow maintenance indication.
1-18
1-91.
FAULT CIRCUIT. Exciter, power supply, RF power module, reflected power high, reflected
1-92.
When a fault condition is removed, the fault circuit latch must be manually reset using
the reset switch. When the reset switch is depressed, a HIGH reset command is applied
to OR gate U12C. U12C will output a HIGH reset command to latches U48A, U48B,
U48C, U48D, U49A, U49B, and U49C. The Q output of each latch will go LOW. The
LOWs are applied to NOR gate U55. U55 will output a HIGH to inverter U54F. U54F
will output a LOW to bias driver transistors Q34 and Q35 off to extinguish the alarm
indicator.
1-93.
OSCILLATOR CIRCUIT. Reference frequencies for controller circuit operation are
1-94.
Integrated circuit U40C compares a 1 kHz signal to a reference voltage. As a result,
U40C will output a ramp signal to comparator U44A. U44A uses the signal to generate
the power control PWM signal. The ramp symmetry is controlled by R30 and R31.
1-95.
OVER-CYCLE OFF CIRCUIT. The controller circuit board is equipped with an over-cycle
1-96.
The circuit monitors the transmitter off, power supply mute, and ac fail conditions. AND
gate U22B provides off signals during manual off operations. NOR gate U23A provides
an off signal during power supply mute conditions. AC fail provides an off signal during
ac fail conditions. During a transmitter off operation, a LOW from AND gate U22B, NOR
gate U23A, or AC fail is applied to AND gate U22A. U22A will output a LOW to inverter
U25F. U25F will output a HIGH: 1) to pulse generator U59B and 2) power inhibit signal.
U59B will output a HIGH to capacitor C132. If the transmitter is operated to off 7 times
within 15 seconds, capacitor C132 will charge and provide a HIGH to comparator U44D.
When the voltage increases above the reference, U44D will output a HIGH over-cycle off
command to OR gate U37B. U37B will output a HIGH emergency off command to operate
the transmitter to off if one of the following conditions occur: 1) open cabinet or external
interlock, 2) power supply emergency, 3) over-cycle off, or 4) the ac line is above 260 Volts.
The emergency off signal is routed to the remote panel by transistor Q56.
1-97.
POWER SUPPLY CIRCUIT. The controller circuit board operates from ±15 volt dc
power emergency, over-temperature, lightning, or a 1.2 : 1 VSWR conditions are
monitored for faults by individual status circuits. In the event of a fault, the appropriate
circuit will latch the fault for display by the controller circuit board indicators. If a circuit
detects a fault condition, a HIGH signal will be applied to NOR gate U55. U55 will output
a LOW to inverter U54F. U54F will output a HIGH to bias alarm driver transistors Q34
and Q35 on to illuminate the alarm indicator.
provided by an oscillator circuit. The oscillator circuit consists of: 1) comparators U40C
and U44B, 2) resistors R24, R28, R27, R29, R30 and R31, 3) capacitor C38, and 4) inverter
U46A. The oscillator is designed to output a 1 kHz square wave signal. Oscillator
symmetry control is provided by resistors R24 and R27. The oscillator frequency is
controlled by resistor R29 and capacitor C38.
circuit. The circuit is designed to prevent damage to the crowbar resistors on the power
supply circuit board during 7 transmitter on/off cycles within 15 seconds. Conditions
causing the transmitter to over-cycle off include ac failure and manual on/off control
operation. The circuit consists of AND gate U22A, inverter U25F, pulse generator U59B,
capacitor C132, and comparator U44D.
supplies. The +15 volt supply is equipped with a battery backup system. A nine volt
battery provides a dc supply to maintain the controller logic during an ac power failure.
Switch S5 allows the battery to be tested. When switch S5 is depressed, the battery
voltage is applied to comparator U44C. If the battery voltage is above the reference, the
output of U44C will go LOW to illuminate battery ok indicator DS1.
1-19
1-98.
The battery backup system is equipped with a battery save function. If no fault
conditions have occurred during a power failure, NOR gate U55 will output a HIGH to
AND gate U71C. With a HIGH shutdown signal, U71C will output a HIGH to latch
U49D. U49D will output a HIGH to bias transistor Q52 off to terminate battery
operation.
1-99.
EXCITER CIRCUIT BOARD.
1-100.
LEFT/RIGHT CHANNEL INPUT CIRCUIT. Left/right channel audio from the studio or
1-101.
Left channel audio is applied to a balanced 600 Ohm resistive impedance network and an
80 kHz RFI filter network. The impedance and RFI filter networks are located on the
motherboard assembly. The output of the circuitry on the motherboard is applied to a
defeatable 10 Hz high-pass filter network consisting of capacitors C147 through C150 and
jumpers P12A and P12B. The 10 Hz high-pass filter is provided to remove low frequency
residual products from specific audio processing units. Jumpers P12A and P12B are
provided to bypass the high-pass filter networks. The output from the high-pass filter
network is applied to an instrumentation amplifier.
1-102.
Integrated circuits U1A, U1B, and U2A are configured as an instrumentation amplifier
circuit. The circuit is designed to provide balanced-to-unbalanced signal conversion.
The output of the instrumentation amplifier is applied to a defeatable high frequency
boost circuit. The high frequency boost circuit is designed to increase high frequency
response to compensate for a Bessel filter in the pulse-width-modulation (PWM)
modulator circuit. If the high frequency boost circuit is enabled, the circuit will result in
a compromise between the frequency and transient response performance. If the high
frequency boost circuit is enabled, the transmitter frequency response will increase
approximately 2 dB at 10 kHz and the transient response will degrade. If the high
frequency boost circuit is disabled, the transmitter frequency response will decrease 2 dB
at 10 kHz and the transient response will improve. Programmable jumper P2 is provided
to bypass the left channel high frequency boost circuit if required. The output of the high
frequency boost circuit is routed to an active PWM filter/equalizer and a mono mode
switching circuit.
1-103.
Integrated circuits U3A and U3B are configured as an active PWM filter/equalizer. The
PWM filter/equalizer is a fifth order low-pass filter. The filter is incorporated into the
circuit to match the characteristics of a filter contained in the pulse-width-modulation
(PWM) circuitry. The filter is required to provide: 1) accurate left and right channel
metering and 2) superior stereo equalization. The output from the PWM filter/equalizer
is routed for application to the stereo circuit board.
audio processing equipment is applied to the exciter circuit board left and right channel
input circuits (refer to Figure 1-2). The input circuits consist of: 1) RFI filters,
2) high-pass filter networks, 3) instrumentation amplifiers, 4) high frequency boost
circuitry, and 5) active PWM filter equalizers. The left and right channel input circuits
are identical. Therefore, only the left channel input circuit is discussed.
1-20
COPYRIGHT
1999 BROADCAST ELECTRONICS, INC
597-1112-24A
FIGURE 1-2. EXCITER CIRCUIT BOARD
SIMPLIFIED SCHEMATIC
(1-21/1-22)
1-104.
MONO MODE SWITCHING. Left and right channel audio from the input circuit is
applied to monophonic mode selection integrated circuit U39. U39 is controlled by:
1) mono L, mono R, and mono SC signals from the stereo circuit board and 2) mono left or
mono right channel select jumper P4. If the transmitter is equipped with the stereo
circuit board and monophonic operation is required, LOW control signals from the
following control lines are applied to configure U39 to select the desired monophonic
audio: 1) mono SC control line and 2) mono L or mono R control lines. If the transmitter
is not equipped with the stereo circuit board, jumper P4 is installed in the left or right
channel position to configure U39 to select left or right channel audio for monophonic
operation. The output of U39 is applied to single channel monophonic boost amplifier
U8A. The monophonic boost circuit is designed to provide up to 6 dB of additional gain
for monophonic operations. This level allows the transmitter to operate at 100%
modulation. Potentiometer R41 allows the adjustment of the monophonic boost level. A
monophonic boost control in most audio processing equipment also provides additional
gain for monophonic conditions. If the transmitter is configured for stereo operation, U39
sums the left and right channels to produce the stereo L+R information. The L+R
information is applied through monophonic boost circuit U8A to the 24 uS delay circuit.
1-105.
24 uS DELAY CIRCUIT. Integrated circuits U8B, U9A, and U9B are configured as a 24
1-106.
NEGATIVE LIMITER. The output from the delay circuit is applied to a negative limiter
1-107.
IPM CORRECTION CIRCUIT. L+R audio from negative limiter U14A is applied through
1-108.
A power control PWM signal from the controller circuit board is applied to low-pass filter
U17B. U17B is designed to convert the power control PWM signal to a dc control voltage.
The output of U17B is applied to inverting amplifier U17A. The output of U17A provides
an IPM power reference signal to the IPM wave shape circuit.
1-109.
PWM CIRCUIT. L+R audio from the negative limiter circuit is applied to amplifier U14B.
uS delay circuit. The delay circuit is incorporated into the L+R audio path to ensure all
required stereo equalization will be performed in the L-R audio path. This eliminates the
requirement for complex adjustable delay circuitry in the L+R path.
circuit. The circuit consists of integrated circuit U14A, diodes D1 and D2, and negative
limit control R76. The circuit is designed to prevent the loss of carrier during negative
modulation. Potentiometer R76 allows the circuit to be adjusted from 90% to 100%. The
output of the limiter is applied a incidental-phase-modulation (IPM) correction circuit
and a PWM circuit. A sample from the negative limiter circuit is applied to comparator
U43. When the negative limiter circuit is enabled, the output of U43 will go high to
illuminate negative limiter indicator DS5.
buffer U15A to a low-pass filter. The filter is a fifth order low-pass filter consisting of
integrated circuits U15B and U16A. The filter is designed to provide: 1) the correct time
delay for IPM correction and 2) the correct frequency response for L+R metering. The
output from the filter: 1) is applied to inverting buffer U16B and 2) provides an IPM
adjust signal to the IPM corrector circuit. Buffer U16B inverts the L+R signal and
removes a dc sample introduced by the negative limiter. The output of U16B is applied to
the L+R metering circuitry.
U14B amplifies the L+R signal to a 4 volt peak-to-peak level with a -0.5 volt dc potential.
This provides a 40% nominal duty cycle at the output of a PWM comparator to allow the
circuitry to modulate the transmitter from -100% to +150%. The output of U14B is
applied to high-speed PWM comparator U22A. U22A compares the L+R signal with a
reference signal from integrator U12 to generate a square-wave PWM control signal. The
square wave duty cycle varies in response to the L+R audio level. The output of U22A is
applied to the PWM driver circuit and an exciter failure detector circuit.
1-23
1-110.
PWM DRIVER CIRCUIT. The PWM control signal from PWM comparator U22A is applied
1-111.
FREQUENCY SYNTHESIZER. The exciter circuit board frequency synthesizer is a
1-112.
The synthesizer operates from binary coded carrier frequency information entered into
frequency programming switch S2. The binary formatted frequency is applied to
frequency synthesizer integrated circuit U25. U25 operates from 10.24 MHz reference
oscillator Y1. Capacitor C108 allows the reference to be calibrated. Regulator U24
provides a stable voltage supply for frequency synthesizer U25.
1-113.
Once programmed, U25 will output a series of rectangular-wave pulses to loop filter
U26B and low-pass filter U26A. U26A and U26B function together to generate a stable
dc control voltage for application to a voltage-controlled-oscillator (VCO) module. The
control voltage is used by the VCO module to generate a precision frequency reference. A
constant current source for the VCO module is provided by transistor Q3.
1-114.
Precision alignment of the VCO output is maintained by the phase-locked-loop design.
Feedback samples are monitored by a lock detector circuit. If the VCO frequency shifts
from the programmed operating state, the output of U25 will change to adjust the control
voltage and maintain a stable VCO output.
1-115.
The output of the VCO module is applied through transistor amplifier Q4 to inverter
U30A. The output of U30A is applied to NAND gate U30B. A sample of U30A is applied
to U25 for feedback.
1-116.
The output of U30B is applied to a synchronous divider consisting of integrated circuits
U29, U31A, U31B, U42A, and U42B. Depending on the carrier frequency: 1) the original
synthesizer frequency or a divide-by-2 frequency is used to generate a 4XFc (four times
carrier frequency) signal for application to the stereo circuit board and 2) a divide-by-4 or
a divide-by-8 signal is used to generate the carrier frequency. The carrier frequency is
applied to NAND gate U30C. Jumpers P6A and P6B program the divider as determined
by the carrier frequency.
1-117.
PWM REFERENCE CIRCUIT. The PWM frequency is generated by oscillator Y2, binary
a PWM driver circuit. The circuit consists of: 1) inverters U21A through U21F, 2) line
drivers U19, U20, and U45, and 3) diodes D6 through D21 and D47 through D50. The
PWM control signal is applied to inverters U21A through U21F. The inverted PWM
signals from U21A through U21F are applied to inverting line drivers U19, U20, and U45.
U19, U20, and U45 operate in parallel to lower the output impedance. The outputs from
U19, U20, and U45 are applied to each RF amplifier module modulator circuit board.
Diodes D6 through D21 and D47 through D50 protect U19/U20/U45 from latch-up
conditions. The PWM circuit is protected from over-modulation conditions by an
over-modulation PWM mute circuit consisting of transistor Q23, capacitor C173, and
diode D65. If the modulation level increases above 150%, the circuit will output a HIGH
to mute line drivers U19, U20, and U45.
phase-locked-loop circuit which generates and maintains the phase and frequency of a
voltage-controlled-oscillator (VCO) to a high level of precision. The circuit is designed
with the ability to synthesize: 1) 119 frequencies within the 522 kHz to 1705 kHz AM
broadcast band in 10 kHz increments or 2) 123 frequencies within the 522 kHz to 1705
kHz AM broadcast band in 9 kHz increments.
counter U44, and switch S1. The PWM frequency generator outputs a 115.4 kHz to 138.5
kHz signal to an integrator circuit. The PWM frequency is: 1) generated by one of four
different crystals and 2) determined by several operating parameters. The output of U44
is applied to Integrator U12. U12 is designed to generate a precision triangle-wave signal
for application to PWM comparator U22A. Programming switch S1 is used to program
the PWM frequency generator circuit. The PWM frequency, crystal, and switch
programming are recorded in the final test data sheets.
1-24
1-118.
LOCK DETECTOR CIRCUIT. The frequency synthesizer circuit is monitored for proper
operation by a lock detector circuit. Integrated circuits U28A, U28B, and U36A function
as a lock detector circuit. The circuit monitors an output sample signal and a divided
VCO sample signal from U25. If the VCO and the reference phases are within ±180
degrees, the VCO is locked to the correct frequency. If the phases are out of tolerance, the
output of U36A will go LOW. The LOW is applied to comparator U27. The output of U27
will go HIGH to extinguish lock indicator DS4 and is inverted at U33A. U33A will output
a LOW to U30B which mutes the output of the frequency synthesizer.
1-119.
A sample from the lock detector circuit is applied to divide-by-3600 circuit. The circuit
consists of integrated circuits U34, U35A, U35B, U35C, and U36B. The divider circuit is
designed to generate a 25 Hz pilot signal for application to the stereo circuit board.
1-120.
STEREO DETECTION CIRCUIT. The presence of a stereo signal is detected by a stereo
1-121.
Stereo signals from the stereo circuit board are applied to programmable jumper P7. P7
selects a stereo signal from the internal stereo circuit board or from an external source.
The external source is applied to a processing circuit consisting of integrated circuit U32C
and the associated circuitry. The processing circuit provides ac coupling, over-voltage
limiting, and square-wave generation.
1-122.
Either an external or internal stereo signal from P7 is applied to an RF detector circuit.
The RF detector consists of: 1) resistors R151 through R155, 2) capacitors C124 and C125,
and 3) diode D27. The detector rectifies the signal for application to an automatic
mono/stereo select circuit consisting of integrated circuits U32A, U30B, U32C, and U32D.
1-123.
The mono/stereo select circuit will route a stereo or mono signal to an RF drive circuit in
response to the presence of stereo. If a stereo signal is present, the output of U32A will be
LOW. The LOW will disable mono on gate U30C and enable stereo on gate U32B. The
stereo signal from U32B will be applied through NAND gate U32D to a phase modulator
circuit. If a stereo signal is not present, the output of U32A will be HIGH. The HIGH
will enable U30C and disable U32B to allow the monophonic RF signal to be applied to the
phase modulator circuit.
1-124.
IPM WAVE SHAPE CIRCUIT. The IPM adjust and IPM power reference signals from the
1-125.
PHASE MODULATOR CIRCUIT. A phase modulator circuit is incorporated into the
detection circuit. This circuit allows the transmitter to be: 1) converted to monophonic
operation by removing the stereo circuit board or 2) converted to stereophonic operation
by inserting the stereo circuit board. The circuit will also detect the presence of an
external stereo signal.
IPM correction circuit are applied to an IPM wave shape circuit. The signals are
amplified at U41A. The output of U41A is applied to an IPM wave shape circuit
consisting of integrated circuit U41B and diodes D30 and D31. The circuit is designed to
output a phase modulated signal which is equal in amplitude and out-of-phase with the
phase modulation component in the RF amplifier section. Potentiometer R198 controls
the shape of the IPM correction signal. Potentiometer R189 controls the amplitude of the
IPM correction signal. Diodes D32 through D37 provide over-voltage protection. The
output of the IPM wave shape circuit is applied to the phase modulator circuit.
exciter circuitry to cancel incidental-phase-modulation (IPM) in the RF amplifier section
of the transmitter. The circuit is designed to insert a phase modulation component which
is equal in amplitude and out of phase with the phase modulation in the RF amplifier
section. This feedforward approach is designed to effectively cancel (IPM) in the
transmitter.
1-25
1-126.
The phase modulator circuit accepts a mono or stereo signal from NAND gate U32D. The
signal is applied to a frequency doubler circuit consisting of integrated circuits U38A,
U38B, U38C, and U38D. The output of the frequency doubler is applied to the gates of
transistors Q6 and Q7. An IPM correction signal from the IPM wave shape circuit is
applied to the drains of Q6 and Q7.
1-127.
Transistors Q6 and Q7 function to produce a triangle-shaped waveform which is equal in
amplitude and out-of-phase with the IPM in the RF amplifier section. The output from
Q6 and Q7 is converted to a square-wave at U33C and U33D. The signal from
U33C/U33D is applied to a divider circuit consisting of integrated circuits U39A, U39B,
and U33E. The output of the divider is used to clock the RF carrier signal from the
frequency doubler circuit at latch U40. U40 outputs a phase compensated carrier
frequency to the RF drive circuit. Potentiometer R170 is provided to adjust the symmetry
of the RF carrier signal.
1-128.
RF DRIVE CIRCUIT. The RF drive circuit consists of high/low side driver U46 and
transistors Q13 through Q22. Complementary phase compensated square-wave signals
at the carrier frequency are applied to U46. U46 outputs high and low driver signals for
application to a transistor array consisting of transistors Q13 through Q20. The
transistors output a +15 volt peak-to-peak square-wave signal at the carrier frequency
for application to the power block motherboard.
1-129.
EXCITER FAILURE DETECTOR CIRCUIT. The exciter circuitry is equipped with an exciter
1-130.
POWER SUPPLY CIRCUITS. The exciter circuit board operates from three power supplies:
1-131.
STEREO CIRCUIT BOARD.
1-132.
EQUALIZATION CIRCUITRY. The stereo circuit board is equipped with two equalization
failure detector circuit. The circuit consists of integrated circuits U22B, U23A, and U23B.
Two signals are routed to the detector circuit: 1) the PWM control signal and 2) an RF
present signal from transistor Q8 and latch U40. The circuit is designed to output a
HIGH during the following conditions: 1) the loss of the PWM signal or 2) the loss of the
RF signal. The HIGH is routed to the circuitry on the controller circuit board.
1) a +5 volt supply, 2) a +15 volt supply, and 3) a -15 volt supply. Each supply is equipped
with a filter network. The +5 volt supply filter consists of inductor L1 and capacitors
C31/C32. The output of the filter is applied to: 1) +5 volt indicator DS1 and 2) the exciter
circuit board components. The +15 volt supply filter consists of inductor L2 and
capacitors C34/C35. The output of the filter is applied to: 1) +15 volt indicator DS2 and 2)
the exciter circuit board components. The -15 volt supply filter consists of inductor L3
and capacitors C36/C37. The output of the filter is applied to: 1) -15 volt indicator DS3
and 2) the exciter circuit board components.
circuits: 1) equalization circuit 1 and 2) equalization circuit 2 (refer to Figure 1-3). The
circuits are designed to provide equalization for two antenna patterns such as: 1) a day
pattern and 2) a night pattern. The equalization circuits are identical and contain
identical left and right channel circuitry. Therefore, only the left channel of equalization
circuit 1 will be discussed.
1-26
COPYRIGHT
1999 BROADCAST ELECTRONICS, INC
597-1111-25
FIGURE 1-3. STEREO CIRCUIT BOARD
SIMPLIFIED SCHEMATIC
(1-27/1-28)
1-133.
Left channel audio from the exciter circuit board is applied to a left channel high
frequency equalizer network in the equalization 1 circuit. The high frequency equalizer
consists integrated circuits U1A, U2, U1B, U3, U4A, and U6A. The equalizer circuit is a
second order state variable low-pass filter designed to compensate for high frequency and
phase problems caused by antenna/phasor units. The filter is equipped with an
adjustable corner frequency. The corner frequency is established by a voltage generated
by potentiometer R20 and buffer U6A. The voltage is applied to
voltage-controlled-amplifiers U2 and U3 which control the corner frequency of the
equalizer circuit. In addition to the variable corner frequency, the filter is equipped with a
variable peak level. Potentiometer R6 controls the signal peak near the corner frequency.
Potentiometer R1 controls the left channel level. The output of the circuit is applied to an
8 microsecond delay circuit.
1-134.
8 MICROSECOND DELAY CIRCUIT. Integrated circuit U4B is configured as an 8
microsecond delay circuit. The delay circuit is a third order low-pass filter designed to
provide 8 microseconds of delay to match low and mid frequency delay equalization
requirements. The output of the circuit is routed to 8 microsecond delay select jumper
P1A. P1A allows the delay circuit to be bypassed if 8 microseconds of delay is not
required for equalization operation.
1-135.
4 MICROSECOND DELAY CIRCUIT. Integrated circuit U5A is configured as a 4
microsecond delay circuit. The delay circuit is a third order low-pass filter designed to
provide 4 microseconds of delay to match low and mid frequency delay equalization
requirements. The output of the circuit is routed to 4 microsecond delay select jumper
J1B. J1B allows the delay circuit to be bypassed if 4 microseconds of delay is not required
for equalization operation.
1-136.
ALL-PASS FILTER. Integrated circuit U5B is configured as an all-pass filter circuit. The
1-137.
EQUALIZATION SELECTION CIRCUIT. The outputs of equalization circuits 1 and 2 are
1-138.
L+R AND L-R MATRIX CIRCUIT. Left and right channel audio from the equalization
selection circuit is applied to an L-R and L+R matrix circuit. The circuit consists of
integrated circuits U24A, U24B, U25A, U26A, U26B, U27A, U29A, U29B, U25B, U31B,
U27B, U27A, and U32. The circuit is designed to generate L+R and L-R audio for
application to a phase modulator circuit.
circuit is designed to provide a continuously adjustable 0-6 microsecond delay for
equalization operation. Potentiometer R26 controls the amount of delay.
applied to an equalization selection circuit consisting of integrated circuits U23 and U28.
U23 and U28 are single-pole switch arrays designed to select audio from the equalization
1 or equalization 2 circuit. U23 and U28 are controlled by: 1) HIGH equalization 1 and
equalization 2 control signals from latch U44A and 2) a HIGH stereo signal from the
mono/stereo mode decoder circuit. The circuit is designed to select audio in response to
the antenna pattern and mode of operation. For example, stereo audio from equalization
circuit 1 is required. A HIGH from latch U44A will enable the equalization 1 switches in
U23 and U28. U23 and U28 respond by routing audio to an L+R and L-R matrix circuit.
1-29
1-139.
To provide an example of circuit operation, stereo audio is required from equalization
circuit 1. Left channel audio from the equalization circuit 1 input of U23 is applied to
buffer U24A. Right channel audio from the equalization circuit 1 input of U28 is applied
to buffer U29A. U24A and U29A will output audio which is summed with a pilot signal
from pilot on/off switch S1. The audio/pilot signal is applied to the inputs of U23/U28.
With a HIGH from the stereo control line of mono/stereo mode decoder circuit: 1) U23 will
route the left channel audio/pilot signal to amplifier U24B and 2) U28 will route the right
channel audio/pilot signal to amplifier U29B. U24B/U29B amplify the signal to
approximately 2.1 volts peak-to-peak. The outputs of U24B/U29B are applied to L+R
summing amplifier U25A and L-R summing amplifier U25B.
1-140.
A dc voltage for application to L+R summing amplifier U25A is provided by regulator
U32. U32 provides a bias voltage for the L+R audio to generate a 1+L+R audio signal.
The output of summing amplifier U25A is applied to a negative limiter circuit consisting
of integrated circuit U26A and diodes D1 and D2. The circuit is designed to limit negative
modulation to -95%. This prevents the loss of carrier during negative modulation. The
output of negative limiter U26A is routed through buffer U26B to a phase modulator
circuit as a 1+L+R signal and inverter U27B. U27B generates a 1+L+R signal for
application to a phase modulator circuit.
1-141.
Left and right channel are summed at U25B to produce an L-R signal. The L-R signal is
applied to: 1) a phase modulator circuit as an L-R signal, 2) to inverter U27B, and
3) buffer U31B. U27B generates a L-R signal for application to a phase modulator
circuit. U31B is designed to buffer the L-R signal for application to an L-R metering
circuit on the ECU display circuit board.
1-142.
PHASE MODULATOR CIRCUIT. 1+L+R, 1+L+R , L-R, and L-R signals are applied to a
1-143.
The phase modulator circuit operates from four phase references generated by a
synchronous divider and latches U35A/U35B. A reference at four times the carrier
frequency from the exciter circuit board is applied to a synchronous divider circuit. The
circuit divides the signal by four and generates two outputs which are 90 degrees
out-of-phase. The outputs are applied to latches U35A/U35B. U35A/U35B generate four
reference signals: 1) 0 degrees, 2) 90 degrees, 3) 180 degrees, and 4) 270 degrees. The
reference signals are used to drive phase modulator U36.
1-144.
Integrated circuit U36 is a switch array configured as a phase modulator. The four
reference signals from latches U35A/U35B are used to drive the 1+L+R, 1+L+R , L-R,
and L-R signals at U36. The output of U36 produces two signals: 1) a normal AM
modulated signal reference to a 0 degree carrier containing the L+R information (I
modulator) and 2) a double side-band suppressed carrier signal referenced to a 90 degree
carrier containing the L-R information (Q modulator). The signals are summed to
produce a quadrature AM signal.
1-145.
The quadrature AM signal is applied to integrated circuit U37. U37 is a high-speed
operational amplifier designed to amplify the quadrature signal to a 1 volt peak-to-peak
level with no modulation. The output of the amplifier is applied to a band-pass filter.
phase modulator circuit. The phase modulator circuit consists of: 1) phase modulator
U36, 2) a synchronous divider consisting of integrated circuits U33, U34A, and U34B, and
3) latches U35A and U35B.
1-30
1-146.
BAND-PASS FILTER. The output of amplifier U37 is applied to a forth order linear phase
1-147.
TRANSISTOR AMPLIFIER CIRCUIT. The output of the band-pass filter is applied to a
transistor array consisting of transistors Q1, Q2, U38B, U38C, U38D, and U38E. The
signal is amplified to a 2 volt peak-to-peak level by transistors U38B, U38C, U38D, and
U38E. The transistors also perform unbalanced-to-balanced signal conversion. The
balanced signal from transistors U38B, U38C, U38D, and U38E are buffered by
transistors Q1 and Q2 for application to the amplitude limiter circuit.
1-148.
AMPLITUDE LIMITER CIRCUIT. The balanced quadrature signal from the transistor
1-149.
OUTPUT NETWORK. The 1 volt peak-to-peak phase modulated signal from the
1-150.
OPERATING MODE SELECTION AND INDICATION CIRCUIT. The stereo circuit board
1-151.
Local control operations are directed by mode select switch S5. S5 controls a mode
counter circuit consisting of integrated circuits U53, U54A, U54B, U54C, and U54D. The
switch operates by advancing the counter each time the switch is depressed. This results
in the circuit advancing through the modes of operation in the following order: 1) stereo,
2) mono left, 3) mono right, or 4) mono L+R. The mode counter circuit selects a mode by
routing a HIGH control command to the OR gates U49A through U49D.
1-152.
OR gates U49A through U49D select a command from the remote control optical couplers
or the local mode counter circuit. For example, the circuit board is desired to be
configured for stereo operation. A HIGH from remote stereo optical coupler U48 or the
local mode control circuit is applied to OR gate U49D. U49D outputs a HIGH through OR
gate U52A to priority encoder U50. U50 monitors the OR gates for additional commands
and determines the highest priority mode of operation. Once the mode of operation is
determined, U50 will output a two bit binary code to a mono/stereo decoder circuit.
band-pass filter. The band-pass filter consists of: 1) inductors L4, L5, L6, and L7,
2) capacitors C110 and C115, and 3) programming switches S2, S3, and S4. The filter
provides proper amplitude limiting during high single channel conditions. Programming
switches S2, S3, and S4 select resistor and capacitor combinations to program the filter
for specific groups of frequencies within the AM broadcast band. Inductors L4, L5, L6,
and L7 tune the filter for proper operation. The output of the filter is applied to a
transistor amplifier array.
amplifier circuit is applied to an amplitude limiter circuit. The amplitude limiter circuit
consists of integrated circuits U39A, U39B, and U39C. The circuit produces phase
modulation containing the L-R information. The output of the limiter is applied to an
output network.
amplitude limiter circuit is applied to transformer T1. T1 is provided to increase the
voltage to a 5 volt peak-to-peak level. The output of T1 is buffered by inverters U40A
and U40B. Potentiometer R193 adjusts the symmetry of the signal to null the second
harmonic frequency. The output of U40B is routed for application to the exciter circuit
board.
can be configured for stereo, mono left, mono right, or mono L+R operation. The circuit
board is configured for the desired mode of operation by a mode selection and indication
circuit. HIGH remote mono left, mono right, mono L+R, and stereo commands are
applied to optical couplers U45 through U48. The outputs of U45 through U48 are
applied to OR gates U49A through U49D.
1-31
1-153.
The mono/stereo mode decoder circuit consists of: 1) latches U44B, U51A, and U51B and
2) mono/stereo decoder logic U41D, U43B, U43C, U52C, and U52D. Latches U51A and
U51B latch the two bit binary code and produce complementary outputs for application to
the mono/stereo decoder logic. Latch U44B operates as a clock for U51A/U51B. The
mono/stereo decoder logic decodes the binary code and outputs a HIGH to: 1) transistors
Q5, Q9, and Q14 and 2) equalization select integrated circuits U23 and U28. Transistor
Q14 will respond by generating a LOW internal stereo status signal. Transistor Q5 will
output a LOW to bias stereo indicator DS3 to on. Transistor Q9 will respond by
generating a LOW remote stereo status signal.
1-154.
Selection and indication of the mono left, mono right, and mono L+R modes of operation
are performed in an identical manner. When the mono left or mono right mode is
selected, a HIGH will be routed to NAND gate U43D. The output of U43D will go HIGH.
The HIGH is inverted at U55D to produce a LOW mono single channel signal for
application to the exciter circuit board. When the mono left, mono right, or mono L+R
mode is selected a HIGH is applied to transistor Q13. Q13 will respond by generating a
LOW remote mono status signal.
1-155.
EQUALIZATION SELECTION. Equalization circuit selection is determined by the antenna
1-156.
Antenna A, B, and C status signals are applied to AND gates U41A and U41B.
Programmable jumper P6 selects equalization circuit 1 or equalization circuit 2 for
antenna C operations.
1-157.
The circuit selects equalization circuit 1 or 2 when a status signal is applied to
U41A/U41B. For example, a LOW is applied to U41B when antenna A is selected. U41B
will output a LOW to NAND gate U43A. Programmable jumper P7 programs the
equalization selection circuit for momentary or continuous signals. With P7 programmed
for momentary signals, U43A will output a HIGH to AND gate U41C. With a HIGH from
U41A, U41C will output a HIGH to latch U44A. U44A will output a HIGH to:
1) integrated circuits U23 and U28 to select equalization circuit 1 and 2) transistor Q4.
Q4 will go LOW to bias equalization 1 indicator DS1 on.
1-158.
PILOT SIGNAL. A 25 Hz square-wave signal from the exciter circuit board is applied
1-159.
The output of the band-pass filter is applied through switch S1 to: 1) integrated circuit
U23 and 2) inverter U31A. U31A inverts the signal for application to integrated circuit
U28. Switch S1 is provided to disable the pilot signal.
1-160.
POWER SUPPLY FILTER NETWORK. The stereo circuit board operates from ±15 volt
power supplies. Each supply is equipped with a filter network. The +15 volt supply filter
consists of inductor L1 and capacitor C92. The output of the filter is applied to the stereo
circuit board components. The -15 volt supply filter consists of inductor L2 and capacitor
C94. The output of the filter is applied to the stereo circuit board components.
1-161.
ECU POWER SUPPLY ASSEMBLY.
1-162.
The ECU assembly is equipped with a modular 40W switching power supply assembly.
The supply provides regulated +5V, +15V, and -15V operating potentials for the ECU
circuit boards.
connected to the transmitter. Antenna A selects equalization circuit 1. Antenna B selects
equalization circuit 2. Antenna C can be programmed to select equalization circuit 1 or
equalization circuit 2.
through potentiometer R132 to a band-pass filter consisting of integrated circuits U30A
and U30B. Potentiometer R132 is designed to provide pilot level control. The band-pass
filter converts the square-wave signal to a sine-wave signal.
1-32
1-163.
The power supply for the ECU controller circuit board is back-up by a 9V battery. During
an ac power failure, the battery will maintain the transmitter operating configuration
stored in the controller logic circuitry. Once power is returned to the transmitter, the
transmitter will automatically resume operation in the configuration appearing prior to
the ac failure. If an extended ac power failure occurs, the transmitter will be operated to
off by an ac loss/auto shutdown circuit on the controller circuit board.
1-33
SECTION II
TRANSMITTER ECU MAINTENANCE
2-1.
INTRODUCTION.
2-2.
This section provides maintenance information for the AM-2.5E/AM-5E transmitter ECU
(exciter/control unit).
2-3.
SAFETY CONSIDERATIONS.
WARNING
WARNING
WARNING
WARNING
THE TRANSMITTER CONTAINS MULTIPLE CIRCUIT
GROUNDS WITH HIGH AC AND DC POTENTIALS
WITH RESPECT TO THE CABINET WHICH IS AT
EARTH POTENTIAL. DO NOT ENERGIZE THE
TRANSMITTER WITH TEST EQUIPMENT CON
NECTED TO THE TRANSMITTER OUTPUT
NETWORK, RF POWER MODULE, RF COMBINER, OR
POWER SUPPLY COMPONENTS.
2-4.
The AM-2.5E/AM-5E 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 transmitter is equipped with many built-in safety features,
however good judgement, care, and common sense must be practiced to prevent accidents.
2-5.
In addition to high voltages and currents, the 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 transmitter 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. The
maintenance procedures presented in this section should be performed only by trained
and experienced maintenance personnel.
2-6.
ECU CIRCUIT BOARD INSTALLATION/REMOVAL.
2-7.
The transmitter ECU is equipped with three circuit boards: 1) exciter, 2) stereo, and
3) controller. Each circuit board is equipped with finger holes for the ease of removal and
installation. To remove a circuit board, grasp the board using the finger holes and firmly
pull the circuit board out of the ECU.
2-1
WARNING: DISCONNECT POWER PRIOR TO SERVICING
CAUTION
CAUTION
2-8.
THE TRANSMITTER MAY BE DAMAGED IF THE ECU
CIRCUIT BOARDS ARE NOT SECURELY SEATED INTO
THE CONNECTORS.
To install the circuit boards: 1) the boards must be inserted into the proper location in the
ECU and 2) the boards must be firmly seated into the ECU motherboard. To install a
circuit board, proceed as follows:
1. Refer to Figure 5-4 in PART I, SECTION V MAINTENANCE to determine the
circuit board location.
2. Insert the circuit board in the appropriate location.
3. Firmly press the circuit board into the connector to engage the connector
housing.
4. Firmly press the circuit board into the connector again to engage the
connector pins.
5. Repeat the procedure for each ECU circuit board.
2-9.
FIRST LEVEL MAINTENANCE.
2-10.
First level maintenance consists of precautionary procedures applied to the equipment to
prevent future failures. The procedures are performed on a regular basis and the results
recorded in a performance log.
2-11.
CLEANING AND INSPECTION.
WARNING
WARNING
NEVER OPEN THE EQUIPMENT UNLESS ALL TRANS
MITTER PRIMARY POWER IS DISCONNECTED. EN
SURE ALL TRANSMITTER PRIMARY POWER IS DIS
CONNECTED BEFORE ATTEMPTING MAINTENANCE
ON ANY AREA WITHIN THE TRANSMITTER.
2-12.
Clean the ECU circuit boards of accumulated dust as required using a nylon bristle brush
and vacuum cleaner. Inspect the circuit boards for improperly seated semiconductors and
components damage by overheating. In addition, inspect the ECU for loose hardware.
Ensure all ECU interconnecting cables are secure.
2-13.
SECOND LEVEL MAINTENANCE.
2-14.
Second level maintenance is the performance of procedures required to restore the ECU to
operation after a fault has occurred. The procedures are divided into electrical
adjustments procedures and troubleshooting.
2-15.
ELECTRICAL ADJUSTMENTS.
2-16.
The following text provides electrical adjustment procedures for the transmitter ECU.
The procedures are presented in the following order.
1. ECU Extender Circuit Board Operation.
2. Controller Circuit Board Adjustments.
3. ECU Meter Switch Circuit Board Adjustments.
2-2
WARNING: DISCONNECT POWER PRIOR TO SERVICING
4. Stereo Circuit Board Adjustments.
5. Exciter Circuit Board Adjustments.
6. Display Circuit Board Adjustments.
2-17.
ECU EXTENDER CIRCUIT BOARD OPERATION.
2-18.
The ECU is equipped with an extender circuit board. The circuit board is designed to
allow access to the ECU circuit board components for maintenance procedures. To use the
circuit board for maintenance procedures, proceed as follows:
1. Refer to Figure 5-4 in PART I, SECTION V MAINTENANCE and locate the
extender circuit board assembly in the ECU.
2. Remove the extender circuit board from the ECU.
3. Loosen the extender circuit board locking nut.
4. Completely extend the circuit board.
5. Tighten the extender circuit board locking nut.
6. Remove the circuit board required for maintenance and place the extender
circuit board in the location in the ECU.
7. Place the desired circuit board onto the extender circuit board.
8. Firmly press the circuit board into the extender circuit board connectors.
2-19.
CONTROLLER CIRCUIT BOARD ADJUSTMENTS.
2-20.
P1 SET - P5 SET CONTROLS. The P1 SET through P5 SET controls adjust the ECU
POWER CONTROL 1 through 5 controls to desired levels. A complete description of the
procedure to adjust the power level controls is presented in SECTION II,
INSTALLATION. Refer to POWER LEVEL AND MODULATION CALIBRATION
ADJUSTMENT in SECTION II for the adjustment procedure.
2-21.
FWD AND RFL CALIBRATIONS. FWD CAL control R56 and RFL CAL control R143
2-22.
ECU METER SWITCH CIRCUIT BOARD ADJUSTMENTS.
2-23.
FORWARD POWER METER LOW AND HIGH SCALE CALIBRATIONS. Low scale control
R501 and high scale control R504 calibrate the forward power meter. Due to the critical
nature of the low scale and high scale meter calibrate controls, the controls are not
considered field adjustable. If the controls are required to be adjusted, contact the
Broadcast Electronics Customer Service Department for information and instructions to
adjust the low and high scale forward power meter controls.
2-24.
REFLECTED POWER METER LOW AND HIGH SCALE CALIBRATIONS. Low scale control
calibrate the transmitter forward and reflected power samples. Due to the critical nature
of the FWD CAL and RFL CAL controls, the controls are not considered field adjustable.
If the controls are required to be adjusted, contact the Broadcast Electronics Customer
Service Department for information and instructions to adjust the FWD and RFL CAL
controls.
R505, high scale control R506, and ac sample control R511 calibrate the reflected power
meter. Due to the critical nature of the low scale, high scale, and ac sample meter
calibrate controls, the controls are not considered field adjustable. If the controls are
required to be adjusted, contact the Broadcast Electronics Customer Service Department
for information and instructions to adjust the low scale, high scale, and ac sample
reflected power meter controls.
2-3
WARNING: DISCONNECT POWER PRIOR TO SERVICING
2-25.
FWD AND RFL CALIBRATIONS. FWD CAL control R56 and RFL CAL control R143
2-26.
STEREO CIRCUIT BOARD ADJUSTMENTS.
2-27.
STEREO ADJUSTMENT. The stereo adjustment consists of configuring the equalization
2-28.
EXCITER CIRCUIT BOARD ADJUSTMENTS.
2-29.
MODULATION CALIBRATION. Modulation calibration control R62 calibrates the exciter
modulation circuit. Due to the critical nature of the modulation calibration control, the
control is not considered field adjustable. If the control is to be adjusted, contact the
Broadcast Electronics Customer Service Department for information and instructions to
adjust the modulation calibration control.
2-30.
PHASE MODULATOR CALIBRATION. Phase modulator calibration control R159
2-31.
SYMMETRY CONTROL. Symmetry calibration control R170 adjusts the exciter RF
2-32.
IPM CORRECTION CIRCUIT CONTROLS. IPM GAIN control R189, IPM TRACK control
2-33.
SINGLE CHAN MONO LEVEL CONTROL. SINGLE CHAN MONO LEVEL control R41
2-34.
AVERAGE MODULATION LIMIT CONTROL. Average modulation limit control R217
2-35.
NEG LIMIT CONTROL. NEG LIMIT control R76 limits the negative L+R information to
calibrate the transmitter forward and reflected power samples. Due to the critical nature
of the FWD CAL and RFL CAL controls, the controls are not considered field adjustable.
If the controls are required to be adjusted, contact the Broadcast Electronics Customer
Service Department for information and instructions to adjust the FWD and RFL CAL
controls.
circuitry on the stereo circuit board to obtain the optimum stereo performance. The
equalization circuitry consists of the equalization circuit 1 and equalization circuit 2
controls. A complete description of the procedure to adjust the equalization controls is
presented in SECTION II, INSTALLATION. Refer to STEREO ADJUSTMENT in
SECTION II for the adjustment procedure.
calibrates the exciter phase modulator circuit. Due to the critical nature of the phase
modulator calibration control, the control is not considered field adjustable. If the control
is to be adjusted, contact the Broadcast Electronics Customer Service Department for
information and instructions to adjust the phase modulator calibration control.
output square-wave signal. Due to the critical nature of the symmetry control, the
control is not considered field adjustable. If the control is to be adjusted, contact the
Broadcast Electronics Customer Service Department for information and instructions to
adjust the symmetry control.
R104, IPM SHAPE CONTROL R198, and IPM ZERO SET control R191 calibrate the IPM
correction circuit. Due to the critical nature of the IPM correction circuit controls, the
controls are not considered field adjustable. If the controls are to be adjusted, contact the
Broadcast Electronics Customer Service Department for information and instructions to
adjust the IPM correction circuit controls.
is designed to boost a remaining audio channel level in the event of a failure in one
channel. A complete description of the procedure to adjust the SINGLE CHAN MONO
LEVEL control is presented in SECTION II, INSTALLATION. Refer to SINGLE
CHANNEL LEVEL in SECTION II for the adjustment procedure.
limits the average tone modulation. The control is adjusted to limit at 110% tone
modulation. Due to the critical nature of the modulation calibration control, the control is
not considered field adjustable. If the control is to be adjusted, contact the Broadcast
Electronics Customer Service Department for information and instructions to adjust the
average modulation limit control.
prevent excessive modulation when the L+R signal is summed with the pilot tone. The
NEG LIMIT control is adjusted in the following procedure.
2-4
WARNING: DISCONNECT POWER PRIOR TO SERVICING
2-36.
Procedure. To adjust NEG LIMIT control R76, proceed as follows:
WARNING
WARNING
DISCONNECT ALL TRANSMITTER PRIMARY POWER
BEFORE PROCEEDING.
2-37.
Disconnect all transmitter primary power.
2-38.
Connect the audio generator to the TB2 LEFT INPUT and RIGHT INPUT audio
terminals on the ECU rear-panel.
2-39.
Adjust NEG LIMIT control R76 on the exciter circuit board fully counterclockwise.
2-40.
Adjust the audio generator for a L=R 1 kHz output at +10 dBm.
2-41.
Adjust the AM stereo modulation monitor to indicate positive L+R modulation.
2-42.
Energize the transmitter primary power and operate the transmitter.
2-43.
Observe the modulation monitor and ensure the monitor indicates 100% positive L+R
modulation. If the monitor does not indicate 100% L+R modulation, adjust the audio
generator level slightly for a +100% L+R modulation indication on the monitor.
2-44.
Adjust the AM stereo modulation monitor to indicate negative L+R modulation.
2-45.
Adjust NEG LIMIT control R76 on the exciter circuit board until the AM stereo
Modulation monitor indicates -95% L+R modulation.
WARNING
WARNING
DISCONNECT ALL TRANSMITTER PRIMARY POWER
BEFORE PROCEEDING.
2-46.
Disconnect all transmitter primary power.
2-47.
Remove all test equipment.
2-48.
FREQUENCY CALIBRATION CONTROL. Frequency calibration control C108 calibrates
2-49.
Procedure. To adjust frequency calibration control C108, proceed as follows:
the exciter frequency synthesizer. The frequency calibration control is adjusted in the
following procedure.
WARNING
WARNING
DISCONNECT ALL TRANSMITTER PRIMARY POWER
BEFORE PROCEEDING.
2-50.
Disconnect all transmitter primary power.
2-51.
Remove the exciter circuit board and install the ECU extender circuit board in the exciter
circuit board location.
2-52.
Install the exciter circuit board on the extender circuit board.
2-53.
Connect a frequency counter to test point TP15 on the exciter circuit board.
2-54.
Energize the transmitter primary power and operate the transmitter.
2-55.
Adjust frequency calibration control C108 on the exciter circuit board for the carrier
frequency.
2-5
WARNING: DISCONNECT POWER PRIOR TO SERVICING
WARNING
WARNING
2-56.
2-57.
2-58.
2-59.
2-60.
Disconnect all transmitter primary power.
Remove all test equipment and replace the exciter circuit board.
DISPLAY CIRCUIT BOARD ADJUSTMENTS.
L/L+R AND R/L-R DISPLAY CALIBRATION CONTROL. L/L+R calibration control R42
and R/L-R calibration control R48 calibrate the L/L+R and R/L-R displays. The L/L+R
and R/L-R calibration controls are adjusted in the following procedure.
Procedure. To adjust L/L+R calibration control R42 and R/L-R calibration control R48,
proceed as follows:
WARNING
WARNING
2-61.
2-62.
2-63.
2-64.
DISCONNECT ALL TRANSMITTER PRIMARY POWER
BEFORE PROCEEDING.
DISCONNECT ALL TRANSMITTER PRIMARY POWER
BEFORE PROCEEDING.
Disconnect all transmitter primary power.
Connect the audio generator to the TB2 LEFT INPUT and RIGHT INPUT audio
terminals on the ECU rear-panel. Operate the transmitter at a normal output power and
the EXCITER MONITOR for L+R/L-R indications.
Adjust the audio generator for an in-phase L=R 1 kHz output at a level to generate 100%
modulation as indicated by the modulation monitor. Adjust L/L+R calibration control R42
until the EXCITER MONITOR just indicates 100% L+R modulation.
Adjust the audio generator for an out-of-phase L=R 1 kHz output at a level to generate
100% L-R modulation as indicated by the modulation monitor. Adjust R/L-R calibration
control R48 until the EXCITER MONITOR just indicates 100% L-R modulation.
WARNING
WARNING
DISCONNECT ALL TRANSMITTER PRIMARY POWER
BEFORE PROCEEDING.
2-65.
2-66.
Disconnect all transmitter primary power and remove all test equipment.
2-67.
SAFETY CONSIDERATIONS. The AM-2.5E/AM-5E transmitters are equipped with
TROUBLESHOOTING.
WARNING
THE TRANSMITTER CONTAINS MULTIPLE CIRCUIT
GROUNDS WITH HIGH AC AND DC POTENTIALS
WITH RESPECT TO THE CABINET WHICH IS AT
WARNING
EARTH POTENTIAL. DO NOT ENERGIZE THE
WARNING
TRANSMITTER WITH TEST EQUIPMENT CON
NECTED TO THE TRANSMITTER OUTPUT
WARNING
NETWORK, RF POWER MODULE, RF COMBINER, OR
POWER SUPPLY COMPONENTS.
extensive indicator and meter circuitry to allow the operator to isolate problems to a
specific area within the transmitter. Due to the hazardous voltages and currents
contained in the equipment, 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. 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. Therefore, the transmitter indicators and
meters must be used to isolate a problem to a specific area. The maintenance procedures
presented in this section should be performed only by trained and experienced
maintenance personnel.
2-6
WARNING: DISCONNECT POWER PRIOR TO SERVICING
2-68.
TROUBLESHOOTING PROCEDURES. The ECU assembly troubleshooting procedures are
presented in Tables 2-1 through 2-4. Table 2-1 presents the exciter circuit board
troubleshooting. Table 2-2 presents the stereo circuit board troubleshooting. Table 2-3
presents the controller circuit board troubleshooting. Table 2-4 presents the ECU power
supply troubleshooting. Refer to Tables 2-1 through 2-4 to isolate the problem to a
specific circuit. Once the trouble is isolated, refer to the circuit board theory of operation
and schematic diagrams to assist in problem resolution.
TABLE 2-1. EXCITER CIRCUIT BOARD TROUBLESHOOTING
(Sheet 1 of 3)
SYMPTOM
LOCK INDICATOR
EXTINGUISHED
CIRCUITRY TO CHECK
1. Refer to the factory test data sheets and ensure
the exciter circuit board frequency synthesizer
(S1, S2, and J6) is programmed for the correct
operating frequency.
2. Check U25 pin 1 for a 0V to 5V square-wave
signal at FcX4 (carrier frequency times four) or
FcX8 (carrier frequency times eight).
A. If the square-wave signal at U25 is not present,
check for a greater than 13 volt dc signal at the
anode of D23.
1. If the dc voltage is present, defective VCO, Q4,
or U30A.
2. If the dc voltage is not present, defective Q3
or C106.
B. If the square wave signal at U25 is below
FcX4 or FcX8, measure the dc voltage at J8
of the VCO assembly.
1. If the dc voltage at TP7 is greater than 13 volts,
defective VCO.
2. If the dc voltage at TP7 is less than 2 volts,
defective U25, U26A, U26B, Y1, or U24.
C. If the square wave signal at U25 is above FcX4 or
FcX8, measure the dc voltage at TP7 of the VCO
assembly.
1. If the dc voltage at TP7 is greater than 13 volts,
defective U25, U26B, U26A, Y1, or U24.
2. If the dc voltage at J8 is less than 2 volts,
defective VCO.
NO L+R MODULATION
OF CARRIER DURING MONOPHONIC OPERATION
1. Remove the stereo circuit board if present and
place J4 in the left or right channel position
as determined by the channel with applied audio.
2. Insert a +10 dBm 1 kHz signal in the appropriate
audio channel and check for audio at U39 pins 3
and 6.
A. If the audio is not present, defective: 1) left
channel - U39, U2A, U2B, U1A, or U1B 2)
right channel - U39, U4A, U4B, U5A, or U5B.
B. If the audio is present, defective U8A, U8B, U9A,
U9B, U14B, or U13.
2-7
WARNING: DISCONNECT POWER PRIOR TO SERVICING
TABLE 2-1. EXCITER CIRCUIT BOARD TROUBLESHOOTING
(Sheet 2 of 3)
SYMPTOM
CIRCUITRY TO CHECK
NO L+R MODULATION DURING
STEREO OPERATION
1. Defective U39, U8A, U8B, U9A, U9B, U14B, or U13.
RF DRIVE INDICATORS
EXTINGUISHED ON A POWER
BLOCK
1. Check for a square-wave carrier frequency signal
at U46 pins 1 and 7.
A. If the carrier frequency signal is present,
defective Q13 through Q22, L4, D38 through D45,
or D51, D52.
B. If the carrier frequency signal is not present,
check for a 0V-5V p-p square-wave carrier
frequency signal present at U40 pins 1 and 16.
1. If the carrier frequency signal is present,
defective U46.
2. If the carrier frequency signal is not present,
defective U40.
PWM DRIVE INDICATOR
EXTINGUISHED ON A POWER
MODULE
1. Defective U21A through U21F, U19, U20, U45, D6
through D21, or D47 through D50.
RED EXCITER INDICATOR
ILLUMINATED ON TRANSMITTER
MONITOR
1. Check the frequency synthesizer programming at S1,
S2, and J6
2. Check for a square-wave carrier frequency signal at
U23 pin 12.
A. If the carrier frequency signal is present, check
for a 4V p-p 125 kHz to 133 kHz PWM trianglewave at TP-5.
1. If the PWM signal is present, defective
U22A or U23A.
2. If the PWM signal is not present,
defective U10, Q1, U42A, U31A.
B. If the carrier frequency signal at U23 pin 12 is
not present, check for a 2XFC (two times carrier
frequency) at TP-9.
1. If the carrier frequency signal is present,
defective U33C or U33D, U39A, U39B, U39C
U40 or Q8.
2. If the carrier frequency signal is not present,
check for a carrier frequency signal at TP-15.
a. If the signal is present, defective Q5,
Q6, Q7, U37, U38A, U38B, U38C, or U38D.
b. If the signal is not present, check for a
0V-5V p-p carrier frequency signal at U29
pin 12.
1. If the carrier frequency signal is
present, defective U31B, U42B, U32A,
U32B, U32C, U32D, U30C or P7.
2. If the carrier frequency signal is not
present, defective U33A, U30B, or U29.
2-8
WARNING: DISCONNECT POWER PRIOR TO SERVICING
TABLE 2-1. EXCITER CIRCUIT BOARD TROUBLESHOOTING
(Sheet 3 of 3)
SYMPTOM
CIRCUITRY TO CHECK
LOW DEMODULATOR LEFT
CHANNEL MODULATION LEVEL
WITH LOW EXCITER
MONITOR LEFT CHANNEL
MODULATION LEVEL
1. Defective U2A, U2B, U1A, U1B, U3A, U3B or
P2 programming.
LOW DEMODULATOR RIGHT
CHANNEL MODULATION LEVEL
WITH LOW EXCITER
MONITOR RIGHT CHANNEL
MODULATION LEVEL
1. Defective U5A, U5B, U4A, U4B, U6A, U6B or
P3 programming.
TABLE 2-2. STEREO CIRCUIT BOARD TROUBLESHOOTING
(Sheet 1 of 2)
SYMPTOM
CIRCUITRY TO CHECK
RED EXCITER INDICATOR
ILLUMINATED ON
TRANSMITTER MONITOR
1. Insert a 1 kHz audio signal at +10 dBm into the left
channel and operate the stereo circuit board to stereo.
Check for a 3.0V p-p quadrature AM signal at TP-7.
A. If the signal is present, defective U40A, U40B,
T1, U39A, U39B, or U39C.
B. If the signal is not present, check for a
quadrature AM signal at U38 pin 3.
1. If the signal is present, defective U38A, U38B,
U38C, U38D, U38E, Q1, or Q2.
2. If the signal is not present, check for a
quadrature AM signal at U37 pin 1.
a. If the signal is present, defective U37, L4,
L5, L6, L7, D3, D4, or the S2, S3, or S4
programming.
b. If the signal is not present, defective U36,
U35A, U35B, U34A, U34B, U33, U32, or
U26.
NO L-R MODULATION PRESENT
AT THE EXCITER MONITOR
METER
1. Defective U25B, U27B or U31B.
2-9
WARNING: DISCONNECT POWER PRIOR TO SERVICING
TABLE 2-2. STEREO CIRCUIT BOARD TROUBLESHOOTING
(Sheet 2 of 2)
SYMPTOM
CIRCUITRY TO CHECK
LOW DEMODULATOR LEFT
CHANNEL MODULATION LEVEL
WITH NORMAL EXCITER
MONITOR LEFT CHANNEL
MODULATION LEVEL
1. Insert a +10 dBm 1 kHz signal into the left channel.
Check for a 2V p-p 1 kHz signal at U4 pin 1.
A. If the signal is present, defective U4B, U5A, U5B,
or J1.
B. If the signal is not present, defective U1A, U2,
U1B, U3, or U4A .
LOW DEMODULATOR RIGHT
CHANNEL MODULATION LEVEL
WITH NORMAL EXCITER
MONITOR RIGHT CHANNEL
MODULATION LEVEL
1. Insert a +10 dBm 1 kHz signal into the right
channel. Check for a 2V p-p 1 kHz signal at U10
pin 1.
A. If the signal is present, defective U10B, U11A,
U11B, or J2.
B. If the signal is not present, defective U7A, U8,
U7B, U9, or U10A.
TABLE 2-3. CONTROLLER CIRCUIT BOARD TROUBLESHOOTING
(Sheet 1 of 2)
SYMPTOM
NO POWER CONTROL PWM
SIGNAL
CIRCUITRY TO CHECK
1. Check for a 1 kHz 15V p-p square-wave
signal at TP-7.
A. If the square-wave signal is present,
defective Q22.
B. If the square-wave signal is not present,
check for a 1 kHz 50% duty-cycle
square-wave signal at TP8.
1. If the square-wave signal is not present,
defective U44B, U40C, or U46E.
C. If the square-wave signal is not present,
check for a dc voltage proportional to power at
TP11.
1. If the dc voltage is present, defective U44A,
U40B, U41A, U42, or U43.
2. If the dc voltage is not present, contact the
Broadcast Electronics Customer Service
Department.
2. Check for a HIGH at U36C pin 8.
A. If the HIGH is present, defective U36C.
B. If the HIGH is not present, contact the
Broadcast Electronics Customer Service
Department.
2-10
WARNING: DISCONNECT POWER PRIOR TO SERVICING
TABLE 2-3. CONTROLLER CIRCUIT BOARD TROUBLESHOOTING
(Sheet 2 of 2)
SYMPTOM
CIRCUITRY TO CHECK
NO TRANSMITTER ON SIGNAL
OUTPUT
1. Check for a HIGH at U23A pin 3.
A. If the HIGH is present, defective Q13.
B. If the HIGH is not present, check for a LOW
at U23A pin 2.
1. If the LOW is present, defective U23A.
2. If a HIGH is present, contact the
Broadcast Electronics Customer Service
Department.
CONFLICT INDICATOR
ILLUMINATED
1. Check U7, U8, U9, S1, S2, S3, U12A, U12B,
U21A, U21B, U21C, U20A, U20B, U20C, U20D,
U19, and U13.
TABLE 2-4. ECU POWER SUPPLY TROUBLESHOOTING
SYMPTOM
NO OUTPUT POWER
NO NORMAL/FAULT
ECU INDICATIONS
2-69.
CIRCUITRY TO CHECK
1. Check the ECU power supply fuse.
2. Check the ECU power supply assembly.
COMPONENT REPLACEMENT PROCEDURE. Component replacement procedures for
the ECU assembly circuit boards are presented in PART I SECTION V. Refer to
COMPONENT REPLACEMENT in SECTION V as required for the replacement
procedures.
2-11
WARNING: DISCONNECT POWER PRIOR TO SERVICING
SECTION III
ECU ASSEMBLY
PARTS LIST
3-1.
INTRODUCTION.
3-2.
This section provides descriptions and part numbers of electrical components, assemblies,
and selected mechanical parts required for maintenance of the ECU assembly. Each table
entry in this section is indexed by reference designators appearing on the applicable sche
matic.
TABLE 3-1. REPLACEABLE PARTS LIST INDEX
TABLE
3-2
3-3
3-4
3-5
3-5
3-6
3-7
3-8
3-9
DESCRIPTION
Exciter/Controller Assembly
ECU Controller Circuit Board Assembly
ECU Extender Circuit Board Assembly
Stereo Circuit Board Assembly
ECU Exciter Circuit Board Assembly
ECU Motherboard Circuit Board Assembly
ECU Display/Control Switch Circuit Board
Meter Switch Circuit Board Assembly
ECU Wire Harness
3-1
PART NO.
957-0009-100
917-0205
917-0208
917-0209
917-0300
917-0301
917-0306-001
917-0306-005
947-0153
PAGE
3-2
3-2
3-11
3-11
3-20
3-29
3-31
3-34
3-34
TABLE 3-2. EXCITER/CONTROLLER ASSEMBLY - 957-0009-100
REF. DES.
-------------------------------------
DESCRIPTION
Varistor, V275LA20A GE
Power Input Connector/RFI Filter, 3 Amperes, 250V ac, 50/60 Hz
Filter, Window, Grey
Power Supply, SMPS, 3 Output, 40W
ECU Controller Circuit Board Assembly
ECU Extender Circuit Board Assembly
Stereo Circuit Board Assembly
ECU Exciter Circuit Board Assembly
ECU Motherboard Circuit Board Assembly
ECU Display/Controller Switch Circuit Board Assembly
Meter Switch Circuit Board Assembly
ECU Harness Assembly
PART NO.
140-0036
339-0008
467-1001-1
540-0006
917-0205
917-0208
917-0209
917-0300
917-0301
917-0306-001
917-0306-005
947-0153
QTY.
TABLE 3-3. ECU CONTROLLER CIRCUIT BOARD ASSEMBLY - 917-0205
(Sheet 1 of 10)
REF. DES.
C1 thru
C33
C34, C35
C36, C37
C38
C39 thru
C48
C49
C50
C51, C52
C53
C54 thru
C56
C57
C58
C59
C60
C61, C62
C63
C64
C65, C66
C67
C68 thru
C71
C72, C73
C74
C75 thru
C87
C88
DESCRIPTION
PART NO.
QTY.
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
003-1066
33
Capacitor, Electrolytic, 10 uF, 35V, Non-Polarized
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Mylar, 0.033 uF, 50V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
023-1075
003-1066
038-1049
003-1066
10
Capacitor, Electrolytic, 10 uF, 35V, Non-Polarized
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Electrolytic, 10 uF, 25V, Non-Polarized
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Electrolytic, 10 uF, 35V, Non-Polarized
023-1075
003-1066
023-1075
003-1066
023-1075
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Electrolytic, 2.2 uF, 25V dc
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Ceramic, 0.001 uF ±10%, 200V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Electrolytic, 2.2 uF, 25V dc
Capacitor, Electrolytic, 10 uF, 35V, Non-Polarized
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Electrolytic, 1 uF, 50V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
003-1066
013-2064
003-1066
030-1033
003-1066
013-2064
023-1075
003-1066
024-1064
003-1066
Capacitor, Ceramic, 0.001 uF ±10%, 200V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Ceramic, 0.001 uF ±10%, 200V
030-1033
003-1066
030-1033
13
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
003-1066
3-2
TABLE 3-3. ECU CONTROLLER CIRCUIT BOARD ASSEMBLY - 917-0205
(Sheet 2 of 10)
REF. DES.
C89
C90, C91
C92
C93
C94
C95
C96
C97
C98, C99
C100
C101
C102
C103
C104, C105
C106
C107
C108
C109
C110
C111 thru
C114
C115
C116
C117, C118
C121
C122 thru
C125
C126 thru
C128
C129
C130
C131
C132
C133, C134
C135
C136, C137
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
D11
D12
DESCRIPTION
PART NO.
QTY.
Capacitor, Electrolytic, 2.2 uF, 25V dc
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Ceramic, 0.001 uF ±10%, 200V
Capacitor, Monolythic Ceramic, .47 uF ±10%, 50V
Capacitor, Electrolytic, 2.2 uF, 25V dc
Capacitor, Electrolytic, 10 uF, 35V, Non-Polarized
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Electrolytic, 2.2 uF, 25V dc
Capacitor, Monolythic Ceramic, .47 uF ±10%, 50V
Capacitor, Mylar Film, 0.1 uF ±10%, 50V
Capacitor, Monolythic Ceramic, .47 uF ±20%, 50V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Ceramic, 0.001 uF ±10%, 200V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Ceramic, 0.001 uF ±10%, 200V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Electrolytic, 1 uF, 50V
Capacitor, Monolythic Ceramic, .47 uF ±10%, 50V
Capacitor, Electrolytic, 10 uF, 35V, Non-Polarized
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
013-2064
003-1066
030-1033
003-4743
013-2064
023-1075
003-1066
013-2064
003-4743
003-1066
003-4743
003-1066
030-1033
003-1066
030-1033
003-1066
024-1064
003-4743
023-1075
003-1066
Capacitor, Monolythic Ceramic, .47 uF ±10%, 50V
Capacitor, Electrolytic, 10 uF, 35V, Non-Polarized
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Electrolytic, 10 uF, 35V, Non-Polarized
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
003-4743
023-1075
003-1066
023-1075
003-1066
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
003-1066
Capacitor, Mylar Film, 0.01 uF ±10%, 200V
Capacitor, Electrolytic, 10 uF, 35V, Non-Polarized
Capacitor, Electrolytic, 1 uF, 50V
Capacitor, Electrolytic, 33 uF, 35V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Mica, 270 pF ±5%, 300V
Capacitor, Ceramic, 0.001 uF ±10%, 200V
Diode, 1N4005, Silicon, 600V @ 1 Ampere
Diode, 1N4148, Silicon, 75V @ 0.3 Amperes
Diode, 1N4005, Silicon, 600V @ 1 Ampere
Diode, 1N4148, Silicon, 75V @ 0.3 Amperes
Diode, 1N4005, Silicon, 600V @ 1 Ampere
Diode, 1N4148, Silicon, 75V @ 0.3 Amperes
Diode, 1N4005, Silicon, 600V @ 1 Ampere
Diode, 1N4148, Silicon, 75V @ 0.3 Amperes
Diode, 1N4005, Silicon, 600V @ 1 Ampere
Diode, 1N4148, Silicon, 75V @ 0.3 Amperes
Diode, 1N4005, Silicon, 600V @ 1 Ampere
Diode, 1N4148, Silicon, 75V @ 0.3 Amperes
030-1043
023-1075
024-1064
024-3374
003-1066
041-2722
030-1033
203-4005
203-4148
203-4005
203-4148
203-4005
203-4148
203-4005
203-4148
203-4005
203-4148
203-4005
203-4148
3-3
TABLE 3-3. ECU CONTROLLER CIRCUIT BOARD ASSEMBLY - 917-0205
(Sheet 3 of 10)
REF. DES.
D13 thru
D18
D19
D20
D21
D22 thru
D29
D30, D31
D32
D33
D34, D35
D36, D37
D38
D39, D40
D41
D42
D44 thru
D45
D49 thru
D51
D53 thru
D64
DS1, DS2
DS3
E10
J1 thru
J3
J4 thru
J20
P1 thru
P3
P6
P8 thru
P19
P301
P302
Q1 thru
Q37
Q38 thru
Q45
Q46 thru
Q51
Q52
Q53, Q54
DESCRIPTION
PART NO.
QTY.
Diode, 1N4005, Silicon, 600V @ 1 Ampere
203-4005
Diode, 1N4148, Silicon, 75V @ 0.3 Amperes
Diode, 1N4005, Silicon, 600V @ 1 Ampere
Diode, 1N4148, Silicon, 75V @ 0.3 Amperes
Diode, 1N4005, Silicon, 600V @ 1 Ampere
203-4148
203-4005
203-4148
203-4005
Diode, HP5082-2800, High Voltage, Schottky Barrier Type,
70V, 15 mA
Diode, 1N4148, Silicon, 75V @ 0.3 Amperes
Diode, HP5082-2800, High Voltage, Schottky Barrier Type,
70V, 15 mA
Diode, 1N4148, Silicon, 75V @ 0.3 Amperes
Diode, HP5082-2800, High Voltage, Schottky Barrier Type,
70V, 15 mA
Diode, 1N4148, Silicon, 75V @ 0.3 Amperes
Diode, HP5082-2800, High Voltage, Schottky Barrier Type,
70V, 15 mA
Diode, 1N4148, Silicon, 75V @ 0.3 Amperes
Diode, HP5082-2800, High Voltage, Schottky Barrier Type,
70V, 15 mA
Diode, 1N4148, Silicon, 75V @ 0.3 Amperes
201-2800
203-4148
201-2800
203-4148
201-2800
203-4148
201-2800
203-4148
201-2800
203-4148
Diode, 1N4148, Silicon, 75V @ 0.3 Amperes
203-4148
Diode, 1N4148, Silicon, 75V @ 0.3 Amperes
203-4148
12
Indicator, LED, Green, 521-9175, 3V @ 40 mA Maximum
Indicator, LED, Yellow, 521-9176, 3V @ 40 mA Maximum
Terminal, Turret, Double Shoulder
Receptacle, Male, 3-Pin In-line
323-9224
323-9225
413-1597
417-0003
Receptacle, Male, 2-Pin In-line
417-4004
17
Jumper, Programmable, 2-Pin
340-0004
Jumper, Programmable, 2-Pin
Jumper, Programmable, 2-Pin
340-0004
340-0004
12
Receptacle, 50-Pin Dual In-line
Connector, Female, 80-Pin, Dual In-Line Printed Circuit Board
Mount
Transistor, 2N7000, FET, N-Channel, TO-92 Case
417-0147
417-0188
210-7000
37
Transistor, VP0106N3, FET, P-Channel, TO-92 Case
210-0106
Transistor, 2N7000, FET, N-Channel, TO-92 Case
210-7000
Transistor, VP0106N3, FET, P-Channel, TO-92 Case
Transistor, 2N3906, PNP, Silicon, TO-92 Case
210-0106
210-3906
3-4
TABLE 3-3. ECU CONTROLLER CIRCUIT BOARD ASSEMBLY - 917-0205
(Sheet 4 of 10)
REF. DES.
Q55
Q57 thru
Q59
R1
R2 thru
R6
R7
R8
R9
R10
R11, R12
R13
R14
R15
R16
R17
R18
R19, R20
R21
R22
R23
R24
R25
R26 thru
R28
R29
R30
R31
R32
R33 thru
R35
R36
R37, R38
R39
R40
R41
R42
R43
R44
R45
R46
R47
R48
R49
R50
R51
R52
R53, R54
DESCRIPTION
PART NO.
QTY.
Transistor, 2N3904, NPN, Silicon, TO-92 Case
Transistor, 2N7000, FET, N-Channel, TO-92 Case
211-3904
210-7000
Resistor, 100 k Ohm ±1%, 1/4W
Potentiometer, 10 k Ohm ±10%, 1 1/4W
103-1062
179-1053
Resistor, 301 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 2.21 k Ohm ±1%, 1/4W
Resistor, 4.42 k Ohm ±1%, 1/4W
Resistor, 2.21 k Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 43.2 k Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 20.0 k Ohm ±1%, 1/4W
Resistor, 2.32 k Ohm ± 1%, 1/4W
Resistor, 1.74 k Ohm ± 1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 2.21 k Ohm ±1%, 1/4W
Resistor, 1.47 k Ohm, ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 301 k Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
103-3061
100-1051
103-2241
103-4441
103-2241
103-1062
103-4325
100-1041
103-2051
103-2341
103-1744
100-1041
103-2241
103-1474
100-1041
103-1062
103-3061
103-1062
Resistor, 20.0 k Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 301 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 2.21 k Ohm ±1%, 1/4W
103-2051
103-1062
103-3061
100-1051
103-2241
Resistor, 392 Ohm ±1%, 1/4W
Resistor, 240 Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 4.75 k Ohm ±1%, 1/4W
Resistor, 240 Ohm ±1%, 1/4W
Resistor, 392 Ohm ±1%, 1/4W
Resistor, 182 Ohm, ±1%, 1/4W
Resistor, 392 Ohm ±1%, 1/4W
Resistor, 4.75 k Ohm ±1%, 1/4W
Resistor, 10 Ohm ±1%, 1/4W
Resistor, 1 Meg Ohm ±1%, 1/4W
Resistor, 10 Ohm ±1%, 1/4W
Resistor, 90.9 k Ohm ±1%, 1/4W
Resistor, 47.5 k Ohm ±1%, 1/4W
Resistor, 121 k Ohm ±1%, 1/4W
Resistor, 301 k Ohm ±1%, 1/4W
Resistor, 10 Ohm, ±1%, 1/4W
103-3923
103-2431
100-1041
103-4741
103-2431
103-3923
103-1823
103-3923
103-4741
103-1021
103-1007
103-1021
103-9095
103-4755
103-1261
103-3061
103-1021
3-5
TABLE 3-3. ECU CONTROLLER CIRCUIT BOARD ASSEMBLY - 917-0205
(Sheet 5 of 10)
REF. DES.
R55
R56
R57
R58
R59
R60, R61
R62
R63, R64
R65, R66
R67
R68 thru
R70
R71
R72
R73
R74
R75
R76
R77
R78
R79, R80
R81, R82
R83
R84
R85
R86
R87
R88
R89
R90
R91
R92
R93
R94
R95
R96
R97
R98
R99
R100
R101
R102
R103
R104
R105
R106
R107
R108
DESCRIPTION
PART NO.
QTY.
Resistor, 392 Ohm ±1%, 1/4W
Potentiometer, 500 Ohm ±10%, 1 1/4W
Resistor, 750 Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 90.9 k Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 392 Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 90.9 k Ohm ±1%, 1/4W
Resistor, 47.5 k Ohm, ±1%, 1/4W
103-3923
178-5001
103-7503
103-1062
100-1041
103-9095
103-1062
103-3923
100-1051
103-9095
103-4755
Resistor, 90.9 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 4.7 Meg Ohm ±5%, 1/4W
Resistor, 150 Ohm ±1%, 1/4W
Resistor, 61.9 k Ohm ±1%, 1/4W
Resistor, 3.92 k Ohm ±1%, 1/4W
Resistor, 1.47 k Ohm, ±1%, 1/4W
Resistor, 4.7 Meg Ohm ±5%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 20.0 k Ohm ±1%, 1/4W
Resistor, 4.7 Meg Ohm ±5%, 1/4W
Resistor, 47.5 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 3.01 k Ohm ±1%, 1/4W
Resistor, 1 Meg Ohm ±1%, 1/4W
Resistor, 150 k Ohm ±1%, 1/4W
Resistor, 90.9 k Ohm ±1%, 1/4W
Resistor, 1 Meg Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 25.5 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 10 Ohm, ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 1 Meg Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 3.01 k Ohm ±1%, 1/4W
Resistor, 1 Meg Ohm ±1%, 1/4W
Resistor, 240 Ohm ±1%, 1/4W
Resistor, 4.75 k Ohm ±1%, 1/4W
Resistor, 2.21 k Ohm ±1%, 1/4W
Resistor, 16.9 k Ohm ±1%, 1/4W
Resistor, 1 Meg Ohm ±1%, 1/4W
Resistor, 3.01 k Ohm ±1%, 1/4W
Resistor, 1.47 k Ohm, ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
103-9095
100-1051
100-4773
100-1531
103-6195
103-3924
103-1474
100-4773
103-1062
103-2051
100-4773
103-4755
100-1051
103-3014
103-1007
103-1561
103-9095
103-1007
100-1051
103-2551
100-1051
103-1021
100-1051
103-1062
103-1007
100-1041
103-3014
103-1007
103-2431
103-4741
103-2241
103-1695
103-1007
103-3014
103-1474
100-1041
3-6
TABLE 3-3. ECU CONTROLLER CIRCUIT BOARD ASSEMBLY - 917-0205
(Sheet 6 of 10)
REF. DES.
R109
R110 thru
R122
R123
R124
R125
R126 thru
R130
R131 thru
R133
R134
R135
R136
R137
R138
R139, R140
R141
R142
R143
R144
R145 thru
R147
R148 thru
R150
R151
R152
R153
R154, R155
R156
R157
R158
R159
R160
R161
R162
R163
R164, R165
R166
R167
R168
R169
R170
R171
R172, R173
R174 thru
R176
R177
R179, R181
DESCRIPTION
PART NO.
QTY.
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 3.3 Meg Ohm ±5%, 1/4W
100-1051
100-3373
13
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 5.76 k Ohm ±1%, 1/4W
Resistor, 3.3 Meg Ohm ±5%, 1/4W
Resistor, 240 Ohm ±1%, 1/4W
103-1062
103-5764
100-3373
103-2431
Resistor, 100 k Ohm ±1%, 1/4W
103-1062
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 90.9 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Potentiometer, 500 Ohm ±10%, 1 1/4W
Resistor, 750 Ohm ±1%, 1/4W
Resistor, 90.9 k Ohm ±1%, 1/4W
100-1051
100-1041
103-9095
100-1051
103-1062
100-1041
103-1062
100-1041
178-5001
103-7503
103-9095
Resistor, 47.5 k Ohm, ±1%, 1/4W
103-4755
Resistor, 90.9 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 499 Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 90.9 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 301 k Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 499 Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 3.3 Meg Ohm ±5%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 26.1 k Ohm, ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
103-9095
100-1051
103-4993
100-1051
100-1041
103-9095
100-1051
103-1062
100-1041
103-3061
103-1062
103-4993
100-1051
103-1062
100-3373
100-1051
103-1062
100-1041
103-2615
103-1062
100-1051
Resistor, 1 Meg Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
103-1007
100-1041
3-7
TABLE 3-3. ECU CONTROLLER CIRCUIT BOARD ASSEMBLY - 917-0205
(Sheet 7 of 10)
REF. DES.
R183, R184
R187, R188
R189
R190
R191
R192 thru
R194
R195
R196
R197
R198
R199
R200
R201 thru
R205
R206
R207, R208
R209
R210
RN1, RN2
RN3, RN4
RN5
RN6, RN7
RN8
S1 thru
S3
S4
S5
TP1 thru
TP6
TP7 thru
TP12
U1 thru
U11
U12
U13
U14
U15
U16
U17
U18
DESCRIPTION
PART NO.
QTY.
Resistor, 392 Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 20.0 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 4.7 Meg Ohm ±5%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
103-3923
103-1062
103-2051
100-1051
100-4773
100-1051
Resistor, 26.1 k Oh ±1%, 1/4W
Resistor, 121 k Ohm ±1%, 1/4W
Resistor, 10 Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 4.75 k Ohm ±1%, 1/4W
Resistor, 2.2 Meg Ohm ±5%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
103-2615
103-1261
103-1021
103-1062
103-4741
100-2273
103-1062
Resistor, 475 k Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 1.47 k Ohm, ±1%, 1/4W
Resistor, 499 Ohm ±1%, 1/4W
Resistor Network, 10 k Ohm ±2%, 1W Resistors, 8-Pin Single
In-Line Package
Resistor Network, 9-100 k Ohm, ±2%, .17W Resistors, 10-Pin Single
In-Line Package
Resistor Network, 10 k Ohm ±2%, 1W Resistors, 8-Pin Single
In-Line Package
Resistor Network, 9-100 k Ohm, ±2%, 2.7W Resistors, 10-Pin Single
In-Line Package
Resistor Network, 10 k Ohm ±2%, 1W Resistors, 8-Pin Single
In-Line Package
Switch, SPST, 4-Position, 8-Pin DIP Dual In-Line
103-4731
103-1062
103-1474
103-4993
226-1051
226-1060
226-1051
226-1060
226-1051
340-0002
Switch, Miniature Toggle, DPDT, 0.4 vA Maximum at 20V ac or dc
Switch, Push, N.O. Momentary Contact, Miniature, 1A @ 120V
Maximum
Test, Jack, Right Angle PC Mounting
340-0060
343-6330
417-0004
Terminal, Turret, Double Shoulder
413-1597
Integrated Circuit, 4N33, Optical Isolator, NPN Photo
229-0033
Transistor/Infared Emitting Diode Type, 1500V Isolation,
Response: 30 kHz Maximum, Current: 50 mA Maximum, 6-Pin DIP
Integrated Circuit, CD4075BE, RCA
225-0006
Integrated Circuit, CD4071B, OR Gate, CMOS, 14-Pin DIP
225-0005
Integrated Circuit, MC14532B, 8-Bit Priority Encoder, CMOS,
228-4532
16-Pin DIP
Integrated Circuit, MC14076, Quad D Register, CMOS, 16-Pin DIP 228-4076
Integrated Circuit, MC14011BCP, Quad 2-Input NAND Gate, CMOS, 228-4011
14-Pin DIP
Integrated Circuit, MC14076, Quad D Register, CMOS, 16-Pin DIP 228-4076
Integrated Circuit, MC14028BCP, BCD-to-Decimal Decoder, CMOS 228-4028
3-8
11
TABLE 3-3. ECU CONTROLLER CIRCUIT BOARD ASSEMBLY - 917-0205
(Sheet 8 of 10)
REF. DES.
U19
U20
U21
U22
U23
U24
U25
U26
U27
U28
U29
U30, U31
U32, U33
U34, U35
U36
U37
U38
U39
U40
U41
U42, U43
U44
U45
U46
U47
U48, U49
U50
U51
U52
U53
U54
DESCRIPTION
PART NO.
Integrated Circuit, CD4075BE, RCA
225-0006
Integrated Circuit, CD4081B, Quad 2-Input AND Gate, CMOS,
225-0008
14-Pin DIP
Integrated Circuit, CD4075BE, RCA
225-0006
Integrated Circuit, MC14073B, Tripple 3-Input AND Gate,
228-4073
CMOS, 14-Pin DIP
Integrated Circuit, MC14001, CMOS, Quad 2-Input NOR Gate,
228-4001
14-Pin DIP
Integrated Circuit, Triple 3 Input NOR Gates, CMOS, 14-Pin DIP
220-4025
Integrated Circuit, CD4069CN, Hex Inverter, CMOS, 14-Pin DIP
228-4069
Integrated Circuit, 14 Stage Counter, CMOS, 16-Pin DIP
228-4020
Integrated Circuit, MC14512B, 8 Channel Data Selector, CMOS
228-4512
Integrated Circuit, MC14532B, 8-Bit Priority Encoder, CMOS,
228-4532
16-Pin DIP
Integrated Circuit, LM3362Z-2.5, Precision Voltage Reference,
229-0336
2.5V ±4%, -0 to ±70°C, TO-92 Case
Integrated Circuit, MC14516B, Binary Up/Down Counter, CMOS,
228-4516
16-Pin DIP
Integrated Circuit, 4N33, Optical Isolator, NPN Photo
229-0033
Transistor/Infared Emitting Diode Type, 1500V Isolation,
Response: 30 kHz Maximum, Current: 50 mA Maximum, 6-Pin DIP
Integrated Circuit, MC14516B, Binary Up/Down Counter, CMOS,
228-4516
16-Pin DIP
Integrated Circuit, CD4081B, Quad 2-Input AND Gate, CMOS,
225-0008
14-Pin DIP
Integrated Circuit, CD4075BE, RCA
225-0006
Integrated Circuit, MC14073B, Tripple 3-Input AND Gate,
228-4073
CMOS, 14-Pin DIP
Integrated Circuit, MC14051, 8-Bit Analog Multiplexer, CMOS,
220-4051
16-Pin DIP
Integrated Circuit, TLO74CN, Quad JFET-Input Operational
221-0074
Amplifier, 14-Pin DIP
Integrated Circuit, MC14053B, Analog Multiplexers/Demultiplexers, 220-4053
CMOS MSI, 16-Pin DIP
Integrated Circuit, DAC-08CP, D-A Converter, 8-Bit, 16-Pin DIP
220-0801
Integrated Circuit, LM339AN, Quad Comparator, 14-Pin DIP
221-0339
Integrated Circuit, CD4071B, OR Gate, CMOS, 14-Pin DIP
225-0005
Integrated Circuit, CD4069CN, Hex Inverter, CMOS, 14-Pin DIP
228-4069
Integrated Circuit, CD4081B, Quad 2-Input AND Gate, CMOS,
225-0008
14-Pin DIP
Integrated Circuit, MC14043BP, CMOS, Quad NOR Gate, 16-Pin DIP 220-4043
Integrated Circuit, CD4071B, OR Gate, CMOS, 14-Pin DIP
225-0005
Integrated Circuit, CD4081B, Quad 2-Input AND Gate, CMOS,
225-0008
14-Pin DIP
Integrated Circuit, MC14001, CMOS, Quad 2-Input NOR Gate,
228-4001
14-Pin DIP
Integrated Circuit, 4N33, Optical Isolator, NPN Photo
229-0033
Transistor/Infared Emitting Diode Type, 1500V Isolation,
Response: 30 kHz Maximum, Current: 50 mA Maximum, 6-Pin DIP
Integrated Circuit, CD4069CN, Hex Inverter, CMOS, 14-Pin DIP
228-4069
3-9
QTY.
TABLE 3-3. ECU CONTROLLER CIRCUIT BOARD ASSEMBLY - 917-0205
(Sheet 9 of 10)
REF. DES.
U55
U56
U57
U58
U59
U60
4011
U61
U62
U63, U64
U65, U66
U67
U68
U69
U70
U71
XS5
XU1 thru
XU11
XU12, XU13
XU14, XU15
XU16
XU17, XU18
XU19 thru
XU25
XU26 thru
XU28
XU30, XU31
XU32, XU33
XU34, XU35
XU36 thru
XU38
XU39
XU40
XU41 thru
XU43
XU44 thru
XU47
XU48, XU49
XU50 thru
XU52
XU53
DESCRIPTION
PART NO.
Integrated Circuit, CD4078BE, RCA
225-0007
Integrated Circuit, 4N33, Optical Isolator, NPN Photo
229-0033
Transistor/Infared Emitting Diode Type, 1500V Isolation,
Response: 30 kHz Maximum, Current: 50 mA Maximum, 6-Pin DIP
Integrated Circuit, MC14538B, Dual Retriggerable, Resettable
228-4538
Monostable Multivibrator, CMOS, 16-Pin DIP
Integrated Circuit, 14 Stage Counter, CMOS, 16-Pin DIP
228-4020
Integrated Circuit, MC14538B, Dual Retriggerable, Resettable
228-4538
Monostable Multivibrator, CMOS, 16-Pin DIP
Integrated Circuit, MC14011BCP, Quad 2-Input NAND Gate, CMOS,
14-Pin DIP
Integrated Circuit, LM339AN, Quad Comparator, 14-Pin DIP
221-0339
Integrated Circuit, CD4071B, OR Gate, CMOS, 14-Pin DIP
225-0005
Integrated Circuit, TLO74CN, Quad JFET-Input Operational
221-0074
Amplifier, 14-Pin DIP
Integrated Circuit, LM339AN, Quad Comparator, 14-Pin DIP
221-0339
Integrated Circuit, MC14043BP, CMOS, Quad NOR Gate, 16-Pin DIP 220-4043
Integrated Circuit, MC14538B, Dual Retriggerable, Resettable
228-4538
Monostable Multivibrator, CMOS, 16-Pin DIP
Integrated Circuit, CD4075BE, RCA
225-0006
Integrated Circuit, LM317LZ, Adjustable Positive Voltage
220-0317
Regulator, 1.2 to 37V @ 0.1 Ampere, TO-92 Case
Integrated Circuit, CD4081B, Quad 2-Input AND Gate, CMOS,
225-0008
14-Pin DIP
Switch Cap, Red
343-6331
Socket, 6-Pin DIP
417-0600
QTY.
2281
11
Socket, 14-Pin DIP
Socket, 16-Pin DIP
Socket, 14-Pin DIP
Socket, 16-Pin DIP
Socket, 14-Pin DIP
417-1404
417-1604
417-1404
417-1604
417-1404
Socket, 16-Pin DIP
417-1604
Socket, 16-Pin DIP
Socket, 6-Pin DIP
Socket, 16-Pin DIP
Socket, 14-Pin DIP
417-1604
417-0600
417-1604
417-1404
Socket, 16-Pin DIP
Socket, 14-Pin DIP
Socket, 16-Pin DIP
417-1604
417-1404
417-1604
Socket, 14-Pin DIP
417-1404
Socket, 16-Pin DIP
Socket, 14-Pin DIP
417-1604
417-1404
Socket, 6-Pin DIP
417-0600
3-10
TABLE 3-3. ECU CONTROLLER CIRCUIT BOARD ASSEMBLY - 917-0205
(Sheet 10 of 10)
REF. DES.
XU54, XU55
XU56
XU57 thru
XU59
XU60 thru
XU66
XU67, XU68
XU69
XU71
XU71
----
DESCRIPTION
PART NO.
QTY.
Socket, 14-Pin DIP
Socket, 6-Pin DIP
Socket, 16-Pin DIP
417-1404
417-0600
417-1604
Socket, 14-Pin DIP
417-1404
Socket, 16-Pin DIP
Socket, 14-Pin DIP
Socket, 14-Pin DIP
Socket, 16-Pin DIP
Blank, ECU Controller Circuit Board, AM-1
417-1604
417-1404
417-1404
417-1604
517-0205
TABLE 3-4. ECU EXTENDER CIRCUIT BOARD ASSEMBLY - 917-0208
REF. DES.
-------------------
DESCRIPTION
Connector, Female, 80-Pin, Dual In-Line, Printed Circuit Board
Mount
Header, Right Angle, 50-Pin
ECU Extender Card Support, AM Transmitter
Header, Right Angle, 80-Pin
Receptacle, 50-Pin Dual In-line
Blank, ECU Extender Circuit Board, AM-1
PART NO.
QTY.
417-0188
417-0152
471-0849
417-8001
417-0147
517-0208
TABLE 3-5. STEREO CIRCUIT BOARD ASSEMBLY - 917-0209
(Sheet 1 of 10)
REF. DES.
C1, C2
C3, C4
C5
C6
C7
C8
C9
C10
C11
C12
C13
C14
C15 thru
C18
C19, C20
C21
DESCRIPTION
PART NO.
QTY.
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Mica, 1000 pF ±1%, 100V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Mica, 500 pF ±1%, 500V
Capacitor, Mica, 1000 pF ±1%, 100V
Capacitor, Silvered Mica, 100 pF ±5%, 500V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Mica, 500 pF ±1%, 500V
Capacitor, Mica, 1000 pF ±1%, 100V
Capacitor, Silvered Mica, 100 pF ±5%, 500V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Mica, 330 pF ±5%, 500V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
003-1066
041-1031
003-1066
042-5021
041-1031
040-1022
003-1066
042-5021
041-1031
040-1022
003-1066
042-3322
003-1066
Capacitor, Mica, 1000 pF ±1%, 100V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
041-1031
003-1066
3-11
TABLE 3-5. STEREO CIRCUIT BOARD ASSEMBLY - 917-0209
(Sheet 2 of 10)
REF. DES.
C22
C23
C24
C25
C26
C27
C28
C29
C30
C31 thru
C34
C35, C36
C37
C38
C39
C40
C41
C42
C43
C44
C45
C46
C47 thru
C50
C51, C52
C53
C54
C55
C56
C57
C58
C59
C60
C61
C62
C63 thru
C80
C81, C82
C83, C84
C85
C86, C87
C88 thru
C90
C91
C92
C93
C94
C95 thru
C98
DESCRIPTION
PART NO.
QTY.
Capacitor, Mica, 500 pF ±1%, 500V
Capacitor, Mica, 1000 pF ±1%, 100V
Capacitor, Silvered Mica, 100 pF ±5%, 500V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Mica, 500 pF ±1%, 500V
Capacitor, Mica, 1000 pF ±1%, 100V
Capacitor, Silvered Mica, 100 pF ±5%, 500V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Mica, 330 pF ±5%, 500V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
042-5021
041-1031
040-1022
003-1066
042-5021
041-1031
040-1022
003-1066
042-3322
003-1066
Capacitor, Mica, 1000 pF ±1%, 100V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Mica, 500 pF ±1%, 500V
Capacitor, Mica, 1000 pF ±1%, 100V
Capacitor, Silvered Mica, 100 pF ±5%, 500V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Mica, 500 pF ±1%, 500V
Capacitor, Mica, 1000 pF ±1%, 100V
Capacitor, Silvered Mica, 100 pF ±5%, 500V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Mica, 330 pF ±5%, 500V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
041-1031
003-1066
042-5021
041-1031
040-1022
003-1066
042-5021
041-1031
040-1022
003-1066
042-3322
003-1066
Capacitor, Mica, 1000 pF ±1%, 100V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Mica, 500 pF ±1%, 500V
Capacitor, Mica, 1000 pF ±1%, 100V
Capacitor, Silvered Mica, 100 pF ±5%, 500V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Mica, 500 pF ±1%, 500V
Capacitor, Mica, 1000 pF ±1%, 100V
Capacitor, Silvered Mica, 100 pF ±5%, 500V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Mica, 330 pF ±5%, 500V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
041-1031
003-1066
042-5021
041-1031
040-1022
003-1066
042-5021
041-1031
040-1022
003-1066
042-3322
003-1066
18
Capacitor, Electrolytic, 100 uF, 50V
Capacitor, Mylar Film, 0.47 uF ±2%, 100V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Mylar Film, 0.47 uF ±2%, 100V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
020-1085
030-4753
003-1066
030-4753
003-1066
Capacitor, Electrolytic, 10 uF, 25V, Non-Polarized
Capacitor, Electrolytic, 22 uF, 50V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Electrolytic, 22 uF, 50V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
023-1075
024-2274
003-1066
024-2274
003-1066
3-12
TABLE 3-5. STEREO CIRCUIT BOARD ASSEMBLY - 917-0209
(Sheet 3 of 10)
REF. DES.
C99 thru
C102
C103, C104
C105
C106, C107
C108
C109
C110
C111
C112
C113
C114
C115
C116
C117
C118
C119
C120
C121
C122 thru
C128
C129, C130
C131 thru
C133
C134
C135, C136
C137
C138 thru
C144
C145
C146, C147
C148 thru
C151
C152 thru
C164
C165 thru
C168
C169, C170
C171, C172
C173, C174
C175
D1, D2
D3, D4
D5 thru
D9
DS1 thru
DS3
DS4 thru
DS6
DESCRIPTION
PART NO.
QTY.
Capacitor, Monolythic Ceramic, 0.0047 uF ±5%, 100V
003-4723
Capacitor, Electrolytic, 10 uF, 25V, Non-Polarized
Capacitor, Ceramic Disc, 3.3 pF, 1000V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Mica, 620 pF ±5%, 300V
Capacitor, Mica, 33 pF ±5%, 500V
Capacitor, Mica, 180 pF ±5%, 500V
Capacitor, Mica, 620 pF ±5%, 300V
Capacitor, Mica, 220 pF ±5%, 500V
Capacitor, Monolythic Ceramic, 0.0015 uF ±5%, 100V
Capacitor, Monolythic Ceramic, .0027 uF ±5%, 100V
Capacitor, Mica, 750 pF ±5%, 500V
Capacitor, Mica, 560 pF ±5%, 500V
Capacitor, Monolythic Ceramic, 0.0015 uF ±5%, 100V
Capacitor, Mica, 820 pF ±5%, 300V
Capacitor, Mica, 270 pF ±5%, 300V
Capacitor, Mica, 180 pF ±5%, 500V
Capacitor, Mica, 620 pF ±5%, 300V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
023-1075
000-3302
003-1066
040-6223
042-3312
042-1822
040-6223
040-2223
003-1523
003-2723
042-7522
040-5623
003-1523
042-8222
041-2722
042-1822
040-6223
003-1066
Capacitor, Electrolytic, 10 uF, 35V, Non-Polarized
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
023-1075
003-1066
Capacitor, Mica, 33 pF ±5%, 500V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Electrolytic, 10 uF, 35V, Non-Polarized
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
042-3312
003-1066
023-1075
003-1066
Capacitor, Electrolytic, 10 uF, 35V, Non-Polarized
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Monolythic Ceramic, 470 pF ±5%, 200V
023-1075
003-1066
003-4713
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
003-1066
13
Capacitor, Mylar Film, 0.01 uF ±10%, 200V
030-1043
Capacitor, Mica, 180 pF ±5%, 500V
Capacitor, Electrolytic, 10 uF, 25V, Non-Polarized
Capacitor, Mica, 33 pF ±5%, 500V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Diode, 1N4148, Silicon, 75V @ 0.3 Amperes
Diode, 1N4737, Zener, 7.5V ±10%, 1W
Diode, 1N4005, Silicon, 600V @ 1 Ampere
042-1822
023-1075
042-3312
003-1066
203-4148
200-4737
203-4005
Indicator, LED, Green, 521-9175, 3V @ 40 mA Maximum
323-9224
Indicator, LED, Yellow, 521-9176, 3V @ 30 mA Maximum
323-9225
3-13
TABLE 3-5. STEREO CIRCUIT BOARD ASSEMBLY - 917-0209
(Sheet 4 of 10)
REF. DES.
E1 thru
E4
J1 thru
J4
J5 thru
J7
L1 thru
L3
L4
L5, L6
L7
P1A
P2A
P1B
P2B
P3B
P4A
P5 thru
P7
P31
P201
Q1, Q2
Q3 thru
Q14
R1
R2
R3
R4
R5
R6
R7
R8
R9
R10
R11
R12
R13
R14
R15
R16
R17 thru
R19
R20 thru
R22
R23, R24
R25
DESCRIPTION
PART NO.
QTY.
Terminal, Turret, Double Shoulder
413-1597
Connector, Header, Right Angle, 8-Pin
417-0807
Receptacle, Male, 3-Pin In-line
417-0003
Coil, Toroid, 22 uH ±10%, 34 Turns of No. 30 Enameled Copper
Wire on B.E. No. 360-0023 Form
Shielded Adjustable Coil, 64-163 uH, 155 mA Maximum,
9.98 Ohms DC Resistance
Shielded Adjustable Coil, 26-71 uH, 185 mA Maximum,
6.97 Ohms DC Resistance
Shielded Adjustable Coil, 12-29 uH, 225 mA Maximum,
4.72 Ohms DC Resistance
Jumper, Programmable, 2-Pin
Jumper, Programmable, 2-Pin
Jumper, Programmable, 2-Pin
Jumper, Programmable, 2-Pin
Jumper, Programmable, 2-Pin
Jumper, Programmable, 2-Pin
Jumper, Programmable, 2-Pin
360-0049
360-0077
360-0062
360-0078
340-0004
340-0004
340-0004
340-0004
340-0004
340-0004
340-0004
Jumper, Programmable, 2-Pin
Receptacle, 50-Pin Dual In-line
Transistor, 2N3904, NPN, Silicon, TO-92 Case
Transistor, 2N7000, FET, N-Channel, TO-92 Case
340-0004
417-0147
211-3904
210-7000
12
Potentiometer, 5 k Ohm ±10%, 1W
Resistor, 8.25 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 6.04 k Ohm, ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Potentiometer, 10 k Ohm ±10%, 1 1/4W
Resistor, 24.9 k Ohm ±1%, 1/4W
Resistor, 51.1 Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Potentiometer, 500 Ohm ±10%, 1 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 4.75 k Ohm ±1%, 1/4W
Resistor, 24.9 k Ohm ±1%, 1/4W
Resistor, 51.1 Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 4.75 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
179-5043
103-8254
100-1051
103-6044
100-1051
179-1053
103-2495
103-5112
103-1062
178-5001
100-1051
103-4741
103-2495
103-5112
100-1051
103-4741
100-1051
Resistor, 4.99 k Ohm ±1%, 1/4W
100-5041
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
100-1051
100-1041
3-14
TABLE 3-5. STEREO CIRCUIT BOARD ASSEMBLY - 917-0209
(Sheet 5 of 10)
REF. DES.
R26
R27
R28
R29
R30
R31
R32
R33
R34
R35
R36
R37
R38
R39
R40
R41
R42
R43 thru
R45
R46 thru
R48
R49, R50
R51
R52
R53
R54
R55
R56
R57
R58
R59
R60
R61
R62
R63
R64
R65
R67
R68
R69 thru
R71
R72 thru
R74
R75, R76
R77
R78
R79
R80
DESCRIPTION
PART NO.
QTY.
Potentiometer, 10 k Ohm ±10%, 1 1/4W
Potentiometer, 5 k Ohm ±10%, 1W
Resistor, 8.25 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 6.04K Ohm, ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Potentiometer, 10 k Ohm ±10%, 1 1/4W
Resistor, 24.9 k Ohm ±1%, 1/4W
Resistor, 51.1 Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Potentiometer, 500 Ohm ±10%, 1 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 4.75 k Ohm ±1%, 1/4W
Resistor, 24.9 k Ohm ±1%, 1/4W
Resistor, 51.1 Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 4.75 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
179-1053
179-5043
103-8254
100-1051
103-6044
100-1051
179-1053
103-2495
103-5112
103-1062
178-5001
100-1051
103-4741
103-2495
103-5112
100-1051
103-4741
100-1051
Resistor, 4.99 k Ohm ±1%, 1/4W
100-5041
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Potentiometer, 10 k Ohm ±10%, 1 1/4W
Potentiometer, 5 k Ohm ±10%, 1W
Resistor, 8.25 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 6.04K Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Potentiometer, 10 k Ohm ±10%, 1 1/4W
Resistor, 51.1 Ohm ±1%, 1/4W
Resistor, 24.9 k Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Potentiometer, 500 Ohm ±10%, 1 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 4.75 k Ohm ±1%, 1/4W
Resistor, 24.9 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 4.75 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
100-1051
100-1041
179-1053
179-5043
103-8254
100-1051
103-6044
100-1051
179-1053
103-5112
103-2495
103-1062
178-5001
100-1051
103-4741
103-2495
100-1051
103-4741
100-1051
Resistor, 4.99 k Ohm ±1%, 1/4W
100-5041
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Potentiometer, 10 k Ohm ±10%, 1 1/4W
Potentiometer, 5 k Ohm ±10%, 1W
Resistor, 8.25 k Ohm ±1%, 1/4W
100-1051
100-1041
179-1053
179-5043
103-8254
3-15
TABLE 3-5. STEREO CIRCUIT BOARD ASSEMBLY - 917-0209
(Sheet 6 of 10)
REF. DES.
R81
R82
R83
R84
R85
R86
R87
R88
R89
R90
R91
R92
R93
R94
R95 thru
R97
R98 thru
R100
R101, R102
R103
R104
R105 thru
R109
R110
R111
R112
R113
R114
R115
R116
R117
R118
R119
R120 thru
R126
R127
R128
R129, R130
R131
R132
R133
R134
R135
R136
R137
R138
R139
DESCRIPTION
PART NO.
QTY.
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 6.04 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Potentiometer, 10 k Ohm ±10%, 1 1/4W
Resistor, 24.9 k Ohm ±1%, 1/4W
Resistor, 51.1 Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Potentiometer, 500 Ohm ±10%, 1 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 4.75 k Ohm ±1%, 1/4W
Resistor, 24.9 k Ohm ±1%, 1/4W
Resistor, 51.1 Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 4.75 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
100-1051
103-6044
100-1051
179-1053
103-2495
103-5112
103-1062
178-5001
100-1051
103-4741
103-2495
103-5112
100-1051
103-4741
100-1051
Resistor, 4.99 k Ohm ±1%, 1/4W
100-5041
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Potentiometer, 10 k Ohm ±10%, 1 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
100-1051
100-1041
179-1053
100-1051
Resistor, 178 k Ohm ±1%, 1/4W
Resistor Network, 10-10 k Ohm 0.5% Resistors, 0.7W Total
Dissipation, 16-Pin DIP
Resistor, 1.15 k Ohm ±1%, 1/4W
Resistor, 6.04 k Ohm ±1%, 1/4W
Resistor, 100 Ohm ±1%, 1/4W
Resistor, 442 Ohm ±1%, 1/4W
Resistor, 100 Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 49.9 k Ohm ±1%, 1/4W
Resistor, 499 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
103-1761
226-0392
103-1156
103-6044
100-1031
103-4423
100-1031
100-1041
103-4951
103-4996
100-1051
Resistor, 178 k Ohm ±1%, 1/4W
Resistor, 24.9 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 24.9 k Ohm ±1%, 1/4W
Potentiometer, 10 k Ohm ±10%, 1 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 82.5 k Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 205 k Ohm, ±1%, 1/4W
Resistor, 71.5 k Ohm ±1%, 1/4W
Resistor, 909 Ohm ±1%, 1/4W
Resistor, 178 k Ohm ±1%, 1/4W
103-1761
103-2495
100-1051
103-2495
179-1053
100-1041
103-8255
100-1041
103-2056
103-7155
103-9031
103-1761
3-16
TABLE 3-5. STEREO CIRCUIT BOARD ASSEMBLY - 917-0209
(Sheet 7 of 10)
REF. DES.
R140, R141
R142
R143
R144
R145
R146, R147
R148 thru
R151
R152, R153
R154, R155
R156
R157, R158
R159
R160
R161
R162, R163
R164
R165, R166
R167
R168
R169
R170 thru
R172
R173
R174
R175
R176
R177
R178
R179
R180
R181, R182
R183 thru
R188
R189
R190
R191
R192
R193
R194
R195
R196
R197 thru
R200
R201, R202
R203
R204
R205
DESCRIPTION
PART NO.
QTY.
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 5.23 k Ohm, ±1%, 1/4W
Resistor, 5.49 k Ohm, ±1%, 1/4W
Resistor, 100 Ohm ±1%, 1/4W
Resistor, 49.9 k Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 100 Ohm ±1%, 1/4W
100-1051
103-5251
103-5494
100-1031
103-4951
100-1041
100-1031
Resistor, 22.1 Ohm ±1%, 1/4W
Resistor, 2 k Ohm ±1%, 1/4W
Resistor, 88.7 Ohm, ±1%, 1/4W
Resistor, 182 Ohm ±1%, 1/4W
Resistor, 442 Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 182 Ohm ±1%, 1/4W
Resistor, 221 Ohm ±1%, 1/4W
Resistor, 182 Ohm, ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 182 Ohm, ±1%, 1/4W
Resistor, 240 Ohm ±1%, 1/4W
Resistor, 5.23 k Ohm, ±1%, 1/4W
Resistor, 442 Ohm, ±1%, 1/4W
103-2212
100-2041
103-8872
103-1823
103-4423
100-1041
103-1823
103-2213
103-1823
100-1041
103-1823
103-2431
103-5251
103-4423
Resistor, 240 Ohm ±1%, 1/4W
Resistor, 3.01 k Ohm ±1%, 1/4W
Resistor, 240 Ohm ±1%, 1/4W
Resistor, 3.01 k Ohm ±1%, 1/4W
Resistor, 22.1 Ohm ±1%, 1/4W
Resistor, 3.01 k Ohm ±1%, 1/4W
Resistor, 22.1 Ohm ±1%, 1/4W
Resistor, 3.01 k Ohm ±1%, 1/4W
Resistor, 1.5 k Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
103-2431
103-3014
103-2431
103-3014
103-2212
103-3014
103-2212
103-3014
103-1504
100-1041
Resistor, 4.75 k Ohm ±1%, 1/4W
Resistor, 3.01 k Ohm ±1%, 1/4W
Resistor, 2 k Ohm ±1%, 1/4W
Resistor, 24.9 k Ohm ±1%, 1/4W
Potentiometer, 10 k Ohm ±10%, 1 1/4W
Resistor, 24.9 k Ohm ±1%, 1/4W
Resistor, 49.9 k Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 49.9 k Ohm ±1%, 1/4W
103-4741
103-3014
100-2041
103-2495
179-1053
103-2495
103-4951
100-1041
103-4951
Resistor, 240 Ohm ±1%, 1/4W
Resistor, 82.5 k Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 49.9 k Ohm ±1%, 1/4W
103-2431
103-8255
100-1041
103-4951
3-17
TABLE 3-5. STEREO CIRCUIT BOARD ASSEMBLY - 917-0209
(Sheet 8 of 10)
REF. DES.
R206
R207
R208
R209
R210
R211
R212
R213
R214
R215
R216
R217
R218 thru
R221
R222 thru
R225
R226
R227
R228
S1
S2 thru
S4
S5
T1
TP1 thru
TP10
U1
U2, U3
U4 thru
U7
U8, U9
U10 thru
U12
U13, U14
U15 thru
U18
U19, U20
U21, U22
U23
U24 thru
U27
U28
U29 thru
U31
DESCRIPTION
PART NO.
QTY.
Resistor, 3.3 Meg Ohm ±5%, 1/4W
Resistor, 49.9 k Ohm ±1%, 1/4W
Resistor, 3.3 Meg Ohm ±5%, 1/4W
Resistor, 49.9 k Ohm ±1%, 1/4W
Resistor, 3.3 Meg Ohm ±5%, 1/4W
Resistor, 49.9 k Ohm ±1%, 1/4W
Resistor, 3.3 Meg Ohm ±5%, 1/4W
Resistor, 49.9 k Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 2 k Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 240 Ohm ±1%, 1/4W
100-3373
103-4951
100-3373
103-4951
100-3373
103-4951
100-3373
103-4951
100-1041
100-2041
100-1041
100-1051
103-2431
Resistor, 1 k Ohm ±1%, 1/4W
100-1041
Resistor, 5.23 k Ohm, ±1%, 1/4W
Resistor, 51.1 Ohm ±1%, 1/4W
Resistor, 22.1 Ohm ±1%, 1/4W
Switch, Toggle, SPDT, 5A @ 125V ac & 28V dc
Switch, SPST, 4-Position, 8-Pin DIP Dual In-Line
103-5251
103-5112
103-2212
348-0123
340-0002
Switch, Push, N.O. Momentary Contact, Miniature, 1A @ 120V
Maximum
Transformer, RF DRIVE
Terminal, Turret, Double Shoulder
343-6330
370-0046
413-1597
10
Integrated Circuit, TL072CP, Dual JFET-Input Operational
Amplifier, 8-Pin DIP
Integrated Circuit, 2150A, Voltage Controlled Amplifier, 8-Pin DIP
Integrated Circuit, TL072CP, Dual JFET-Input Operational
Amplifier, 8-Pin DIP
Integrated Circuit, 2150A, Voltage Controlled Amplifier, 8-Pin DIP
Integrated Circuit, TL072CP, Dual JFET-Input Operational
Amplifier, 8-Pin DIP
Integrated Circuit, 2150A, Voltage Controlled Amplifier, 8-Pin DIP
Integrated Circuit, TL072CP, Dual JFET-Input Operational
Amplifier, 8-Pin DIP
Integrated Circuit, 2150A, Voltage Controlled Amplifier, 8-Pin DIP
Integrated Circuit, TL072CP, Dual JFET-Input Operational
Amplifier, 8-Pin DIP
Integrated Circuit, DG212CJ, QUAD SPST Switch, CMOS,
16-Pin DIP
Integrated Circuit, TL072CP, Dual JFET-Input Operational
Amplifier, 8-Pin DIP
Integrated Circuit, DG212CJ, QUAD SPST Switch, CMOS,
16-Pin DIP
Integrated Circuit, TL072CP, Dual JFET-Input Operational
Amplifier, 8-Pin DIP
221-0072
220-2150
221-0072
220-2150
221-0072
220-2150
221-0072
220-2150
221-0072
220-0212
221-0072
220-0212
221-0072
3-18
TABLE 3-5. STEREO CIRCUIT BOARD ASSEMBLY - 917-0209
(Sheet 9 of 10)
REF. DES.
U32
U33
U34
U35
U36
U37
U38
U39
U40
4132
U41
U42
U43
U44
U45 thru
U48
U49
U50
U51
U52
U53
U54
U55
XU1
XU4 thru
XU7
XU10 thru
XU12
XU15 thru
XU18
XU21, XU22
XU23
XU24 thru
XU27
DESCRIPTION
PART NO.
Integrated Circuit, LM317LZ, Adjustable Positive Voltage
220-0317
Regulator, 1.2 to 37V @ 0.1 Ampere, TO-92 Case
Integrated Circuit, 74HC4022, Octal Counter/Divider, CMOS,
221-4022
16-Pin DIP
Integrated Circuit, 74HC4002N, Dual 4 Input NOR Gate
221-4002
14-Pin DIP
Integrated Circuit, 74HC74N, Dual D-Type Flip Flop, 14-Pin DIP
221-7474
Integrated Circuit, DG-271, 201HS, CMOS SPST Analog Switch
220-0017
16-Pin DIP
Integrated Circuit, NE5539N, UHF Operational Amplifier,
220-5539
14-Pin DIP
Integrated Circuit, CA3183E, Five Transistor Array, NPN,
220-3183
16-Pin DIP
Integrated Circuit, MC10116P, Triple Differential Amplifier,
220-0116
16-Pin DIP
Integrated Circuit, 74HC132N, Quad NAND Gate, Schmitt Trigger,
14-Pin DIP
Integrated Circuit, CD4081B, Quad 2-Input AND Gate, CMOS,
225-0008
14-Pin DIP
Integrated Circuit, MC14584, Hex Schmitt Trigger, CMOS,
228-4584
14-Pin DIP
Integrated Circuit, MC14093B, Quad 2-Input NAND Schmitt Trigger 220-4093
CMOS, 14-Pin DIP
Integrated Circuit, MC14013BCP, Dual D-Type Flip-Flop, CMOS,
228-4013
14-Pin DIP
Integrated Circuit, 4N33, Optical Isolator, NPN Photo
229-0033
Transistor/Infared Emitting Diode Type, 1500V Isolation,
Response: 30 kHz Maximum, Current: 50 mA Maximum, 6-Pin DIP
Integrated Circuit, CD4071B, OR Gate, CMOS, 14-Pin DIP
225-0005
Integrated Circuit, MC14532B, CMOS, 8-Bit Priority Encoder
228-4532
Integrated Circuit, MC14013BCP, Dual D-Type Flip-Flop, CMOS,
228-4013
14-Pin DIP
Integrated Circuit, CD4071B, OR Gate, CMOS, 14-Pin DIP
225-0005
Integrated Circuit, CD4017B, 10-Output Counter/Divider, CMOS,
220-4017
16-Pin DIP
Integrated Circuit, CD4081B, Quad 2-Input AND Gate, CMOS,
225-0008
14-Pin DIP
Integrated Circuit, MC14584, Hex Schmitt Trigger, CMOS,
228-4584
14-Pin DIP
Socket, 8-Pin DIP
417-0804
Socket, 8-Pin DIP
417-0804
QTY.
2211
Socket, 8-Pin DIP
417-0804
Socket, 8-Pin DIP
417-0804
Socket, 8-Pin DIP
Socket, 16-Pin DIP
Socket, 8-Pin DIP
417-0804
417-1604
417-0804
3-19
TABLE 3-5. STEREO CIRCUIT BOARD ASSEMBLY - 917-0209
(Sheet 10 of 10)
REF. DES.
XU28
XU29 thru
XU31
XU33
XU34, XU35
XU36
XU37
XU38, XU39
XU40 thru
XU44
XU45 thru
XU48
XU49
XU50
XU51, XU52
XU53
XU54, XU55
----------
DESCRIPTION
PART NO.
QTY.
Socket, 16-Pin DIP
Socket, 8-Pin DIP
417-1604
417-0804
Socket, 16-Pin DIP
Socket, 14-Pin DIP
Socket, 16-Pin DIP
Socket, 14-Pin DIP
Socket, 16-Pin DIP
Socket, 14-Pin DIP
417-1604
417-1404
417-1604
417-1404
417-1604
417-1404
Socket, 6-Pin DIP
417-0600
Socket, 14-Pin DIP
Socket, 16-Pin DIP
Socket, 14-Pin DIP
Socket, 16-Pin DIP
Socket, 14-Pin DIP
Socket/Spacer, LED
Switch Cap, Red
Blank, Stereo Circuit Board, AM1, AM5
417-1404
417-1604
417-1404
417-1604
417-1404
407-0074
343-6331
517-0209
TABLE 3-6. ECU EXCITER CIRCUIT BOARD ASSEMBLY - 917-0300
(Sheet 1 of 10)
REF. DES.
C1, C2
C3 thru
C5
C6
C7
C8
C9
C10
C11
C12
C14
C15
C16, C17
C18 thru
C20
C21
C22
C23
C24
C25
C26
DESCRIPTION
PART NO.
QTY.
Capacitor, Electrolytic, 10 uF, 35V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
023-1075
003-1066
Capacitor, Mica, 1000 pF ±1%, 100V
Capacitor, Mica, 150 pF ±5%, 500V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Mica, 500 pF ±1%, 500V
Capacitor, Mica, 1000 pF ±1%, 100V
Capacitor, Mica, 150 pF ±5%, 500V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Mica, 1000 pF ±1%, 100V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Electrolytic, 10 uF, 35V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
041-1031
040-1522
003-1066
042-5021
041-1031
040-1522
003-1066
041-1031
003-1066
023-1075
003-1066
Capacitor, Mica, 1000 pF ±1%, 100V
Capacitor, Mica, 150 pF ±5%, 500V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Mica, 500 pF ±1%, 500V
Capacitor, Mica, 1000 pF ±1%, 100V
Capacitor, Mica, 150 pF ±5%, 500V
041-1031
040-1522
003-1066
042-5021
041-1031
040-1522
3-20
TABLE 3-6. ECU EXCITER CIRCUIT BOARD ASSEMBLY - 917-0300
(Sheet 2 of 10)
REF. DES.
C27
C29
C30, C31
C32
C33
C34
C35
C36
C37 thru C39
C40
C41
C42
C43
C44
C45
C46
C47
C48
C49
C50
C51
C52
C53
C54
C55, C56
C57, C58
C59
C60
C61, C62
C63 thru C67
C68
C69, C70
C71, C72
C73, C74
C75
C76
C77
C78
C79 thru C81
C82
C83
C84
C85, C88
C89
C90
C91 thru C93
C93
C94
DESCRIPTION
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Mica, 1000 pF ±1%, 100V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Electrolytic, 10 uF, 50V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Electrolytic, 22 uF, 50V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Electrolytic, 22 uF, 50V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Mica, 33 pF ±5%, 500V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Mica, 500 pF ±1%, 500V
Capacitor, Mica, 1000 pF ±1%, 100V
Capacitor, Silvered Mica, 100 pF ±5%, 500V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Mica, 500 pF ±1%, 500V
Capacitor, Mica, 1000 pF ±1%, 100V
Capacitor, Silvered Mica, 100 pF ±5%, 500V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Mica, 500 pF ±1%, 500V
Capacitor, Mica, 1000 pF ±1%, 100V
Capacitor, Silvered Mica, 100 pF ±5%, 500V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Electrolytic, 10 uF, 50V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Polyester, 0.0022 uF ±10%, 100V
Capacitor, Mica, 150 pF ±5%, 500V
Capacitor, Polyester, 0.0022 uF ±10%, 100V
Capacitor, Electrolytic, 10 uF, 50V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Mica, 1000 pF ±1%, 100V
Capacitor, Electrolytic, 10 uF, 50V
Capacitor, Electrolytic, 100 uF, 35V
Capacitor, Mica, 1000 pF ±1%, 100V
Capacitor, Mica, 390 pF ±5%, 100V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Mica, 1000 pF ±1%, 100V
Capacitor, Mica, 250 pF ±1%, 500V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Monolythic Ceramic, .47 uF ±10%, 50V
Capacitor, Electrolytic, 1 uF, 50V, Non-Polarized
Capacitor, Mylar Film, 0.047 uF ±10%, 100V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Electrolytic, 1 uF, 50V, Non-Polarized
Capacitor, Mica, 390 pF ±5%, 100V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Electrolytic, 10 uF, 50V
Capacitor, Electrolytic, 22 uF, 50V
3-21
PART NO.
003-1066
041-1031
003-1066
023-1076
003-1066
024-2274
003-1066
024-2274
003-1066
042-3312
003-1066
042-5021
041-1031
040-1022
003-1066
042-5021
041-1031
040-1022
003-1066
042-5021
041-1031
040-1022
003-1066
023-1076
003-1066
031-2033
040-1522
031-2033
023-1076
003-1066
041-1031
023-1076
023-1084
041-1031
042-3922
003-1066
041-1031
042-2521
003-1066
003-4743
020-1064
030-4743
003-1066
020-1064
042-3922
003-1066
023-1076
024-2274
QTY.
TABLE 3-6. ECU EXCITER CIRCUIT BOARD ASSEMBLY - 917-0300
(Sheet 3 of 10)
REF. DES.
C96, C97
C98
C99
C100
C101, C102
C103
C104
C105, C106
C107
C108
C109
C110
C111
C112, C113
C114
C115 thru
C117
C118
C119, C120
C121
C122 thru
C124
C125
C126 thru
C129
C130
C131
C132
C133, C134
C135, C136
C137
C138
C140
C141
C143, C144
C145
C146
C147 thru
C154
C155
C156
C157
C158, C159
C160
C162
C163 thru
C165
C166
DESCRIPTION
PART NO.
QTY.
Capacitor, Polycarbonate, 0.10 uF ±1%, 100V
Capacitor, Monolythic Ceramic, 0.0047 uF ±5%, 100V
Capacitor, Mylar, 0.01 uF ±10%, 100V
Capacitor, Mica, 500 pF ±1%, 500V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Monolythic Ceramic, 0.0047 uF ±5%, 100V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Electrolytic, 22 uF, 50V
Capacitor, Monolythic Ceramic, 56 pF ±10%, 200V
Capacitor, Variable, Polycarbonate, 2-27 pF
Capacitor, Mica, 150 pF ±5%, 500V
Capacitor, Ceramic Disc, 68 pF ±5%, N1500, 63V dc
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Monolythic Ceramic, 0.0015 uF ±5%, 100V
Capacitor, Mylar, 0.01 uF ±10%, 100V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
030-1051
003-4723
031-1043
042-5021
003-1066
003-4723
003-1066
024-2274
001-5613
096-0009
040-1522
000-6814
003-1066
003-1523
031-1043
003-1066
Capacitor, Electrolytic, 10 uF, 50V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Electrolytic, 10 uF, 50V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
023-1076
003-1066
023-1076
003-1066
Capacitor, Electrolytic, 1 uF, 50V, Non-Polarized
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
020-1064
003-1066
Capacitor, Mica, 68 pF ±5%, 500V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Silvered Mica, 100 pF ±5%, 500V
Capacitor, Mica, 33 pF ±5%, 500V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Mica, 33 pF ±5%, 500V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Electrolytic, 10 uF, 50V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Mica, 33 pF ±5%, 500V
Capacitor, Electrolytic, 33 uF, 25V
Capacitor, Polycarbonate, 0.10 uF ±1%, 100V
040-6813
003-1066
040-1022
042-3312
003-1066
042-3312
003-1066
023-1076
003-1066
003-1066
042-3312
020-3374
030-1051
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Monolythic Ceramic, 0.0047 uF ±5%, 100V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Monolythic Ceramic, .47 uF ±10%, 50V
Capacitor, Mica, 22 pF ±5%, 500V
Capacitor, Mica, 22 pF ±5%, 500V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
003-1066
003-4723
003-1066
003-4743
040-2213
040-2213
003-1066
Capacitor, Monolythic Ceramic, .47 uF ±10%, 50V
003-4743
3-22
TABLE 3-6. ECU EXCITER CIRCUIT BOARD ASSEMBLY - 917-0300
(Sheet 4 of 10)
REF. DES.
C167
C168 thru
C170
C171, C172
C173
C174
C175, C176
D1, D2
D4 thru
D21
D22
D23
D24 thru
D27
D29 thru
D46
D47 thru
D50
D51 thru
D67
D68
D69
DS1 thru
DS5
E1 thru
E4
J2 thru J5
J6
J7
J8 thru
J11
J12, J13
L1 thru L4
L5
L6
P2 thru P5
P6A, P6B
P7
P12A
P12B
P13A
P13B
P101
Q3, Q4
Q5
Q6, Q7
DESCRIPTION
PART NO.
QTY.
Capacitor, Electrolytic, 1 uF, 50V, Non-Polarized
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
020-1064
003-1066
Capacitor, Electrolytic, 1 uF, 50V, Non-Polarized
Capacitor, Monolythic Ceramic, 0.0015 uF ±5%, 100V
Capacitor, Electrolytic, 2.2 uF ±30%, 50V, Non-Polarized
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Diode, 1N4148, Silicon, 75V @ 0.3 Amperes
Diode, HP5082-2800, High Voltage, Schottky Barrier Type,
70V, 15 mA
Diode, 1N4148, Silicon, 75V @ 0.3 Amperes
Diode, 1N4005, Silicon, 600V @ 1 Ampere
Diode, 1N4148, Silicon, 75V @ 0.3 Amperes
020-1064
003-1523
020-2264
003-1066
203-4148
201-2800
18
203-4148
203-4005
203-4148
Diode, 1N4148, Silicon, 75V @ 0.3 Amperes
203-4148
18
Diode, HP5082-2800, High Voltage, Schottky Barrier Type,
70V, 15 mA
Diode, 1N4148, Silicon, 75V @ 0.3 Amperes
201-2800
203-4148
17
Diode, Zener, 1N4739A, 9.1V ±5%, 1W
Diode, Zener, 1N4732A, 4.7V ±5%, 1W
Indicator, LED, Green, 521-9175, 3V @ 40 mA Maximum
200-0009
200-4732
323-9224
Terminal Test Point, Oval Red
413-0106
Receptacle, Male, 3-Pin In-line
Receptacle, Male, 20-Pin In-Line
Receptacle, Male, 3-Pin In-line
Receptacle, Single Pin
417-0003
417-0200
417-0003
417-0071-001
Receptacle, Male, 20-Pin In-Line
Coil, Toroid, 22 uH ±10%, 34 Turns of No. 30 Enameled Copper
Wire on B.E. No. 360-0023 Form
Coil, Molded, Shielded, 56 uH
Coil, Molded, 2.2 uH
Jumper, Programmable, 2-Pin
Jumper, Programmable, 2-Pin
Jumper, Programmable, 2-Pin
Jumper, Programmable, 2-Pin
Jumper, Programmable, 2-Pin
Jumper, Programmable, 2-Pin
Jumper, Programmable, 2-Pin
Connector, Female, 80-Pin, Dual In-Line, PCB Mount
Transistor, 2N3904, NPN, Silicon, TO-92 Case
Transistor, 2N3906, PNP, Silicon, TO-92 Case
Transistor, 2N7000, FET, N-Channel, TO-92 Case
417-0200
360-0049
360-0093
364-2200
340-0004
340-0004
340-0004
340-0004
340-0004
340-0004
340-0004
417-0188
211-3904
210-3906
210-7000
3-23
TABLE 3-6. ECU EXCITER CIRCUIT BOARD ASSEMBLY - 917-0300
(Sheet 5 of 10)
REF. DES.
Q8
Q13 thru
Q22
Q23
R1
R2
R3
R4
R5
R8, R9
R10 thru
R12
R14
R15
R16
R17
R18
R18
R19
R20
R23, R24
R25 thru
R27
R29
R30
R31
R32, R33
R34
R35
R36, R37
R38, R39
R40
R41
R41
R42
R43 thru
R54
R55
R58 thru
R61
R62
R63
R64
R65
R66
R67
DESCRIPTION
Field Effect Transistor, J3100, RF, N-Channel, TO-92 Case
Field Effect Transistor, VN88AD, Metal-Oxide/Silicon,
N-Channel Enhancement Type, TO-220-AB Case
Transistor, 2N7000, N-Channel, TO-92 Case
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 221 k Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 221 k Ohm ±1%, 1/4W
Resistor Network, 10-10 k Ohm 0.5% Resistors, 0.7W Total
Dissipation, 16-Pin DIP
Resistor, 26.7 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
PART NO.
QTY.
212-0310
210-0088
10
210-7000
103-1062
103-2216
103-1062
103-2216
226-0392
103-2675
100-1051
Resistor, 15 k Ohm ±5%, 1/4W
Resistor, 100 Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 221 k Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 221 k Ohm ±1%, 1/4W
Resistor Network, 10-10 k Ohm 0.5% Resistors, 0.7W Total
Dissipation, 16-Pin DIP
Resistor, 26.7 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
100-1551
100-1031
103-1062
103-2216
100-1041
103-1062
103-2216
226-0392
103-2675
100-1051
Resistor, 15 k Ohm ±5%, 1/4W
Resistor, 100 Ohm ±1%, 1/4W
Resistor, 221 Ohm ±1%, 1/4W
Resistor, 1.24 k Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 39.2 k Ohm ±1%, 1/4W
Resistor, 221 Ohm ±1%, 1/4W
Resistor, 3.83 k Ohm ±1%, 1/4W
Potentiometer, 20 k Ohm ±10%, 1/2W
Resistor, 20.0 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
100-1551
100-1031
103-2213
103-1244
103-1062
100-1051
103-1062
100-3951
103-2213
103-3841
178-2054
103-2051
100-1051
12
Resistor, 51.1 Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
103-5112
103-1062
Potentiometer, 10 k Ohm ±10%, 1/2W
Resistor, 34 k Ohm ±1%, 1/4W
Resistor, 2.2 Meg Ohm ±5%, 1/4W
Resistor, 10 Ohm ±1%, 1/4W
Resistor, 2.2 Meg Ohm ±5%, 1/4W
Resistor, 10 Ohm ±1%, 1/4W
177-1054
103-3405
100-2273
103-1021
100-2273
103-1021
3-24
TABLE 3-6. ECU EXCITER CIRCUIT BOARD ASSEMBLY - 917-0300
(Sheet 6 of 10)
REF. DES.
R68
R69
R70
R71
R72
R73
R74
R75
R76
R77
R78
R79
R80, R81
R82, R83
R84
R85
R86 thru
R88
R89, R90
R91
R92, R93
R94
R99
R100
R101, R102
R112
R113, R114
R115
R116, R117
R118
R119
R120
R121
R122 thru
R125
R126 thru
R128
R129
R130
R131
R132
R133
R134
R135
R136
R137
R138 thru
R140
DESCRIPTION
PART NO.
QTY.
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 10 Ohm ±1%, 1/4W
Resistor, 121 Ohm ±1%, 1/4W
Resistor, 845 Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 47.5 k Ohm ±1%, 1/4W
Resistor, 453 k Ohm ±1%, 1/4W
Resistor, 2.21 k Ohm ±1%, 1/4W
Potentiometer, 1 k Ohm ±10%, 1/2W
Resistor, 34 k Ohm ±1%, 1/4W
Resistor, 22.1 k Ohm ±1%, 1/4W
Resistor, 1.33 k Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 10 Ohm ±1%, 1/4W
Resistor, 845 Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 9.09 k Ohm ±1%, 1/4W
100-1051
103-1021
100-1231
103-8453
100-1041
103-4755
100-4561
103-2241
178-1044
103-3405
103-2211
103-1331
100-1041
103-1021
103-8453
100-1051
103-9041
Resistor, 8.45 k Ohm ±1%, 1/4W
Resistor, 5.6 Meg Ohm ±5%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 100 Ohm ±1%, 1/4W
Resistor, 34 k Ohm ±1%, 1/4W
Resistor, 66.5 k Ohm ±1%, 1/4W
Resistor, 26.7 k Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 10 Ohm ±1%, 1/4W
Resistor, 34 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 121 Ohm ±1%, 1/4W
Resistor, 365 Ohm ±1%, 1/4W
Resistor, 51.1 Ohm ±1%, 1/4W
Resistor, 9.53 k Ohm ±1%, 1/4W
103-8454
100-5673
100-1051
100-1031
103-3405
103-6655
103-2675
103-1062
103-1021
103-3405
100-1051
103-1062
100-1231
103-3631
103-5112
103-9534
Resistor, 7.50 k Ohm ±1%, 1/4W
103-7541
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 10 Ohm ±1%, 1/4W
Resistor, 4.75 k Ohm ±1%, 1/4W
Resistor, 221 Ohm ±1%, 1/4W
Resistor, 26.7 k Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 2.2 Meg Ohm ±5%, 1/4W
Resistor, 100 Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
100-1041
103-1021
103-4741
103-2213
103-2675
103-1062
100-1051
100-2273
100-1031
100-1051
3-25
TABLE 3-6. ECU EXCITER CIRCUIT BOARD ASSEMBLY - 917-0300
(Sheet 7 of 10)
REF. DES.
R142
R143
R144
R145
R146
R147
R148
R149, R150
R151
R152
R153
R154
R155
R156
R157
R158
R159
R160
R161
R162
R163
R164
R165
R166
R167
R168
R169
R170
R171
R172 thru
R179
R180
R181
R182
R183
R184
R185
R186
R187
R188
R189
R190
R191
R192 thru
R194
R195
R196
R197
DESCRIPTION
PART NO.
QTY.
Resistor, 2.2 Meg Ohm ±5%, 1/4W
Resistor, 221 Ohm ±1%, 1/4W
Resistor, 3.83 k Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 221 Ohm ±1%, 1/4W
Resistor, 24.9 Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 4.75 k Ohm ±1%, 1/4W
Resistor, 100 Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 3.83 k Ohm ±1%, 1/4W
Resistor, 453 k Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 121 Ohm ±1%, 1/4W
Resistor, 845 Ohm ±1%, 1/4W
Resistor, 221 Ohm ±1%, 1/4W
Potentiometer, 2 k Ohm ±10%, 1/2W
Resistor, 1.24 k Ohm ±1%, 1/4W
Resistor, 3.83 k Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 100 Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 2.21 k Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 2.21 k Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 15 k Ohm ±5%, 1/4W
Potentiometer, 20 k Ohm ±10%, 1/2W
Resistor, 15 k Ohm ±5%, 1/4W
Resistor, 22.1 Ohm ±1%, 1/4W
100-2273
103-2213
103-3841
100-1041
103-2213
103-2490
100-1041
103-4741
100-1031
100-1051
103-3841
100-4561
100-1041
100-1231
103-8453
103-2213
177-2044
103-1244
103-3841
100-1041
100-1031
100-1041
103-2241
100-1041
103-2241
103-1062
100-1551
178-2054
100-1551
103-2212
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 68.1 k Ohm ±1%, 1/4W
Resistor, 7.50 k Ohm ±1%, 1/4W
Resistor, 46.4 k Ohm ±1%, 1/4W
Resistor, 113 k Ohm ±5%, 1/4W
Resistor, 4.75 k Ohm ±1%, 1/4W
Resistor, 18.2 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Potentiometer, 1 k Ohm ±10%, 1/2W
Resistor, 2.10 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 113 k Ohm ±5%, 1/4W
100-1041
100-1051
103-6815
103-7541
103-4645
103-1136
103-4741
103-1825
100-1051
178-1044
103-2104
100-1051
103-1136
Resistor, 100 Ohm ±1%, 1/4W
Resistor, 121 Ohm ±1%, 1/4W
Resistor, 2.94 k Ohm ±1%, 1/4W
100-1031
100-1231
103-2941
3-26
TABLE 3-6. ECU EXCITER CIRCUIT BOARD ASSEMBLY - 917-0300
(Sheet 8 of 10)
REF. DES.
R198
R199
R200
R201
R202
R203 thru
R209
R210, R211
R212
R213, R214
R215
R216
R217
R218
S1
S2
TP1 thru
TP19
U1, U2
DESCRIPTION
PART NO.
QTY.
Potentiometer, 1 k Ohm ±10%, 1/2W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 2.21 k Ohm ±1%, 1/4W
Resistor, 10 Meg Ohm ±5%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 22.1 Ohm ±1%, 1/4W
178-1044
100-1051
103-2241
100-1083
100-1041
103-2212
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 1 Meg Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Potentiometer, 2 k Ohm ±10%, 1/2W
Resistor, 10 k Ohm ±1%, 1/4W
Switch, SPST, 4-Position, 8-Pin DIP Dual In-line
Switch, SPST, 8-Segment, 16-Pin DIP
Terminal Test Point, Oval Red
100-1051
103-1062
100-1051
103-1007
100-1051
178-1044
100-1051
340-0002
340-0003
413-0106
19
221-0072
221-4227
221-0072
221-4227
220-0212
221-4227
220-4526
228-4013
221-5534
220-0317
221-4227
220-4240
228-4069
221-0319
228-4538
220-0317
221-4227
220-0311
220-2123
Integrated Circuit, TL072CP, Dual JFET-Input Operational
Amplifier, 8-Pin DIP
U3
Amplifier, Dual Operational, RC4227GNB, Raytheon, 8-Pin DIP
U4, U5
Integrated Circuit, TL072CP, Dual JFET-Input Operational
Amplifier, 8-Pin DIP
U6
Amplifier, Dual Operational, RC4227GNB Raytheon, 8-Pin DIP
U7
Integrated Circuit, DG212CJ, Quad, SPST Switch, 16-Pin DIP
U8, U9
Amplifier, Dual Operational, RC4227GNB Raytheon, 8-Pin DIP
U10
Integrated Circuit, MC14526BCP, Programmable Divide-by-N 4-Bit
Counter, CMOS, 16-Pin DIP
U11
Integrated Circuit, MC14013BCP, Dual D-Type Flip-Flop, CMOS,
14-Pin DIP
U12
Integrated Circuit, NE5534AN, Low Noise Operational Amplifier,
8-Pin DIP
U13
Integrated Circuit, LM317LZ, Adjustable Positive Voltage
Regulator, 1.2 to 37V @ 0.1 Ampere, TO-92 Case
U14 thru U17 Amplifier, Dual Operational, RC4227GNB, Raytheon, 8-Pin DIP
U19, U20
Integrated Circuit, 74C24ON, Inverting Tri State, 20-Pin DIP
U21
Integrated Circuit, CD4069CN, Hex Inverter, CMOS, 14-Pin DIP
U22
Integrated Circuit, LM319N, Dual Comparator, 14-Pin DIP
U23
Integrated Circuit, MC14538B, Dual Retriggerable, Resettable
Monostable Multivibrator, CMOS, 16-Pin DIP
U24
Integrated Circuit, LM317LZ, Adjustable Positive Voltage
Regulator, 1.2 to 37V @ 0.1 Ampere, TO-92 Case
U26
Amplifier, Dual Operational, RC4227GNB, Raytheon, 8-Pin DIP
U27
Integrated Circuit, TL311P, JFET-Input Differential Comparator,
8-Pin DIP
U28
Integrated Circuit, 74LS123, Schottky Dual Monostable
Multivibrator, 16-Pin DIP
3-27
TABLE 3-6. ECU EXCITER CIRCUIT BOARD ASSEMBLY - 917-0300
(Sheet 9 of 10)
REF. DES.
U29
U30
U31
U32
U33
U34
U35
U36
U37
U38, U39
U40
U41
U42
U43
U44
U45
U46
U47
XU1 thru
XU6
XU4
XU7
XU8, XU9
XU10
XU11
XU12
XU14 thru
XU17
XU19, XU20
XU21, XU22
XU23
XU25
XU26, XU27
XU28
XU29
XU30 thru
XU33
XU34
XU35, XU36
XU38, XU39
DESCRIPTION
PART NO.
QTY.
Integrated Circuit, 74HC4022, Octal Counter/Divider, 16-Pin DIP
Integrated Circuit, 74HC132N, Quad Schmitt Nand Gates
Integrated Circuit, 74HC4002N, Dual 4 Input NOR Gate
14-Pin DIP
Integrated Circuit, 74HC132N, Quad Schmitt Nand Gates
Integrated Circuit, MC74HC14, Hex Schmitt Trigger Inverter,
Integrated Circuit, MC14040B, CMOS MSI, 12-Bit Binary Counter,
16-Pin DIP
Integrated Circuit, MC14073B, Tripple 3-Input AND Gate,
CMOS, 14-Pin DIP
Integrated Circuit, MC14013BCP, Dual D-Type Flip-Flop, CMOS,
14-Pin DIP
Integrated Circuit, LM317LZ, Adjustable Positive Voltage
Regulator, 1.2 to 37V @ 0.1 Ampere, TO-92 Case
Integrated Circuit, 74HC132N QUAD Schmitt Nand Gates
Integrated Circuit, 74HC75N, Quad D Latch
Amplifier, Dual Operational, RC4227GNB, Raytheon, 8-Pin DIP
Integrated Circuit, 74HC74N Dual D Flip Flop
Integrated Circuit, TL311P, JFET-Input Differential Comparator,
8-Pin DIP
Integrated Circuit, MC14060B, 14-Bit Binary Counter and
Oscillator, CMOS MSI, 16-Pin DIP
Integrated Circuit, 74C24ON, Inverting Tri State, 20-Pin DIP
Driver, High and Low Side, IR2112, 14-Pin DIP
Integrated Circuit, LM319N, Dual Comparator, 14-Pin DIP
Socket, 8-Pin DIP
221-4022
221-4132
221-4002
221-4132
220-4106
220-4040
228-4073
228-4013
220-0317
221-4132
221-7475
221-4227
221-7474
220-0311
220-4060
220-4240
227-2112
221-0319
417-0804
Socket, 14-Pin DIP
Socket, 16-Pin DIP
Socket, 8-Pin DIP
Socket, 16-Pin DIP
Socket, 14-Pin DIP
Socket, 8-Pin DIP
Socket, 8-Pin DIP
417-1404
417-1604
417-0804
417-1604
417-1404
417-0804
417-0804
Socket, 20-Pin DIP
Socket, 14-Pin DIP
Socket, 16-Pin DIP
Receptacle, 28-Pin DIP
Socket, 8-Pin DIP
Socket, 16-Pin DIP
Socket, 16-Pin DIP
Socket, 14-Pin DIP
417-2004
417-1404
417-1604
417-2804
417-0804
417-1604
417-1604
417-1404
Socket, 16-Pin DIP
Socket, 14-Pin DIP
Socket, 14-Pin DIP
417-1604
417-1404
417-1404
3-28
TABLE 3-6. ECU EXCITER CIRCUIT BOARD ASSEMBLY - 917-0300
(Sheet 10 of 10)
REF. DES.
DESCRIPTION
XU40
XU41
XU42
XU43
XU44
XU45
XU46, XU47
Socket, 16-Pin DIP
Socket, 8-Pin DIP
Socket, 14-Pin DIP
Socket, 8-Pin DIP
Socket, 16-Pin DIP
Socket, 20-Pin DIP
Socket, 14-Pin DIP
Y1
PART NO.
QTY.
417-1604
417-0804
417-1404
417-0804
417-1604
417-2004
417-1404
Crystal, 48PD1002, 10.24 MHz, HC-18 Cinox
390-0013
Y1
Crystal, 9.216 MHz, HC-18 Cinox
390-0017
-------
Potentiometer, 2k Ohm ±10%, .5W
Integrated Circuit, MC145151P, Parallel Input, PLL
Frequency Synthesizer, CMOS, 28-Pin DIP
Blank, ECU Exciter Circuit Board
VCO Module Circuit Board Assembly
178-2044
220-5151
517-0300
917-0069
10 kHz SPACING
9 kHz SPACING
-------
TABLE 3-7. ECU MOTHERBOARD CIRCUIT BOARD ASSEMBLY - 917-0301
(Sheet 1 of 2)
REF. DES.
C1, C2
C3, C4
C5, C6
C7, C8
C9 thru
C59
C61 thru
C65
C66
C67 thru
C84
C85
C86, C87
C88 thru
C90
C91 thru
C109
D1
J7
J8
J9, J10
DESCRIPTION
PART NO.
QTY.
Capacitor, Polyester, 0.0022 uF ±10%, 100V
Capacitor, Polyester, 0.015 uF ±10%, 100V
Capacitor, Polyester, 0.0022 uF ±10%, 100V
Capacitor, Polyester, 0.015 uF ±10%, 100V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
031-2033
030-1532
031-2033
030-1532
003-1066
51
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
003-1066
Capacitor, Electrolytic, 100 uF, 35V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
023-1084
003-1066
18
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Mica, 680 pF ±5%, 300V
Capacitor, Polyester, 0.015 uF ±10%, 100V
003-1066
040-6824
030-1532
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
003-1066
19
Diode, 1N4005, Silicon, 600V @ 1 Ampere
Receptacle, 6-Pin
Connector, AMP 1-87502-8, Header Straight Post Double Row,
40-Pin
Receptacle, Male, 13-Pin Dual In-Line
203-4005
417-0677
417-4040
417-2600
3-29
TABLE 3-7. ECU MOTHERBOARD CIRCUIT BOARD ASSEMBLY - 917-0301
(Sheet 2 of 2)
REF. DES.
J11
J12
J101
J201
J301
J302
L1 thru L4
L5, L6
P4 thru P6
P12
R1
R2, R3
R4
R5
R6
R7, R8
R9
R10
R11
R15 thru R18
R19 thru R22
R23 thru R28
R29 thru R34
R35 thru R40
R41 thru R45
R47 thru R51
R53, R54
R55
R56, R57
R56
R58
R59
R60 thru R62
R63, R64
R65
R66 thru R72
R73
R74
R75
R76
R77
R78 thru R84
R84
R86 thru R95
TB1, TB2
----
DESCRIPTION
Receptacle, BNC
Connector, Male, 2-Pin In-Line
Connector Header, 80-Pin, Dual In-Line
Connector, AMP 102567-6, Header Straight Post Double Row,
50-Pin
Connector, AMP 102567-6, Header Straight Post Double Row,
50-Pin
Connector Header, 80-Pin, Dual In-Line
Coil, Shielded, 560 uH ±10%, Molded
RF Choke, 910 uH ±5%, 79 mA Maximum, 15.8 Ohms DC Resistance
Connector, 25-Pin D-Type
Switch, Jumper Programmable
Resistor, 1.15 k Ohm ±1%, 1/4W
Resistor, 442 Ohm ±1%, 1/4W
Resistor, 1.15 k Ohm ±1%, 1/4W
Resistor, 604 Ohm ±1%, 1/4W
Resistor, 1.15 k Ohm ±1%, 1/4W
Resistor, 442 Ohm ±1%, 1/4W
Resistor, 1.15 k Ohm ±1%, 1/4W
Resistor, 604 Ohm ±1%, 1/4W
Resistor, 47 Ohm ±5%, 1W
Resistor, 1.15 k Ohm ±1%, 1/4W
Resistor, 51.1 Ohm ±1%, 1/4W
Resistor, 1.15 k Ohm ±1%, 1/4W
Resistor, 51.1 Ohm ±1%, 1/4W
Resistor, 1.15 k Ohm ±1%, 1/4W
Resistor, 51.1 Ohm ±1%, 1/4W
Resistor, 1.15 k Ohm ±1%, 1/4W
Resistor, 442 Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 1.15 k Ohm ±1%, 1/4W
Resistor, 51.1 Ohm ±1%, 1/4W
Resistor, 200 Ohm ±1%, 1/4W
Resistor, 442 Ohm ±1%, 1/4W
Resistor, 1.15 k Ohm ±1%, 1/4W
Resistor, 3.92 k Ohm ±1%, 1/4W
Resistor, 47 Ohm ±5%, 1W
Resistor, 51.1 Ohm ±1%, 1/4W
Resistor, 47 Ohm ±5%, 1W
Resistor, 10 Ohm ±1%, 1/4W
Resistor, 442 Ohm ±1%, 1/4W
Resistor, 10 Ohm ±1%, 1/4W
Resistor, 51.1 Ohm ±1%, 1/4W
Resistor, 1.15 k Ohm ±1%, 1/4W
Resistor, 10 Ohm ±1%, 1/4W
Resistor, 10 Ohm ±1%, 1/4W
Barrier Strip, 30-Position
Blank, ECU Motherboard Circuit Board
3-30
PART NO.
QTY.
417-0203
417-4004
417-0254
417-0255
417-0255
417-0254
360-0072
360-0047
418-2500
340-0004
103-1156
103-4423
103-1156
100-6031
103-1156
103-4423
103-1156
100-6031
120-4723
103-1156
103-5112
103-1156
103-5112
103-1156
103-5112
103-1156
103-4423
100-1051
103-1156
103-5112
103-2003
103-4423
103-1156
103-3924
120-4723
103-5112
120-4723
103-1021
103-4423
103-1021
103-5112
103-1156
103-1021
103-1021
412-3000
517-0301
10
TABLE 3-8. ECU DISPLAY/CONTROL SWITCH CIRCUIT BOARD - 917-0306-001
(Sheet 1 of 4)
REF. DES.
C1 thru
C11
C12
C13 thru
C23
C24, C25
C26, C27
C28
C29
C30 thru C32
C33
C34
C35
C36
C37
C38, C39
C40 thru C43
D1 thru D9
D10, D11
D12 thru D14
D15, D16
D17 thru D19
D20, D21
DS1, DS2
DS7
DS8, DS9
DS10
DS11, DS12
DS13, DS14
DS15, DS16
DS17, DS18
DS19, DS20
DS22 thru
DS25
J1
J2
Q1, Q2
Q3 thru Q6
Q7
R1 thru
R3
R4
R5, R6
R7
R8
R9
R10
R11
R12
DESCRIPTION
PART NO.
QTY.
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
003-1066
11
Capacitor, Electrolytic, 1 uF, 50V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
024-1064
003-1066
11
Capacitor, Electrolytic, 10 uF, 50V
Capacitor, Electrolytic, 33 uF, 35V
Capacitor, Ceramic, 0.001 uF ±10%, 200V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Electrolytic, 100 uF, 35V
Capacitor, Electrolytic, 10 uF, 50V
Capacitor, Electrolytic, 33 uF, 35V
Capacitor, Ceramic, 0.001 uF ±10%, 200V
Capacitor, Electrolytic, 33 uF, 35V
Capacitor, Electrolytic, 10 uF, 50V
Capacitor, Monolythic Ceramic, 0.1 uF ±10%, 50V
Capacitor, Ceramic, 0.001 uF ±10%, 200V
Diode, 1N4148, Silicon, 75V @ 0.3 Amperes
Diode, 1N4005, Silicon, 600V @ 1 Ampere
Diode, Zener, 1N4733A, 5.1V ±5%, 1W
Diode, 1N4005, Silicon, 600V @ 1 Ampere
Diode, Zener, 1N4733A, 5.1V ±5%, 1W
Diode, 1N4148, Silicon, 75V @ 0.3 Amperes
Indicator, LED, Yellow, 521-9176, 3V @ 30 mA Maximum
LED, MV57164, Red, High Efficiency 10-Segment Bar Graph Array
LED, MV54164, Green, High Efficiency 10-Segment Bar Graph Array
LED, MV57164, Red, High Efficiency 10-Segment Bar Graph Array
LED, MV54164, Green, High Efficiency 10-Segment Bar Graph Array
Indicator, LED, Green, 521-9175, 3V @ 40 mA Maximum
Indicator, LED, Red, 521-9212, 1.7V @ 50 mA Maximum
Indicator, LED, Yellow, 521-9176, 3V @ 30 mA Maximum
Indicator, LED, Green, 521-9175, 3V @ 40 mA Maximum
LED, Tri-Color Common Cathode
023-1076
024-3335
030-1033
003-1066
023-1084
023-1076
024-3335
030-1033
024-3335
023-1076
003-1066
030-1033
203-4148
203-4005
200-4733
203-4005
200-4733
203-4148
323-9225
320-7164
320-4164
320-7164
320-4164
323-9224
323-9217
323-9225
323-9224
320-0031
Receptacle, Male, 13-Pin Dual In-Line
Connector, AMP 1-87502-8, Header Straight Post Double Row,
40-Pin
Field Effect Transistor, J271, P-Channel JFET, TO-92 Case
Transistor, 2N27000, FET, N-Channel, TO-92 Case
Transistor, 2N3904, NPN, Silicon, TO-92 Case
Resistor, 100 k Ohm ±1%, 1/4W
417-2600
417-4040
210-0271
210-7000
211-3904
103-1062
Resistor, 11.0 k Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 11.0 k Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 24.3 k Ohm ±1%, 1/4W
Resistor, 825 Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 22 Meg Ohm ±5%,1/4W
103-1105
103-1062
103-1105
103-1062
103-2435
103-8253
100-1041
100-2283
3-31
TABLE 3-8. ECU DISPLAY/CONTROL SWITCH CIRCUIT BOARD - 917-0306-001
(Sheet 2 of 4)
REF. DES.
R13
R14
R15
R16
R17
R18
R19
R20
R21
R22
R23
R24
R25
R26
R27
R28
R29
R30
R31
R32
R33 thru R36
R37
R38
R39
R40
R41
R42
R43
R44
R45
R46
R47
R48
R49
R50, R51
R52, R53
R54, R55
R56
R57
R58
R59 thru R61
R62
R63
R64
R65
R66
R67
R68
R69 thru R71
DESCRIPTION
Resistor, 22.1 k Ohm ±1%, 1/4W
Resistor, 221 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 2.21 k Ohm ±1%, 1/4W
Resistor, 24.3 k Ohm ±1%, 1/4W
Resistor, 825 Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 22 Meg Ohm ±5%,1/4W
Resistor, 22.1 k Ohm ±1%, 1/4W
Resistor, 221 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 2.21 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 240 Ohm ±1%, 1/4W
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 10 Meg Ohm ±5%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 2.21 k Ohm ±1%, 1/4W
Potentiometer, 1 k Ohm ±10%, 1/2W
Resistor, 100 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 10 Meg Ohm ±5%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 2.21 k Ohm ±1%, 1/4W
Potentiometer, 1 k Ohm ±10%, 1/2W
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 10 k Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 499 Ohm ±1%, 1/4W
Resistor, 1.21 k Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 499 Ohm ±1%, 1/4W
Resistor, 1.21 k Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
Resistor, 499 Ohm ±1%, 1/4W
Resistor, 1.21 k Ohm ±1%, 1/4W
Resistor, 1 k Ohm ±1%, 1/4W
PART NO.
103-2211
103-2216
100-1051
100-1051
103-2241
103-2435
103-8253
100-1041
100-2283
103-2211
103-2216
100-1051
103-2241
100-1051
103-1062
100-1051
103-1062
100-1041
103-1062
100-1041
103-2431
103-1062
100-1051
100-1083
100-1051
103-2241
175-1034
103-1062
100-1051
100-1083
100-1051
103-2241
175-1034
100-1041
100-1051
100-1041
100-1051
100-1041
103-4993
103-1214
100-1041
103-4993
103-1214
100-1041
100-1041
100-1041
103-4993
103-1214
100-1041
3-32
QTY.
TABLE 3-8. ECU DISPLAY/CONTROL SWITCH CIRCUIT BOARD - 917-0306-001
(Sheet 3 of 4)
REF. DES.
DESCRIPTION
R72
Resistor, 82.5 k Ohm ±1%, 1/4W
R73
Resistor, 15 k Ohm ±5%, 1/4W
R74
Resistor, 121 Ohm ±1%, 1/4W
R75
Resistor, 604 Ohm ±1%, 1/4W
R76, R77
Resistor, 240 Ohm ±1%, 1/4W
R78
Resistor, 10 k Ohm ±1%, 1/4W
R79
Resistor, 82.5 k Ohm ±1%, 1/4W
R80
Resistor, 15 k Ohm ±5%, 1/4W
R81
Resistor, 499 Ohm ±1%, 1/4W
R82
Resistor, 1.21 k Ohm ±1%, 1/4W
R83 thru R85 Resistor, 1 k Ohm ±1%, 1/4W
R86
Resistor, 499 Ohm ±1%, 1/4W
R87
Resistor, 1.21 k Ohm ±1%, 1/4W
R88 thru R90 Resistor, 1 k Ohm ±1%, 1/4W
R91
Resistor, 499 Ohm ±1%, 1/4W
R92
Resistor, 1.21 k Ohm ±1%, 1/4W
R93 thru R95 Resistor, 1 k Ohm ±1%, 1/4W
R96 thru R102 Resistor, 240 Ohm ±1%, 1/4W
R103
Resistor, 1 k Ohm ±1%, 1/4W
R104, R105
Resistor, 100 k Ohm ±1%, 1/4W
R106 thru
Resistor, 240 Ohm ±1%, 1/4W
R112
R113
Resistor, 174 Ohm ±1%, 1/4W
R114
Resistor, 825 Ohm ±1%, 1/4W
S1, S2
Switch, SPDT, Momentary MP Series, 2 Green, C&K
MP01R2266 CBE
S3
Switch, SPDT, Momentary MP Series, 1 Red, C&K
MP01R123 CBE
S4, S5
Switch, SPDT, Momentary MP Series, 1 Yellow, C&K
MP01R125 CBE
S6 thru S10
Switch, SPDT, Momentary MP Series, 1 Green, C&K
MP01R126 CBE
S11
Switch, SPDT, Momentary MP Series, 1 Red, C&K
MP01R123 CBE
U1
Integrated Circuit, DG212CJ, QUAD SPST Switch, CMOS,
16-Pin DIP
U2
Amplifier, Dual OP, RC4227GNB Raytheon, 8-Pin DIP
U3
Integrated Circuit, TLO74CN, Quad JFET-Input Operational
Amplifier, 14-Pin DIP
U4
Integrated Circuit, MC14584, Hex Schmitt Trigger, CMOS,
14-Pin DIP
U5
Integrated Circuit, MC14013BCP, Dual D-Type Flip-Flop, CMOS,
14-Pin DIP
U6
Integrated Circuit, TL072CP, Dual JFET-Input Operational
Amplifier, 8-Pin DIP
U7
Integrated Circuit, DG212CJ, QUAD SPST Switch, CMOS,
16-Pin DIP
U8
Integrated Circuit, TLO74CN, Quad JFET-Input Operational
Amplifier, 14-Pin DIP
U9 thru U11 Integrated Circuit, LM3914N, Dot/Bar Display Driver, 18-Pin DIP
3-33
PART NO.
QTY.
103-8255
100-1551
100-1231
100-6031
103-2431
100-1051
103-8255
100-1551
103-4993
103-1214
100-1041
103-4993
103-1214
100-1041
103-4993
103-1214
100-1041
103-2431
100-1041
103-1062
103-2431
100-1731
103-8253
340-0130
340-0030
340-0162
340-0161
340-0030
220-0212
221-4227
221-0074
228-4584
228-4013
221-0072
220-0212
221-0074
229-3914
TABLE 3-8. ECU DISPLAY/CONTROL SWITCH CIRCUIT BOARD - 917-0306-001
(Sheet 4 of 4)
REF. DES.
DESCRIPTION
U12, U13
U14
Integrated Circuit, NE555N, Timer, 8-Pin DIP
Integrated Circuit, LM317T, Adjustable Positive Voltage
Regulator, 1.2V to 37V, 1.5 Ampere, TO-220 Case
U15 thru U17 Integrated Circuit, LM3914N, Dot/Bar Display Driver, 18-Pin DIP
XU1
Socket, 16-Pin DIP
XU2
Socket, 8-Pin DIP
XU3 thru XU5 Socket, 14-Pin DIP
XU6
Socket, 8-Pin DIP
XU7
Socket, 16-Pin DIP
XU8
Socket, 14-Pin DIP
XU9 thru
Socket, 18-Pin DIP
XU11
XU12, XU13 Socket, 8-Pin DIP
XU15 thru
Socket, 18-Pin DIP
XU17
---Blank, ECU Display/Control Switch Circuit Board
PART NO.
QTY.
229-0555
227-0317
229-3914
417-1604
417-0804
417-1404
417-0804
417-1604
417-1404
417-1804
417-0804
417-1804
517-0306-001
TABLE 3-9. METER SWITCH CIRCUIT BOARD ASSEMBLY - 917-0306-005
REF. DES.
C501
D501
J501
J502
R501
R503
R504
R505
R506
R507
R508
R509, R510
R511
S501, S502
----
DESCRIPTION
Capacitor, Monolythic Ceramic, 0.1 Ohm ±10%, 50V
Diode, Zener, 1N4733A, 5.1V ±5%, 1W
Receptacle, 6-Pin
Socket, 4-Pin
Potentiometer, 500 Ohm, 1/2W
Potentiometer, 2 k Ohm ±10%, 1/2W
Resistor, 3.01 k Ohm ±1%, 1/4W
Potentiometer, 500 Ohm, 1/2W
Potentiometer, 2 k Ohm ±10%, 1/2W
Resistor, 3.01 k Ohm ±1%, 1/4W
Resistor, 2.74 k Ohm ±1%, 1/4W
Resistor, 1.62 k Ohm ±1%, 1/4W
Potentiometer, 50 k Ohm ±10%, 1/2W
Switch, Rotary, 3 Position 2 Pole
Blank, Meter Switch Circuit Board
PART NO.
003-1066
200-4733
417-0677
418-0255
178-5030
178-2044
103-3014
178-5030
178-2044
103-3014
103-2744
103-1624
178-5054
340-0134
517-0306-005
QTY.
TABLE 3-10. ECU WIRE HARNESS - 947-0153
(Sheet 1 of 2)
REF. DES.
P1
P1
DESCRIPTION
Housing, SL-156, 3 Position
Plug, Ribbon Cable, 26-Pin Dual In-line
3-34
PART NO.
417-0306
418-2600
QTY.
TABLE 3-10. ECU WIRE HARNESS - 947-0153
(Sheet 2 of 2)
REF. DES.
P2
P2
P3
P7
P8
P10
P502
P801
----
DESCRIPTION
Connector, Ribbon Cable, 40 Conductor
Housing, SL-156, 6 Position
Plug, Ribbon Cable, 26-Pin Dual In-Line
Connector Housing, 6-Pin
Connector, Ribbon Cable, 40 Conductor
Plug, Ribbon Cable, 26-Pin Dual In-line
Plug, Housing, 4-Pin
Plug, Ribbon Cable, 26-Pin Dual In-Line
Pins, Connector
3-35
PART NO.
418-4001
417-0606
418-2600
418-0670
418-4001
418-2600
418-0240
418-2600
417-0053
QTY.
10
SECTION IV
ECU ASSEMBLY DRAWINGS
4-1.
INTRODUCTION.
4-2.
This section provides assembly drawings, wiring diagrams, and schematic diagrams as
listed below for the Broadcast Electronics ECU assembly.
FIGURE
4-1
4-2
4-3
4-4
4-5
4-6
4-7
4-8
4-9
4-10
4-11
4-12
4-13
4-14
TITLE
NUMBER
SCHEMATIC DIAGRAM, ECU CONTROLLER CIRCUIT
BOARD
ASSEMBLY DIAGRAM, ECU CONTROLLER CIRCUIT
BOARD
COMPONENT LOCATOR, ECU CONTROLLER BOARD
SCHEMATIC DIAGRAM, ECU MOTHERBOARD
ASSEMBLY DIAGRAM, ECU MOTHERBOARD
SCHEMATIC DIAGRAM, EXCITER CIRCUIT BOARD
ASSEMBLY DIAGRAM, EXCITER CIRCUIT BOARD
COMPONENT LOCATOR, ECU EXCITER BOARD
SCHEMATIC DIAGRAM, STEREO CIRCUIT BOARD
ASSEMBLY DIAGRAM, STEREO CIRCUIT BOARD
COMPONENT LOCATOR, ECU STEREO BOARD
SCHEMATIC DIAGRAM, ECU DISPLAY/CONTROL
SWITCH CIRCUIT BOARDS
SCHEMATIC DIAGRAM, ECU METER SWITCH
CIRCUIT BOARD
REFER TO PART I, SECTION VII FOR THE ECU DISPLAY
CIRCUIT BOARD ASSEMBLY-002/-003/-004/-005
SB917-0205
AC917-0205
---------SB917-0301
AC917-0301
SB917-0300
AC917-0300
---------SD917-0209
AC917-0209
---------SB917-0306-001
SB917-0306-005
AD917-0306-001/
/-006/-007/-009/-014
4-1
REF
ZONE
REF
ZONE
REF
ZONE
REF
ZONE
REF
ZONE
C1
C2
C3
C4
C5
C6
C7
C8
C9
C10
C11
C12
C13
C14
C15
C16
C17
C18
C19
C20
C21
C22
C23
C24
C25
C26
C27
C28
C29
C30
C31
C32
C33
C34
C35
C36
C37
C38
C39
C40
C41
C42
C43
C44
C45
C46
C47
C48
C49
C50
C51
C52
C53
C54
C55
C56
C57
C58
C59
C1
C1
C2
C2
C2
C2
C2
C2
C2
C2
C2
C2
C2
C2
C3
C2
C2
C3
C3
C3
C3
C2
C3
C2
C3
C3
C3
C3
C3
C3
C3
C3
C3
B3
C3
C3
B3
B3
B3
B2
C2
B2
B2
B2
B2
B2
B1
B3
B3
B1
C1
C1
B3
B3
B2
B2
C2
B2
B2
C60
C61
C62
C63
C64
C65
C66
C67
C68
C69
C70
C71
C72
C73
C74
C75
C76
C77
C78
C79
C80
C81
C82
C83
C84
C85
C86
C87
C88
C89
C90
C91
C92
C93
C94
C95
C96
C97
C98
C99
C100
C101
C102
C103
C104
C105
C106
C107
C108
C109
C110
C111
C112
C113
C114
C115
C116
C117
C118
B3
B3
B3
B3
B2
B2
B2
B2
B2
B2
B2
C2
B2
B2
B2
C1
C1
C2
C2
C2
C2
B1-C1
B1-C1
B2-C2
B2-C2
B2-C2
B1
B1
B3
B3
B3
B3
B3
A2
B3
B3
B3
B3
B2
B2-B3
B2
B2-B3
B2
A2-B2
B3
B2
B1
B1
B2
B2
B2
B2
B2
B2
B2
A2
B2
B3
B2
C119
C120
C121
C122
C123
C124
C125
C126
C127
C128
C129
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
D11
D12
D13
D14
D15
D16
D17
D18
D19
D20
D21
D22
D23
D24
D25
D26
D27
D28
D29
D30
D31
D32
D33
D34
D35
D36
D37
D38
D39
D40
D41
D42
D43
D44
D45
D46
D47
D48
B2
C3
B2
B2
B2
B2
B2
B2
B2
B3
B2
C1
C1
C1
C1
C1
C1
C2
C2
C2
C2
C2
C2
C1
C1
C2
C2
C2
B1
A1
B1
A1
B1
B1-B2
B3
B1
B1
B1
B2
B3
B2
B2
C2
B2
B2
B3
B3
A2
B3
B3
B3
B2
B2
B2
B3
B3
B2
C3
B3
D49
D50
DS1
DS2
DS3
E10
J1
J2
J3
J4
J5
J6
J7
J8
J9
J10
J11
J12
P1
P2
P3
P6
P8
P9
P10
P11
P12
P301
P302
Q1
Q2
Q3
Q4
Q5
Q6
Q7
Q8
Q9
Q10
Q11
Q12
Q13
Q14
Q15
Q16
Q17
Q18
Q19
Q20
Q21
Q22
Q23
Q24
Q25
Q26
Q27
Q28
Q29
Q30
B3
C1
B3
C3
C3
B3
C2
B3
B3
B1
B1-B2
B1-B2
B1
C3
C3
C3
B2
C2
C2
B3
B3
B1
C3
C3
C3
B2
C2
C1
B1-C1
C1
C1
C1-C2
C1-C2
C2
C2
C2
C1
C1
C1
C1
C1
B1
C2
B1
C1
C2
C2
C1
C1-C2
B1
B1
C1
C2
B1
B1
B1
B1
B1
B1
Q31
Q32
Q33
Q34
Q35
Q36
Q37
Q38
Q39
Q40
Q41
Q42
Q43
Q44
Q45
Q46
Q47
Q48
Q49
Q50
Q51
Q52
Q53
Q54
Q55
Q56
Q57
Q58
R1
R2
R3
R4
R5
R6
R7
R8
R9
R10
R11
R12
R13
R14
R15
R16
R17
R18
R19
R20
R21
R22
R23
R24
R25
R26
R27
R28
R29
R30
R31
B1
B1
B1
B1
C2
C1
C1
C2
C2
C1
C1
C2
C2
C2
C1-C2
C1
B1
C3
B2
C3
B1
B2
B3
B3
B2
B2
B3
B3
C2
C3
C3
C3
C3
C3
C3
C3
B3
C3
B3
B3
B3
B2
C3
C3
C3
C3
C3
C3
C3
C3
B3
B3
B3
B3-C3
B3
B3
B3
B3-C3
B3-C3
FIGURE 4-3. COMPONENT LOCATOR, ECU CONTROLLER BOARD
(Sheet 1 of 2)
REF
ZONE
REF
ZONE
REF
ZONE
REF
ZONE
REF
ZONE
R32
R33
R34
R35
R36
R37
R38
R39
R40
R41
R42
R43
R44
R45
R46
R47
R48
R49
R50
R51
R52
R53
R54
R55
R56
R57
R58
R59
R60
R61
R62
R63
R64
R65
R66
R67
R68
R69
R70
R71
R72
R73
R74
R75
R76
R77
R78
R79
R80
R81
R82
R83
R84
R85
R86
R87
R88
R89
R90
C3
C3
C3
C3
C3
C1
C1
B3
B3
C1
B3
B3
B3
B3
B2
B3
B2
B3
B2
B3
B2-B3
B2
B2
C3
B3
B3
B3
B3
B3
B3
B2
B3
B3
C3
C3
B3
B2
B2
B3
B3
B3
B2
B2
B2
B2
B2
B2
C3
C3
B2
B2
B2
B2
C3
B2
B2
B2
B2
B2
R91
R92
R93
R94
R95
R96
R97
R98
R99
R100
R101
R102
R103
R104
R105
R106
R107
R108
R109
R110
R111
R112
R113
R114
R115
R116
R117
R118
R119
R120
R121
R122
R123
R124
R125
R126
R127
R128
R129
R130
R131
R132
R133
R134
R135
R136
R137
R138
R139
R140
R141
R142
R143
R144
R145
R146
R147
R148
R149
B2
B2
B2
B2
B2
C2
B2
B2
B2-B3
B2
B3
B3
B2-B3
C3
B2-B3
B3
B2
C3
B3
C1
C1
C2
C2
C2
C2
C1
C1
C2
C2
C2
B1
B1
C3
C3
B2
C1
C1
C1
C1
C1
B2
B2
B2
B2
B3
B3
B3
B3
B2
C2
B3
B3
B3
B3
B3
B3
B3
B2
B2-B3
R150
R151
R152
R153
R154
R155
R156
R157
R158
R159
R160
R161
R162
R163
R164
R165
R166
R167
R168
R169
R170
R171
R172
R173
R174
R175
R176
R177
R178
R179
R180
R181
R182
R183
R184
R185
R186
R187
R188
R189
R190
R191
R192
R193
RN1
RN2
RN3
RN4
RN5
RN6
RN7
RN8
S1
S2
S3
S4
S5
TP1
TP2
B3
B3
A3-B3
B3
B3
B3
B3
B3
B3
B2-B3
C2
B2
C2
B3
B3
B3
B1
B1
B2
B2
B2
B2
B3
B2
B2
B2
B2
B2
A2
B2
B2
C2
B2
B3
C3
C3
C3
B3
C1
B2-B3
B2
B2
B2
B1
C1
C2
C2
C2
B1
A2
B2
B1
C2
C2
C2
C3
B3
B3
B3
TP3
TP4
TP5
TP6
TP7
TP8
TP9
TP10
TP11
U1
U2
U3
U4
U5
U6
U7
U8
U9
U10
U11
U12
U13
U14
U15
U16
U17
U18
U19
U20
U21
U22
U23
U24
U25
U26
U27
U28
U29
U30
U31
U32
U33
U34
U35
U36
U37
U38
U39
U40
U41
U42
U43
U44
U45
U46
U47
U48
U49
U50
B3
B3
B3
B3
B1
C2
C3
C3
C3
C1
C1
C1-C2
C2
C2
C2
B1-C1
B1-C1
B2-C2
B2-C2
B2-C2
C2
C2
C1
C1
C2
C2
C2
C2
C2
C2
C3
C2
C2
C2
C2
C2
C2
B2
C3
C3
B1
B1
C3
C3
B2-C2
B2-C2
B3-C3
B3
B3-C3
B3
C3
C3
B3
B2
B2-C2
B2
B2-C2
B2
B2
U51
U52
U53
U54
U55
U56
U57
U58
U59
U60
U61
U62
U63
U64
U65
U66
U67
U68
U69
U70
U71
B2
B2
B1
B1
B2
B1-B2
B2
B1
B2
B2
B3
B2
B3
B3
B2
B2
B2
B2
B2
C3
B3
FIGURE 4-3. COMPONENT LOCATOR, ECU CONTROLLER BOARD
(Sheet 2 of 2)
REF
ZONE
REF
ZONE
REF
ZONE
REF
ZONE
REF
ZONE
C1
C2
C3
C4
C5
C6
C7
C8
C9
C10
C11
C12
C14
C15
C16
C17
C18
C19
C20
C21
C22
C23
C24
C25
C26
C27
C29
C30
C31
C32
C33
C34
C35
C36
C37
C38
C39
C40
C41
C42
C43
C44
C45
C46
C47
C48
C49
C50
C51
C52
C53
C54
C55
C56
C57
C58
C59
C60
C61
B3
B3
B3
B3
B3
B3
B3
B3
B3
B3
B3
B3
B3
B3
B3
B3
B3
B3
A3
B3
B3
B3
B3
B3
B3
B3
B3
B3
C2
C2
C2
B2
B2
B2
B2
B3
B3
B3
A3
B3
B3
B3-A3
B3
A3
B3
B3
A3
B3
B3-B4
A3
B3
B2
B2
B2
B2
B2
B2
B2
B2
C62
C63
C64
C65
C66
C67
C68
C69
C70
C71
C72
C73
C74
C75
C76
C77
C78
C79
C80
C81
C82
C83
C84
C85
C86
C87
C88
C89
C90
C91
C92
C93
C94
C95
C96
C97
C98
C99
C100
C101
C102
C103
C104
C105
C106
C107
C108
C109
C110
C111
C112
C113
C114
C115
C116
C117
C118
C119
C120
B2
B4
B3-B4
B3
B3
B3
B2
A2-B2
B2
B2
B2
B3-B4
B3-B4
B3
B3
B3
B3
B3
B3
C3
B3
B3
B3-C3
B3
B3
B3
B2
B2
B3
B2
C2
C2
C2-C3
C3
C2
C2
C2
C2
C2
C2
C2
C2
C2
C2
C2
C3
C3
C3
C3
C3
C3
C3
C3
C3
C3
C3
C2
C3
C2
C121
C122
C123
C124
C125
C126
C127
C128
C129
C130
C131
C132
C133
C134
C135
C136
C137
C138
C139
C140
C141
C142
C143
C144
C145
C146
C147
C148
C149
C150
C151
C152
C153
C154
C155
C156
C157
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
D11
D12
D13
D14
D15
D16
D17
D18
D19
D20
D21
D22
C2
C2
C2
C2
C2
C2
C3
C3
C3
B3
C3
C3
C3
C3
C3
C3
B3
B3
B3
C2
C2
C2
C3
C3
C3
C3
B2
B2
B2
B2
B2
B2
B2
B2
C2
C3
C3
B3
B3
C3
B2
B2
B2
B2
B2
B2
B2
B2
B2
B2
B2
B2
B2
B2
B2
B2
B2
B2
C2
D23
D24
D25
D26
D27
D30
D31
D32
D33
D34
D35
D36
D37
D38
D39
D40
D41
D42
D43
D44
D45
DS1
DS2
DS3
DS4
E1
E2
E3
E4
E5
E6
E7
E8
E9
E10
J2
J3
J4
J5
J6
J7
J8
J9
J10
J11
J12
J13
L1
L2
L3
L4
P2
P3
P4
P5
P6A
P6B
P7
P12A
C2
C3
C2
C2
C2
C3
C3
C3
C3
C3
C3
C3
C3
C2
B2
C2
B2
C2
B2
C2
B2
C4
C4
C4
C4
B3
B3
B3
B3
B2
B2
C2
B2
B2
B2
B3
B3
B3
C3
C2
C2
C2
C2
C2
C2
B3
B3
C2
B2
B2
C2
B3
B3
B3
C3
C2
C2
C2
B3
P12B
P13A
P13B
P101
Q1
Q2
Q3
Q4
Q5
Q6
Q7
Q8
Q9
Q10
Q11
Q12
Q13
Q14
Q15
Q16
Q17
Q18
Q19
Q20
R1
R2
R3
R4
R5
R8
R9
R10
R11
R12
R14
R15
R16
R17
R18
R19
R20
R23
R24
R25
R26
R27
R29
R30
R31
R32
R33
R34
R35
R36
R37
R38
R39
R40
R41
B3
B3
B3
B2-C2
B2
C4
C2
C2
C3
C3
B3-C3
B3
B3-C3
C3
B3
B3
B2-C2
B2
B2-C2
B2
B2-C2
B2
B2-C2
B2
B3
B3
B3
B3
B3
B3
B3
B3
B3
B3
B3
B2
B3
B3
B3
B3
B3
B3
B3
B3
B3
B3
B3
B2
C3-C4
C3-C4
C3-C4
B3
B3
B3
B3
B3
B3
B3
B4
FIGURE 4-8. COMPONENT LOCATOR, ECU EXCITER BOARD
(Sheet 1 of 2)
REF
ZONE
REF
ZONE
REF
ZONE
REF
ZONE
R42
R43
R44
R45
R46
R47
R48
R49
R50
R51
R52
R53
R54
R55
R56
R57
R58
R59
R60
R61
R62
R63
R64
R65
R66
R67
R68
R69
R70
R71
R72
R73
R74
R75
R76
R77
R78
R79
R80
R81
R82
R83
R84
R85
R86
R87
R88
R89
R90
R91
R92
R93
R94
R95
R96
R97
R98
R99
R100
B3
B3
B3
B3
A3
A3
B3
B3
B3
B3
C3
C3
C3
B2
B2
B2
B2
B2
B2
B2
B2
B2
B2
B2
B2
A2-B2
B2
B2
B4
B4
B3
B3
B3
B4
B4-A4
A3-A4
B3
B3
B3
B2
A2
B2
B2
B2
B3
B3
B3
B3
B3
B3
B3
B3
B2
C3
C3
C3
B3
B3
B3
R101
R102
R103
R104
R105
R106
R107
R108
R109
R110
R111
R112
R113
R114
R115
R116
R117
R118
R119
R120
R121
R122
R123
R124
R125
R126
R127
R128
R129
R130
R131
R132
R133
R134
R135
R136
R137
R138
R139
R140
R141
R142
R143
R144
R145
R146
R147
R148
R149
R150
R151
R152
R153
R154
R155
R156
R157
R158
R159
B3
B3-B4
B3
B4
C3-C4
C3-C4
C3
C3-B3
C3-B3
C3-B3
C3-B3
B2
B2
B2
B2
B2
B2
B2
C2
C2
C2-C3
C2
C2
C2
C2
C2
C2
C2
C2
C2
C2
C2
C3
C3
C3
C3
C3
C3
C3
C3
C3
C3
C3-C4
C2
C2
C2
C2
C2
C2
C2
C2
C2
C2
C2
C2
C3
C3
C3
C3
R160
R161
R162
R163
R164
R165
R166
R167
R168
R169
R170
R171
R172
R173
R174
R175
R176
R177
R178
R179
R180
R181
R182
R183
R184
R185
R186
R187
R188
R189
R190
R191
R192
R193
R194
S1
S2
T1
TP1
TP2
TP3
TP4
TP5
TP6
TP7
TP8
TP9
TP10
TP11
TP12
TP13
TP14
TP15
U1
U2
U3
U4
U5
U6
C3
C3
B3
C3
C3
C3
B3
B3
B3
C4
C4
C3-C4
B2-C2
B2
B2-C2
B2
B2-C2
B2
B2-C2
B2
C3
B4
C3
C3
C3
B2
C3
C3
C3
B4
B3
B4
B3
B2
B3
B2
C3
B2
C3
C3
C3
C3
B2
B2
C2
C2
C3
C3
B2
B3
B4
C3
C3
B3
B3
B3
B3
B3
B3
U7
U8
U9
U10
U11
U12
U13
U14
U15
U16
U17
U18
U19
U20
U21
U22
U23
U24
U25
U26
U27
U28
U29
U30
U31
U32
U33
U34
U35
U36
U37
U38
U39
U40
U41
U42
Y1
B3
B3
B3
B2
B2
B2
B4
B3
B3
B3
B3-C3
B3-C3
B2
B2
B2
B2
B2
C2
C3
C2
C3
C3
C2
C2
C2
C2
C3
C3
C3
C3
C3
B3-C3
C3
B3-C3
C3
C2
C3
FIGURE 4-8. COMPONENT LOCATOR, ECU EXCITER BOARD
(Sheet 2 of 2)
REF
ZONE
REF
ZONE
REF
ZONE
REF
ZONE
REF
ZONE
REF
ZONE
C1
C2
C3
C4
C5
C6
C7
C8
C9
C10
C11
C12
C13
C14
C15
C16
C17
C18
C19
C20
C21
C22
C23
C24
C25
C26
C27
C28
C29
C30
C31
C32
C33
C34
C35
C36
C37
C38
C39
C40
C41
C42
C43
C44
C45
C46
C47
C48
C49
C50
C51
C52
C53
C54
C55
C56
C57
C58
C59
C2
C2
C2
C3
C3
C3
C3
C3
C3
C3
C3
C3
C3
C3
C3
C3
C2
B2
B2
C3
B3
B3
B3
B2
C3
C3
C3
C3
B3
B3
C3
C2
B2
B2
B2
B3
B3
B3
B3
B3
B3
B3
B3
B3
B3
B3
B3
B3
B2
B2
B2
B3
B3
B3
B3
B2
B3
B3
B3
C60
C61
C62
C63
C64
C65
C66
C67
C68
C69
C70
C71
C72
C73
C74
C75
C76
C77
C78
C79
C80
C81
C82
C83
C84
C85
C86
C87
C88
C89
C90
C91
C92
C93
C94
C95
C96
C97
C98
C99
C100
C101
C102
C103
C104
C105
C106
C107
C108
C109
C110
C111
C112
C113
C114
C115
C116
C117
C118
B3
B3
B3
B3
B2
B2
C2
C2
C2
C2
C2
B2
B2
B2
B2
B2
B2
B2
B2
C2
B2
B2
B2
C2-D2
C2-D2
C3
C3-D3
C3-D3
D3
C2
C2
C2
C1
C1
C1
C1
B2
B2
B2
B2
B2
B2
B2
B2
B2
B2
B2
B2
B1
B1
B1
B1
B1
B1
B1
B1
B1
B1
B1
C119
C120
C121
C122
C123
C124
C125
C126
C127
C128
C129
C130
C131
C132
C133
C134
C135
C136
C137
C138
C139
C140
C141
C142
C143
C144
C145
C146
C147
C148
C149
C150
C151
C152
C153
C154
C155
C156
C157
C158
C159
C160
C161
C162
C163
C164
C165
C166
C167
C168
C169
C170
C171
C172
C173
C174
C175
D1
D2
B1
B1
B1
B1
B1
B2
B1
B2
B2
C2
C1-C2
C2
C2
B1
C1
C1
C1
B1-C1
C1
C1
C2
C2
C2
C2
C2
C2
C2
C2
C2
C2
C2
C2
C2
C2
C2
C2
C2
C3
C2
C2
C2
C2-C3
D1
D1
D1-D2
D2
C2
C2
C2
C2
B2
B2
B1
B1
B1
B2
B1
B2
B2
D3
D4
D5
D6
D7
D8
D9
DS1
DS2
DS3
DS4
DS5
DS6
E1
E2
E3
E4
J1
J2
J3
J4
J5
J6
J7
L1
L2
L3
L4
L5
L6
L7
P1A
P1B
P2A
P2B
P3A
P3B
P4A
P4B
P5
P6
P7
P201
Q1
Q2
Q3
Q4
Q5
Q6
Q7
Q8
Q9
Q10
Q11
Q12
Q13
Q14
R1
R2
B2
B2
C2
C1
C1
C1
C1
C3
B3
C3
C3
C3
C3
C1
C1
C1
C1
C3
B3
B3
B3
B2
C2
C2
C1
C1
C1
B2
B2
B2
B2
C3
C3
B3
B3
B3
B3
B3
B3
B2
C2
C2
C1-D1
B1
B2
B3
C3
C3
C3
C3
C3
D1
D1
D1-D2
D2
D1
D1
C3
C2
R3
R4
R5
R6
R7
R8
R9
R10
R11
R12
R13
R14
R15
R16
R17
R18
R19
R20
R21
R22
R23
R24
R25
R26
R27
R28
R29
R30
R31
R32
R33
R34
R35
R36
R37
R38
R39
R40
R41
R42
R43
R44
R45
R46
R47
R48
R49
R50
R51
R52
R53
R54
R55
R56
R57
R58
R59
R60
R61
C2
C2
C2
C3
C2
C2
C2
C3
C3
C2
C2
C3
C3
C3
C3
C3
C3
C3
C3
C3
C3
C3
C3
C3
C3
C2
C2
C2
C2
C3-B3
C2
C2
C2
C3
C3
C2
C2
C3
C3
C3
B3-C3
B3
B3
C3
C3
C3
B3
B3
B3
B3
B3
B2
B2
B2
B2
B3
B2
B2
B2
FIGURE 4-11. COMPONENT LOCATOR, ECU STEREO BOARD
(Sheet 1 of 2)
REF
ZONE
REF
ZONE
REF
ZONE
REF
ZONE
REF
ZONE
R62
R63
R64
R65
R66
R67
R68
R69
R70
R71
R72
R73
R74
R75
R76
R77
R78
R79
R80
R81
R82
R83
R84
R85
R86
R87
R88
R89
R90
R91
R92
R93
R94
R95
R96
R97
R98
R99
R100
R101
R102
R103
R104
R105
R106
R107
R108
R109
R110
R111
R112
R113
R114
R115
R116
R117
R118
R119
R120
B3
B3
B2
B2
B3
B3
B3
B3
B3
B3
B3
B3
B3
B3
B3
B3
B3
B3
B2
B2
B2
B2
B3
B2
B2
B2
B3
B2-B3
B2
B2
B3
B3
B3
B3
B3
B3
B3
B3
B3
B3
B3
B3
B3
C2
B2
C2
C2
B2
C2
B2
C2
B2
B2
B2
B2
C2-B2
B2
B2
B2
R121
R122
R123
R124
R125
R126
R127
R128
R129
R130
R131
R132
R133
R134
R135
R136
R137
R138
R139
R140
R141
R142
R143
R144
R145
R146
R147
R148
R149
R150
R151
R152
R153
R154
R155
R156
R157
R158
R159
R160
R161
R162
R163
R164
R165
R166
R167
R168
R169
R170
R171
R172
R173
R174
R175
R176
R177
R178
R179
B2
B2
B2
B2
B2
B2
B2
B2
B2
B2
B2
D3
C3-D3
D3
D2
C2
D3
D3
C3
C2
C2
B2
C2-B2
B2
C2
C1
C1
B2
B2
B2
B2
B2
B2
B2
B2
B2
B2
B2
B2
B2
B2
B2
B1
B1
B1
B1
B1
B1
B1
B1
B1
B1
B1
B1-C1
B2
B2-C2
B1-C1
B2-C2
B2-C2
R180
R181
R182
R183
R184
R185
R186
R187
R188
R189
R190
R191
R192
R193
R194
R195
R196
R197
R198
R199
R200
R201
R202
R203
R204
R205
R206
R207
R208
R209
R210
R211
R212
R213
R214
R215
R216
R217
R218
R219
R220
R221
R222
R223
R224
R225
R226
R227
R228
S1
S2
S3
S4
S5
T1
TP1
TP2
TP3
TP4
B2-C2
B2-C2
B2-C2
C2
C2
C2
C1
C2
C1
C1
B1
C1
C3
C3
C3
C1
C1
C2
C2
C2
C2
B3
C3
C2
C2
C2
C2
C2
C2
C2
C2
C2
C2
C2
C2
C2
C3
C3
C3
C3
C3
C3
D1
D1
D2
D2
B1
B1
C2
C3-D3
B1
B1
B1
C3
C1
C1
C1
B2
B2
TP5
TP6
TP7
TP8
TP9
TP10
U1
U2
U3
U4
U5
U6
U7
U8
U9
U10
U11
U12
U13
U14
U15
U16
U17
U18
U19
U20
U21
U22
U23
U24
U25
U26
U27
U28
U29
U30
U31
U32
U33
U34
U35
U36
U37
U38
U39
U40
U41
U42
U43
U44
U45
U46
U47
U48
U49
U50
U51
U52
U53
B2
C1
B2
B2
B2
B2
C2
C2-C3
C2-C3
C3
C3
C2-C3
B2-C2
B2-B3
C2-C3
B3-C3
B3-C3
B2
B2-B3
B2-B3
B3
B3
B2-B3
B2
B2-B3
B2-B3
B3
B3
C2
C2
C2
B2
B2
B2
B2
C3-D3
C2
B2
B2
B2
B2
B2
B2
B1
C1-C2
C1
C2
C2
C2
C2
C1-C2
C1-C2
C1-C2
C1-C2
C2
C2
C2
C2
C2
U54
U55
C2
C2
FIGURE 4-11. COMPONENT LOCATOR, ECU STEREO BOARD
(Sheet 2 of 2)
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