50kW TX Operation Manual

CONTENTS
SECTION1 - GENERAL INFORMATION..................................................................5

1-1. INTRODUCTION..........................................................................................5
1-1.1 Section1 - General Description..............................................................5
1-l.2 Section 2 -1nstallation............................................................................5
l-1.3 Section 3 - Operation..............................................................................5
1-l.4 Section 4 -Theory of Operation..............................................................5
l-1.5 Section 5 - Maintenance.........................................................................5
1-2 GENERAL DESCRIPTION............................................................................5
l-2.1 Control and Low Voltage Distribution, Unit 1.....................................10
l-2.2 Utility Cabinet, Unit 2..........................................................................10
l-2.3 RF Amplifier, Unit 3.............................................................................11
l-2.4 Modulator Power Enclosure, Unit 4.....................................................11
l-2.5 Cooling System, Unit 5.........................................................................12
l-2.6 Control Panel, Unit 6............................................................................13
l-2.7 Balun, Unit 7 (Optional).......................................................................13
l-2.8 Harmonic Filter, Unit 8.........................................................................13
1-2.9 Modulator Controller, Unit 9...............................................................13
1-3. TECHN1CAL CHRACTERISTICS.............................................................16
1-4 LIST OF EQUIPMENT SUPPLIED.............................................................18
1-5 EQUIPMENT REQUIRED BUT NOT SUPPLIED.....................................20
1-6 TUBE COMPLEMENT.................................................................................20
SECTION2 - TRANSMITTER INSTALLATION......................................................21
2-l. GENERAL.....................................................................................................21
2-2. TRANSMITTER BUILDING REQUIREMENTS....................................21
2-3. ELECTRICAL POWER REQUIREMENTS...............................................22
2-4. PRELIMINARY INSTALLATION STEPS..................................................22
2-5. UNPACKING...............................................................................................22
2-6. INSTALLATION OF MAJOR UNITS.........................................................23
2-6.l Cooling System, Unit 5.........................................................................23
2-6.2 Utility Cabinet, Unit 2.........................................................................24
2-6.3 Control and Low Voltage Distribution, Unit l.....................................24
2-6.4 RF Amplifier, Unit 3............................................................................25
2-6.5 Harmonic Filter, Unit 8........................................................................28
2-6.6 Balun, Unit 7........................................................................................28
2-6.7 Modulator Power Enclosure, P/O Unit 4.............................................29
2-6.8 Assembly Procedure, Unit 4................................................................29
2-6.9 Heat Exchanger, P/O Unit 5.................................................................31
2-7. INTER-UNIT WIRING.................................................................................31
2-8. INITIAL ADJUSTMENTS AND PREPARATION......................................32
1
2-8.1 General.................................................................................................32
2-8.2 Final RF Amplifier Bias Adjustment...................................................36
2-8.3 Adjustment of Servo Motor Drives......................................................36
2-8.4 Initial Adjustment of Tuning Components...........................................38
2-8.5 Band Switch Control Adjustment........................................................39
2-8.6 Fiber Optic Cable Termination............................................................40
SECTION3 - OPERATIONS.......................................................................................41
3-l. OPERATING PROCEDURES......................................................................42
3-2. TURN-ON PROCEDURE............................................................................58
3-2.1 Pretuned Operating Frequency..............................................................59
3-2.2 New Operating Frequency....................................................................60
3-3. CONTROL CARRIER-LEVEL MODULATION........................................67
3-3.1 CCM Setup..........................................................................................67
3-4. CLIPPER OPERATION...............................................................................68
3-4.1 Clipper Setup.......................................................................................68
3-5. TURN-OFF TRANSMITTER......................................................................68
3-5.l Normal Turn-Off...................................................................................68
3-5.2 Emergency Shutdown, Limited...........................................................69
3-5.3 Emergency Shutdown, Complete.........................................................69
SECTION 4 - THEORY OF OPERATION.................................................................70
4-1. GENERAL....................................................................................................70
4-2. RF CIRCUITS...............................................................................................70
4-2.l Solid State Amplifier, 3Al.....................................................................70
4-2.l Solid State Amplifier, 3Al.....................................................................71
4-2.2 Intermediate Power Amplifier (IPA)....................................................71
4-2.3 Power Amplifier (PA)..........................................................................72
4-2.4 Output Network...................................................................................73
4-2.5 Harmonic Filter, Unit 8........................................................................74
4-2.6 Balun Network, Unit 7.........................................................................75
4-3. BAND SWITCHING CIRCUITRY.............................................................75
4-4. MODULATOR.............................................................................................75
4-4.1 Modulator Controller. Unit 9............................................................75
4-4.2 Synthesizer, Modified (Option l).........................................................93
4-4.3 Switch Housing Assembly, 4A5..........................................................93
4-4.4 Modulator.............................................................................................94
4-5. POWER SUPPLIES.....................................................................................98
4-5.1 1PS1 Indicator Power Supply..............................................................98
4-5.2 IPA Power Supply, 1PS6......................................................................98
4-5.3 PA Bias Supply, lPS5...........................................................................99
4-5.4 PA Screen Supply.................................................................................99
4-6. CONTROL CIRCUITS..............................................................................100
4-6.l Start-Up Control Circui1 Analysis......................................................100
2
4-6.2 Power Select Control Circuit Analysis..............................................102
4-6.3 Overload and Reclosure Circuit Analysis..........................................103
4-6.4 Remote Control Assembly, Unit 11...................................................104
4-7. COOLING SYSTEM..................................................................................105
4-8. TUNING MOTOR CONTROL SYSTEM..................................................108
4-9 RF Gain Control 1A9..................................................................................109
SECTION 5 - MAINTENANCE................................................................................111
5-1. GENERAL..................................................................................................111
5-l.l Major Assembly Locators....................................................................111
5-l.2 Equipment Required But Not Supp1ied..............................................111
5-l.3 Consumable Materials.........................................................................111
5-2. MAINTENANCE CONCEPT....................................................................111
5-3. ELECTROSTATIC HANDLING...............................................................112
5-3. l General...............................................................................................117
5-3.2 Implementation..................................................................................117
5-3.3 Grounding..........................................................................................118
5-3.4 Summary............................................................................................118
5-4. ACCESS AND EXIT PROCEDURES.......................................................119
5-4. l Modulator HV Vault Access..............................................................119
5-4.2 Modulator HV Vault Exit...................................................................121
5-4.3 RF Amplifier Cabinet Access............................................................121
5-4.4 RF Amplifier Cabinet Exit.................................................................122
5-4.5 Utility Cabinet Access.......................................................................122
5-4.6 Utility Cabinet Exit............................................................................124
5-4.7 Distribution Cabinet Access...............................................................124
5-4.8 Distribution Cabinet Exit...................................................................125
5-5 PREVENTIVE MAINTENANCE PROGRAM..........................................125
5-5. l General...............................................................................................125
5-5.2 Preventive Maintenance Schedule.....................................................125
5-6. CORRECTIVE MAINTENANCE PROGRAM.........................................131
5-6.1 Troubleshooting Procedures...............................................................131
5-6.2 Systematic Fault Isolation...................................................................131
5-6.3 Modu1ator Controller, Unit 9.............................................................132
5-6.4 Fault Isolation Using Modu1ator LEDs..............................................134
5-7. REMOVE AND REPLACE PROCEDURES............................................135
5-7.l. Lamp Remove and Replacement Procedure......................................135
5-7.2 Switch Removal and Replacement Procedure...................................135
5-7.3 Purification Resin Remove and Replace Procedure..........................136
5-7.4 Power Amplifier Tube Remove and Rep1ace Procedure....................142
5-7.5 Fiber Optic Cable Termination...........................................................143
5-7.6 Tuning Capacitor Removal and Replacement Procedure...................152
5-8 ALIGNMENT PROCEDURES...................................................................156
3
5-8.l Water Resistivity Meter Calibration...................................................156
5-8.2 Audio Path Alignment, 9A4...............................................................157
5-8.3 Power Control Alignment, 9A5.........................................................159
5-8.4 Harmonic Filter Alignment, Unit 8....................................................160
4
SECTION1 - GENERAL INFORMATION.
1-1. INTRODUCTION
This Technical Manual contains instructions for installation, operation, and
maintenance of the BBEF Type DF50A, 50kW, HF Broadcast Transmitter. The
Technical Manual is divided into five sections as follows:
Section l Genera1 Information
Section 2 Installation
Section 3 Operation
Section 4 Theory of Operation
Section 5 Maintenance
The following paragraphs describe the contents of each section of the manual.
1-1.1 Section1 - General Description.

This section contains a physical and functional description of the transmitter and it's
major subunits. Also included in section l is a list of technical characteristics (Table l-
1), list of equipment supplied (Tab1e l --2), list of equipment required but not supplied
(Table 1--3).
1-l.2 Section 2 -Installation.

This section contains instructions to be followed while uncrating, unpacking, staging
and installing the transmitter units and the major components which were removed for
Shipment. Also included are steps necessary to prepare the transmitter for initial turn--
on.
l-1.3 Section 3 - Operation.

This section contains a description of controls and indicators, turn-on procedure,
operating procedure, shutdown procedure, and emergency shutdown procedure.
1-l.4 Section 4 -Theory of Operation.

This section includes general functional theory and detailed theory of operation for
the transmitter and it's subassemblies.
l-1.5 Section 5 - Maintenance.

This section includes preventive and corrective maintenance procedures for the
transmitter system. Also included are instructions for troubleshooting and remove and
replace procedures as appropriate. Alignment and performance checks are included as
appropriate.
5
1-2 GENERAL DESCRIPTION
The Type DF 50A SW Transmitter, produced by BBEF Provides 50 kilowatts of
amplitude modulated (AM) power (A3E) over the frequency range of 3.6 to 22 MHz,
optional to 26.1 MHz.
The synthesizer, which operates in the same frequency range as the transmitter, is
required for transmitter operation. The synthesizer power output is 1 Vrms into 50
Ohms.
The transmitter consists of a main cabinet group, a harmonic filter, balun unit cooling
system and power enclosure equipment. Figure l-1 illustrates the main cabinet group
of the DF50A, 50kW, HF Broadcast transmitter. Figures l-2 and 1-3 identify the
various units of the Type DF50A Transmitter. The balun unit can be mounted at some
point between the harmonic filter and the balanced transmission line. The modulator
power enclosure is an enclosed area containing the distribution transformer,
modulation transformers, switching supplies and high voltage control (switch housing
assembly). The external cooling equipment consists of a heat exchanger with water
cooling coils.
6
Figure1-1.Type DF50A ,50kW Broadcast Transmitter
7
Figure 1-2 Type DF50A Transmitter Unit Locator, Front
View.
8
Figure 1-3 Type DF50A Transmitter Unit Locator, Top View.
9
l-2.1 Control and Low Voltage Distribution, Unit 1.
WARNING
HIGH VOLTAGE HAZARD
115 VAC SINGLE PHASE AND 230 VAC POLYPHASE VOLTAGES ARE
PRESENT IN UNIT 1. THESE AC VOLTAGES ARE PRESENT AT ALL
TIMES THAT THE MAIN POWER IS APPLIED TO THE DF50A
TRANSMITTER. CAUTION MUST BE USED WHEN ENTERING UNIT
1.FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY OR DEATH.
WARNING
HIGH VOLTAGE HAZARD
ACCESS TO HIGH VOLTAGE AREAS ARE PROTECTED BY ELECTRICAL
INTERLOCKS. DO NOT DISABLE INTERLOCK CIRCUITS. FAILURE TO
COMPLY MAY RESULT IN SERIOUS INJURY OR DEATH.
The control and low voltage distribution unit provides control, tuning and monitoring
functions for the transmitter. It also provides dc power to several stages. The unit
contains a protective circuit breaker panel, control and distribution relays and
contactors, the low voltage plate supply, a tuning motor power supply and bias power
supplies.
The Control Panel, Unit 6, is mounted on the front of the control and low voltage
distribution unit. Band Switch Control, 6A2, is mounted on the control panel; RF
Gain Control, 1A9, IPA Auto Tune Control, 1A10, RF Exciter; and frequency control
card on the back of 6A2 along with the local remote switch. Access doors are
provided on the rear of the control and low voltage distribution unit.
l-2.2 Utility Cabinet, Unit 2.

WARNING
HIGH VOLTAGE HAZARD
PRESENT IN UNIT2. THESE AC VOLTAGES ARE PRESENT AT ALL TIMES
THAT THE MAIN POWER IS APPLIED TO THE DF50A TRANSMITTER.
CAUTION MUST BE USED WHEN ENTERING UNIT2. FAILURE TO
WARNING
HIGH VOLTAGE HAZARD
The Uti1ity Cabinet, Unit 2, contains the PA screen switching regulator supplies, the
cooling-system steam- separator tank and the water pump. The pressure and
temperature gauges for both the boi1er water feed line and the auxi1iary cooling
water line are also contained in the utility unit cabinet. Access doors are provided on
10
both the front and rear of the unit.
l-2.3 RF Amplifier, Unit 3.

WARNING
HIGH VOLTAGE HAZARD
WARNING
HIGH VOLTAGE HAZARD
The RF amplifier unit contains the RF circuitry, the three band- switching drive motor
assemblies, the main coolingair blower, and the tuning drive assemb1ies. The RF
power amplifier stage utilizes a single type 4CV100,000C tube. There are six access
doors on the RF amplifier unit.
l-2.4 Modulator Power Enclosure, Unit 4.

WARNING
HIGH VOLTAGE HAZARD
WARNING
HIGH VOLTAGE HAZARD
HIGH VOLTAGES ARE CONTAINED WITHIN THE MODULATOR POWER

ENCLOSURE, UNIT4. BEFORE SERVICING MODULATOR, REMOVE
PRIMARY POWER BY OPENING THE HIGH VOLTAGE CIRCUIT
BREAKER, ALLOW SUFFICIENT TIME FOR CAPACITOR DISCHARGE,
AND USE GROUND STICK ON ALL COMPONENTS WITHIN THE
MODULATOR.. FAILURE TO COMPLY MAY RESULT IN DEATH OR
SERIOUS INJURY.
The power enclosure is located in a fenced area behind the main cabinet group. It
11
includes the switch housing assembly, the distribution transformer, and the solid state
modulator. The power enclosure is accessible through a door or gate.
l-2.4.l Switch Housing Assembly, 4A5.
The switch housing assembly includes two three phase contactors, and three resistors
in a step-start (or soft-start) configuration. This unit controls the application of the
high voltage to the primaries of the modulators' transformers. The step start sequence
provides a gradual charging of the modu1ator power switch module capacitors and of
the modulator transformer magnetization currents through current limiting resistors.
After the modulator capacitors are charged and the transformers are magnetized, the
current limiting resistors are shorted by the second contactor.
l-2.4.2 Solid State Modulator.

The Solid State Modulator 48 solid-state switching power modules, each contributing
approximately 500 Volts to the total anode voltage. As the required anode voltage
rises and falls, the number of modules contributing to the total anode vo1tage is
increased or decreased as required. Pulse-width modulation (PWM) techniques are
used to smooth the transition as modules are added and removed. Each of the modules
is controlled through fiber-optic lines from the Modulator Controller. Unit 9. During
normal carrier operation at 50 kW carrier output, the dc anode vo1tage is
approximately 10kV. Program audio waveforms are super-imposed on the dc voltage
by circuits within the modulator controller. Adjusting the anode voltage from the
modulator will smoothly vary the transmitter's output from no output to the fu1l rated
RF output.
1-2.4.2.l Power Switch.

The power switch is a pulse width modulating unit which is capable of switching
frequencies up to 10kHz and de1ivering an average of 1.1 kW of power to its load.
The power switch can supply a 500V pulse with rise and fall times less than 400 ns.
The 48 power switches are used in a series configuration to form a 50kW solid state
modulator. Two power switches are also used as the PA screen supply.
l-2.4.2.2 Power Switch Control.

The power switch control is a sub-assemb1y of the power switch. The switch control
serves as an interface between the modulator control1er and the power switch. The
switch control communicates with the controller via fiber optic cables and controls the
operation of the power switch. The switch control drives two insulated gate bipolar
transistors (IGBT) on the power switch and is capable of detecting internal fai1ures
on the power switch and removing the switch from the modulator's circuit.
l-2.5 Cooling System, Unit 5.

The purpose of the Cooling System is to dissipate operating temperatures from RF
Amplifier Unit components. These components inc1ude the PA Tube (3V3), tuning
capacitors and resistors, shorting plunger, pi-network coil, and blocking capacitor. The
Cooling System includes the water-to-air heat exchanger unit and the associated
coolant lines between the Transmitter main cabinet and the heat exchanger.
12
l-2.6 Control Panel, Unit 6.
The control panel provides control, tuning and monitoring for the entire transmitter.
The control panel contains all of the controls and indicators used in normal operation,
with the exception of the circuit breakers and the bell disable switch. The rear of the
control panel is accessible through the rear doors on the control and low voltage
distribution unit.
l-2.7 Balun, Unit 7 (Optional).

The balun unit provides an impedance match between the final RF amplifier and the
300 Ohm balanced transmission line. The balun is a U-shaped tubular transmission
line comprised of a transformer and associated baluntuning element, containing
motor-driven capacitors which allow the unit to be tuned from the transmitter control
front panel. The balun unit can be mounted at any convenient point between the
output of the harmonic filter and the balanced transmission line.
l-2.8 Harmonic Filter, Unit 8.

The harmonic filter is a low pass, two-section, tunable filter which is mounted on the
top of the power amplifier cabinet. The capacitors and inductors in the filter are
mechanically connected and driven by a single tuning motor.
1-2.9 Modulator Controller, Unit 9.

The modulator controller is a self-contained unit that receives external commands,
processes them, and controls the operations of the individual power switches. The
individual circuit cards are of Type 6U (double height) Eurocard construction. The
individual circuit cards are identified as fol1ows.
Al Single Side band Generator (Option l)
A2 Single Side band Equa1ization (Option 1)
A3 Hum Reduction
A4 Audio Path
A5 Power Control
A6 F1ash Converter
A7 Ring Modulator
A8 Status
A9 Status
A10 Power Supply
A11 Input Output
Al2 Optical Transmitters
Al3 Optical Receivers
Al4 Backplane
A general description of the circuit cards follows. For a more in depth description see
Theory of Operation, in this manual.
1-2.9.l SSB Generator, A1(Option).
1-2.9.2 SSB Equalization, A2(Option).
13
1-2.9.3 Hum Reduction, A3.
One unwanted characteristic of power supplies that are operated from AC sources is
ripple. Ripple is the result of imperfect filtering of the rectified ac signal. Power
supply ripple can cause the appearance of hum on the unmodulated carrier. Additional
filtering, capacitance or inductance, can reduce the ripple. However large capacitors
and inductors are required for large power supplies. These capacitors and inductors
can be large and expensive. Another method of reducing the hum is to introduce a
modulation component that is opposite to that of the noise modulation. The Noise
Reduction board uti1izes feedback to cancel out low frequency noise components.
This is accomplished by retrieving and demodulating a RF sample from the PA anode.
This signa1 is sent to the Noise Reduction card where its DC component is removed
and the resultant waveform is fed into a multiplier. This signal is either multiplied by
a DC value when audio is absent, or the signal is multiplied by 0V when audio is
present. The product of this multiplier is then routed to the Audio Path board where it
is summed with the modulation signal in such a way as to be out of phase with the
original RF sample.
l-2.9.4 Audio Path, A4.

Incoming audio is processed within the audio path board. The audio is ac coupled, and
peak limited. The corner of the high pass filter is low enough to permit a clean 50 Hz
square wave. The remaining circuitry is completely dc coupled to the PA. A dc voltage
is summed with the audio to represent the amplitude of the carrier. This dc voltage can
be fixed, or variable for a dc voltage that is generated within the power control board.
Multiplication of the power control voltage with the audio plus dc signal permits
continuously adjustable power control. This power control scheme permits constant
depth of modulation at any output power. A triangular wave of small amplitude is
added to the now variable audio. The triangle wave is used within the flash converter
to provide superior resolution of the analog to digita1 conversion. The now processed
audio is routed to the flash converter for conversion.
l-2.9.5 Power Control, A5.

The power control board receives and processes all of the external commands arriving
from the transmitter. Some of the signals include:
1. Operate/Not Operate
2. High Power/Low Power
3. Tune Power
4. Fault
5. Power Raise/Power Lower
These signals determine if, and at what power level the transmitter operates. Fault
signals will immediate1y terminate the operation of the modulator. Fault signals are
also tallied to determine if the modulator will return to high power, low power, or stay
off. A dc voltage is generated to control the modulator output level. This dc vo1tage is
selected and varied by some of the commands listed above. Various status signals of
the modulators operational mode are made available as output. All of the external
signals are terminated at the Input/Output board, 9A11.
l-2.9.6 Flash Converter, A6.

The flash converter is the modulators' analog to digital converter. The variable audio
from the Audio Path board is compared with 48 distinct reference voltages. The main
14
reference voltage is generated in the audio path board, and represents the total
available modulator voltage. This comparison determines how many power switches
are on at any given time. At any given time some comparison levels will be on, one
level will be pulse width modulated, and the rest wil1 be off. A synchronization clock,
from the Audio Path board, latches the comparator outputs. The 48 parallel outputs
are resistively summed and routed to the Ring Modu1ator board.
1-2.9.7 Ring Modulator, A7.

The ring modulator establishes a sequential method of address rotation. The purpose
of address rotation is to assure that all of the power switches are equally used. In
addition to rotation, the ring modu1ator is able to avoid a power switch that is non-
functional. A command from the status board signals the ring modulator of a non-
functional power switch. A synchronization clock, from the audio path board, assures
that the f1ash converter and the ring modulator are operating concurrently. The 48
parallel outputs are routed to the optical transmitter board.
l-2.9.8 Status, A8 and A9.

The status board decodes the status signals that are generated on each of the 48 power
switches. The status signals are 37 kHz frequency modulated pulses that represent the
available switch voltage. Once decoded the now dc voltage is compared with a
reference to determine if the power switch has enough voltage to operate. This
determination illuminates a front panel led and commands the ring modulator that the
switch is functiona1. Unit A8 supervises numbered switches 25 through 48, while unit
A9 supervises numbered switches 1 through 24.
1-2.9.9 Power Supply, A10.

The power supp1y board receives l15 volts ac from the transmitter, and converts it to
the dc voltages necessary for proper operation of the modulator controller.
1-2.9.l0 Input Output, A11.

The input output board is the interface between the modulator controller and the rest
of the transmitter. The connections are made by terminal board, fiber optic, or BNC
connectors as appropriate. All of the wired control signals are low pass filtered to
reduce RF signals within the controller.
l-2.9.11 Optical Transmitter, A12.

The optical transmitter board contains the 48 fiber optic transmitters for controlling
the power switches. A means for fast shut down of the modulator is also provided.
The 48 outputs from the ring modulator are the command signals for this board.
1-2.9.l2 Optical Receiver, A13.

The optical receiver board contains the 48 fiber optic receivers for receiving the status
information from the power switches. The outputs of the optical receivers are routed
to the two status boards.
1-2.9.l3 Backplane, A14.

The backplane is a passive circuit board to which all of the above circuit boards plug
into. Units A1 through A9 plug into the front of the board. Units Al0 through Al3 plug
into the back of the board to simplify wiring to the transmitter.
15
1-3. TECHN1CAL CHRACTERISTICS
Technical characteristics of the Type DF50A Transmitter are listed in Table 1-1.
Table 1-1. Technical Characteristics.
Parameter Performance Characteristics
Electrical:
Carrier Output Power 50 kW
Types of Emission Amplitude Modulation (A3E)
Frequency Range 3.6 to 22MHz typical
Type of Modulation High Level plate modulation
Final Power Amplifier Class C
Output Impedance 50 Ohms unbalanced
Maximum Load VSWR 2: l
Spurious Emissions Complies with CCIR recommendations
Audio Input Impedance 600/150 ohms, balanced or unbalanced
Audio Input Leve1s l0 dBm at l,000 Hz
Audio Frequency Response l dB from 50 to 5,000 Hz at 75% modu1ation +l
or -2 dB from 5,000 to 7,500 Hz at 75%
modulation
Total Harmonic Distortion (Sine) 4% between 50 and 5,000 Hz at 90% modulation
Residual Carrier Noise 55 dB (unweighted) below l00% modulation level
at 1000 Hz
Primary Power 360 to 480 Vac, 3-phase, 50/60 Hz (Other voltages
available on special order)
Power Consumption (Typical):
Unmodu1ated 71kW
l00% Sine 107 kW
Overal1 Efficiency 70% at any modulation level
Environmental:
Maximum Altitude 6,000 feet
Relative Humidity 95% relative humidity, non-condensing
Ambient Temperature Range 5C to 50C
Mechanical:
Transmitter, 50 kW, HF Length l92", Width 60", Height 84-5/16", Weight
5,400 lbs.
Control and LV Distribution
,Unit 1 Length 48", Width 60", Height 84-5/l6", Weight l,400 lbs.
Utility Cabinet, Unit2 Length 48", Width 60", Height 84-5/l6", Weight
l,500 lbs.
RF Power Amplifier,Unit3 Length 96',, Width 60", Height 84--5/16",Weight
2,500 lbs.
AC Switching, Unit 4A5 Length 30", Width 30", Height 54", Weight 300 lbs.
Distribution Transformer,4Tl Length 24", Width 20", Height 12", Weight 500 lbs.
Modulator Transformer,4AlTl/4A2Tl
Length 60", Width 48", Height 50", Weight 2,500 lbs.
Water Cooling, Unit 5A1 Length 58", Width 55", Height 3l ", Weight 450 lbs.
Balun Assembly, Unit 7 Length 72", Width 24", Height 55", Weight 200 lbs.
Harmonic Filter, Unit 8 Length 48.', Width 36", Height 45", Weight 470 lbs.
16
1-4 LIST OF EQUIPMENT SUPPLIED
Table 1-2 list of Equipment supplied

Ref.Des. Description
Transmitter, 50 kW HF, Type DF-50A
Unit1 Control & LV Distribution-SSB
1A1 Tuning Drive Amplifier
1A2-1A8lA8 Tuning Drive Amplifier
lA9 RF Gain Control
lAl0 Tune Timer Discriminator
lAl0Al Tune Timer Discriminator Board
lA15 Frequency Synthesizer, Altered
lAl6 Frequency Setting
lAl7 High speed VSWR Detector
lPS5 Power Supply, PA Bias
lPS5A1 Grid Current Sensor CCA
lPS6 Power Supply, IPA
lPS7 Power Supply, RF Driver
lPS8 Power Supply, Tuning Motor
Unit2 Utility Cabinet Assembly

2A1-2A2 l50 kW Power Switch Module
2AlAl-2A2Al Power Switch CCA
2AlA2-2A2A2 Switch Status
2L2,2L3 Series Inductor
2L4 Inductor Screen Assembly
2S1 Grounding Switch Assembly
2S7 Flow Switch Assembly
Unit3 RF Power Amplifier Assembly

3Al RF Driver Assembly
3A2 IPA Tuning Motor Drive Assemb1y
3A3 PA Tuning Motor Drive Assembly
3A4 PA Loading Motor Drive Assembly
3A5-3A7 PA Coi1Servo Assemb1y
3A8 RF Sample Assembly
3A9 Envelope Feedback Probe
3A9Cl Capacitor Fixed
3All-3Al4 Electric Door Lock Assembly
3C35 Blacker Capacitor Assembly
3L8 Resistor Mounting Assembly
3L9 Low Level Stage
3Ll0 RF Driver Anode Coil
3Lll Coil
3L12 RF Coil
3L13 RF Coil
3Ll4 Choke Coil Assembly
3Ll5 Coil
3Ll6 RF Driver Anode Coil
3S8-3Sll Grounding Switch Assembly
3XV3 Tube Socket
Unit4 50 kW Modulator Assemb1y

4A1,4A2 High Voltage Power Supply
17
4A1Al,4A2Al Power Column
4AlA1Al-A24, l50 kW Power Switch Module CCA
4A2AlAl-A24
4AlA1AlA1-A24A1, Power Control Switch Module
4A2AlAlAl-A24A1
4AlAlAlA2-A24A2, Switch Status
4A2AlA1A2-A24A2
4A1AlLl-L24 Series Inductor
4A2AlLl-L24
4A3-4A4 Ground Fault Shunt
4A3Al, 4A4Al Ground Fault Sensor
4A3R1, 4A4Rl Resistor
4A5 Switch Housing Assemb1y
4A5CBl Circuit Breaker Altered
4A5S7 High Voltage Ground Switch
4Ll Low Pass Filter Coil
4L2 Low Pass Filter Coil
4L3 Series Inductor
4L4 Electric Door Lock
Unit5 Cooling System Water Flow
Unit6 Control Panel
6A2 Tuning Control
6A2Al Tuning Control Timer CCA
6Sl4 Switch Altered
Unit7 Ba1un Assembly
7Al Balun Mo1or Drive Assembly
Unit8 Harmonic Fi1ter Drive Servo Assembly
8Ll Harmonic Filter Coil Assembly
8L2 Harmonic Fi1ter Coil Assembly
Unit9 Modulator Controller Assembly
Modulator Controller Assembly w/SSB Option l
9Al SSB Generator CCA (Option l)
9A2 SSB Equalizer CCA (Option l )
9A3 Noise Reduction CCA
9A4 Audio Path CCA
9A4Al Clock Modification CCA
9A5 Power Control CCA
9A6 Flash Converter CCA
9A7 Ring Modulator CCA
9A8 Switch Module Status
9A9 Switch Module Status
9Al0 SS Modulator Power Supply CCA
9All Input/Output CCA
9Al2 Optical Transmitter CCA
9Al3 Optical Receiver CCA
9Al4 Back Plane CCA
Unitl0 Remote Computer (Option 2)
Unit11 Remote Control Assembly

llA1 Metering Amplifier CCA (Option 2)
llA2 Remote Control Interface
18
1-5 EQUIPMENT REQUIRED BUT NOT SUPPLIED
Table 1-3. Equipment Required but not Supplied..
l. Oscilloscope DC to 100 MHz or equivalent
2. Audio Analyzer 20 Hz to 100 kHz or equivalent
3. Spectrum Analyzer 0.0l to 350 MHz plug-in and display or equivalent
4. Spectrum Analyzer l0 Hz to 40 MHz, 300 Hz Resolution Bandwidth or equivalent
5. Frequency Counter l0 Hz to 80 MHz, 7 digit LED display, accuracy 1 count or
equivalen1
6. Electrician Tools (Any Mfg.) One (1) set
7. Wrenches (Any Mfg.) One (1) set
8. Solder A solder which contains no lead is required on all plumbing joints
in the water cooling
9. Tape, Electrical (Any Mfg.) Electrical tape (approximately 2 rolls)
10. Lamp Tool
1-6 TUBE COMPLEMENT

The function, quantity, and type of tubes used in the type DF50A transmitter are listed
below.
Function Qty. Type
Power Amplifier 1 4CVl00,000C
Intermediate Power Amplifier 1 4CX3,000A
19
SECTION 2 - TRANSMITTER INSTALLATION
2-l. GENERAL
The Typical Equipment Layout, Assembly Drawing 178484, shows the relative
location of the units which comprise the Type DF50A Transmitter and the proper
positioning of special items which should be included in the transmitter bui1ding.
Wiring trenches and/or overhead wire duct, and the plumbing systems are not shown.
This typical layout has been planned to eliminate most installation prob1ems. The
layout should be followed as closely as possible for each individual installation.
2-2. TRANSMITTER BUILDING REQUIREMENTS

The required size and general layout of the transmitter building can be determined
from the typical transmitter layout drawing and from the dimensions given in Table l-
2. The minimum building entrance requirements are 5'4" by 7'4" high and an 1829mm
wide by 2438mm high loading door is recommended.
The plumbing trench and the wiring trench (if used) can be built into the floor of the
building so that the transmitter can be placed directly on the floor. Weight distribution
and loading must be taken into consideration when the floor is constructed.
In constructing a new building or in using one presently constructed, the method of

routing the transmission lines to the antenna from the balun must be considered.
These 1ines shou1d he shielded from radiating into the power enclosure area.
It may be advantageous to construct a wall across the width of the transmitter room to
separate the operating area in front of the transmitter from the area in the rear. If this
is done, access doors should be provided on each side of the main cabinet group of the
transmitter. These doors should be at least 762mm by 2134mm.
The water heat exchanger can be located inside or outside the transmitter building. Air
for the heat exchanger enters the bottom of the unit and is exhausted through the top.
This exhaust air should be ducted to the outside of the transmitter building either
directly above or to the rear of the building. If it is possible to locate the heat
exchanger near the rear wall of the transmitter building, a removable panel of
sufficient size to facilitate insta1lation and maintenance can be built in to the wall.
This panel can contain the filtered louvers (if required), for the air intake of the water
cooling. The air which passes into the water heat exchanger can come from the
transmitter room or from the outside through these filtered louvers. If the heat
exchanger is located in an environment that is subject to freezing temperatures,
appropriate measures must be taken to prevent damage to the heat exchanger.
If a basement is provided in the transmitter building, the Power Enclosure equipment

can be located in that area, since all high voltage cables and other inter unit wiring
from the power enclosure to the main cabinet group can enter either the bottom or
tops of the units of the main cabinet group.
20
2-3. ELECTRICAL POWER REQUIREMENTS
The customer must provide a route to connect the 3-phase primary power lines to the
line side of the circuit breaker 4CBl. These three lines should have a current capability
of 600 amperes. The 3120mm2 conductor or an equiva1ent is recommended. The
customer must also furnish a source of single phase 220 Vac power for the cabinet
lights and convenience outlets.
Taps are provided on the primary winding of the 230 Vac distribution transformer 4T1
and power supply transformers 4A1T1 and 4A2T1 to accommodate primary power
voltages from 360 to 480 Vac. The customer furnished 220 Vac, 50/60 Hz primary
power lines must be connected to the cabinet lights and convenience outlets in the
transmitter so work can be performed on the equipment with all transmitter Primary
power removed. If 220 Vac is not available externally, the lights and convenience
outlet can be connected to a 220 Vac source in the transmitter.
2-4. PRELIMINARY INSTALLATION STEPS
Perform the following procedures before placing the cabinets in position over the
trench (or trenches) or on the transmitter base if trenches are not used.
Make sure that the copper grounding straps are properly bonded to the main
grounding strap and that the entire grounding system is properly connected. After
installation is complete, the main cabinet group, all self supporting transformer cases
(4T1, 4A1T1 and 4A2T1), assembly frames (4A1A1. 4A2A1 and 4A5), the
modulator 1owpass filter, the ba1un (Unit 7), and the water heat exchanger frame
must be connected to the site grounding system.
2-5. UNPACKING
All components which are fragile or might be damaged in shipment are removed from
the cabinets at the factory and packed in separate boxes. Inspect all crates and boxes
included in the shipment. If there is any evidence of damage to any part of the
shipment, save the packing material and file a c1aim with the transportation company.
The uncrating of large items should start with the components which will be located
to the rear of the transmitter main cabinet group. The best possible order must be
determined by the individua1 installation. If the typical equipment 1ayout is followed
and the loading door of the transmitter building is located in front of the main cabinet
group, uncrate the heat exchanger and all components included in the Cooling System
first.
NOTE
Before the main unit 8 of the transmitter are placed in position, the trench
plumbing must be completed as outlined in Steps 1 through 6 of paragraph 2-
6.a.
21
After the trench plumbing is completed, uncrate the main units of the transmitter and
p1ace them in position as outlined in Section 2-6. Install the major units in the
following order:
a. Power Vault Equipment, Unit 4
b. Utility Cabinet, Unit 2 (includes Unit 9)
c. Control and Low Voltage Distribution, Unit l (includes Unit 6)
d. RF Amplifier, Unit 3
e. Balun, Unit 7
f. Harmonic Filter, Unit 8
g. Cooling System, Unit 5
After the large units and components of the transmitter have been uncrated and placed
in position, the remainder of the boxes and shipping crates may be opened. A tag
bearing the associated unit number is provided with each part. All parts should be
separated according to unit number. Bags of hardware for each unit are labe1ed with
the unit numbers. Some spare hardware is provided in each bag. Refer to the
installation drawings and to the illustrations in this handbook for the proper location
of parts and components.
Bolt the cabinets of the main cabinet group together (use the a1uminum washer plates
included with the cabinet hardware when bolting the cabinets together), making sure
that they are properly lined up before tightening the bolts. Check the opening and
closing of the cabinet doors after the cabinets have been bolted together.
As soon as units in the main cabinet group are bolted in place. the main blower air
duct should be bolted in place. This duct extends across the top of a1l units in the
main cabinet group.
2-6. INSTALLATION OF MAJOR UNITS

2-6.l Cooling System, Unit 5.
Use the fo1lowing procedure to install the cooling system:
1. Place the water heat exchanger in its mounting position. If the heat exchanger is
installed outside, it should be mounted at a higher e1avation than the water tank
in Unit 2. This allows the heat exchanger to properly drain when the transmitter is
not in service. Proper drainage of the heat exchanger is necessary to prevent
damage from cold weather conditions.
2. All plumbing exterior to the Utility cabinet, Unit 2 should be installed in
accordance with the water-cooling-system flow diagram. The two 1-1/2 inch
diameter water lines which connect the heat exchanger to the uti1ity cabinet must
be insta1led so that the lines come in at the bottom of the unit. When insta1ling
plumbing make sure all joints are water tight.
NOTE
The inlet of the de-ionizer bottle should be supplied by the return water of
the heat exchanger.
3. Confirm that the thermostat, which controls the heat exchanger fan, is installed at
the inlet of the heat exchanger.
22
4. Install the water over-temperature switch at the outlet side of the heat exchanger.
5. After the uti1ity cabinet is in place, attach the line from the utility cabinet to the
water input of the water heat exchanger. Joints may be placed in this line at any
convenient position to meet the needs of the individual installation. These joints
must be soldered.
2-6.2 Utility Cabinet, Unit 2.
Use the following procedure to install the Utility Cabinet.
l. Connect the two 1-1/2 inch water lines from the heat exchanger to the PA water
system header. See paragraph 2-6.1 and complete the plumbing of the utility
water system. Included in the Plumbing is the temperature and pressure gauge
which is shipped in the utility cabinet.
2. Install any other components, which may have been removed for shipment, in
their proper positions.
3. Check the intra-unit wiring connections against those shown in the Utility
Cabinet, Unit 2, Schematic l78803.
2-6.3 Control and Low Voltage Distribution, Unit l.

NOTE
The transmitter is shipped with the wires already connected at one end. Before
routing wiring review the following steps.
Perform the following steps to insta1l the control and low voltage distribution unit.
l. All relays are either taped closed or b1ocked open for shipment. Remove the
shipping blocks or tape from all relays.
2. Route wires from the Control and Low Voltage Distribution Unit1 and Contro1
Panel Unit 6 to the Uti1ity Cabinet Unit 2, the RF Amplifier Unit 3, and the
Power Enclosure Unit 4. They are permanently lugged and tagged with
destination information.
3. All the wires which terminate in the Cooling System (Unit 5), must be run and
cut to length on site at the time of insta1lation.
4. All tuning-motor control cables are precut to the correct lengths and are provided
with properly "phased" p1ugs and sockets.
5. If the balun unit is to be mounted externa1 to the transmitter, an extra

interconnecting cable will be furnished. Refer to the inter-unit wiring list.
23
2-6.4 RF Amplifier, Unit 3.
Use the following procedure to install RF Amplifier, Unit 3. Refer to the schematics,
electrical parts lists, and tube socket photographs included in this handbook.
l. Remove the PA header plumbing assembly from its shipping position at the base
of the PA tube boiler assembly and mount it on the wall of the PA cabinet so that
the plumbing fittings protrude into the utility cabinet. Mount the assembly with
furnished l/4" hardware.
2. If the tuning and loading capacitors 3C36 through 3C39 are shipped in place
proceed to step (27).
CAUTION
BE CAREFUL NOT TO MOVE INDUCTOR 3Ll2 WHILE INSTALLING
CAPACITORS 3C36 THROUGH 3C39. FAILURE TO COMPLY MAY
RESULT IN DETUNING THE CIRCUIT.
3. Remove the metal shipping supports from the top of inductor 3L12.
4. Instal1 a water cooling coil on each of the two PA loading capacitors, 3C38 and
3C39. These cooling coils should not be permanently tightened until the
capacitors are mounted in place.
5. Remove the four mounting screws which secure PA tune motor drive assembly
3A3 in place. Remove the drive motor assembly and lay it aside in a safe place.
6. Place capacitors 3C36 and 3C37 in position and install their mounting screws.
Only finger tighten the capacitor mounting screws.
7. Turn the capacitor shafts clockwise (CW) by hand until the mechanical stop is
encountered. This procedure should involve approximately 40 to 50 full turns.
Turn each capacitor shaft counterclockwise one-quarter turn away from the
maximum (CW) mechanical limit.
8. Replace motor drive assembly 3A3 making sure the capacitor shafts line up
properly. Do not connect the coup1ing from the capacitor to the drive shaft at this
time. The drive shaft must be free to turn without engaging the capacitor shaft.
9. Tighten the capacitor mounting bolts.
10. Remove four mounting screws which secure PA loading drive-motor assembly
3A4. Lay drive-motor assembly 3A4 aside.
11. Remove the drive chain which mechanica11y 1inks drive-motor assembly 3A4
with the drive shaft of inductor 3L13. Lay the drive chain aside. Turn the drive
shaft of inductor 3Ll3 to within one-quarter turn of minimum inductance.
12. Place capacitors 3C38 and 3C39 in position and install their mounting screws. Do
not tighten the capacitor mounting screws at this time.
13. Turn the capacitor shafts clockwise by hand until the mechanical stop is
encountered. This procedure should involved approximately 40 to 50 full turns.
14. Turn each capacitor shaft counterclockwise one- quarter turn. At this point the
capacitor is set at minimum capacity.
15. Rep1ace the drive-chain and motor drive assembly 3A4, making sure the
capacitor shafts line up properly and that the rubber spacer is installed in each
24
coup1er. DO NOT connect the coupling from the capacitor to the drive shaft at
this time.
16. Tighten the capacitor mounting screws.
CAUTION
DO NOT DAMAGE THE CONTACT SPRINGS WHEN INSTALLING
RESISTORS 3R29 AND 3R30 IN THEIR CONTACT BLOCKS. FAILURE TO
COMPLY MAY RESULT IN EQUIPMENT DAMAGE.
17. Insert resistors 3R29 and 3R30 into their contact blocks, one resistor at a time,
applying pressure against the contact spring with the resistor and twisting the
resistor in a c1ockwise direction. Do not twist the resistor in a counterclockwise
direction at any time during installation.
18. Line up the mounting holes in the contact blocks on resistors 3R29 and 3R30 with
the holes in the capacitor mounting plate which is to be connected between
capacitors 3C36 and 3C37.
19. Install the mounting plate and resistor assembly on the capacitors.
CAUTION
DO NOT DAMAGE THE CONTACT SPRINGS WHEN INSTALLING
RESISTORS 3R31 AND 3R32 IN THEIR CONTACT BLOCKS. FAILURE TO
COMPLY MAY RESULT IN EQUIPMENT DAMAGE.
20. Insert one end of resistors 3R3l and 3R32 into one of their contact blocks, one
resistor at a time, applying pressure against the contact spring with the resistor and
twisting the resistor in a c1ockwisc direction. Do not twist the resistor in a
counterc1ockwise direction at any time during installation.
21. Insert a Pyrex-glass cooling-water tube over each resistor and push the tube into
its slotted hole in the resistor contact block.
22. Make sure the o-rings which seal the glass tubes are properly seated.
23. Insta1l the other resistor contact block on the other end of the assembly, being
careful not to damage the contact springs in the contact block.
24. Make sure the O-rings which seal the other ends of the g1ass tubes are properly
seated.
25. Line up the mounting holes in the contact blocks on resistors 3R3l and 3R32 with
the holes in the capacitor mounting place which is to be connected between
capacitors 3C38 and 3C329.
26. Install the mounting plate and resistor assembly on the capacitors, securing them
with 1/4-20 machine screws.
27. Mount the IPA box assembly in its position next to the power amplifier tube
socket.
28. Remove the bolts that secure the low leve1 RF shelf. This shelf is hinged in the
rear.
29. Disconnect the two filament leads from the socket, 3XV3.
30. Loosen the set screws and disconnect the two drive connector of the IPA tuned
circuit (3C19 and 3L9).
25
31. Remove the resistor/choke assembly 3R18 and 3L11, and the resistor 3R16.
32. Remove the neutralizing capacitor, C34 (the paddle connected to the feed thru
capacitor C33).
33. Raise the low level RF she1f
34. Remove the anode plate ring from the top of the boiler and lay it aside.
35. Apply a non-deteriorating heat-resistant 1ubricant, DC4 or equivalent, to al1
surfaces of the o-ring in the PA tube boiler.
36. Install the type 4CV 100,000C tube (3V3) in its boiler.
37. With the tube centered in the boiler replace the anode ring which was removed in
Step (34) of this procedure. Clamp the tube in place.
38. Carefully lower the low level RF shelf into position making sure that tube 3V3
centers and seats into its socket (3XV3) properly. It may be necessary to
reposition the boiler-blocker assembly slightly.
NOTE
It is critical that the filament contacts are centered and have equal contact
pressure. Watch for over-deflection or under-deflection of the filament contacts.
39. Replace all hardware and components which were removed previous1y in this
procedure (with the exception of the IPA servo coupling). Connect a1l
interconnecting water and air hoses in this unit.
40. Install the 4CX3.000A tube in its socket.
4l. Assemble the parasitic suppressor assembly, resistor 3R15 and inductor 3L8.
42. Install the parasitic suppressor assembly by securing the flattened end under its
clamp on power amplifier tube 3V2 and connecting the lug on the other end to the
terminal on inductor 3L9 with a machine screw.
NOTE
It may be necessary to bend the flattened end of the parasitic suppressor
assembly slightly to facilitate connection of the other end of the assembly to
inductor 3L9.
43. Carefully install the Pyrex steam line between the PA boiler and the steam
separator tank in Unit 2.
44. Install any other components removed for shipment.
45. Check all connections in the RF amplifier unit against the connections shown in
the RF amplifier Schematic 178811.
46. Confirm the following ball gaps are set as indicated:

Control Grid: 0.762mm
Screen Grid: 0.762mm
IPA Anode 1.778mm
26
2-6.5 Harmonic Filter, Unit 8.
Use the fol1owing procedure to install the harmonic filter unit:
1. Set the harmonic filter on top of the RF amplifier unit. Use the 6-1/8" coaxial
elbow (furnished with harmonic filter) to connect the transmitter output to the
harmonic filter input.
2. Install the customer furnished 6-1/8" coaxial transmission line from the harmonic
filter output to the ba1un input. Make sure that the transmission line is suitably
braced to remove the full weight of the line from the balun and harmonic filter
connections.
2-6.6 Balun, Unit 7.

Use the following Procedure to install the balun unit:
l. Mount the balun in the desired location. Connect the 6-l/8" coaxial transmission
line to the balun.
2. Connect the 300 ohm transmission line to the balun balanced output terminals.
3. If the two ba1un tuning capacitors are shipped in place, continue with Steps (4)
and (5). If the capacitors are shipped separately, continue with Steps (6) through
(l2).
4. Turn the shaft of both capacitors by hand in the clockwise direction until the
mechanical stop is encountered, then turn each shaft one-quarter turn
counterclockwise.
5. Mount the motor drive assembly on the balun. DO NOT connect the coupling
from the capacitor to the drive shaft at this time.
6. Remove the balun bottom cover plate.
7. Replace capacitors 7C1 and 7C2 in position and install their mounting screws. Do
not tighten the capacitor mounting screws at this time.
8. Turn the shaft of both capacitors by hand in the clockwise direction until the
mechanical stop is encountered, then turn each shaft one-quarter turn
counterclockwise.
9. Replace the motor drive assemb1y 7A1 making sure the capacitor shafts 1ine up
properly. Do not connect the coupling from the capacitor to the drive shaft at this
time. The motor drive shaft must be free to turn without engaging the capacitor
drive shaft.
10. Tighten the capacitor mounting bolts.
11. Replace the Balun bottom cover plate.
27
2-6.7 Modulator Power Enclosure, P/O Unit 4.
Use the fol1owing procedure to install the components which comprise the modulator
power enclosure.
l. Place all power enclosure components in their proper locations as shown in the
typical equipment layout drawing.
2. Connect all power enclosure inter-unit wiring as outlined in the inter-unit wiring
list.
2-6.8 Assembly Procedure, Unit 4.
Unit 4 contains much of the equipment associated with so1id state modu1ation and
power distribution. Schematic 178808 illustrates the electrical components and
connections of Unit 4. Units 4Al and 4A2 are identical assemblies; each assembly
contains a power supp1y transformer (T1), blower assembly (B1), an air flow switch
(S1), a wire tray for T1, 24 power switches (A1-A24), and the chassis support for A1-
A24. Units 4A3 and 4A4 are also identical assemblies and serve as ground fault
detectors. The low pass filter is comprised of L1, L2, and C1 through C6 in Unit 4.
The plate voltage of the PA is metered by use of the resistive divider R10 through R25
and R9 is a current shunt used to meter plate current. R27 is the shunt for the Plate
current overload circuit. All other components in Schematic l78808 are part of the
switch housing assembly (4A5) which is pre-assembled in the factory.
Installation of the equipment in Unit 4 should be preceded by proper installation of

the grounding system. Ground straps should be insta1led so that convenient
connections can be made to 4A1T1, 4A2T1, 4T1, the low pass fi1ter, the chassis
bases of 4A1 and 4A2 , and the switch housing assemb1y (4A5). An illustration of the
grounding system can be found in the site plans of the building in use.
Installation of Unit 4 shou1d begin with the proper p1acement and orientation of the
two power supply transformers 4A1T1 and 4A2T1. The placement and orientation of
these transformers are illustrated in the site plans and the Assembly Drawing 179476-
l. After the transformers are placed, the core of each transformer should be directly
tied to the nearest ground strap.
After the transformers have been grounded, place the chassis bases in the Proper
position with respect to the power supply transformers as shown in assembly drawing
179477-1. The chassis bases must be spaced exactly 16" apart (see assembly drawing
179476-1) and level with respect to each other. Each chassis base is supplied with two
ground pads but only one pad from each base should be tied to the nearest ground
strap. After this is done, assemb1e blower (B1) and air flow switch (S1) assemblies
and mount to the two chassis bases as shown in assembly drawing 179477- 1. Now
assemb1e the two wire trays and place over blower assemblies as shown in Assemb1y
Drawing 179477-1.
The assembly of the power columns of 4A1 and 4A2 is illustrated in Assembly
Drawing l79478-1. Begin by mounting the vertical supports. If you are using an
overhead fiber optic tray, it shou1d be mounted at this time. After this is comp1eted,
28
mount the spacer plates and the 24 power switches for both 4Al and 4A2. Verify the
correct mounting orientation of the power switches as shown in Assembly Drawing
l79476-l. After the power columns have been built, add the ground fault sensor (4A3),
the current shunt (4R9), and the PA Anode overload shunt (4R27) to the power
column (4A1) as shown in Assembly Drawing l79476-l.
The low pass filter consists of two inductors, 4L1 and 4L2, and six capacitors, 4C1
-4C6 (some capacitors may not be used, see PL179476-1 for details). The assembly of
the low pass filter is illustrated in Assembly Drawing 179476-1. After the low pass
filter is assembled, it should be mounted on top of the wire tray assembly and the
resistive divider should be added as shown in Assembly Drawing 179476-1. Confirm
the ball gap at the output of the low pass filter is set at 19.05mm.
After the low pass filter is mounted, the Switch Housing assembly (4A5) and the
distribution transformer (4T1) should be placed according to the site plan of the
building in use.
The Schematic 178808 and the appropriate wiring lists shou1d be used when wiring
Unit 4. Many of the wires have been pre-cut and numbered in the factory and should
be used as noted in the wiring list. Close attention shou1d be observed when wiring
the secondaries of 4A1T1 and 4A2T1 (which have been partially wired in the
factory). Refer to Table 2-1 and Figure 2-1 when laying these wire bund1es through
the wire tray assemb1ies.
Table 2-1 Wire Tray Assignment
29
(See Figure 2-1)
Wire # Wire Tray #
Unit 2A1
#101 through #121 Tray#3
Unit 2A2
2-6.9 Heat Exchanger, P/O Unit 5.
For installation information see the manufacturer's instruction manual located in

Section 8 of this manual.
2-7. INTER-UNIT WIRING
Table 2-5 is a list of inter-unit wiring lists for the standard Type DF50A Transmitter.
The table shows wire size and type, from and to termination points, wire lengths, and
remarks as appropriated. The required on-site wiring has been held to a minimum by
shipping most of the inter-unit wiring a1ready connected at one end and tagged with
destination information at the other end. Wire lists for options will be included in
Section 8 with the associated option equipment. To complete all wiring proceed as
follows:
l. Remove all wire duct covers both inside and on top of Control and Low Voltage
Distribution Unit l, Utility Cabinet Unit 2, and RF Amplifier Unit 3.
2. Uncoil the wire group which is shipped in Control and Low Voltage Distribution
Unit 1, lay each wire down into the wire duct, and route each wire to the
30
Destination indicated on its tag.
3. Many of the cables that connect the transmitter to various terminals in the power
enclosure are contained in a factory prepared wire harness (WL179475-5). Refer
to the Interconnect List (WL179475-3) for any wires not included in this harness.
4. Visually check all connections against the listings in the inter-unit wiring list.
2-8. INITIAL ADJUSTMENTS AND PREPARATION
2-8.1 General.
After installation and assembly, use the following procedure to turn the Type DF50A
Transmitter on for the first time:
CAUTION
IF ANY FORM OF MALFUNCTION OCCURS DURING ANY STEP OF THIS

PROCEDURE, MAKE SURE THAT THE TROUBLE IS CORRECTED BEFORE
PROCEEDING TO THE NEXT STEP. FAILURE TO COMPLY MAY RESULT IN
MISALIGNED EQUIPMENT.
1. Set all circuit breakers on the contro1 and low voltage distribution unit to their
OFF positions. Set HV circuit breaker 4CB1 to its OFF position. Set the 230
DIST circuit breaker 4CB2 to its OFF position.
2. Before applying power to the transmitter, confirm that the distribution

transformer (4T1) and the modulator transformers (4A1T1 and 4A2T1) are
tapped properly for the local 1ine voltage.
3. Apply power to the transmitter and set the 230 DIST circuit breaker 4CB2 to its
ON position.
4. Set LINE VOLTAGE switch 6S15 to each of its three positions and observe the
indications on LINE VOLTMETER meter 6M2. An indication of 230Vac5%
should be obtained.
CAUTION
BEFORE ANY CIRCUIT BREAKER ON CONTROL AND LOW VOLTAGE

DISTRIBUTION UNIT 1 IS PLACED IN THE ON POSITION, THE VOLTAGE
APPLIED TO DISTRIBUTION BUS BARS 1E1, 1E2, 1E3, AND 1E4 MUST BE
CHECKED. DAMAGE TO EQUIPMENT MAY RESULT IF THIS VOLTAGE IS
NOT WITH1N 4% OF THE VOLTAGE LISTED BY STEP (5) OF THIS
PROCEDURE.
5. Check the voltage on the distribution busses using a VOM. The following
indications should be obtained:
E1 to E4 - 115Vac
E2 to E4 - 199 Vac
31
E3 to E4 115 Vac
If these voltage indications are not obtained on the VOM, reconnect the incoming
feed lines to the bus as required.
6. Make sure a1l latch-reset relays are in the reset mode.
7. Set CONTROL circuit breaker 1CB15 to ON and check all indicator lamps to
determine that they provide the proper indications for transmitter shut-down
conditions as 1isted in Paragraph 3-1 of this technical manual.
8. Momentarily press MASTER ON switch 6S3.
9. Check the rotation of the main blower and the heat exchanger blower. Station one
man near the blower being checked and momentarily set the MAIN BLOWER
circuit breaker 1CB12 to ON then return circuit breaker to OFF. If the direction of
rotation is incorrect, reverse the connection of any two of the three ac wires
connected to the primary or the distribution transformer 4T1. Repeat this
procedure for the CONDENSER BLOWER using circuit breaker 1CB9. If the
direction of rotation is incorrect, reverse the connection of any two of the three ac
wires connected to the condenser blower. When the direction of rotation of both
blowers is correct, set MAIN BLOWER circuit breaker 1CB12 and the
CONDENSER BLOWER circuit breaker 1CB9 to ON.
10. Make sure all water valves are opened or closed as necessary for normal
operation.
11. Fill cooling system water tank to its normal operating level with high qua1ity
distilled water. The water tank should initially be filled until the water level is
25mm visible in the Pyrex header under the PA boiler.
CAUTION
CLOSE THE VALVE AT THE OUTLET OF THE BOILER PUMP. FAILURE

TO COMPLY MAY RESULT IN EQUIPMENT DAMAGE.
12. Station a man near the water pump and momentarily set the Boiler Pump circuit
breaker (1CB13) to the ON position and then turn it OFF. Check the rotation of
the pump. It is essential that the pump be energized with three phase power in the
proper phase sequence or else damage may occur to the pump. If the sequence
was incorrect then reverse the leads on the upper terminals of terminals 2 and 3 of
2TB6.
13. Turn on the Boiler Pump circuit breaker 1CB13. Partially open the outlet valve of
the Boiler Pump. Let the system fill very slowly with an ou1et pressure of about 5
psi.
NOTE
When the pump motor is energized, check the system for water leaks
immediately. Repair any water leaks before proceeding.
Do not open out1et valve more until return water pressure is noted, indicating that
32
the air has been purged from the system. At this point, continue to open the outlet
va1ve until an outlet pressure of 35-45 psi is indicated. A pressure drop of 3-5 psi
across the system should be indicated on the return pressure gauge
14. When the boiler pump has run long enough to build up pressure and the water is
flowing, BOILER WATER FLOW lamp 6DS30 should light green. At this point
all status lamps should be green and the filament contactors shou1d be energized.
CAUTION
TAPS ARE PROVIDED ON THE FILAMENT TRANSFORMER (3T4) FOR

50/60 Hz SERVICE. IF 50 Hz SERVICE IS PROVIDED, WIRE #2 SHOULD BE
CONNECTED TO TAP #10. IF 60 Hz SERVICE IS PROVIDED, WIRE #2
SHOULD BE CONNECTED TO TAP #9. FAILURE TO COMPLY MAY
RESULT IN EQUIPMENT DAMAGE.
15. Set IPA FILAMENT circuit breaker lCB2, PA FILAMENT circuit breaker lCB3,
to ON, one at a time, observing the associated filament voltage applied to each
tube on a separate ac voltmeter. Measure the filament vo1tage of each TUBE
directly at the associated tube socket.
NOTE
The IPA air switch 3S7 should trip when the access panel to the IPA socket is opened
approximately one inch. To measure IPA filament voltage open access panel, attach
voltmeter clip lead to the tube socket, and return the access panel to the closed
position. Check the various positions of FILAMENT AMMETER 6Ml2 and compare
the filament currents for IPA and PA with the typical meter readings shown in
Chapter3.
NOTE
The filament voltage applied to the type 4CX3000A tube should be 9.0 Volts. The
Type 4CV100,000C tubes require l0 Volts. The filament transformers are provided
with taps for adjustment of these filament voltages. Make any necessary adjustments
until the filament voltages measured at the respective tubes are correct.
NOTE
To extend transmitter tube life:
a. If possible, run filaments continuously. Minimize filament turn on and turn off.
b. After the tube is seasoned, reduce filament voltage as low as possible while
maintaining transmitter performance specifications (refer to the manual of the tube
factory).
16. Make sure the grounding stick is in its ho1der in the power enclosure and close
all interlocked doors. DOOR INTERLOCK lamps 6DS37 through 6DS39 should
be lighted green. Open and close all doors, one at a time, to make sure the
auxiliary interlock circuits are working. The associated DOOR INTERLOCK
lamp should change from green to yellow when each door is opened.
33
17. When a1l door interlock lamps are lighted green and PLATE DELAY RELEASE
lamp has extinguished (time delay relay 1K2l completes its timing cyc1e) set PA
BIAS SUPPLY circuit breaker 1CB7 to ON. Observe the bias voltage outputs as
indicated on BIAS VOLTMETER 6M6. If no output voltage appears on any or all
of the bias voltmeter metering positions set circuit breaker 1CB7 to OFF
immediately and check the circuit for trouble.
18. At this point bias voltage should be applied to all stages in the transmitter which
require fixed bias. Observe BIAS VOLTMETER 6M6 and compare the bias
voltages for IPA and PA with the typical meter readings shown in Section 3.
19. Remove the RG58 coaxial cab1e from the lower termina1 of 1PS6R1. Also
remove the wire from the upper terminal of lPS6TB2-10. Close the control
cabinet doors. After the STATUS lamps have lighted green, close IPA POWER
SUPPLY circuit breaker lCBl0. Press the HI VOLTAGE ON switch 6S7. The IPA
PLATE position of the HV VOLTMETER 6M8 should read as indicated in the
typical meter readings in Chapter3. Also the IPA position of the SCREEN
VOLTAGE meter 6M10 should read as indicated in Chapter3. Press the HI
VOLTAGE OFF switch. 6S8. Open circuit breaker lCBl0 and replace the two
wires on their proper terminals.
20. Confirm all overloads are set properly. Use the fol1owing procedures to set the
overload circuits. A fifteen amp (DC) power supply will be necessary to set the
overloads.
Screen Current: Refer to schematic l78803. Place the positive load of the power
Supply on a ground point and place the negative load on 2A2El9.
Adjust the slider of 2R6 so that the screen current over1oad
occurs at 3 amps.
IPA Overload: Refer to schematic l78091. Place the positive lead of the power
supply on either side of lPS6L2 and place the negative lead on
either side of 1PS6R33. Adjust the slider of 1PS6R7 and lPS6R8
so that the IPA overload occurs at 8 amps. Both sliders should be
adjusted evenly so that the ohm value of 1PS6R7 and 1PS6R8 is
equa1.
Plate Current: Refer to schematic l78808. Place the positive lead of the power
supply on the grounded end of 4R27 and place the negative load
on 4A3E1. Adjust the slider of 4R27 so that a p1ate current
overload occurs at l5 amps.
2l. Set the following breakers to ON.

IPA POWER SUPPLY lCBl0
PA SCREEN lCB8
HV 4CBl
Confirm the modulator controller (Unit 9) is powered and the four circuit
breakers on 9A10 and 9Al5 are closed.
22. Press LOWER switch for 10 seconds. Press HI VOLTAGE ON switch 6S7.
Check the PA plate voltage on HV VOLTMETER 6M8. Check the PA screen
34
voltage on SCREEN VOLTAGE meter 6M10. Both reading should be at or near 0
volts.
23. If all meter readings are normal and reasonably close to the typica1 meter
readings listed in Section 3, Press HI VOLTAGE OFF switch 6S8.
2-8.2 Final RF Amplifier Bias Adjustment.
The PA bias can be set by adjusting variable resistors 3R23. The PA bias is factory
adjusted fie1d. Resistors lPS6R1 through lPS5R4 should be adjusted to obtain an
indication of 380 Vdc (with no excitation) on BIAS VOLTMETER 6M6 with BIAS
VMMETER switch set to PA BIAS. Resistor 3R23 is then adjusted for a reading of
-600 to -880 Vdc at full carrier output when PA grid current is 0.4 to 0.87 ampere.
2-8.3 Adjustment of Servo Motor Drives.
This adjustment was performed at the factory and normally no further work is
required in the field. However, if re-alignment is required it should be done in the
following manner. The a1ignment may be performed on a lab bench or in the
transmitter. If done outside the transmitter, a 28 Vdc (6 ampere) power supply wi1l be
needed.
1. Loosen the screws of the bracket that holds the follow pot R1. and unmesh the
gears on the shaft of R1 so that the follow pot is no longer ganged to the drive. Be
careful not to lift the bracket too much so that the limit switch actuator lever will
stay properly between the arms of the switches.
2. Connect the positive and negative leads of the dc power supply to pin l and 2 of
J1. Turn the supply on, and observe if the motor drive starts running toward the
HIGH FREQUENCY position until it stops. The high frequency position is when
S2 stops the motor on the IPA, balun, PA tuning, PA 1oading, and harmonic filter
motor drives (and when S l stops the motor on the plunger motor drive). If the
motor runs in the opposite desired direction simply reverse the lead connections
to the power supply.
3. Connect a multimeter between the slider tap 2 and CW tap 3 of the follow pot R1
for the IPA, PA Tune, PA Load, Ba1un and Harmonic Filter Motor Drive, or
between the slider tap 2 and CCW tap l of the follow pot R1 for the plunger motor
drive. Turn the follow pot by hand until the desired resistance as outlined in Table
2-2 is obtained.
35
Table 2-2.Follow Pot Settings
Tuning Motor Drive Follow Pot R1 Initial Setting
IPA Plate Tank Between Slider 2 and full CC3,set to 300ohms with drive at
HIGH FREQUENCY LIMIT(S2 switched)
PA Plate Tuning Between slider 2 and full CW3, set to 320ohms with drive at
HIGH FREQUENCY LIMIT (S2 switched)
PA Plate Loading Between slider 2 and full CW3, set to 300ohms with drive
at HIGH FREQUENCY LIMIT (S2 switched)
Balun Between slider 2 and full CW3, set to 300ohms with drive at
Harmonic Filter Between slider 2 and full CW3, set to 1400ohms with drive
at HIGH FREQUENCY LIMIT (S2 switched)
Plunger Between slider 2 and full CCW1, set to 800ohms with drive at
4. Engage the gear of the follow pot to the drive shaft, making sure the drive is still
at HIGH FREQUENCY limit and the multimeter reading the correct value of
resistance. Tighten the screws on the follow pot mounting bracket. The motor
drive is now ready to be installed in the transmitter and coupled to the tuning
component.
5. If re-alignment is required while the motor drive is mounted in the transmitter. The
same procedure as outlined above is used, with the exception that the transmitter
power is used instead of an external power supply.
a. Disengage the gear of the follow pot.
b. The transmitter power should be turned ON.
c. Control circuit, tuning contro1 and tuning motors circuit breakers should be
turned ON.
d. Energize the tune button and a1low the motor to run to HIGH FREQUENCY
position. Unplug P1 from the motor drive and set the follow pot to the correct
resistance value as outlined in the above table.
NOTE
If the motor drive does not run to the HIGH MQUENCY limit after turning the
control pot in the front of the transmitter toward HIGHER numbers, simply rotate the
follow pot by hand one way or another until the motor starts running toward the
HIGH FREQUENCY position.
2-8.4 Initial Adjustment of Tuning Components.
Use the following procedure to initially adjust the motor- driven tuning components
(except the p1unger coil 3L12).
1. Loosen the set screw on the flexib1e coupling assembly on the drive shaft of each
tuning component.
2. Slide the half of the coup1ing which was secured by the set screw down the shaft
toward the tuning component.
36
3. Remove the rubber coupling spacer and lay it aside in a safe place.
4. Make sure CONTROL, TUNING CONTROL, and TUNING MOTORS circuit
breakers are closed.
5. Push Channel No. l0 select switch. Press TUNE ENABLE switch 6S1 to activate
the servo system. While keeping 6S1 pressed, turn the control pot for the selected
component toward higher numbers until the HIGH FREQUENCY limit switch is
engaged.
6. Confirm all tuning components are in their high frequency position (this should
have been done in section 2-6.)
7. Place the rubber spacer back in the coupling, s1ide the coupling halves together
and tighten the coupling set screw.
37
Table 2-3. Tuning Component Adjustments.
Tuning Motor Drive Tuning Component Initial Position
IPA Plate Tank Circuit,3A2 Capacitor 3Cl9 Set to l/4-turn from min.
capacity stop.
Inductor 3L9
Set to minimum inductance.
PA Plate tuning Circuit,3A3 3C36 and 3C37 Set both to l/4-turn from min. capacity
PA Loading Circuit,3A4 3C38 and 3C39 Set both to 1/4-turn from min. capacity.
3L13 Set 1 /4--turn from minimum inductance.
Balun Tuning Circuit,7Al 7Cl and 7C2 Set both to l/4-turn from capacity
Harmonic Fi1ter: ( Refer to harmonic filter tuning procedure.)
2-8.5 Band Switch Control Adjustment.
The band switch control is preset at the factory, but may require minor adjustments at
the field. Use the following procedure.
1. Make sure CONTROL circuit breaker, TUNING CONTROL circuit breaker and
TUNING MOTORS circuit breakers are closed.
2. Using a jumper lead, connect Tuning Control Timer, 6A2Al, pin 5 to ground. This
will energize the relay on the 28 Vdc supply and provide voltage for the Plunger
servo amplifiers.
3. Push channe1 select switch to Channe1 No.1. Set the plunger select switch
associated with Channel No. l to position No.1. This is LOW FREQUENCY
position. Refer to Table 2-4, Band Switch Control Adjustment. Adjust R1 back
plunger, R5 top plunger, and R10 front plunger of Tuning Control, 6A2, so that
the three plungers are fully engaged with the first contacts of the coil (maximum
inductance).
NOTE
A plunger is fully engaged when it is protruding 6.5mm beyond the contact ring
holder.
4. Turn the plunger select switch to position No.2, only the top plunger should
move, adjust R6 so that the upper plunger is engaged with 2 contacts.
5. Turn the plunger select switch to position No.3, only the back plunger should
move. Adjust R2 so that the back plunger is engaged with 2 contacts.
6. Continue this procedure for all 11 band positions. Refer to Table 2-4 for band
switch control adjustment.
7. After all the adjustments are performed, remove the jumper from timer board pin.
8. Push channel select switches in sequence from Channel 1 to Channel 10 and
observe the coil plungers engage in the proper contact position as outlined in
Table 2-4:
Band Position Adjustment Number of Contacts Engaged Shorted
No. resistor,6A2 Turns
Top Front Back Top Front Back
38
1 R5 R10 R1 1 1 1 0
2 R6 R10 R1 2 1 1 1
3 R6 R10 R2 2 1 2 1-1/3
4 R7 R11 R2 2 2 2 1-2/3
5 R7 R11 R2 3 2 2 2
6 R7 R11 R3 3 2 3 2-1/3
7 R8 R12 R3 3 3 3 2-2/3
8 R8 R12 R3 4 3 3 3
9 R8 R12 R4 4 3 4 3-1/3
10 R8 R13 R4 4 4 4 3-2/3
11 R9 R13 R4 5 4 4 4
NOTE: On Band 1,even though each plunger is engaged in one contact, no coil-
turns are shorted.
2-8.6 Fiber Optic Cable Termination.
Wire lists WL 179475-2 is the fiber optic cable inter-unit wiring list between Unit 4
and Unit 9. WL l79475-3 includes the optic connections for the screen supply (Unit 2)
and the ground fault sensors (4A3 and 4A4). Use the following instructions when
terminating the fiber optics associated with the ground fault sensors (wire number 51
and 52).
Note
That incorrect fiber optic terminations may result in reduced optical performance and
increased modulator noise.
1. Cut cable squarely with sharp b1ade or hot knife.
2. Strip jacket back with l8 gauge wire stripper to expose 0.l0 to 0.l8 inches of bare
fiber core. Avoid nicking the fiber core.
3. Polish the end of the optical core by first using 600 grit abrasive paper and
finishing with 3m lapping fi1m. When polishing the optical core use a figure
eight pattern to insure a proper finish.
4. Loosen the locking nut on the optic device but do not completely remove. Insert
the fiber through the locking nut and into the device until the core tip seats against
the molded lens inside the optic device.
CAUTION
DO NOT OVER-TIGHTEN THE LOCKING NUTS. FAILURE TO COMPLY MAY
RESULT IN DEGRADATION OF OPTIC PERFORMANCE.
5. Tighten the locking nut until it is just finger tight.
Termination instructions for the optic cable used with the Hewlett Packard system is
described in the Supplemental Data section of this manual.
Table 2-5 Index of Wiring Lists.
Wire List Intra-1 / Inter-2 Description
39
WL139411-3 1 Control and Low Voltage Dist Unit 1
WL139412-1 1 Amplifier Motor Control, 1A2 through 1A8
WL139412-2 1 IPA Motor Control 1A1
WL139420-7 1 400V PA Bias Power Supply 1PS5
WL139421-1 1 IPA Power Supply 1PS6
WL139423-1 1 RF Driver Supply 1PS7
WL139424-1 1 Timing Motor Power 1PS8
WL139435-2 1 Control Panel Unit 6
WL139436-1 1 Tuning Control Panel
WL139482-312-B 2 RF Amplifier to IPA box 3A9
WL139482-312-C 1 RF Amplifier Unit 3
WL139498-1 1 IPA Motor Drive,3A2
WL139544-33 1 Motor Drive PA Tune, 3A3
WL139545-36 1 Motor Drive PA Loading, 3A4
WL139546-1 1 Balun Motor Drive 7A1
WL139620-2 1 Harmonic Filter Motor Drive, 8A1
WL139965-1 1 RF Gain Control 1A9
WL154620-1-A 1 Motor Drive Band Switch Rear 3A5
WL167612-1 1 Tune Time Discriminator, 1A10
WL178838-1 1 Remote Control Unit11
WL179474-1 1 Utility Cabinet Unit2
WL179475-1 2 From Unit1 to Unit 6
WL179475-2 2 Unit 4 to Unit 9
WL179475-3 2 Interconnect List (1000 to 6000 series)
WL179475-4 2 Remote Control Interconnect List
WL179475-5 2 Unit Cable Harness
WL179476-1-A 1 Power Enclosure(Modulator), Unit4
WL179476-1-B 1 Power Stacks, Unit4-4A1 and 4A2
WL179476-1-C 1 AC Connections to Switch Modules
WL179476-1-D 1 Jumpers to Coils Between Switch Modules
40
SECTION3 - OPERATIONS
3-l. OPERATING PROCEDURES
A description of the controls and indicators are 1isted. Turn on and turn-off
procedures are outlined. Tuning curves and typical meter readings are also included.
The primary controls of the Type DF50A transmitter are located on the front of the
Control Panel Unit 6. This control panel is mounted in the upper part of the Control
and LV Distribution Unit l. The function of controls, indicators, and meters for the
transmitter are described in Tables 3-1 through 3-7. Reference Figures 3-1 through 3-
6.
41
Figure 3-1. Transmitter Control Panel, Unit6
4 5 6 7 8 9 10
2
3
11
1
12
15
13
14
16
17
26
25 18
24 19
27
23 20
22
21
42
Table 3-1 Control Panel, Unit 6, Controls and Indicators.
Index Control or
No. Indicator Function
NOT USED Ml
NOT USED M3
1. LOW LEVEL MULTIMETER M4, Indicates voltage and current as
switched and designated by LOW LEVEL
MULTIMETER switch 6S13. Scale: 0-l0
and 0-50.
2. LINE VOLTAGE meter M2, Indicates voltage as switched and
designated by LINE VOLTMETER switch
6S15. Scale: 0-300 Vac.
3. BIAS VOLTMETER M6.Indicates voltages as switched and
designated by BIAS VOLTMETER switch
6S12. Scale: 0-l000 Vdc.
4. IPA CATHODE CURRENT M5,Indicates cathode current of IPA tube
3V2. Scale: 0-1.0 adc.
5. HV VOLTMETER M8, Indicates voltage as switched and
designated by HV VOLTMETER switch
6S10. Scale: 0-3/0-15 kVdc.
6. PA GRID CURRENT M7, Indicates grid current of power
amplifier tube 3V3. Scale: 0-l.0 A
7. SCREEN VOLTMETER Ml0, Indicates voltage as switched and
designated by SCREEN VOLTAGE switch
6S11. Scale: 0-l000 Vdc.
8. PA SCREEN CURRENT M9, Indicates screen current of power
amplifier tube 3V3. Scale:1.0-0-3.0 Adc.
9. FILAMENT AMMETER Ml2, Indicates amperes as switched and designated by
FILAMENT AMMETER switch 6Sl4.
Scale:0-l00/0-500 amperes ac.
10. PA PLATE CURRENT Ml1, Indicates plate current of power
amplifier tube 3V3. Scale: 0-25 Adc.
11. INCIDENT KILOWATTS Al, Indicates transmitter power output.
Scale: 0-250 kW.
12. REFLECTED KILOWATTS A2, Indicates reflected power. Scale: 0-50
kW.
13. STATUS LAMPS
MAIN BLOWER DS29, Illuminates green when main-blower air flow is

normal. illuminates yellow when main b1ower
air flow drops below normal.
PA BOILER WATER FLOW DS30, Illuminates green when return water
flow is normal in the return line of the PA
boiler. Illuminates yellow when water flow
drops below normal.
HEAT EXCHANGER BLOWER DS31,Illuminates when the heat exchanger
cooling-air flow is normal. Illuminates yellow
when air flow drops be1ow normal.
LOW POWER DS28, Illuminates green when high power command to

modulator. I1luminates yellow when low
43
power command to modulator.
HIGH POWER DS35, 1l1uminates green when high power

command to mod. Illuminates yellow when
low power command to modulator.
SEPARATOR LOW WATER DS36. Illuminates green when water in
separator tank is normal.
ALARM Illuminates yellow to indicate water shou1d be added to
separator.
SEPARATOR LOW WATER DS37, Illuminates green when separator water 1evel
is norma1.
CUTOFF Illuminates yellow to indicate water 1evel is
be1ow safe operating level.
SEPARATOR HI WATER DS38, Illuminates green when water level in
steam separator is normal.
CUTOFF Illuminates yellow when water level increases above safe
operating level.
l4. RESET SWITCHES/LAMPS

OVERLOAD LAMP RESET S5/DS5, When pressed, switch resets overload
relays and modulator.
l5. OVERLOAD LAMPS
POWER REDUCTION DS23, Lamp illuminates green during normal
operation. Illuminates yellow when output
power has been reduced due to clipping.
MODULATOR LOAD FAULT DSl7, Lamp illuminates green during normal
operation. Illuminates yellow when a load
fau1t has been sensed by the modulator's
ground fault sensors(4A3 or 4A4).
PA CATHODE DS18, Lamp illuminates green during normal
operation. Illuminates yellow when an
overload occurs in the cathode circuit of power
amplifier tube 3V3.
IPA DS l9. Lamp illuminates green during normal
overload occurs in the cathode of IPA tube
3V2.
PA SCREEN DS20, Lamp illuminates green during normal
overload occurs in the screen circuit of the
power amplifier tube 3V3.
LOCKOUT LATCH DS22, Lamp illuminates green during normal
operation. Illuminates yellow when the
modulator's controller has shut down high
vo1tage due to faults.
LOW LATCH DS2l. Lamp illuminates green during normal
modulator's controller has reduced Output
power to the low power setting due to faults.
REFLECTOMETER CUTOFF DS l6, Lamp illuminates green during norma1
44
reflected power indicated by meter 6A3
increases to a level above the setting of the red
cutoff pointer on the meter.
16. DOOR INTERLOCK LAMPS

CONTROL & LV DIST DS24. Illuminates green when al1 doors on contro1 and
low voltage distribution are closed. Illuminates
yellow if either door is open.
UTILITY DS25, Illuminates green when al] doors on the utility unit are
closed. Illuminates yellow if one or more of
these doors is open.
RF DS26,Illuminates green when all doors on the rf amplifier unit
are closed. Illuminates yel1ow if one or more
of these doors is open.
POWER ENCLOSURE DS27. Illumil1ates green when power
enclosure door is closed and the grounding
stick is on its holder. Illuminates yellow if the
power enclosure door is open and/or the
grounding stick is not in its holder.
17. METER INPUT SELECTOR SWITCHES
LINE VOLTMETER S15, Switches LINE VOLTAGE meter, 6M2, to monitor

line voltage to all three phases of primary power
or OFF.
LOW LEVEL MULTIMETER S13, Switches LOW LEVEL MULTIMETER,
6M4, to monitor the RF AMP 50V or RF AMP
50A circuits.
BIAS VOLTMETER S12, Selects PA, IPA, voltage readings on BIAS
VOLTMETER, M6.
HV VOLTMETER S10, Switches HV VOLTMETER, 6M8,to
indicate the following high-voltage power
supply outputs: PA PLATE or IPA PLATE.
SCREEN VOLTMETER S1l. Permits selection of output switch readings
of IPA screen supply (1PS5) or PA screen supply
on SCREEN VOLTMETER. 6M10.
FILAMENT AMMETER S14, Permits selection of OFF, PA, or IPA
filament current readings on FILAMENT
AMMETER. 6M12.
18. HI VOLTAGE ON S7/DS7, When switch is momentarily pressed,
the high voltage turn-on sequence is started.
Lamp illuminates white in standby condition and
extinguishes when HI VOLTAGE ON switch is
pressed. Lamp illuminates red when high
voltage auxiliary relay 1K40 is energized.
l9. HIGH VOLTAGE OFF S8/DS8, When switch is momentarily pressed,
high voltage turn-off sequence is initiated. Lamp
illuminates white when high voltage is on and
illuminates green when high voltage is off.
20. TUNE SET CONTROLS
45
CHANNEL SELECT S6, Set to operating channel as desired. The five tuning
controls in each channel must be preset before
operation can be accomplished in the selected
channel.
IPA TUNE 6A2R10l-R110, One each 10 turn
potentiometer for each of 10 channels. Adjust
to preset position for tuning to frequency or
channel when selected. Refer to tuning curves.
PA TUNE 6A2R201-R2l0, One each l0 turn
potentiometer for each of l0 channels. Adjust
to preset position for tuning to frequency on
PA LOAD 6A2R301-R3l0, One each l0 turn
channel when selected. Refer to tuning
Curves.
BALUN 6A2R40l-R410, One each l0 turn
HARMONIC FILTER 6A2R50l-R5l0, One each l0 turn
potentiometer for each of 10 channels. Adjust
BAND SWITCH 6A2S1-S10. Set to required band, 1 through
l2. for operating frequency of channel as
selected. Refer to tuning curves.
TUNING CONTROLS
21. RF DRIVE R4, Adjusts rf output power by varying the

gain of a transmitter amplifier. Set fully CW.
22. MASTER OFF S4/DS4, When switch is momentarily pressed. Master
start relay 1K1 is returned to the reset
position, removing a1l filament and bias
voltage. (The coo1ing blowers and pumps will
not stop until holdover timer lK2 has
completed its timing cycle.) Lamp illuminates
white when relay 1Kl is latched closed
(MASTER ON). Lamp illuminates green
when relay 1Kl is in the reset position
(MASTER OFF).
23. MASTER ON S3/DS3, When switch is momentarily pressed
switch/lamp filament and bias voltage turn-on
sequence is started after master start relay 1Kl
latches.
24. TUNE ENABLE S1/DS1. When switch is held in, channel
switch/lamp tune potentiometers can be
adjusted to manually position the
correspondi11g tuning motor. Lamp
46
illuminates green normally and illuminates
white when Tune Enable switch is pressed.
25. IPA TUNE S16, When switch is in AUTO position, the IPA tuning
circuit will automatically tune the IPA to
resonance. In the MANUAL position, the
tuning must be accomplished manual1y.
26. AUDIO INPUT (attenuator) AT1. Adjusts the AUDIO INPUT level to
attenuator the modulator.
47
1 2
3 5
4 6
3 8
9
16
15 14 17 13 12 11 10
Figure 3-2 Circuit Breaker Panel, Unit 1
48
Table 3-2. Circuit Breaker Panel, Control and Distribution, Unit l, Controls and
Indicators.
Index Control or
1 PTS-040 See Supplemental Data Section 8 for PTS-040
controls and indicators description.
2 PTS 40 switch S19, Permits selection of integrated PTS-040
Synthesizer in LOCAL position or external
synthesizer in the REMOTE posi1ion.
CIRCUIT BREAKERS
3 IPA FILAMENT CB2/S7,5 ampere circuit breaker protects
primary of filament transformer 3T3. Switch
opens bias interlock circuit when circuit
breaker trips, removing bias and high voltage.
4 PA FILAMENT CB3/S8, 25 ampere circuit breaker protects
primary of filament transformer 3T4. Switch
opens bias interlock circuit when circuit
breaker trips, removing bias and high voltage.
5 PA BIAS SUPPLY CB7/S l2, 2 ampere circuit breaker protects
primary of power transformers IPS5Tl and
IPS6T3. Switch opens bias interlock circuit
when circuit breaker trips, removing bias and
high voltage.
6 RF DRIVER CB14,6 ampere circuit breaker protects the
primary of power transformer 1PS7Tl.
7 PA SCREEN SUPPLY CB8/Sl3, l0 ampere circuit breaker protects
primary of power transformer 2Tl. Switch
opens high voltage interlock circuit when
circuit breaker trips, removing high voltage.
8 BELL DISABLE S2, Switch disables water level a1arm
bel1,1DSl.
9 CABINET LIGHTS CB16, 15 ampere circuit breaker protects
cabinet illuminates and convenience outlet
circuitry.
l0 PLATE SUPPLY CONTROL CB18, 8 ampere circuit breaker protects
control voltage 1ine to PA screen supply
contactor 4K4 and HV contactor 4K1.
11 TUNING MOTORS CB17, 6 ampere circuit breaker protects the primaries
of power transformers lPS8Tl and lPS8T2 and
TUNING CONTROL.
12 TUNING CONTROL CB6,0.4 ampere circuit breaker protects the 24 Vdc
power supply for the low level tuning control
circuit.
CIRCUIT BREAKERS
l3 CONTROL CBl5, l5 ampere circuit breaker protects
control circuitry.
l4 CONDENSER BLOWER CB9, 30 ampere circuit breaker protects heat
exchanger blower motor.
l5 BOILER PUMP CB13, l0 ampere circuit breaker protects boiler
pun1p motor 2Bl.
l6 MAIN BLOWER CBl2, 20 ampere circuit breaker protects main
49
blower motor 3Bl.
l7 IPA POWER SUPPLY CB l0/S l6, 20 ampere circuit breaker protects
primary of power transformer 1PS6Tl and
lPS6T2. Switch opens high voltage interlock
circuit when circuit breaker trips, removing
high vo1tage.
l8 (Convenience Outlet ) No Ref Des.
REAR PANEL
- HV PLATE HOURS M1, Indicates total number of high voltage p1ate power
supply operating hours. Scale: 0-99999.9
hours.
- FILAMENT HOURS M2, Indicates total number of filament voltage
applied operating hours. Scale: 0-99999.9
hours.
50
FRONT VIEW
REAR VIEW
Figure 3-3. Utility Cabinet, Unit2.
51
Table 3-3. Utility Cabinet, Unit 2, Controls and
Indicators.
Index Control or
RESISTIVITY MONITOR
l WATER RESISTIVITY 2Ml, Meter displays resistivity of cooling
water continuously when system is operating.
Scale: 0 to 5 meg ohms.
MODULATOR CONTROLLER
2 (See Figures 3-4 to 3-6)
WATER SYSTEM (Rear of Unit 2)
3 WATER PRESSURE GAUGE 2MPl, Indicates the input water pressure.
Scale: 0 to 60 psi.
4 WATER PRESSURE GAUGE 2MP2, Indicates the output water pressure.
Scale: 0 to 60 pig.
5 THERMOMETER 2MP3, Indicates the inlet water temperature. Scale:
20to 240F.
Figure 3-4, Modulator Controller,9A1 and A2(optional)
52
Table 3-4. Modulator Controller, 9Al and A2 (Optional).
Index Control or
No. Indicator function
SSB Generator, A1
1 SSB CARRIER LEVEL Ten position thumb--wheel switch, selects SSB
Carrier Level.
SSB Equalization, A2:
2 SSB/AM Toggle switch; selects SSB in the up position

or AM in the down position.
Figure 3-5, Modulator Controller,9A4 and 9A5
53
Table 3-5. Modulator Controller, 9A4 and A5.
Index Control or
Audio Path,A4:
l NEG CLIP ADJUST Resistor to set negative level of clipping.
2 CLIPPER ON 2 Position ON or OFF switch to select CLIPPER.
CLIPPER OFF
3 POS CLIP ADJUST Resistor to set positive level of clipping.
4 OPERATE Lamp is OFF when modulator is on.
5 SCREEN STATUS Lamp on indicates Screen Power Supply switches are
available.
6 CCM dB REDUCTION 6 Position switch, selects CCM attenuation in 1 dB
steps.
7 SCREEN ADJUST Resistor to adjust screen supply voltage.
Power Control, A5:
8 MODULATOR INTERLOCK The modu1ator is enabled when the following five

lights are illuminated.
l. Counted fault, light blinks when a VSWR problem has been detected by the
high speed or RMS VSWR detectors.
2. Counted fault, hard wired to +24 volt supply to insure control voltage is
present in the transmitter.
3. Counted fault, light blinks when one of the modulator's two ground fault
sensors have detected a load fault.
4. Non-counted fault, light is illuminated when high voltage is switched on
and the modulator's step- start cycle is complete.
Non-counted fault, light is illuminated when the tuning cycle is complete
and grid Current is sufficient for modulator operation.
RESET Light illuminates when a reset signal has been received by the modulator
controller.
9 FAULT COUNT SELECT l0 Position thumb-wheel switch: selects allowed
number of faults with a given period of time.
54
Figure 3-6 Modulator Controller, 9A8 and A9
55
56
Table3-6 Modulator Controller, 9A8 and A9
Index Control or
Switch Status, A8(25-48):
1 25 One lamp for each switch module indicating switch is available
26
27
28
29
30
31
32
33
34
35
36
2 37 One lamp for each switch module indicating switch is available.
38
39
40
41
42
43
44
45
46
47
48
Switch Status,A9(1-24):
3 24 One lamp for each switch module indicating switch is available.
23
22
21
20
19
18
17
16
15
14
13
Switch Status, A9(1-24):-Continued
4 12 One lamp for each switch nodule indicating switch is available.
11
10
9
8
7
6
5
4
3
2
1
57
58
59
3-2. TURN-ON PROCEDURE
The Type DF50A Transmitter turn-on sequence will consist of either pretuned or new
frequency conditions. The following paragraphs describe the pretuned frequency
operation and new operating frequency procedures.
3-2.1 Pretuned Operating Frequency.
Use the following procedure to turn the Type DF50A Transmitter on and to make
minor tuning adjustments during routine day-to-day operation. This procedure is
applicable only when the transmitter has been previously operated on the desired
operating frequency and when the adjustments of the tuning components have not
been changed.
1. Make sure all circuit breakers on the front panel of Control and Low Voltage
Distribution, Unit l, are set to ON.
2. Set PA HIGH VOLTAGE circuit breaker 4CBl and 230 V DIST circuit breaker
4CB2 to ON.
3. Press MASTER ON switch 6S3 to initiate the control circuit starting sequence.
When the associated status indicator lamps illuminate yellow, the tube filament
circuitry is energized. When the filaments are energized the bias power supp1ies
are energized and the plate delay relay will begin its two minute timing cycle. At
the end of this timing cycle PLATE DELAY RELEASE lamp 6DS9 should
illuminate yellow, indicating the transmitter is ready for application of high
voltage. If PLATE DELAY RELEASE lamp 6DS9 remains extinguished instead of
illuminating yellow, one or more of the protective circuits is not in operation. In
this event, make sure all cabinet doors are securely closed and the grounding stick
is on its holder in the Power Enclosure. CONTROL and LV DIST DOOR lamp
6DS4, RF DOOR 1amp 6DS26, and MOD. POWER ENCLOSURE DOOR lamp
6DS27 should illuminate yellow if all doors are closed and the grounding stick is
in place. When the trouble is corrected, PLATE DELAY RELEASE lamp 6DS9
will illuminate yellow.
4. The transmitter has ten channels, and ten different frequencies may be pre-set. Push
the CHANNEL SELECT button corresponding to the frequency that the
transmitter is to be operated on. The tuning component servo motors and the
plunger motors will run and tune the components to the values corresponding to
that particular frequency dictated by the settings of the control pots under the
selected channels. The Frequency Setting circuit card 1Al6 will set exciter to
desired frequency.
5. Press power lower switch for about 10 seconds. Turn RF drive control 6R4
clockwise. Turn the audio input attenuator AT1 completely counterclockwise.
6. Press HIGH VOLTAGE ON switch 6S7. The PA high voltage will come on only
after all the tuning components and plunger motors have stopped running. Switch
the Auto/Manual switch (6Sl6) from the Auto position to the Manual position, and
60
back to the Auto position. This will begin a cycle that automatically tunes the IPA
circuit to resonance.
7. When PA grid current is present, start bringing up PA plate and screen voltages.
Stop at desired power output.
8. Observe the reflected power indication on REFLECTED KILOWATTS meter

6A3. With 50 kW incident power, the reflected power should not exceed 6 kW.
Normally the reflected power readings should be considerably less than 6 kW and
close to 0 kW.
9. Observe the IPA cathode current meter. For a 50 kW output it should read
between 350 mA and 600 mA. Also the PA grid current meter should read
between 450 and 650mA.
10. The transmitter should pre-position tune very accurately and no component
should require returning. If, however, any meter reading varies from the normal
values, the tuning component may be touched up by following the tuning
procedure for new frequencies outlined in the next section.
11. When the transmitter is operating and a change in frequency to a previously

selected channel is desired, perform the following:
a. Lower output slightly.
b. Push CHANNEL SELECT button for desired new frequency. The high voltage
should be muted and the tuning component motors and plunger motors should
start running toward the new position. When all motor drives are complete, set
the output level.
3-2.2 New Operating Frequency.
Use the following procedure to turn the Type DF50A Transmitter on and tune the
transmitter to a new frequency for the first time.
All tuning components in the Type DF50A Transmitter are motor driven and are
controlled from the control panel in Unit 6. Each tuned component has ten control
potentiometers associated with the component. There is one control potentiometer per
channel for each tuned component. The digital readout on the potentiometer indicates
the relative position of the tuned component. The component is tuned to the selected
frequency by setting the appropriate control potentiometer to the pot setting shown on
the associated tuning chart for the selected frequency. Once the transmitter is tuned to
a selected frequency the pot settings of the five control pots associated with each
channel should be logged and recorded for future reference. Refer to Figures 3-7
through 3-11.
61
Tab.3-8 Band Frequency Range/Band Switch
Band No. Low Freq. Limit High Freq. Limit Recommended
International
(MHz) (MHz)
Broadcast
Band(MHz)
1 3.2 4 3.2
2 3.95 5.8 3.95
3 5.8 7.0 6
4 7.0 8.0 7
5 8.0 10.0 9.5
6 10.0 12.0 11.7
7 12.0 14.0 13.6
8 14.0 17.0 15.1
9 17.0 19.0 17.7
10 19.0 22.5 21.45
11 22.5 26.1 25.6
62
Note: If a problem is encountered while tuning to any frequency, a different band may
have to be used.
63
64
To tune the transmitter to a new operating frequency, perform the following
procedure:
l. Select the desired pre-set channel on the CHANNEL SELECT switch 6S6. Set
frequency on Frequency Setting circuit card (lAl6). Also switch 6S16 into manual
position.
2. Locate the digital readout potentiometer in the column under the selected channel
number and on the row marked IPA TUNE. Refer to IPA Tuning Chart, Figure 3-
7. for the IPA TUNE pot setting at the desired frequency. Set the pot according to
this chart.
3. Locate the digital readout potentiometer in the column under the selected channe1
numbers and on the row marked PA TUNE. Refer to PA Tuning/Band Switch
Chart, Figure 3-8, for the PA TUNE pot setting at the desired frequency. Set the
pot according to this chart.
4. On the PA Tuning/Band Switch Chart note the number of the BAND listed at the
desired frequency. Set the BAND SWITCH (located at the bottom of the column
under the selected channel number) to the noted band number.
5. Locate the digital readout potentiometer in the column. Under the selected channel
number and on the row marked PA LOAD. Refer to PA Loading/Band Switch
Tuning Chart, Figure 3-9, for the PA LOAD pot setting at the desired frequency.
Set the pot according to this chart.
6. Locate the digital readout potentiometer in the column under the selected channe1
number and on the row marked BALUN. Refer to Balun Tuning Chart, Figure 3-
65
10. for the BALUN pot setting at the desired frequency. Set the pot according to
this chart.
7. Locate the digital readout potentiometer in the column under the selected channel
number and on the row marked HARMONIC FILTER. Refer to Harmonic - Filter
Tuning Chart, Figure 3-1l. for the HARMONIC FILTER pot setting at the desired
frequency. Set the pot according to this chart.
8. Make sure all circuit breakers on Control and Low Voltage Distribution Unit 1 are
set to ON.
9. Set HIGH VOLTAGE circuit breaker 4CB l and 230V DIST circuit breaker 4CB2
to ON.
l0. Press MASTER ON switch 6S3 to initiate the control circuit starting sequence.
When the associated status indicator lamps illuminate green, the tube filament
circuitry is energized. When the filaments arc energized, the bias power supplies
are energized and the plate delay relay will begin its two minute timing cycle. At
the end of this timing cycle PLATE DELAY RELEASE lamp 6DS9 should
illuminate green, indicating the transmitter is ready for application of high voltage.
If PLATE DELAY RELEASE lamp 6DS9 remains extinguished instead of
illuminated green, one or more of the protective circuits is not energized. In this
event, make sure a1l cabinet doors are securely closed and the grounding stick is
on its holder in the Power Enclosure. If a problem is encountered, while tuning to
any frequency, a different band may have to be used. CONTROL & LV DIST lamp
6DS24, MOD lamp 6DS25, RF lamp 6DS26, and MOD POWER ENCLOSURE
lamp 6DS27 should illuminate green if all doors are closed and the grounding stick
is in place.
11. Press 6S28 LOW POWER SELECT and XDS28 and XDS35 should illuminate
yellow. Press 6S39 LOWER for l0 seconds to lower power.
l2. Turn RF GAIN potentiometer 6R4 fully counterclockwise. Turn the audio input
attenuator All completely counterclockwise.
l3. Push any one of the CHANNEL SELECT buttons other than the desired channel.
Then push the button for the desired channel, This allows the timers to reset and
enables the tuning components to pre-position.
l4. Press HIGH VOLTAGE ON switch 6S7. The high voltage will come on after all
the tuning component motors have stopped running. Check the meter indications
to see if they correspond to the readings listed in Table 3-9 for low power
operation with no excitation.
15. Slowly turn the RF DRIVE control clockwise until the IPA CATHODE meter
indicates approximate]y 200 mA.
l6. Press and hold down the TUNE ENABLE switch 6Sl.
a. Select the IPA tune pot that corresponds to the operating channel. Turn the pot
slowly one way or the other to obtain a dip in the IPA cathode current meter
simu1taneously with a maximum indication on the PA grid current meter. Turn RF
66
Drive (6R4) fully clockwise then press power raise switch 6S9 until there is some
PA plate current.
b. Select the PA TUNE pot that corresponds to the operating channel. Turn the pot
slowly to obtain a dip in the indication on the PA PLATE CURRENT meter.
Simu1taneous peak indications should be obtained on PA SCREEN CURRENT
meter and INCIDENT KILOWATTS meter. All indication of 10 to 30 kW should
be obtained on INCIDENT KILOWATTS meter and a small indication of reflected
power may be obtained on REFLECTED KILOWATTS meter.
c. Select the BALUN pot that corresponds to the operating channel. Turn the pot
slowly to obtain a minimum indication on REFLECTED KILOWATTS meter.
d. Select the PA TUNE pot that corresponds to the operating channel. Turn the pot
slowly one way or the other to obtain a dip in the indication on the PA PLATE
CURRENT meter, Simultaneous peak indications should be obtained on PA
SCREEN CURRENT meter and INCIDENT KILOWATTS meter. Release the
TUNE ENABLE switch.
l7. Press 6S9 POWER RAISE until an indication of approximately 7.5 kV PA plate
voltage is obtained.
l8. Press and hold down the TUNE ENABLE switch 6Sl.
a. Select the PA TUNE pot that corresponds to the operating channel. Turn the pot
one way or the other to obtain a maximum indication on INCIDENT
KILOWATTS meter 6Al.
b. Select the BALUN pot that corresponds to the operating channel. Turn the pot
one way or the other to obtain a minimum indication on REFLECTED
KILOWATTS meter 6A3.
c. Retune the PA and readjust the PA loading as required until all indication of
approximately 30 kW is obtained on INCIDENT KILOWATTS meter 6A1 and all
other meter indications correspond to the meter readings listed in Table 3-9 for 30
kW carrier operation.
d. Press the HIGH POWER switch. The HIGH POWER and LOW POWER lamps
should both illuminate green. Press 6S9 POWER RAISE until an indication of
approximately 10 kV PA plate voltage is obtained.
e. Retune the PA and readjust the PA loading as required until an indication of
approximately 50 kW is obtained on INCIDENT KILOWATES meter 6A1 and all
other meter indications correspond to the meter readings listed in Table 3-9 for 50
kW carrier operation.
f. Switch the Auto/Manual switch (6Sl6) from the Auto position to the Manual
position, and back to the Auto position. This wil1 begin a cycle that automatically
tunes the IPA circuit to resonance. Check all meter readings.
67
Table 3-9. Typical Meter Readings.
LOW POWER 50 kW CARRIER
No 30 kW % Modulation
Meter Scale Excitation Output 0% 90% sine
Line Voltage, 6M2: (Reading depends on position of LINE VOLTMETER switch 6S l5:)
A-B 0-300 Vac 230 Vac 230 Vac 230 Vac 230 Vac
A-C 0-300 Vac 230 Vac 230 Vac 230 Vac 230 Vac
B-C 0-300 Vac 230 Vac 230 Vac 230 Vac 230 Vac
Low Level Multimeter, 6M4: (Reading depends on position of LOW LEVEL MULTIMETER
switch 6Sl3)
RF Amp V 0-30 Vdc 24 Vdc l5-24 Vdc l5-24 Vdc l5-24 Vdc
RF Amp I 0-50 Adc 0 5-l2 A 5-l2 A 5-l2 A
IPA Cathode Current, 6M5:
0-l Adc 0.l A 0.35-0.60 A 0.35-0.60 A 0.35-0 60 A
Bias Multimeter, 6M6: (Reading depends on position of BIAS VOLTMETER switch 6S12)
PA 0-2 kVdc -400 Vdc -650 Vdc -650 Vdc -650 Vdc
IPA 0-2 kVdc -600 Vdc -600 Vdc -600 Vdc -600 Vdc
PA Grid Current, 6M7:
0-lA 0 0.45-0.65A 0.45-0.65A 0.45-0.65A
HV Voltmeter, 6M8: (Reading depends on position of HV VOLTMETER switch 6S10)
PA 0-l5kVdc 0 7.5 kVdc 10 kVdc 10.kVdc
IPA 0-15 kVdc 4.0 kVdc 4.0 kVdc 4.0 kVdc 4.0 kVdc
PA Screen Current. 6M9:
-l/0/3Adc 0 l.0 A 1.3 A 1,5 A
Screen Voltmeter, 6Ml0:(Reading depends on position of SCREEN VOLT34ETER switch 6S11 )
PA 0-2 kVdc 0 450-600 Vdc 600-700 Vdc 600-700 Vdc
IPA 0-2 kVdc -500 Vdc -500 Vdc -500 Vdc -500 Vdc
PA Plate Current. 6M11:
0-25 A 0 4.5 A 5-6 A 5-6 A
Filament Ammeter, 6Ml2 (Reading depends on position of FILAMENT AMMETER switch 6Sl4)
PA 0-500 Aac 280 Aac 280 Aac 280 Aac 280 Aac
IPA 0-100 Aac 37 Aac 37 Aac 37 Aac 37 Aac
l These readings are typical and vary slightly between transmitters.

2 Small variations between phases is normal.
3.Varies slightly with tubes age, different line voltage, operating frequency, exciter
drive level, etc.
3-3. CONTROLLED CARRIER-LEVEL MODULATION

Controlled Carrier-level Modulator (CCM), a standard feature of the DF50A,
maintains the carrier level at a sufficient level to be 100% modulated by the incoming
audio. With the CCM system enabled and setup correctly. The carrier level will fall to
a preset level in the absence of modulation, and rise to a level compatible with the
instantaneous peak level of the program audio. The level to which the carrier will be
reduced is adjustable in 1dB steps from 0 to 6 dB.
3-3.1 CCM Setup.
Use the following procedure when setting up and enabling the CCM function of the
DF50A broadcast transmitter
68
1. Confirm the CCM is disabled by adjusting the CCM knob (on the front panel of
the 9A4) to 0 dB.
2. With the transmitter operating at rated power, set the input audio level so that
100% modulation is achieved on program peaks.
3. Set the CCM knob (on 9A4)to the desired attenuation level.
3-4. CLIPPER OPERATION
A protective clipper circuit has been incorporated into the solid-state modulator. We
highly recommends that this circuit be enabled at all times and adjusted to allow a
maximum of l00% modulation. Correctly adjusted, this circuit will have no
measurable influence during normal operation. It will, however. Protect the
modu1ator during inadvertent overdrive conditions.
3-4.1 Clipper Setup
The following procedure will allow the clippers to be adjusted without High Vo1tage
or Master On enabled.
Refer to Schematic PF2.810.6000DL, Audio Path. Place the Audio Path (9A4) circuit
board on an extender card and apply power to the modulator controller (Unit 9).
Confirm the CCM control knob is set to 0 dB on the front pane1 of the 9A4 and your
audio source is turned off. Place your scope probe at U28 pin l. This point is the
summation or DC plus audio and at this time you should measure approximately 5.l
Volts DC.
Adjust your scope so that you can measure modu1ation levels. Turn your clipper off
and add a l kHz test tone. Set the level of the tone to l00% modulation (your peak to
peak voltage should be double the DC vo1tage you measured previously, about l0.2
volts). Turn on the clipper and adjust R97 and R1l2 (these are adjusted through the
front panel of 9A4) until the desired clipping 1evel is reached (l00%).
Test the clipper by increasing the audio level beyond the l00% level. The test tone
should clip (flatten) at the 100% level. The clipping levels ca11 be fine tuned with the
transmitter operating at rated power.
3-5. TURN-OFF TRANSMITTER
3-5.l Normal Turn-Off.
Use the following procedure to shut the transmitter down during normal operation.
l. Press HIGH VOLTAGE OFF switch 6S8. HIGH VOLTAGE OFF lamp 6DS8
should illuminate green.
NOTE
To extend transmitter tube life:
l). If possible, run filaments continuously. Minimize filament turn on and turn off.
69
2). After the tube is seasoned, reduce filament voltage as low as possible while
maintaining transmitter performance specifications (refer to EIMAC
Application Bulletin No.18 located in Supplementary Data section of this
manual).
2. If it is desired to turn off the filaments, Press MASTER OFF switch 6S4. MASTER
OFF lamp 6DS4 should illuminate green. After the filaments have been shut off
the b1owers and water pump will continue to operate for several minutes.
3. After cooling hold-over time delay relay 1K2 has comp1eted its timing cyc1e, the
blowers and water pump will shut off. Set the HIGH VOLTAGE circuit breaker
4CBl and 230 V DIST circuit breaker 4CB2 to their OFF positions if it is desirable
to shut down all transmitter primary power.
3-5.2 Emergency Shutdown, Limited.
Use the following procedure to quickly shut the transmitter down in case of arcing or
fires.
l. Press HIGH VOLTAGE OFF switch 6S8, HIGH VOLTAGE OFF lump 6DS8
2. Press MASTER OFF switch 6S4. MASTER OFF lamp 6DS4 should illuminate
green.
NOTE
The cooling system pump and blower motors will remain energized until cooling hold
over time delay relay lK2 completes its timing cycle.
3-5.3 Emergency Shutdown, Complete.
Use the following procedure to quickly shut the transmitter down in case of serious
water leaks or when it is necessary to remove all power.
l. Press the HIGH VOLTAGE OFF switch 6S8. HIGH VOLTAGE OFF lamp 6DS8
2. Set CONTROL circuit breaker lCBl5 to OFF.
3. If all primary Power must be removed from the transmitter circuitry, set HIGH
VOLTAGE circuit breaker 4CBl and 230V DIST circuit breaker 4CB2 to OFF.
70
SECTION 4 - THEORY OF OPERATION
4-1. GENERAL
The Type DF50A Transmitter is genera1 represented by Figure 4-1. Type DF50A, HF,
Broadcast Transmitter Block Diagram. The radio frequency circuits and their
associated power and protective equipment are illustrated in this diagram. The
interrelations of the power control and protective functions are also shown.
4-2. RF CIRCUITS
Any synthesizer capable of operating within the transmitter's frequency range and
producing an output of l Vrms can be used as an exciter for the Type DF50A
Transmitter. The transmitter RF input impedance is 50 ohms. The signal from the
exciter is amplified in three stages to an RF output 1evel of 50 kW.
71
4-2.l Solid State Amplifier, 3Al.
An appropriate Amp1ifier is used as the broadband amplifier for the DF50A

Transmitter. Refer to Supplemental Data for the description of the Amplifier and the
schematic.
4-2.2 Intermediate Power Amplifier (IPA).
Refer to Schematic Diagram l788ll for the following discussion. The 2nd RF
amplifier, IPA, utilizes a type 4CX3,000A ceramic tetrode tube, V2. The tube is a
forced air-cooled ceramic and metal electron tube which is used in a grounded screen
circuit. This configuration provides a flat broadband load for the solid state amplifier
and requires no neutralization.
The IPA plate tuning circuit is a conventional parallel tank which is capacitive
coupled by C2l to the control grid of the final RF power amplifier.
The RF tube amplifier chain is shown in the Figure of RF chain.
4.2.2.1 AC Circuit
1. The IPA cathode is driven by SSA via coupling capacitor C22 and C25 due to
grounded control grid. L2, C23 and C25 due to grounded control grid. L2, C23
and C24 prevent the filament power supply from RF interference.
2. The control grid is at RF ground level through C2~C9.
3. The screen grid is directly grounded for more efficient shielding.
4. The plate tank circuit consists of C19, L9, C21(block C), C in(input C of PA), and
C33(feed thru C) to form a resonant circuit.
5. For Uk=Ua+Ug, SSA drives not only IPA, but also directly 1/2 UgIa1, therefore
the load of SSA is quiet heavy.
4-2.2.2 Anti-Parasitic-Oscillation Measures
1. Low input impedance of grounded-grid (Rin=Ug/Ie1). This can suppress the

fundamental and low frequencies parasitic oscillation.
2. The grounded grid circuit is more effective to the shielding between plate and
grid.
3. Low impedance provides the SSA a flat broadband load, and simplifies the
compensation techniques of the SSA.
4. R13(220) is paralleled with Rin. Even if IPA is open (such as filament broken ),
a fixed load is still existing.
5. All R11, R12 and R16 as well as R17 paralleled RFC and connected resistor in
series are called SWAMPED circuits preventing RFC oscillations.
6. Prevention for VHF oscillation
72
A parallel circuit of R15(50) and L8(0.01uH) added at IPA plate is used for suppress
the VHF parasitic oscillation. Its structure is movable. A copper bar of 0.01uH
inserting in a magnetic tube(a 50carbon resistor outside the tube) combine together.
L8 presents a short circuit during operating frequency band. But its inductance will be
large while VHF band, and must be paralleled with R15; then their resulting
impedances will be resistive to suppress the VHF oscillation.
4.2.2.3 DC Circuit
See Fig. 4-4
1. Because the screen is grounded, so the negative terminal of Eg2(500v)is connected

to the cathode and positive one to ground.
2. The grid bias Eg=-500V. Its +is connected to the cathode, -to the control grid.
The voltage between control grid and cathode will be 650v when the grid bias
voltage is applied.
3. The plate voltage is Ea=4kv(between the plate and ground). For the sake of the
cathode at 500 Vdc, so the actual plate-cathode voltage is 4500V.
4-2.3 Power Amplifier (PA).
Refer to Schematic Diagram l78811 for the following discussion. The RF Power
amplifier utilizes a single type 4CV100,000C vapor-Phase-cooled ceramic tetrode
tube, V3.
The PA requires an RF drive level of approximately 500W at the higher frequencies
and approximately 250 watts at the lower frequencies within the frequency range of
the transmitter. The grid circuit of the PA stage is swamped to prevent cross-over
resonances of RF chokes in either resonant or anti--resonant modes.
73
The PA is neutralized with a Bruene (bridge) circuit for tetrodes. The neutralization is
broadband and requires adjustment only when the PA tube is replaced. The screen grid
of the PA tube is bypassed with a special low inductance capacitive socket which
effective1y keeps the screen at RF ground maintaining broadband neutralization and
unconditionally stable operation.
The PA stage is high-1evel modulated. Modulating voltages are applied directly to the
plate to provide modulating voltages in correct proportion for both the plate and
screen elements.
The screen grid of the PA is self-modulated which improves performance at the
modulation crest. Self modulation of the control grid is achieved by inserting a
resistor between the grid and the PA bias supply.
4-2.4 Output Network.
Refer to Schematic Diagram 1788l1 for the following discussion. The output network
is a - network. All elements are continuously adjustable with the exception of the
tank coil. The tank coil is band switched in eleven bands to cover the frequency
range of the transmitter, 3.6 to 22 MHz. The bands of operation are chosen to provide
optimum operating Q. The tank coil and-loading capacitors are water cooled.
The impedance level at the output of the-is 75 Ohms. A directional coupler is
provided at the output terminals of the-network to provide measurements of
incident and reflected power on the 75 Ohms coaxial feeder line. The accuracy of
these power measurements after factory calibration is 15%. The power levels are
presented on INCIDENT KILOWATTS meter 6A1 and REFLECTED KILOWATTS
meter 6A2 on Contro1 Pane1, Unit 6.
74
4-2.5 Harmonic Filter, Unit 8.
Refer to schematic l25384. The harmonic filter consists of two series connected
networks. Both of these are 75 Ohms, 90 degree, lagging networks. The center
capacitor of the harmonic filter (C2) is the combined capacitance for the input
capacitor of one network and the output capacitor of the second network. The
reactance of each or the filter inductors (L1 and L2) at resonance is +75 Ohms. The
reactance of input and output capacitors (C3 and C1 ) at resonance is -75 Ohms. The
reactance of the center capacitor (C2) is -37.5 Ohms.
The harmonics filtering of -network is not well enough, such as only 40 dB for the
second harmonic. So the Tx employs a harmonics filter to meet the specifications
requirements and to filter the VHF for a harmonics radiation less than 50 mW. This
filter is actually a T network consisting of 2 butting sections of 90 network, as
shown in Fig. 4-6. C1=C3=C, C2=2C, and L1 as well as L2, totaling 5 components,
are adjusted at the same time. The operating frequency band is 3.6~22MHz. Among
the band any frequency can be preset.
Due to the Q of the load is 1 and the low circuit voltage, and the harmonics filter is
preset at a certain frequency (being not a load adjusting equipment) therefore the filter
is not used to improve the VSWR after presetting at wanted frequency.
All elements of the harmonic filter are ganged together so that tune simultaneously.
The capacity of the center arm capacitor increases twice as rapidly as the input and
output capacitors. The harmonic filter is aligned in the factory and a calibration table
is attached to the cover. The numbers on the calibration table refer to the counter on
the harmonic filter's servo assembly. These counter numbers are reflected to operating
75
frequencies.
4-2.6 Balun Network, Unit 7.
Refer to Schematic Diagram 125385 for the following discussion. A 4:1 semi-
broadband balun is supplied with the Type DF50A Transmitter to provide a 300
ba1anced output.
The balun is tuned by motor-driven capacitors C1 and C2 which arc controlled from
Control Panel, (Unit 6, on the front panel of Control and Low Voltage Distribution,
Unit 1.) The directional coupler at the output of the-network permits adjustment of
the balun for minimum ref1ected power. The balun is capable of working into a
VSWR of 2: l. The insertion VSWR of the balun is unity.
4-3. BAND SWITCHING CIRCUITRY
The band switching circuitry consists of control circuitry in Unit 6A2. drive-motor
assemblies 3A5, 3A6, and 3A7, and inductor 3Ll2 with its associated shorting
plungers.
In general, band switching is accomplished by changing the inductance of inductor

3Ll2 by increasing or reducing the number of turns of the inductor which are shorted
by one or more of the three shorting plungers. The relative position of these plungers
for a specific frequency range is controlled by the BAND SWITCH selector switch
for each channel in Unit 6A2. The three drive motor assemblies 3A5, 3A6 and 3A7,
position the associated plungers to the preset position which corresponds to the band
se1ected. When the active channel BAND SWITCH selector switch is set to position
l, all three plungers are extracted from inductor 3Ll2, connecting the entire inductor in
the circuit. With the se1ector switch in positions 2 through 10 an increasing number of
turns on inductor 3Ll2 are shored in l/3 increments. In position 11. all three plungers
are fully extended into inductor 3L12 (shorting the entire inductor).
4-4. MODULATOR
The modulator is a solid state unit which provides high level pulse width
modulation(PWM) to the PA stage. The modulator consist of a modulator controller
assembly, a HV control unit, 48 digitally controlled power switches, a low- pass
fi1ter, and fiber optic control signal system.
4.4.1 Modulator Controller. Unit 9.
CAUTION
FAILURE OF PERSONNEL TO FOLLOW APPROVED ESD PROCEDURES MAY
RESULT IN DAMAGE TO MOS TYPE DEVICES. SEE PARAGRAPH VIII IN
THE SAFETY SLMMARY SECTION OF THE MANUAL
Control of the solid state modulator is performed by the Modulator Controller, Unit 9.
This controller includes a card cage assembly and various printed wiring boards
associated with modulator control. Included are status indications for each modulator
power switch, inter-lock, and overall operational status. Refer to Figure 4-2,
Modulator Controller B1ock Diagram. The controller receives program audio inputs
and external commands, processes them and controls the operations of the forty-eight
76
individual power switches in the modulator. The following paragraphs will describe
each of the controller circuit cards.
77
Figure4-8, Unit9, A4 Audio Path Board
78
Figure 4-9 Simplified Troubleshooting Block
Diagram.
79
4-4.1.1 SSB Generator, A1(Option 1)
See Section 8, Tab l for Single Sideband Option.
4.4.1.2 SSB Equalization, A2.(Option 1)
See Section 8, Tab l for Single Sideband Option.
4-4.1.3 Noise Reduction, A3.
The Noise Reduction Board, A3, is used to reduce any of the residual power line hum
components that may appear on the unmodulated carrier. This is accomplished by
utilizing feedback to cancel out low frequency noise components.
Refer to Schematic 175772. Power for the audio path board is regulated to +l5 volts
by VR1 and to -15 volts by VR2. Decoupling from the +24 volt bus is provided by R1
and C1. Decoupling from the -24 volt bus is provided by R24 and C22. Power supply
bypassing is provided by C2, C21. And various distributed capacitors. Diodes CR1
and CRl0 protect their respective voltage regulators from reverse voltages.
A demodulated sample of the PA anode is connected to P2-l6 and P2-l7. This signal is
further filtered and attenuated by R15, R16, Rl7. and C16. Diode CR2 through CR5
are clamping diodes to protect the inputs of differential amplifier U4. The output of
U4 is passed through a 2 kHz low pass filter and amplified by U3A. The output (U3-l)
is coup1ed to mu1tiplier U2 and integrator-U3B. The integrator is fed back to the
reference connections of U4. This configuration permits dc blocking as well as
nul1ing the dc offset of the output of U4. With the dc component removed, the input
signal to mu1tip1ier U2 wil1 be a demodulated replica of the PA anode voltage.
At P2-27 and P2-29, a sample of the audio signal is fed to differential amplifier U6.
The output of this amplifier is tied to a pair of comparators (U5A and B). These
comparators serve as audio detectors. If audio is present, the output of U5 will pull
low to 0V. If there is no audio present, the output of U5 is pulled up by R5 to a
voltage set by potentiometer R6. The U5 output is low pass filtered, buffered, and
forms the second input to multiplier U2.
Therefore, the product of multiplier U2 will be either a gain controlled replica of the
PA anode voltage (if audio is not present), or 0 V (if audio is present), The product of
this multiplier is then routed to the audio path board where it is summed with the
modulation signal in such a way as to be out of phase with the original rf signal.
4.4.4.1.4 Audio Path, A4.
The audio path board has two modes of operation, the AM mode and the SSB mode.
The audio path board is used to pre-process incoming audio in preparation for the
f1ash converter. Functions that the audio path provides include:
l. Peak clipping
2. Bandwidth limiting
3. Time and amplitude equa1ization of Low Pass Filter
4. Carrier insertion including Controlled Carrier Modulation
6. Screen power supply control
80
Refer to Schematic PF2.810.6000DL. Power for the audio path board is regulated to
+l5 volts by VR1 and to -l5 volts by VR2.Decoupling from the +24 volt bus is
provided by Rl28 and C14. Decoupling from the -24 volt bus is provided by R1l0 and
C80. Power supply bypassing is provided by C15, C79, and various distributed
capacitors. Diodes CR3 and CR9 protect their respective voltage regulators from
reverse voltages.
NOTE
The incoming audio is connected to P2-22 and P2-23. These connections are
routed (through the backplane) from the input/output card.
The USB connection is used to faci1itate rapid changing between Single-Sideband

(SSB) and regular Amplitude Modulation (AM) operations. Device U26 is an
operationa1 amplifier (Op-Amp) with internal resistor networks to configure it as a
differential amplifier. The output (U26-6) is coupled to integrator U25B and
associated components. The integrator is fed back to the reference connections of
U26. This configuration permits dc blocking as well as nulling the dc offset of the
output of U26. From this point on the entire audio circuitry is dc coupled. Device
U25A, Rl06, and jumper J1 are used to set the gain of the system. The gain of the
system determines what audio input 1evel corresponds to l00% modulation. Device
U24 is a Bessel filter that is used to set the high frequency response of the overall
system. Device U27 and associated circuitry is used as a peak clipper. This clipper
should be set to protect the transmitter from over modulation. Transistor Q7 is used to
mute the audio when the transmitter is in the TUNE mode.
NOTE
The TUNE mode of operation is used in auto tune transmitters only.
Devices U23B and U28B are time and amplitude equalizers respectively. They are
used to correct for errors in time and amplitude that may occur in the post modu1ator
low-pass filter. Device U28A is a summing amplifier that wil1 sum the audio with the
output of the Hum Reduction board, and a dc component that represents the carrier.
The dc voltage that represents the carrier is derived from R1, R2, and U1A. This
voltage is typically 2.5 volts and is routed through bilateral switch U2 to R6 for
normal AM operations. For Controlled Carrier Modulation conditions U2 connects R6
to R4, or R5, or open to vary the carrier level to follow the variable modu1ation
conditions. Comparator U3A compares the voltage of U28A out with the voltage
present at R27. If the negative peak of U28A goes more negative than the voltage at
R27, U3A will switch to 1ogic one. This logic state will cause switch U2 to close the
connection between R4 and R6. At the same time, timer U4 will be triggered. When
U4 is active the connection between R5 and R6 wi1l be open. The voltage at R5 is
determined by the Position of S1 and determines the maximum amount of carrier
reduction. When various levels of negative modulation peaks occur, the variable duty
cycle of switch U2 will maintain the negative most peak of U28A output to be
consistent with the level that represents 90% negative modulation at full carrier level.
The audio signal is now summed with a dc component that represents the carrier. The
amplitude of this signal is 5 volts average and 10 vo1ts peak. It is constant regardless
of the output power of the transmitter. The output Power is varied by multip1ying this
"audio plus dc" with a voltage that is derived within the power control board. The
81
multip1ication takes p1ace within U29. The output of U29 is equal to: (Vy*(Vz/10),
Where Vy is the "audio plus dc", and Vz is the power control voltage. Potentiometer
R120 allows a fraction of the "audio plus dc" to be app1ied to Vz. This will cause a
second harmonic to occur which is useful in correcting distortions that may occur
within the transmitter. Potentiometer R1l9 allows adjustment of the output offset of
U29. The output of U29 is summed with a triangu1ar wave by U30 and is now the
drive signal for the flash converter.
The triangle wave that is necessary for proper digitization is produced, refer to
Schematic PF2.810.6000DL. The "audio plus dc" is fed into N1 where it is passed
through dc blocking capacitor Cl08. This signa1 is fu1l-wave rectified by U38B and
associated components. This rectified signal is summed with a dc voltage, set by
R152, at summing amplifier U38A. Device U39A and its associated components
create a random noise signal which is summed with the output of U38A. These three
combined signals are fed into the frequency modulation input of function generator
U37.
This dc voltage will set the quiescent frequency of the triang1e wave while the noise
signal will randomly modulate the triangle wave's frequency. The rectified signal will
vary the triangle wave's frequency according to the modulation amplitude and
frequency. The triangle wave output of U37 is coupled into multiplier U36 where it is
mu1tiplied by a control signal which originated from the 48 status sum signal on the
audio path board. This function allows the triang1e wave's output to be amplitude
modulated according to available power supply voltage.
The clock signal required to drive the flash converter and the ring modulator cards
82
also originates from the function generator U37. Typically, the function generator's
quiescent output frequency is approximately 70 kHz. The square wave at U37-9 is
divided by 7 by divider U35 and fed into the phase comparator input of phase lock
loop U31. Device U32, U33, and U34 divides the voltage controlled oscillator's
output by 225 and feeds the second phase comparator input at U31-3. In this manner,
a 2.25 MHz square wave is developed at N. This square wave is related to the triangle
wave, although not harmonica1ly, by a factor of 32.l4.
The 48 status sum signal originates from the status cards, A8 and A9, and is connected
to P1-2 through the backplane. This signal is the summation of 48 variable frequency
pulses with each pulse train representing the voltage available on one of each of the
48 power switches. Since this signal is the Sum of 48 non-related pulses the spectrum
will tend to have a lot of trash around the frequency of the pulses.
Components Ul2A, R14, R15, R52, C13, C29, and C30 form a Bessel filter to remove
the switching spectrum and yet maintain a minimum of delay. The output of Ul2A is
routed to the f1ash converter and is used as the reference voltage for the analog-to-
digita1 conversion (ADC). This provides for the self regulation properties of the
modulator. Transistor Q2 and associated components provide a minimum reference
voltage in case the 48 status Sum should disappear.
Another function of the audio path board is to provide signals for the proper
functioning of the screen voltage regulator. Since the screen voltage should always
track the plate voltage, this is a most appropriate place for the control. Status signals
from the two screen regulator circuit boards arrive on pins P1-23 and P1-25. These
signals provide information as to the operational status of the individual cards. As
explained in the Theory of Operation for the switch module status cards, U14
demodulates the frequency modulated information. Device U10 and associated
circuitry perform the low-pass filtering to derive a replica of the total available power
supply voltage. A sample of the "audio plus dc" is divided by R20 and is divided by
R37 and Cl9. The resulting voltage is representative of the average dc plate voltage.
This average voltage is processed in U1l with the voltage from U10A being the
control voltage, much the same as U29. The output of U11 is compared with a triangle
wave from Ul5. Because the output of Ul5 is offset by 5 volts, R47 is provided to
offset the output of U11 by the same voltage. The output of Ul6 is the typical Pulse
Width Modulated (PWM) wave form that controls both of the screen regu1ator power
switches.
4-4.l.5 Power Control, A5.
The power control board is used to determine if the modulator should be operating,
and at what power level. Multiple signals that are made available from the
input/output board are used to determine operational status. This description will be
broken down into three basic stages:
1. operational status,
2. power level selected,
3. actual required operating power.
Refer to schematic 179088.
83
Power for the power control board is regulated to + l5 Volts by VR2, +5 Volts by
VR1. and -l5 Volts by VR3. Decoupling from the +24 Volts bus is provided by R4l
and C4. Decoupling from the -24 Volts bus is provided by R42 and C6. Power Supply
bypassing is provided by C1, C2, C3, and multiple distributed capacitors. Diodes
CR1, CR2, and CR3 protect their respective voltage regu1ators from reverse voltages.
4.4.4.1.5.1 Operation Status
Refer to Sheet 2 of Schematic l79088 and note that there are six operational status
inputs. All of these signals are routed through the backplane from the input/output
board. There are three basic operational status signa1s.
a. Fault (Control l, Control 2, HV DC Overload)
b. Non-Fault (Control 3, Control 4)
c. Reset
If all interlock conditions are met, the five control inputs will provide a logic zero to
the inputs of U2A and U3A and the modulator will be enabled by the operate bus (P2-
32). At this condition the operate bus wi11 be 1ogic one. When a logic one appears at
any one of the NOR Gate inputs, the modulator will immediately cease operation. The
modulator is shut-down by a 1ogic zero at the operate bus (P2-32). The operate bus is
made available to various control boards through the backplane. Device U1 is a one-
shot pulse generator that will "stretch" the pulse from the fault input. The purpose of
stretching the pulse is to keep the modulator off for approximate1y 300ms after a fault
has occurred. In addition to muting the modulator, the pulse will be counted to
determine if too many faults are occurring. This will be explained later in "power
level selected." The non-fault inputs wi1l on]y mute the modulator. The reset input
will cause the modulator to return to normal operational status shou1d there be a 1ow
power or lockout latch (to be explained 1ater). There is also a power up reset that is
performed when power is first applied to the power supply board. The power-up reset
function is performed by C28, CR4, and R49.
4.4.4.1.5.2. Power Level Selection
The power control board receives three power 1evel select commands to determine
whether the modulator will be operating at HIGH, LOW, or TUNE power levels. The
HIGH or LOW power levels are selected by U9 and Ul0 respectively. Jumper J1 can
be used to automatica1ly select HIGH or LOW power upon a reset command. It is
recommended that the jumper be placed across pins l-2 to always start out at the LOW
power level. Latch U26-B remembers the power leve1 that was last selected. As
mentioned previously the number of faults that occur are counted. The counting
process occurs within U30 and U3l. Device U30 is a divide by l0 counter that
provides access to a1l l0 of the counter stages. Device U31 is a timer circuit that will
reset U30 back to zero after the time delay. Upon the first fault command that is
received from pulse stretcher U1, U3l starts a timing period and U30 counts to one. If
no other faults are received, U3l will time out and reset U30 to zero. If additional
faults are received within the U31 time period, U30 will advance one additional count
for each fault occurrence. Switch S1 selects outputs one through nine of U30 to
correspond to faults one through nine. If the modulator is operating at HIGH power,
and a number of faults equal to the selection of S1 occurs, the modulator will be
84
forced to operate at LOW power. This condition is known as LOW POWER LATCH.
Once in the LOW POWER LATCH mode the modulator can only be returned to
normal operation by actuation of the reset control.
The same situation can occur when the modulator is operating at the LOW power
mode, either LOW POWER or LOW POWER LATCH. If a number of faults occurs,
equal to the number selected by S1. The modulator will shut off. This condition is
known as LOCKOUT LATCH. Once in LOCKOUT LATCH the modulator will not
operate until actuation of the reset control. Devices U31B and U32 are pulse
generators that will reset U31A (and thus reset U30) any time that there is a toggle
between HIGH and LOW power.
4.4.4.1.5.3. Practical Required Operating Power
It must be remembered that HIGH and LOW are on1y generic terms when relating to
operating power with this modulator. Typica1ly "High Power" is set to the maximum
rated carrier power of the transmitter. "Low Power" is then usually one half (-3 dB) of
the maximum rated carrier power. However the power levels are set, "Low Power"
should always be lower than "High Power". The actual operating power of the
modulator is determined by a variable dc voltage that is multiplied with an audio + dc
signal that is processed within the audio path board. This variable dc voltage is
generated within the power control board. There are three individual voltages that are
generated to represent TUNE. LOW, and HIGH power.
NOTE
TUNE POWER is only used in fully automatic tuned transmitters.
This description will be based on the circuitry that generates the voltage that
determines HIGH POWER. Rl2 and R59 form a voltage divider that drives buffer
amplifier U21. R59 is used to set the maximum plate voltage in the HIGH POWER
mode. The output of U2l applies a reference voltage to U18-3. Device U18 is an
electronic potentiometer that divides the voltage that is applied across pins 3 and 6
into 100 equal steps. The electronic potentiometer is actually a counter circuit with a
memory and electronic switches connected to a l0l resistor divider circuit. The
potentiometer wiper is controlled by the signals that are present on pins 1, 2, and 7.
U18 is enabled by a logic zero at pin l. Two conditions must exist to enable U18. The
first condition is the High power state must be active, and the second condition is a
Raise or Lower command must be active (reference U16 pins 5 and 6). The up/down
input at pin 2 is controlled by the Raise and Lower commands. When a Raise or
Lower command is given, the potentiometer's wiper moves at a 9 Hz rate. This 9 Hz
originates from U24 which is a 555 timer operating in an astable mode. The output of
electronic potentiometer is se1ected and routed to the Audio Path board by switch
U23.
4.4.4.1.6 Flash Converter. A6.
The f1ash converter converts composite audio (audio plus dc Plus triangle wave)
From the audio path board to a 48 level digitized signal using a parallel conversion
method. Refer to schematic l79903.
85
Power for the flash converter is regulated to + l5 volts by VR1, and to +5 volts by
VR2. Resistor Rl4, R76, capacitors C1l and C4l provide decoup1ing from the
unregulated +24 volt supp1y. Capacitors C10, C42, and various 0.1 f and l0 f
capacitors provide local power supply bypassing. Voltage regulators VR1 and VR2
are protected from reverse voltage conditions by CR1 and CR2.
Reference for the analog-to-digital conversion (A/D) is developed in the audio path
board. For highest noise immunity the reference source (P1A12) and return (P1-Al4)
both originate from within the audio path board. This reference not only sets the gain
of the modulator, but can also be used for noise and distortion reduction. Since each
comparator in the flash converter must have a different reference voltage, a voltage
divider is created with a string of 20 Ohm resistors. Since the vo1tage across the total
voltage divider is approximate1y l0 volts, each of the 20 Ohm resistors provides a
voltage drop of approximate1y 208 mV. Thus each of the voltage comparators has a
unique reference voltage differing on1y 208 mV from an immediate1y adjacent
comparator.
The audio to be digitized (composite audio), that is processed on the audio path board,
is made available on P2- A26. This composite audio is parallel connected to the
inverting input of each of the 48 comparators, For any given comparator, if the
reference voltage is more positive than the composite audio, the comparator output
will be logic one. If the reference voltage is more negative than the composite audio,
86
the comparator output will be logic zero. The output of the comparator is of an open
collector type, thus requiring a 1 K pull-up resistor for each comparator. Each of the
48 comparator outputs is further buffered by a Schmidt trigger inverter. The purpose
of the buffering is to provide a l0w impedance source, for both logic one and logic
zero, to the input of the following latch stage.
For the ring modulator to function properly it is important that the signal from the
f1ash converter does not change when an address conversion is being made. This is
comparable to the sample-and-hold circuitry that is used in other types of ADCs. The
only difference is that this sample-and-hold circuitry is digital. Each of the 48,
buffered, comparator outputs has an individual latch. A digital latch is a one bit
memory device that transfers the logic level that is present on it's input to the output
when commanded to by the edge of a clock signal. If the input logic level changes the
output will not change until the next clock edge. The synchronizing clock is generated
on the audio path board and is routed to both the flash converter, and the ring
modulator. The incoming clock signal is buffered and inverted by U24. The inputs to
U24 are protected from external transients by CR2, CR3, R70, and R77.
The outputs from the 48 latches are now summed to create a zero to five volt rep1ica
of what the modulator output should be. This summing action is accomplished by
connecting the output of the 48 latches to a common node with l0 K resistors. This
summing point should be viewed as the center tap of a variable voltage divider that is
connected between a five volt source and ground. This voltage divider has one resistor
(RA) connected from the plus five volt supply to the common node. Another resistor
(RB) is connected from the common node to ground. The value of RA is determined
by the number of latches (parallel l0 Kresistors) at logic one (5 volts). The value of
RB is determined by the number of latches (parallel l0K resistors) at logic zero
(ground). The result of this variable voltage divider is 48 discrete voltage steps from
zero to five volts. The zero to five volt modulator signal is routed to the ring
modulator board through P1-C32.
4-4.1.7 Ring Modulator, A7.
The Ring Modulator, A7, is an address rotation circuit that performs a controlled but
varying sequence determining which comparator operates which power switch. Each
of the 48 comparators from the flash converter could directly drive one of the 48
power switches. The problem with the f1ash converter directly driving the power
switches is that not all of the power switches would be equally used. This would result
in unequal heating and life distribution of the power switches.
The instantaneous voltage output of the modu1ator is a function of the number of

active switches. Not which switches are active. The ring modulator receives the
commands from the f1ash converter and signals the correct number of power switches
to operate.
The output of the flash converter is 2.5 Volt peak-to-peak signal representing what the
output of the modulator should be. Just like the output of the modulator. This low
level signal also has 48 discrete levels. Each level is representative of the number of
power switches that are to be operating. It is the job of the ring modulator to
accurately fol1ow the the number of ON switches" while simultaneously using all
power switches equally.
87
Through a process of comparing the present f1ash converter output to the present ring
modulator output a determination is made to subtract a switch, remain the same, or
add a switch. This decision making process occurs at a greater than 2 MHz rate that is
determined by the master clock located on the clock modification board. The master
clock is divided into two phases, phase one latches both the flash converter, and the
ring modulator, to a specific output. A comparison is made between the summed
output of both the flash converter and the ring modulator. This comparison will
determine if the ring modulator has the same number of output levels as the flash
converter.
The determination of which power switch is to be turned on or off is made on the

principle of First-On-First-Off (FOFO). FOFO can be likened to a long conveyor bell.
The first item that is placed on the conveyor will be the first item available at the end
of the conveyor. When a power switch is turned on its address is placed on the
conveyor belt. When a command to turn a power switch off is received, the first
address that is received at the end of the conveyor bell is the module that is turned off.
When that module is turned off its address is placed on a different conveyor belt. That
conveyor belt now contains the address information of the power switches that can be
turned on. When a command to turn on a power switch is received, the address that is
at the far end of the conveyor is the power switch that is turned on. In this
configuration the module that is about to be turned on is the module that has been off
the longest. Conversely the modu1e that is about to be turned off is the module that
has been on the longest.
Refer to schematic 179906 for a detailed description of the Ring Modulator circuit.
Power for the ring modulator is regulated to + l2 volts by VR3, +5 volts by VR2, and
-l2 volts by Vr1. Resistor Rl9 and capacitor C45 provide decoupling from the
unregulated +24 volt supply while resistor R6 and capacitor C35 provide decoupling
from the unregulated -24 volt supply. Voltage regulators VR1, VR2, and VR3 are
protected from reverse voltage conditions by CR4, CR5, and CR6.
Device U49 is an operational amplifier which compares the Flash Sum (Pl-32) to the
Ring Sum ("Z", sheet 3, zone Al. A3, A5, and A6). The Ring Sum is an indication of
how many power switches have been commanded on. This signal should be a delayed
replica of the Flash Sum. The purpose of U49 is to determine if a switch should be
added, subtracted, or if no change should take place.
If the f1ash sum is at a higher voltage than the ring sum, a positive voltage will be
present at the output of U49. If this voltage is greater than 50 mV, the output of
comparator U46 (pin 11) will go to a logic 1. This logic l will be passed through the
D-Type flip-flop U44 at the next clock pu1se and the point labeled "Y" will go to a
logic 1.
If the flash sum is at a lower voltage than the ring sum, a negative voltage will be
present at the output of U49. If this voltage is more negative than -50 mV, the output
of comparator U47 (pin 11) will go to a logic l. This logic l will be passed through the
D-Type flip-flop U44 at the next clock pulse and the point labeled "X" will go to a
logic 1.
Whenever point "Y" or "X" goes to a logic 1, the combination of U5l.R16, and C4l
send a c1ear pulse to U44. This clears the output of U44 to a logic 0 which forms a
pulse at "Y" or "X". In this manner, the signals at the points labeled "Y" and "X"
88
become clock signals for "turn on a switch" and "turn off a switch" respectively.
Schematic 179906 sheet 2 illustrates the shift registers used in the Ring Modulator.
Devices U1. U15, U29. U52, U66, and U80 form a 48 bit shift register driven by the
"Y" (turn on a switch) clock. A single bit (Logic l ) is rotated through this 48 bit shift
register. The 48 outputs of this shift register drive the "J" inputs of 48 J-K f1ip-f1ops
shown on Schematic l79906 sheet 3. A second 48 bit shift register, which is driven by
the "X" (turn on a switch) clock, is formed by U2, Ul6, U30, U53, U67 and U81. A
single bit is also rotated through this 48 bit shift register. The 48 outputs of this shift
register drive the "K" inputs of the 48 J-K f1ip-f1ops already mentioned.
Each of these 48 J-K f1ip-f1ops are responsible for driving a particular power switch.
If the rotating bit of the "turn on a switch" shift register is in the J1 (U80-3) position, a
logic 1 will drive the "J" input (pin 7) of U85 (sheet 3, zone A2). This will cause U85-
9 and U87-l0 to go to a logic l. If the #l power switch is operational, a logic l
(originating from the status board) will be present at P2-C27 and U87-9. This will
allow output U87-8 and P2-A27 to go to a logic 1. This results in turning on the #l
power switch because P2- A27 is routed to the fiber optic transmitter that controls this
power switch. This power switch will remain on until the hit rotating through the
"turn off a switch" shift register reaches the K1 (U8l-3) position. Notice on sheet 3
that the Ring Sum "Z" is derived by resistively summing the outputs of the 48 AND
gates. This Ring Sum, which was discussed earlier, is fed back to U49 and compared
to the Flash Sum.
As an example, let us assume the modu1ator is operating with three switches on and
one switch pulsewidth modulating. This means that three comparators on the flash
converter card are on and a fourth comparator is switching on and off. At the
beginning of our example, let's assume that the fourth comparator is off and power
switch #2, 3, and 4 are on. This means that the rotating bit is at the J4 position on the
"turn on a switch" shift register and that the other rotating bit is at the K1 position on
the "turn off a switch" shift register. This also means that the voltage at the Ring Sum
should be approximately equal to the Flash Sum (312 millivolts) and the output of
comparator U49 is close to 0 Volts.
At this point, the fourth comparator on the flash converter card turns on and the f1ash
sum increases in voltage to approximately 4l6 millivolts. This voltage is compared to
the ring sum by differential amplifier U49. Because the flash sum voltage is now
greater than the ring sum voltage by 104 millivolts, the output of U49 becomes + l04
millivolts. This voltage at U49-6 is compared to the 50 millivolt reference at U46-4
and the output of U46 is pulled high by R5 to a logic l. This logic l at U46-11 causes a
pulse on the "turn on a switch" clock and increments the rotating bit to the J5 position
on the "turn on the switch" shift register. A logic l at the "J" input of the #5 J-K flip-
l1op will cause its output (U84- l2) to go to a logic l. If the Status 5 input (P2--C23) is
also a logic 1, AND gate output U86-8 will go high and turn on switch # 5. Note that
when U86-8 goes high, the ring sum voltage will increase by approximately 104
millivolts. At this point, power switch #2, 3. 4, and 5 are on and the ring sum voltage
equa1s the f1ash Sum voltage of 4l6 millivo1ts. As time continues in our example, a
point is reached when the fourth comparator on the flash converter card turns off and
the flash sum voltage drops 3l2 millivolts. This voltage is compared to the 4l6
millivolts of the ring sum by differential amplifier U49. The output of U49 (pin 6)
becomes -l04 millivolts which causes U47-11 to go to a logic 1. This logic l forms a
pulse on the "turn off a switch" clock and increments the rotating to the K2 position of
89
the "turn off a switch" shift register. The logic 1 at the "K" input of the #2 J-K f1ip-
f1op will cause U85-l2 and U87-l1 to go to a logic 0 and turn off switch #2. At this
point, power switch #3, 4, and 5 are on and the ring sum voltage equals the flash sum
voltage of 3l2 millivolts.
In the examp1e discussed above, note that eventually all switches will be used
equally. Also note that if a switch was not available, the corresponding status input
from the status card would be a logic 0 and the AND gate on the ring modulator card
for that specific switch would be disabled.
When the ring modulator tries to use this defective switch, the ring Sum would not
increase by l04 millivolts. At the next master clock cycle, the Ring Modulator wou1d
turn on the next switch in line and effectively bypass the detective switch.
4-4.l.8 Status, A8 and A9.
The power switch status card provides information as to whether or not a switch is
available for use and how much that switch can contribute to the output. This helps
the ring modulator to bypass an unavailable power switch and the f1ash converter to
compensate for power supply variations. There are two identica1 power switch status
cards each supervising 24 power switches. A variable frequency digital signal is
coupled from the fiber optic receivers card. This signal is generated on a switch
control card and represents the amount of dc voltage that is across that power switch's
dc storage capacitor. The digital signal is a frequency modulated signal that can vary
from a few hertz to about 38 kHz. This frequency variation is directly related to the
voltage range of 0 to 750 volts dc that is available from that particular power switch.
Refer to Schematic 179938 for a detailed description of the status card. The +l5 vo1t
power for the switch module status board is provided by voltage regulator Vr1.
Resistor R63, R124, and capacitor C67 provide decoupling from the unregulated +24
volt bus. On-board power supply bypassing is provided by various 0.lf and l0 f
capacitors, Voltage regulator Vr1 is protected from reverse voltage conditions by CR1.
There are 24 identical pu1se count detectors on the switch module status board. A
pulse count detector is a form of a frequency modulation detector. This description
will make reference to one of these pulse count detectors. Device U2 is one half of a
556 dual timer. The 556 is configured to produce an output pulse each time the trigger
input (U2-8) is switched low. The input pulse (from the optical receivers board is
connected to the board through Pl-A4 and Pl-C4, and is ac coupled by Rl0, C11 and
R9. The output pu1se width of U2 is determined by R6 and C7. The pulse width is
equal to (1,1 *R6 * C7) about 11 s. Initially U2-l2 and U2-l3 are held low. When an
output pulse is received, the output (U2-9) goes high and R6 starts to charge C7.
When C7 has charged to +10 volts the output (U2-9) will go low and C7 will be
discharged. This constant width pulse is generated each time that U2 is triggered by
an optical receiver.
The output of the pulse count detector is thus a constant width pulse at a variable
frequency. This combination of constant on-time with variable off-time results in a
variable pu1se width signal. Just like a pu1se width modulation signal, this variable
pulse width signal can be low-pass filtered to extract the modulation of the variable
frequency input signal (U2-8). The low-pass fi1ter is comprised of R17 and C2l. The
output of the low-pass filter (U4-7 and Ul-6) is a dc voltage that is representative of
90
the dc voltage that is available from that particular power switch. A voltage divider
comprising of R6l and R62 provides a 2.3 volt reference for voltage comparators U1
and U4. If the voltage from low-pass filter R17 and C2l is greater than 2.3 volts, the
output of U1 wil1 be low and LED DS1 will be illuminated. At the same time the
output of U4 will be a logic one. A pul1-up resistor located on the ring modulator will
provide a logic one level of +5 volts. This condition indicates that the power switch is
available for use. If the voltage from 1ow-pass filter Rl7 and C2l is less than 2.3 vo1ts
the output of U1 will be high and LED DS1 will be dark. At the same time the output
of U4 wi1l be a logic zero indicating to the ring modulator that the power switch is
not available for use.
If the vo1tage from low-pass filter Rl7 and C2l is added to the low-pass filtered
voltage from the other 47 switches, a replica of the total availab1e modu1ator voltage
wi11 be formed. This same total available modulator voltage can be formed by adding
the pulses from the 48 individua1 pulse count detectors and then low--pass filtering.
This summing action is accomplished by connecting the output of each of the 48
pu1se count detectors l0 a common node by a l0 k resistor. This "48 Status sum" is
connected to Pl-A2 and Pl-C2, and is routed to the audio path board through the
backplane. The low-pass filtering is now performed on the audio path board for use as
the reference for the flash convertor board.
4.4.4.1.9 Power Supply, A10 and A15.
The power supply is a simple linear ac to dc converter. Refer to Schematic 179894.

AC power. 115Vac, provided from the host transmitter, is connected to TB1 pins 1 and
2. Circuit breakers CB1 and CB2 are l ampere, used for over current protection. They
can a1so be used as on/off switches for the modulator contro1ler by pulling up on the
buttons. Transformers T1 through T4 are 24 volt, 0.5 ampere step-down transformers.
Transformers T1 through T3 are used for +24 Volts and T4 is used for -24 Volts. Ful1-
wave bridge rectifiers U1 through U3 convert ac to +24 Volts dc, and perform a diode
"O-Ring" of the three power supplies. Capacitors C1 through C6 provide ripple
filtering. The output of T4 is rectified to -24Volts dc by U4. Ripple filtering is
provided by C7 and C8. Since the positive and negative power supplies are
unregulated, they may acquire an unusually high potential if they are unloaded. To
prevent this high voltage from damaging components, a high voltage clamp is
provided. On the +24 Volts supply, zener diodes VR1, VR2, and VR3 provide a 30
Volts reference for resistors R1, R2, and R3. Regulator VR4 and R4 provide
protection to the -24 Volts supply. Any time that the unregulated voltage becomes
greater than 30 Vo1ts. Current will start to flow and thus load the power supply.
The voltages on both the positive and negative power supplies are unregulated and
will typically vary from +24 Volts to +30 Volts, this is normal.
4-4.1.l0 Input output, A11.
The input/output card serves as an interface between the modulator controller and the
outside world. The e1ectrica1 connections of the input/output card are illustrated in
Schematic l81540.
The input output card is powered by a regulated l5 volt power supply. This supply
consists of current limiting resistor R47, a l5 volt regu1ator VR1, a reverse voltage
protection diode CRl4 and energy storage capacitors C42 and C43. Four interlock
91
connections are provided and are denoted as Control l, Control 2, Control 3 and
Control 4. All four interlocks require a 24 Volts signal at TB l-5, -7, -9, and -11 and a
24 Volts return at TBl-6. -8, - l0, and -l2 for the modulator to be enabled for operation.
The controller is also interlocked by two ground fault sensors. When one of these
ground fault sensors detects a short circuit, an optic signal is transmitted to a
corresponding fiber optic receiver (U4 or U5) and its output goes low. This low output
signal triggers a monostable multivibrator (U1 ) at pins 5 and 11, and causes an output
pulse at Ul-6 and Ul-l0. The output pulse at pin 6 temporarily disables the modulator
from operation and the output at pin 9 turns on Q2 and pu1ls TB3-7 low for
monitoring the ground fault. The inputs denoted as High, Low and Tune are all
adjustable power levels for the modulator. A temporary 24 Volt signal applied across
TB2-3 and 4 will set the modulator at the high power level. Likewise, a temporary 24
Volt signal applied across TB2-5 and 6 will set a low power level. Unlike the high and
low power levels, the tune power level is only achieved as long as a 24 Vo1t signal is
applied across TBl-l3 and l4. All three of these power levels are adjustable by the
power raise input across TB2-7 and 8, and the power lower input across TB2-9 and l0.
The status of the modulator controller can be monitored through terminals on the
input output card. All of the status circuit operate by going low and sinking current
from a monitoring source. These status circuits inc1ude the following:
A. High Power at TB3-l E Low Power at TB3-2
B. Fault Timer at TB3 3 F. Low Power Lockout at TB3-4
C. Lockout Latch at TB3-5 G Power Reduction at TB3-6
D. HVPS Status at TB3-7 H Operate Bus at TB3-9
The reset for the latches of the power control board is applied by a temporary 24 Volt
signal at TB2-ll and a return at TB2-l2, and the controlled carrier modulation can be
defeated by a 24 Volt signal at TB3-l0 and a return at TB3- 11. The (Optional) SSB
operation of the modu1ator is enab1ed by a 24 volt signal at TB2-1 and a return at
TB2-2. A connection for SSB GND 2 is located at TB3-l2 and Coaxial connections
for 2 MHz Out B. l00 kHz Out B, 100 kHz Phase Out, and l0 MHz reference are
located at P3, P4, P5, and P6 respectively. The audio path boards' inputs for external
levels B, W, and T are located at TB4-l. 2, and 3. The input terminals for the USB
audio signal are 1ocated at TBl-3 and 4, and the LSB audio signal are found at TB1-l
and 2. Each of the audio input circuits contain a low pass filter with -3 dB of
attenuation at approximately l00 kHz.
The control signal for the PA screen supply is optically transmitted by DS1 and DS2.
When the screen supply is to be turned on, Pl-C27 is pulled high by R46 (assuming
the operate bus is high) and turns on Q1. With Q1 turned on, R43 and R44 are pulled
low and optic signals are transmitted by DS1 and DS2. When the screen supply is to
be turned off, an audio path board circuit will pu1l-down R46 and turn off Q1.
consequently tuning off the fiber optic transmitters. The status signals of the two
power switches of the screen supply are converted from optic signals to electrical
signals by the fiber optic receivers U2 and U3.
4-4.1.11 Optical Transmitter, A12.
The fiber optic transmitter card converts electrical signals from the ring modulator
card into optical signals. These signals control the operation of the 48 power switches.
The electrical connections of the optical transmitter card are illustrated in Schematic
l8l530.
92
The optical transmitter card is powered by two regu1ated 5 Volt power supplies, PS1
and PS2. These two supplies are independent and each powers a separate half of the
circuit. The outputs of these supplies (+5VA and +5VB) must not be connected
together. The outputs of both power supplies are monitored to confirm that the voltage
is sufficient to properly drive the fiber optic transmitters. Since both of these circuits
are identical, the circuit that monitors the +5VA output will be discussed (Refer to
sheet l. zone B7). Zener diode Vr1 provides a 2.5 Volt reference to pins 2 and 5 of
comparator U43. If the voltage provided by PS1 (+5VA) remains above
approximately 4 volts, the output of comparator U43-A (pin l ) will remain high. This
output is app1ied to pin 6 of U43 and compared to the 2.5 volts at pin 5. The result is
a logic 0 at pin 7 and at the gate of transistor Q7. When a logic 0 is applied to the gate
of Q7, the transistor will conduct and allow the operate Bus (P2-A32/C32) to enable
the fit1er optic transmitters. If the voltage provided by PS1 drops below 4 volts, both
comparators will change states and the transistor Q7 will no longer conduct. When
this occurs, the fiber optic transmitters are disabled by pulling the operate Bus low.
A high on the operate Bus enables the fiber optic transmitters by providing l5 volts to
the gates of Ql-Q6 (only when Q7 and Q8 are conducting). The l5 volts at the gates of
these transistors cause them to conduct and provide a path to ground for the 48 fiber
optic circuits. If the operate Bus is disabled (Pulled low), the optical transmitters are
immediately muted.
Each of the 48 identical fiber optic circuits is controlled by a11 output of the ring
modulator circuit. A logic l from the ring modulator drives an individual circuit and
causes current to flow through the fiber optic transmitter. This current is converted
into an optical signal which will turn on a power switch.
4.4.4.1.12 Optical Receiver, A13.
The optical receiver card converts optical signals from the 48 power switches into
electrical signals for use by the switch module status board.
These optical signals carry information concerning the status of the individua1 power
switches. The electrical connections of the optical receiver card are illustrated in
Schematic l82533. The optical receiver card is powered by a regulated 5 Volt power
supply. This supply includes a current limiting resistor R1, power Supply PS1, bypass
capacitor C50 and the energy storage capacitors C49 and C50. The circuit card
contains 48 identical circuits reserved for a specific power switch. Each circuit is
provided with a bypass capacitor which is tied to the power supp1y at pin 3 of the
optic receiver. When an optical signal is received, the output at pin l pulls down a
3,300 Ohm resistor located on the status card and delivers a logic 1ow output. When
the optica1 signal disappears, the output is pulled up and a logic high is delivered.
4-4.l.13 Backplane, A14.
The modulator contro1ler's backplane serves as a11 interface between the thirteen
cards (Al-Al3) of the modulator controller. Schematic l79275 illustrates all traces) that
exist on the backplane. Each trace is given a specific name which describes the signa1
applied to it. This name is duplicated at the signal's origin and at all points where it
terminates. For example, the CLOCK signal originates at the audio path board at
A4P2J8-A1,C1, and connects to the power control board at A5P2Jl0-A1,Cl,the f1ash
converter board at A6P2Jl2-Al,Cl,and the ring modulator board at A7 P2Jl4-Al, C1.
93
Although a trace may be connected to a contro1 card, the card does not necessarily
use that signal. For example, the CLOCK signal is connected to the power control
board which does not use the CLOCK signal.
4-4.2 Synthesizer, Modified (Option l).
4-4.2.l SSB Phase Modulator, 1A15A1 (Option 1).
4-4.3 Switch Housing Assembly, 4A5.
Refer to Schematic Diagram l78808 and l78484 for the following discussion. The
high voltage (HV) control unit includes two three phase contactors, and three resistors
in a step-start(or soft-start) configuration. This unit controls the application of the
three phase high voltage to the modulator primaries. The step start sequence provides
a gradual charging of the modulator power switch modu1e capacitors and of the
modulator transformer magnetization currents through current limiting resistors. After
the modulator capacitors are charged and the transformers are magnetized,
the current limiting resistors are shorted by the second vacuum contactor. Prior to the
application of high voltage, the following conditions exist:
l. 115 Vac (to neutral) is present at TB2-l2. This originates from the 1El bus bar via
the P1ate Supply breaker lCB180.
2. 1l5 Vac (to neutral) is present at TB2-20. This originates from the lE3 bus bar via
the Control breaker lCB15.
3. Neutral is present at TB2-l5.
4. 24 Vdc is present at TB2-2l.
5. ll5 Vac (to neutral) is present at TB2-16. This originates from the lE3 bus bar via
the Control breaker lCBl5 and several interlocks. These interlocks include:
a. The external dummy load interlock.
b. The plate delay aux. relay lK16.
c. The bias supp1y relay lK2l.
d. The IPA circuit breaker's (lCBl0) auxiliary switch lS16.
e. The Screen circuit breaker's (lCB8) auxiliary switch 1S13.
f. The HV latch lK22.
When the HV latch (lK22) is energized, the plate auxiliary re1ay (lK23) is energized
and ll5 Vac is applied to TB2-ll and l9. At the same time, K11 is energized and the
vacuum contactor K1 is enabled in the standby mode. Relay Kl1 provides high speed
control to open the contacts of vacuum contactor K1 if the high voltage interlock is
lost for any reason. The l15 Vac at TB2-1l energizes pilot relay K10. This causes time
delay relay K9 to energize, its contacts 1 and 3 to close, and begin its 5 second timing
cycle. The closure of contacts l and 3 of K9 allows 230 Vac to be applied across the
coi1s of K2 and K13 and energizes these contactors. Relay K2 is the surge contactor
for the modulator and K13 is the surge contactor for the screen. These contactors
94
allow their respective supplies to charge via current limiting resistors. When the
auxiliary contact of K2 closes, voltage is applied to the coil of time delay relay K12
and a 2 second timing cycle begins. After a 2 second period, the contacts of K12 close
and 230 Vac is applied across the coils of contactor K4 and vacuum contactor K1.
Relay K4 is the contactor for the screen supply and K1 is the contactor for the
modulator. The current limiting resistors for both the screen and modulator are
shorted when these contactors energize. When the auxiliary contacts of K1 c1ose, the
24 Vdc at TB2-2l is applied to TB2-10 and the modulator is enabled. 1 second 1ater
the timing cycle of K9 ends and its contacts open. This de-energizes surge contactors
K2 and K13 and the surge resistors are removed from the high voltage circuit.
When the HV latch is de-energized, the l15 Vac at TB2-l9 is removed and the
contactors K1 and K4 immediately open. This removes high voltage from the
modulator and screen supplies.
4-4.4 Modulator.
WARNING
HIGH VOLTAGE HAZARD ACCESS TO HIGH VOLTAGE AREAS ARE

PROTECTED BY ELECTRICAL INTER LOCKS. DO NOT DISABLE
INTERLOCK CIRCUITS. FAILURE TO COMPLY MAY RESULT IN SERIOUS
INJURY OR DEATH. HIGH VOLTAGES ARE CONTAINED WITHIN THE
MODULATOR POWER ENCLOSURE,UNIT 4. BEFORE SERVICING
MODULATOR, REMOVE HIGH VOLTAGE BY OPENING THE HIGH VOLTAGE
CIRCUIT BREAKER (4A5CBl), ALLOW SUFFICIENT TIME FOR CAPACITOR
DISCHARGE, AND USE GROUND STICK ON ALL COMPONENTS WITHIN
THE MODULATOR. FAILURE TO COMPLY MAY RESULT IN DEATH OR
SERIOUS INJURY.
Refer to Schematic Diagram 178808 for the following discussion. The Modulator,
Unit 4 employs a series of 48 solid state switching power modules, each contributing
approximately 500 Volts to the total anode voltage. As the required anode voltage
rises and falls, the number of modules contributing to the total anode voltage is
increased or decreased as required. Pulse-width modu1ation (PWM) techniques are
used to smooth the transition as modules are added and removed. Each of the modules
is controlled through fiber-optic lines from the Modulator Controller, Unit 9. During
normal carrier operation at 50 kW carrier output, the dc anode voltage is
approximately 10kV. Program audio waveforms are superimposed on the dc voltage
by circuits within the modulator controller. Adjusting the anode voltage from the
modulator will smoothly vary the transmitter from no output to the ful1 rated rf
output.
The modulator is organized as two assemblies, designated 4Al and 4A2, each with a
power transformer, 24 power switch modules in two 12 module power columns, an
associated blower and control wiring. The two modulator assemblies are connected in
series to form a complete 48 module unit. The output from the modules is then fed
through the low pass fi1ter assembly and then to the transmitter PA anode circuit.
Ground fault sensors 4A3 and 4A4 sense any overcurrent conditions and furnish a
fault signal to the modulator controller for rapid shutdown of the modulator. Each
modulator power switch module includes a power switch control assembly which
monitors the input and output voltages of the power switch and controls it's turn-on
95
and turn-off Control of the power switch modules is accomplished through two fiber-
optic cables to each power switch control from Modulator Controller Assembly, Unit
9.
4-4.4.1 Power Switch.
The power switch is a pulse width modulating unit which is capable of switching
frequencies up to l0 kHz and delivering an average of l kW of power to its load. The
power switch can supply a 500V pulse with rise and fall times less than 400 ns. Forty-
eight power switches are used in a series configuration to form a 50 or 75 kW solid
state modulator. Schematic l79900 illustrates the electrical connections of the power
switch.
The power switch is powered by a 3-Phasc 500 Vrms source at El, E2, and E3.
Varistors RV1, RV2, and RV3 are voltage sensitive resistors which protect the power
switch from transients on the power line. Three phase, full-wave. rectification is
achieved by use of the 3 dual diode modules CR2, CR4, and CR6. Energy storage of
the rectified output is accomplished by C3 and C4. The resistors R3 and R4 serve as
bleeders for these capacitors and DS1 is an indication of the voltage on the capacitors
for maintenance situations. The transformers T1 and T2 are step-down transformers
which supply two isolated power Supplies on A1 with l2 Vrms.
Transistor Q1 is a dual Isolated Gate Bipolar Transistor (IGBT) device. Both

transistors are rated for Vcc 1,000 Vdc and Ic = 50 amperes continuous. The
transistor whose collector is indicated as pin 3 is referred to as the ac transistor and
the second transistor whose collector is indicated as pin l is referred to as the dc
transistor. The gates of both transistors are loaded by resistors R8 and R9; and
protected by transient suppressing diodes CR7 and CR9 and clamping diodes CR8
and CRl0. Each gate is controlled by the Power Switch Control Card, Al. Assembly
Number l81535-1. The ac transistor supplies 500V to the dc transistor under normal
operation of the power switch; and the dc transistor switches this 500 V to form the
output pulse of the power switch.
Diode CR11 serves as a backswing diode and is located across the output of the power
switch. This diode is rated for a reverse bias of 1,000 Vdc, a forward current of 50
96
amperes, and a reverse recovery time of l00 ns. The backswing diode allows the
power switches to be series connected and allows the load current of the modulator to
bypass a power switch that is not turned on.
The power switch is capable of detecting internal problems and removing itself from
the solid state modulator's circuit. If the dc transistor fails in the short circuit or open
circuit mode, a phase detector circuit on card A1 will recognize this problem and turn
off the ac transistor. By turning off the ac transistor, the defective power switch will
be removed from the modulator's circuit. This removal will also be recognized by the
modulator controller and the detective switch will be bypassed by the controller. If
there is a short circuit at the output of the power switch, an increased voltage will be
developed across the resistive wires between E4 through El1. This increased voltage
will turn on an opto-isolator on A1 through resistors R5 and R6, which wil1 turn off
the dc transistor. If this short circuit persists, the phase detector circuit wil1 be
triggered and the power switch wi1l be removed from the modulators circuit.
Resistors R12 and R13 are part of a voltage to frequency converting circuit on card
A1 and resistors R9, Rl0, and R1l are part of the phase detector circuit mentioned
earlier.
4-4.4.2 Power Switch Control.
The power switch control(Assembly Drawing 181535-1), is a sub-assembly of the

power switch (Assembly Drawing l79899-2), which was discussed earlier. The switch
control communicates with the modulator controller through fiber optic cables and
controls the operation of the power switch. Schematic 18l536 il1ustrates the electrical
connections of the power switch control.
The power switch consists of two isolated circuits, each of which has its own power
supply and ground plane. The first circuit, referred to as the ac control, drives the gate
of the ac transistor on the power switch. Because the ground of this circuit is tied to
the emitter of the ac transistor, it will sit at a potential of 500V (with respect to the
power switch's ground) during normal operation. The second circuit, referred to as the
dc control, drives the gate of the dc transistor on the power switch. The ground of this
circuit is tied to the emitter of the dc transistor, which switches between 0 and 500V
during normal operation. Therefore, it can be seen that the two isolated circuits may
attain a potential difference of 500V during the standard operation of the power
switch.
The AC control circuit is powered by a l2 Vdc power supply. This power supply
consists of a full- wave rectifier CR6, a voltage regulator VR2, two voltage reference
resistors R9 and Rl0, and three storage capacitors C1, C2, and C3. When power is
first applied to the power switch control, the voltage at pin 5 of comparator U2 will
charge up exponentially to a level of 6 Vdc because of R1, R2, and C4. As this
voltage exceeds the zener diode's (Vr1 ) voltage of 5.1 Vdc, the comparator's output
will go high. The output of this comparator drives the "set" input of a NAND R/S
latch (U4). The RC network of R4 and C8 drive the "reset" input of this 1atch.
Because the RC time constant of R4 and C8 charges up slower than that of R2 and
C4, the latch will reset and its output wi1l go low. This causes the outputs of U5 to go
high, which drive the gate of the ac transistor on the power switch. When the gate of
the ac transistor is driven, the transistor turns on and the ac control circuit connects to
700 V. As the ac control circuit connects to 500 V, the voltage at the common node of
97
resistors Rl1 and R12 becomes -3.7 Vdc with respect to the ac control circuit's ground
and +500 Vdc with respect to the power switch's ground. This voltage is set because
of the parallel combination of R11 and R12 in series with R12 and R13 on the power
switch. This voltage of -3.7 Vdc along with R l2 and C1l set the output frequency of
the voltage to frequency (V/F) converter (U3). This frequency can be determined by
the following equation:
Fout = 37V/(R12 * C1l * 10V) = 37 kHz
The open collector output of the V/F converter is pulled up to l2 Vdc through R8. The
fiber optic transmitter DS1 is driven by U1 and controlled by the output of the V/F
converter. This fiber optic transmitter conveys information to the modulator controller
concerning the status of the power switch's power supply. The controller uses this
information to determine how much power is available from each power switch, and
also to determine if a power switch has been turned off due to internal failure. As
mentioned earlier in the discussion of the power switch, a failed module can be
effectively removed from the modu1ators circuit by opening the ac transistor. This
transistor is opened by setting the RJS latch (U4) and cutting off the drive to its gate.
This latch ca11 be set by two possib1e conditions. The first condition occurs if the ac
control circuit's power supply drops excessively. This will cause the voltage at pin 5
of U2 to drop below the zener diode's voltage at pin 6. Which changes the output state
of the comparator. The second possible condition occurs when the phase detector of
the dc control circuit is activated and the transistor of U7 is turned on and pulls Rl3
low.
The power supply of the dc control circuit is identical to that of the ac control circuit.
The l2 Vdc power supply includes rectifier CR7, regulator VR3, resistors R18 and
R19, and energy storage capacitors C15, C22, and C23. The fiber optic receiver U8,
receives the control signal from the modulator controller which governs the power
switch's operation. An optic signal is transmitted to U8 when the power switch is to be
turned on. When U8 receives this optic signal, its output goes 1ow and causes U1l pin
4 to go high. Device U1l pin l3 is the output of the power switch's short circuit
detection network and is high under normal operation. Therefore, when U8 receives
an optic signal, U11 pin 11 goes low and turns on driver Ul2 of the power switch's dc
transistor. When the dc transistor is driven, it turns on and the dc switch control circuit
connects to 500 V. If there is a short circuit at the output of the power switch, an
increase of current will flow through the diode of U14 and pull pin 5 low. This will
trigger the timer U10 and disable the drivers to the dc transistor. The dc control
circuit's phase detector compares the output of the power switch to the control signal
that governs the dc transistor. In this manner. a dc transistor that has failed in the short
circuit or open circuit mode can be detected and the ac transistor can be opened. The
phase detector uses Rl7 on the power switch control card, and R9, Rl0. and R1l on the
power switch to determine the output state of the power switch. As the output of the
power switch switches from 0V to 500 V, U9-1l will switch from low to high
respectively. This signal at U9 pin11 is compared to the signal at U1l pin 4 by an
exclusive OR gate. If these signals are in phase, U9 pin 4 will be low indicating the
normal operation of the power switch. If these signals are out of phase, U9 pin 4 wi1l
be high indicating a problem with the power switch. This problem may be an open or
shorted dc transistor, or a short circuit at the output of the power switch.
If this problem continues, C16 will charge up and cause pin 3 or U9 to go high. This
will cause Q1 to turn on and draw current through the diode of the opto-isolator U7
98
and pull pin 5 low. With U7 pin 5 low, the latch of U4 will be set and the ac transistor
will be turned off Exclusive OR gate U9 (pin1 ) is also controlled by a pulse detecting
circuit. Timer Ul0 is configured as a two minute timer which controls driver U6.
When a pu1se is received by optical receiver U8, the timer is retriggered (via U11
pins 9, 10 and U9 pins 9, l0) and the two minute timer is reset. If a pu1se is not
received by the optical receiver within a two minute period. Ul0 pin 5 will go 1ow.
This causes U9 pin l to go high which leads to the ac transistor being turned off.
4-5. POWER SUPPLIES
WARNING
HIGH VOLTAGE HAZARD ACCESS TO HIGH VOLTAGE AREAS ARE

PROTECTED BY ELECTRICAL INTER- LOCKS. DO NOT DISABLF
1NTERLOCK CIRCUITS. FAILURE TO COMPLY MAY RESULT IN SERIOUS
INJURY OR DEATH.
4-5.1 1PS1 Indicator Power Supply
1PS1 is a small rectifier unit converting 115 Vac into 24 Vdc to provide power to the
indicators on the front panel.
The IPA and PA tube power supplies described in the following paragraphs are for
screen and bias voltages.
4-5.2 IPA Power Supply, 1PS6.
Refer to Schematic Diagram l7809l for the following discussion. Supply lPS6
provides all plate, screen and bias voltages for the intermediate power amplifier stage.
Included in this supply are metering shunts and multipliers for 4 kV, -500V, -150V
and IPA cathode current. Over-load relay shunts for the -500V (R7) and 4 kV (R8)
supplies are included. A cathode current sample (R33) for the drive limit, lA9, is also
provided.
IPA Plate Supply Voltage.
Primary voltage for transformer T1 is 230 Vac, 3-phase power, which develops 4
kVdc using a 3-phase full-wave bridge rectifier, CR1 through CR12. The 4 kVdc plate
voltage is routed through El to the IPA plate circuit.
IPA Screen Supply Voltage.
Primary voltage for transformer T2 is 230 Vac, 3-phasc power is routed through fuses
Fl,F2, and F3. The secondary of T2 is used to develop -500 Vdc using a 3-phase full-
wave bridge rectifier, CR13 through CR18. The -500 Vdc screen vo1tage is applied to
the IPA cathode since the screen of this stage is connected directly to ground.
IPA Bias Supply Voltage.
99
A -l50 Vdc bias voltage is a1so supplied. It is derived from one phase on the main 3-
phase bias contactor 1K2l. a 1l5 Vac, single phase voltage applied to the primary of
transformer T3 through fuse F4.
The secondary of transformer T3 is rectified by CR19 and CR20, and provides -l50
volts between the cathode and grid of the IPA and operated below ground at the DC
cathode potential.
4-5.3 PA Bias Supply, lPS5.
Refer to Schematic Diagram l788l3 for the following discussion. This supp1y has a
high rated bleeder resistor.
These bleeder resistors provides the correct va1ue of fixed bias for the rf power
amplifier. Also included in this supply is a metering shunt (R2) for the PA bias current
meter. A PA grid current sample (R6) for drive limit, lA9, is also provided.
4-5.4 PA Screen Supply.
The PA screen supply is a pulse width modulating unit, which can supply a 840 Vdc
pulse at a wide range of duty cycles. The duty cycle of this supply is variable and is
proportional to the average PA plate voltage. The electrical connections of the PA
screen supply arc i1lustrated in Schematic Diagram l78803 and the supply is located
in Unit 2 of the transmitter.
The PA screen supply consists of the following components. A step-up transformer

T1: two, 150 kW power switch assemblies Al and A2; four chokes L1, L2, L3 and L4;
a l0K ohm load resistor R8; a screen overload shunt R6; a screen current meter shunt
R7, and a screen voltage meter divider R4 and R5.
The primary of transformer T1 is powered by 230 Vac, 3-phase power. With the 1:2
step-up, transformer (T1) develops 460 Vac on each secondary. These secondaries
power two 75 kW power switches, Al and A2. Both power switches are driven by a
common signal from the Modulator Controller, Unit 9, and supply a 420 volt pulse at
their output. Because these switches are series connected, their outputs add to form a
840 volt pulse. Inductors L2 and L3 are 50H inductors and serve as short circuit
protection for the power switches. Capacitor C1 and inductor L4 form a low pass
filter. Inductor L1 is a 10 henry audio choke and serves as a constant current source
for self modu1ation of the PA screen. The 840 volt pulse from the power switches is
integrated by the combination of L1, L2, L3, L4, C1, the capacitance of the coaxial
cable, the RF bypass capacitor and the inherent capacitance of the tubes screen.
4-6. CONTROL CIRCUITS
An understanding of the operation of the control circuits of the transmitter will be

helpful when it is necessary to locate control malfunctions. Refer to Section 3, Tables
3-l through 3-7 which list the transmitter controls and indicators and their functions.
Refer to Schematic Diagram 178269 during the following description.
100
4-6.l Start-Up Control Circui1 Analysis.
When the standby control circuit sequence is complete, the cooling pump, cooling-air
blowers, tube filaments and bias power supplies are all energized and the transmitter
is ready for the application of high voltage. When the following conditions are
established and the following control functions have taken place, the transmitter
starting sequence will be complete. Refer to the Type DF50A Transmitter Block
Diagram, Figure 4-1. Reference to the Control Ladder (l78484) may also be helpful.
When the 230V DIST circuit breaker 4CB2 and HV circuit breaker 4CB1 are in the
ON positions and when all circuit breakers on Control and Low Voltage Distribution,
Unit l are in the ON positions the following indicator lamps should illuminate green:
Overload 6DSl6-6DS23
Door Inter-lock 6DS24-6DS27
Overload Lamp Reset 6DS5
Separator Hi Water Cutoff 6DS38
Separator Low Water Alarm 6DS36
Separator Low Water Cutoff 6DS37
Master Off 6DS4
Hi Voltage Off 6DS8
Heat Exchanger Blower Air 6DS3
Main Blower Air 6DS29
PA Boiler Water Flow 6DS30
The MASTER ON lamp 6DS3 and HI VOLTAGE ON lamp shou1d illuminate white.
A yellow lamp indicates a fault or off for all indicators except HV ON, HV OFF,
MASTER ON, and MASTER OFF.
When the MASTER ON switch 6S3 is pressed, control voltage will be applied to the
latch coil of the master-start relay 1K1. When the latch coil of relay 1K1 is energized,
one set of normally open contacts of relay 1K1 will close, energizing the pumps and
blowers holdover time delay relay 1K2. Another set of normally open contacts of
relay 1K1 will close in the filament interlock string.
When the pumps and blowers holdover time--delay relay 1K2 is energized, a set of
normally-open contacts of 1K2 will close, energizing pump contactor 1K3, heat
exchanger blower contactor 1K4 and the main blower contactor 1K5. If the systems
water temperature is less than approximately 150 DF, switch 5S1 will close applying
control voltage to the heat exchanger-air-flow auxiliary relay l K6 coil. When all
blowers are energized, their associated pressure switches (3S7, 4AlSl. and 4A2S1 )
will close, energizing the main-blower air--f1ow auxiliary relay 1K7. When the air-
flow auxiliary relays are energized, a set of normally-open contacts on each relay will
close and the associated air-flow indicator 1amps on the control panel will change
from yellow to green. Another set of normally-open contacts on each air-f1ow
auxiliary relay will close in the filament interlock circuit.
After the pump is energized, all water flow should be normal. If water f1ow is normal,
the PA boiler water-flow switch 2S7 will close and energize boiler-water-flow
auxiliary relays 1K8. When all water-f1ow auxiliary relays are energized, a set of
101
normally-open contacts of each relay will be closed and the associated water-flow
indicator lamps on Control Panel, Unit 6, will illuminate green. Another set of
normally-open contacts on each water-flow auxiliary relay will close in the filament
inter1ock circuit.
When the water level in the separator tank is normal, separator low-water-cutoff
switch 2S4 and separator high-water-cutoff switch 2S6 are closed, energizing
associated water-level auxiliary relays 1K10 and 1K11. A set of normally-open
contacts of each water-level auxiliary relay will close, and associated indicator lamps
on Control Panel, Unit 6, will illuminate green. Another set of normally-open contacts
of each water-level auxiliary relay will c1ose in the fi1ament-interlock circuit. If the
water level drops below a critical level in the tank, the low-level indicating switch in
the tank will open, dc-energizing the associated auxiliary relay and the associated
low-level indicator lamp will change to yellow. Another set of normally-open contacts
of the associated water-level auxiliary relay will open in the filament inter1ock circuit.
If the water level in the tank drops below the level where water should be added, but
sufficient water for continued operation is still present, then 2S5 will open, de-
energizing relay lK9. The associated lamp will change to yellow and control voltage
will be applied to alarm bell lDS1 (provided bell disable switch 1S2 is closed). When
the water level in the separator tank is normal, separator-low-water alarm switch S
will close, energizing water-leve1 auxiliary relay 1K9. One set of normally-open
contacts of this relay will close and the associated indicator lamp on Control Panel.
Unit 6, will change to green. Another set of normally-closed contacts of relay 1 K9

will open, removing control voltage from alarm bell 1DS1.
When all contacts are closed in the filament-interlock circuit, control voltage is
applied to plate time-de1ay relay 1K12, PA filament contactor 1K14, and IPA filament
1K47. When the contacts of 1K14 close, voltage is applied to the PA filaments
through current limiting resistor 1R1. Simultaneously, control voltage is applied to
time delay relay 1K26 and a 2 second timing cycle is started. At the end of this timing
cycle, a set of contacts on 1K26 close and voltage is applied across the coil of 1K27.
When 1K27 is energized, a set of its contacts apply a short circuit across 1Rl and
effectively remove it from the filament circuit. At this point all tube filaments should
be energized and a set of normally-open contacts for contactors 1K13, 1K14, and
1K47 will close in the bias-interlock circuit.
NOTE
If at any time the indicator lamps flash or fail to light properly, this may be an
indication of dirty relay contacts and does not necessarily indicate a transmitter
malfunction.
When plate time-delay relay 1K12 completes its timing cycle, or if plate-delay-release
switch 6S2 is depressed, control voltage will be applied to the plate delay auxiliary
relay 1K16. When relay 1K16 is energized, one set of its normally-open contacts will
close in the High Voltage interlock circuit. Another set of normally-closed contacts of
relay 1K16 will open and PLATE DELAY RELEASE lamp 6DS2 wi1l extinguish.
When al1 interlocked cabinet doors are closed and the power fault grounding stick is
on its holder, the associated auxiliary relays (1K17 through 1K20) will be energized.
102
A set of normally-open contacts for each of these auxiliary relays will close in the bias
inter1ock circuit. Another set of normally-open contacts of these relays will close, and
associated indicator lumps 6DS24 through 6DS27 on Control Panel Unit 6 will light
green.
When all bias interlock circuit contacts arc closed, bias contactor 1K2l wi1l be
energized. A set of normally-open contacts of bias contactor 1K2l will close in the
high-voltage interlock circuit. Another set of normally-open contacts of bias contactor
1K2l will close, lighting PLATE DELAY RELEASE lamp 6DS2 green. Bias voltage
will be applied to all points in the transmitter where required. At this point, the
transmitter standby control circuit functions are complete and the transmitter is ready
for the application of high voltage. PA filament control is energized. The 28V power
supply for the solid state RF amplifier stage is energized when the high voltage is
turned on.
4-6.2 Power Select Control Circuit Analysis.
Select high power with 6S35, lamps 6XDS35 and 6XDS28 will illuminate green; or
se1ect low power with 6S28, lamps 6XDS35 and 6XDS28 will illuminate yellow.
When HV ON switch 6S7 is depressed, control voltage is applied to the latch coil of
high-voltage on/off re1ay 1K22. Normally-open contacts L3 and L10 of relay 1K22
will close in the high-voltage interlock circuit. Normally-closed contacts R3 and R9
of relay 1K22 will open, de-energizing the white lamps in HV ON indicator 6DS7 and
HV OFF indicator lamp 6DS8. Norma1ly-open auxiliary switches 1S13 (lCB8) and
1S16 (1CB10) are connected in the high-vo1tage interlock circuit. Also included in
the high-voltage interlock circuit are contacts from the previously discussed relays
1K21 (Bias Supply) and 1Kl6 (Plate Delay Aux.).
A provision for an external interlock is provided in the high-voltage interlock circuit

at terminals lTB4-25 and 26. Examples of external interlocks include dummy load
proofs, switch matrix interlocks, and safety interlocks.
At this point the normally-closed contacts 3 and 9 of relay 1K29 will allow control
voltage to be applied to the coils of plate-auxiliary relay 1K23 and relay 4A5K11.
Contacts 2 and 3 of 4A5K11 enable the vacuum contactor 4A5Kl in the standby
mode. 4A5K11 provides high speed control to open the contacts of vacuum contactor
4A5Kl if the high voltage interlock is lost for any reason. Holding contacts l and 2 of
relay 1K23 a11ow relay 1K23 to remain energized when contacts 3 and 9 of 1K29
open. Contacts 5 and 6 of 1K23 will apply control voltage to 1K25 (IPA power
Supply contactor) and 1K15 (RF driver power supply contactor).
When the plate auxiliary relay (1K23) is energized, 115 Vac is applied to 4A5TB2-11
and l9. The 1l5 Vac at 4A5TB2-l1 energizes pilot relay 4A5K10. This causes time
delay relay 4A5K9 to energize, its contacts 1 and 3 to close, and begin its 5 second
timing cycle. The closure of contacts l and 3 of 4A5K9 allows 230 Vac to be applied
across the coils of 4A5K2 and 4A5K 13 and energizes these contactors. 4A5K2 is the
surge contactor for the modulator and 4A5K13 is the surge contactor for the screen.
These contactors a11ow their respective supplies to charge via current limiting
resistors. When the auxiliary contact of 4A5K2 closes, voltage is applied to the coil of
time delay relay 4A5K12 and a 2 second timing cycle begins. After a 2 second period,
103
the contacts of 4A5K12 close and 230 Vac is applied across the coils of contactor
4A5K4 and vacuum contactor 4A5K1. 4A5K4 is the contactor for the screen supply
and 4A5Kl is the contactor for the modulator. The current limiting resistors for both
the screen and modulator are shorted when these contactors energize. When the
auxiliary contacts of 4A5K1 close, the 24 Vdc at 4A5TB2-21 is applied to 4A5TB2-
10 and the modulator is enabled. l second later the timing cycle of 4A5K9 ends and its
contacts open. This de-energizes Surge contactors 4A5K2 and 4A5K13 and the surge
resistors are removed from the high voltage circuit.
When the HV OFF switch 6S8 is depressed, 1K23 is de-energized. The 115 Vac at
TB2-19 is removed and the contactors K1 and K4 immediately open. This removes
high voltage from the modu1ator and screen Supplies.
4-6.3 Overload and Re-closure Circuit Analysis.
There are three overload relays and a lockout latch relay that can turn off the HV ON
relay 1K22. The following are the over1oad relays:
PA OVERLOAD lK38
PA SCREEN OVERLOAD 1K40
IPA OVERLOAD 1K41
Each of these relays have one set of contacts (6 and 7) connected in parallel. When
one of these relays operate, contacts 6 and 7 close applying control voltage to the off
coil of lK22. The contacts (9 and l0) of overload relays lK38, 1K40, and 1K4l control
the auxiliary relays 1K3l, 1K33, and lK34 respectively. Contacts 4 and 7 of these
auxiliary relays will hold the relay coils energized. In addition, the associated
overload indicator lamp and OVERLOAD LAMP RESET indicator lamp 6DS5 will
illuminate yellow. When a fault occurs, the corresponding overload indicator lamp
and OVERLOAD LAMP RESET indicator lamp 6DS5 will remain yellow (even if
the transmitter has been turned back on) until OVERLOAD LAMP RESET switch
6S5 is depressed. This switch removes control voltage from all overload lamp
auxiliary relays, thereby releasing the holding contacts of the re1ays which have been
energized. At this time, the over1oad lamps and OVERLOAD LAMP RESET
indicator lamp 6DS5 will change to green.
The LOCKOUT LATCH relay 1K53 is operated from the modulator controller
circuitry. The VSWR cutoff and the load fau1t detector inputs control the LOCKOUT
LATCH circuitry in the modulator circuitry. (See section 4-4.1.5 for a discussion of
the Lockout latch circuitry). If a LOCKOUT LATCH occurs, relay 1K53 is energized.
Contacts 6 and 7 of I K53 are in para1lel with the overload relay contacts mentioned
above and will turn off the transmitter high voltage. Pressing the OVERLOAD LAMP
RESET wi1l reset lK53 and the modulator controller circuitry. Plate voltage can now
be turned on again.
The VSWR cutoff and ground fault sensor have associated latching lamp relays which
operate the same as the overload lamp relays. These faults operate in the modulator
controller to electronically inhibit the high vo1tage output (if the modulator power
supply without turning off the plate contactors. Therefore, only a momentary outage
will be noticed.
104
4-6.4 Remote Control Assembly, Unit 11.
Two versions of the remote control assembly exist. The standard version contains only
the Remote Control Interface circuit card assembly 11A2. This card is used to make
channel changes via the 10 position channel select switch 6S6. The optional version
contains several other components to allow extended computer control. If the optional
version was purchased, the details of this version are contained in Section 8. Table 2.
The following discussion is for the standard version of the remote control assembly.
The 10 position channel select switch 6S6 is illustrated in the Control Panel schematic
178573. As the schematic shows, a wiring harness is connected between 6Pl and 11J1.
The connections from 11J1 to the remote control interface circuit card (11A2) are
shown on the schematic for the remote control interface 178839.
The channel select switches (6S6) are connected directly to the ten (10) magnetically
latched relays on remote control interface card (11 A2). Once latched these relays will
retain the channel selection when power is removed. Refer to Schematic Diagram
182597 which shows all relays in the unlatched position, no channel selected.
When channel 1 is selected, the set coil of K1 is energized and its contacts change
states. Simultaneously, U1 is pulled low through diode CR1. This low is coupled
through C11 to pull the trigger input to U1 low. Timer U1 is a one-shot with an
approximate 20 millisecond output. This output turns on Q11 and all reset coi1s are
energized. With normal operation the set coil of K1 (channel 1) will be energized
before the reset coi1 and therefore no change occurs in the state of K1. The reset pulse
is only 20 mil1iseconds and this time has expired before the operator releases the
channe1 1 select button. Therefore K1 will remain set.
A second timer is also triggered by the reset pulse. The duration for the second timer
is approximately 2 seconds. This will allow the servo motors to start running. When
channel l select relay is energized one set of contacts connects a ground through pin
C10 to the channel1 tuning re1ay on the Tuning Panel, Unit 6. The channel select
switch is also illuminated.
The second set of contacts is the frequency control for the synthesizer. A common is
brought out and routed through the relay contacts to the frequency setting card lA16.
This card has switches which program the frequency synthesizer to the proper
frequency.
4-7. COOLING SYSTEM
A single high-pressure, low-speed, blower 1ocated in the RF amplifier cabinet

provides cooling air to the solid state RF amplifier, the IPA, the RF power amplifier,
and the low-level audio amplifier stages. This blower also provides cabinet cooling air
for the units of the main cabinet group. Cooling air from this blower is also distributed
to the grid and filament seals of the RF power amplifier tubes where die1ectric
heating must be controlled at the high transmitter operating frequencies.
105
Refer to Figure 4-3 for the following discussion. The water/vapor cooling uses a
single pump to supply water to the vapor boiler and the water cooled RF components.
A single reservoir/separator tank is located in the Utility Cabinet, Unit 2, under the
shelf for Unit 9 and the PA screen circuitry. Warm water is pumped from the tank and
is fed directly to the cooling coils of the heat exchanger. Cool water from the heat
exchanger is fed to the inlet manifold where the cool water is sent to the following
106
components:
1. The 3 shorting plungers of 3Ll2 al a rate of 2 gallons per minute (GPM).
2. The coil 3L12 at a rate of 6 GPM.
3. The components 3C38, 3C39, 3R31. and 3R32 at a rate of 2 GPM.
4. The boiler for 3V3 at a rate of 6 GPM.
The overflow water in the boiler is returned to the tank for recirculation. The water
cooling the other components is recombined at the return manifold and returned to the
separator tank.
The separator tank is equipped with over/under pressure safety valves, a high water
level cutoff switch (2S6), a low water level alarm switch (2S5), and a low water level
cutoff switch (2S4). Pressure and temperature gauges are located in the inlet and
outlet lines of the reservoir.
A water demineralizer is used to keeps the water purity in the system acceptable at all
times.
Pure disti1led water, when introduced into the cooling system of the transmitter,
becomes contaminated by the system components and electrolysis. The presence of
oxygen and carbon dioxide in a copper plumbing system enhances the dissolution of
copper into the water and its subsequent deposition as copper oxide on the hot plate
structure of the tubes. The rate of formation of this oxide is dependent on the plate
dissipation of the system. Corrosion and electrto1ysis will rapidly contaminate the
water and eventually scale formation will result. In order to counteract the results of
the precipitated oxide, water can be replaced from time to time, however, this adds to
the sca1e formation because with each water change, additional impurities are added.
It can be seen that it is essential that high qua1ity water be used to fill the system
initially. It is important a1so that provision be made for continuous regeneration
(purification) of the water system, and that steps be taken to eliminate, insofar as
possible, the sources of contamination. Some of the contaminants which are
conducive to scale formation include oxygen, carbon dioxide, metal ions and organic
solids.
By filling the system origina1ly with distilled water, the introduction of organic or
colloidal matter that may exist in deionized water is avoided. To maintain acceptable
quality, continuous regeneration (purification) of the water in the system is
recommended. This regeneration is achieved by passing a portion of the now through
suitable ion exchangers.
Regeneration of the water makes regular overhauls and water replacement almost
unnecessary because the introduction of additional foreign matter is avoided. In a well
maintained system, the followil1g contaminants should not be present in excess of the
following concentrations:
Copper 0.05 parts per million by weight
Oxygen 0.5 parts per million by weight
Carbon dioxide 0.5 parts per million by weight
Total solids 3 parts per million by weight
Although an accurate chemical analysis is the absolute method of checking system

water quality, a measurement of the waters resistivity may be used as a guide to
107
determine whether ionized contaminants are excessive. Dissolved gasses, metals, and
other contaminants reduce the resistivity of the water in varying amounts. Some
contaminants, such as oxygen, has no direct effect, while others, such as carbon
dioxide, greatly reduce the resistivity. However, if the specific resistivity of the water
falls below l meg-ohm per cm, it can be assumed that the contaminants are excessive.
Also, if the pH of the water is outside of the range from 6.8 to 7.2, the water contains
excessive contaminants.
The water purification system furnished with the transmitter includes a fiberglass
resin tank and the typical plumbing components required to connect the tank to the
transmitter heat exchanger system. The return water line from the heat exchanger
provides the source of water for the resin filter and the deionized water from the filter
is tied into the condensate return line from the heat exchanger. A flow valve in the line
to the deionizer filter limits the water f1ow through the fi1ter to one gallon per
minute. The repurification loop is capable of continuously repurifying 5 to l0% of the
total vo1ume of the main cooling system every hour.
A direct reading water resistivity meter is mounted on the front of Uti1ity Cabinet,
Unit 2. A cell attached to this meter measures the resistivity of the incoming water.
The cell contains two nickel electrodes which are plated with platinum. The metering
circuit contains a variable resistor and a meter. The meter scale is calibrated in ohms
resistance from l5,000 to infinity. The variable resistor is preset at the factory.
4-8. TUNING MOTOR CONTROL SYSTEM
The transmitter has ten preset channels tunab1e to any frequency between 3.2 and 22
MHz (tuning up to 26.1 MHz is optional). Once a channel is tuned to a specific
frequency, the transmitter can return to that frequency with no re-tuning required.
Each tuning component has its own associated drive motor with follow pot. Each
drive motor has an independent control pot with a digital dial for accurate tuning.
When a tune cycle is initiated, the dc voltage of the motor follow pot is compared
with the dc voltage of the target control pot and summed at the input of the motor
control amplifier. The difference in voltage triggers the amplifier and a positive or
negative 28 Vdc is applied to the motor. When the motor starts running, its associated
follow pot changes its output voltage and the motor continues to run until the follow
pot voltage is of the same magnitude, but opposite polarity of the control pot.
The tuning cycle is controlled by the TUNING CONTROL TIMER, 6A2A1. This
timer consists of two separate timers; one is triggered by TUNE ENABLE switch and
the second is triggered by CHANNEL SELECT BUTTON. When the TUNE
ENABLE switch is momentarily pressed a ground through the timer is provided to
6A2K24 re1ay. When 6A2K24 is energized, 115 Vac is provided through its closed
contacts to 1K48 relay. When lK48 is energized 230 Vac, 3-phase, is applied to the
TUNING MOTOR POWER SUPPLY, lPS8, which provides 28 Vdc to all the motor
control amplifiers except the plungers. If one of the lead pots has changed, the tuning
component's motor wil1 tune until a null voltage is reached at the amplif1er input.
The timer is set to provide an initial ground for a period of 0.1 seconds, provided no
motor runs the timer will time-out and relays 6A1K24 and 1K48 will de-energize. The
de-energized relays will turn on the 28 Vdc Supply. And remove voltage from the
108
motor control amplifier. However, if a motor starts to run, the associated amplifier's
re1ay K1 will energize and provide a ground to the TIMER. The ground is provided
as long as the motor is running.
When the LAST MOTOR stops running the ground to the timer is removed, and the
timer will time-out and de-activate the system after 0.1 seconds. When it is desired to
manually tune any component in the transmitter the TUNE ENABLE switch should
be depressed until tuning is completed. This will provide a continuous ground to the
timer and keep the tuning system energized.
When a CHANNEL SELECT button is pushed a ground through the timer is provided
to 6A2K25 relay. When the 6A2K25 is energized, 115 Vac is provided through its
closed contacts to relays 1K48 and lPS8K1. Relay 1K48 contacts provide 230 Vac to
tuning motor power supply lPS8. Relay 1PS8K1 contacts provide 28 Vdc to the
plungers motor control amplifier (1A4, 1A5, and lA6). Therefore, when changing
channels, the tuning component motors and plunger motors can run. The timer will
stay energized as long as any component motor or plunger motor is running, and then
it will time-out 3 seconds after all the motors stop.
The channel select switch also energizes a relay (there is one relay for each channel)
that grounds a set of binary switches for the channel selected. These binary switches
control the frequency of the Exciter. The te11 preset frequencies are stored in the
Frequency Setting circuit card assembly 1A16 (see schematic l54835 ).
4-9 RF Gain Control 1A9
The RF Gain Control Assembly see Schematic 148362 monitors the PA grid current
and driver cathode current and adjusts the output level of the Synthesizer so that these
currents are correct. The Gain Control Assembly accepts as its inputs a pair of signals.
One is derived from the PA grid circuitry and is a dc voltage proportional to PA grid
current. The other is derived from the driver IPA cathode circuitry and is a dc voltage
proportional to the driver cathode current. The exterior interfering signal is blocked
by the photo-isolator in the RF Gain Control Amplifier. In which the DC bias of the
PIN diode performs the auto-tuning of RF level output by the synthesizer.
In addition to the above automatic operation, the unit allows contro1ling the drive
level from the transmitter's front panel using the front panel RF Gain control.
The normal mode of operation of this device is to monitor PA grid current and adjust
the level from the synthesizer to maintain the correct current.
When the driver plate circuit is mistuned, there may be little or no PA grid current but
the driver cathode current may be excessive. Under these conditions a second mode of
operation takes place. The device adjusts the level from the synthesizer to maintain a
safe value of driver cathode current. The largest sample (PA grid current or driver
cathode current) will control the synthesizer output level; the output of the synthesizer
is automatically adjusted so that the PA grid current is correct providing that the driver
cathode current is not excessive.
The PA grid current sample is applied to the RF Gain Contro1 assembly TB 1-5. The
driver cathode current sample is applied to TB l-6. The transmitter's front-panel RF
109
Gain contro1 is also connected to this unit using TB l-3. The dc control voltage output
from this unit appears at TB l-4: this voltage is routed to the synthesizer gain-contro1
port. Plus 28 Vdc to power the unit is applied to TB1-l, Terminal TB 1-2 is connected
to ground.
110
SECTION 5 - MAINTENANCE
5-1. GENERAL
Section 5 provides information required for transmitter equipment maintenance.
These procedures are performed on site, and the maintenance concept is primarily
based on resident maintenance personnel and remote operation of transmitter.
Maintenance data provided in this section include safety procedures, system access
and exit procedures, preventive maintenance program, troubleshooting concepts, and
assembly removal and installation procedures, where procedures are not obvious.
WARNING
READ AND UNDERSTAND THE SAFETY SUMMARY CONTENTS AT THE
FRONT OF THIS MANUAL PRIOR TO ATTEMPTING MAINTENANCE
PROCEDURES. FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY OF
DEATH.
5-l.l Major Assembly Locators.

The DF50A Broadcast transmitter is illustrated in Figure 5-l. Major assemblies are
identified in Figures 5-1 and 5-2.
5-l.2 Equipment Required But Not Supp1ied.

A recommended list of equipment required but not supp1ied is provided in Table 5-l.
5-l.3 Consumable Materials.

A list of recommend consumable materials for transmitter maintenance is identified in
Table 5-2.
5-2. MAINTENANCE CONCEPT

Most maintenance and repair of the transmitter may be performed with the equipment
remaining in place. Certain assemblies and Subassemblies should be removed and
returned to the manufacture for repair or repaired on the bench.
Removal and replacement procedures are included in this section for those
assemblies, subassemblies, and components where specia1 attention is required.
WARNNING
AVOID CONTACT WITH HIGH VOLTAGES PRESENT IN THIS
TRANSMITTER. FAILURE TO COA1PLY MAY CAUSE INJURY OR DEATH.
Proper safety procedures should be used while maintenance is being performed. Do

not defeat system interlock circuits to gain access to a transmitter unit. Shorting sticks
are provided at each of the transmitter entrances. The shorting stick should be used on
any high voltage buses and high voltage components, leave the stick hanging on the
bus while performing maintenance.
111
5-3. ELECTROSTATIC HANDLING
CAUTION
FAILURE OF PERSONNEL TO FOLLOW THESE INSTRUCTIONS MAY
RESULT IN DAMAGE TO MO OF THE DEVICES.
This paragraph is intended to increase awareness in all personnel who handle static
sensitive devices. Component destruction is bothersome and costly but is usually
caught before the circuit board or device leaves the factory (vendor). Problems that
are expensive and hard to find result from devices that are only slightly altered or
degraded after exposure to static electricity. They might function within specifications
during the final quality assurance check, but their life can be severely shortened.
The problems associated with static charges in the electronics environment can be
controlled. To accomplish this, programs must be instigated throughout the user's
facility to increase the level of awareness in all personnel who handle static sensitive
devices.
Once educated, personnel must be provided with the proper equipment to implement
these techniques of static control. At the work bench this includes conductive table
mats, conductive wrist straps, conductive floor mats and ionized air. When parts are
removed from the work station, conductive packages or carriers are required to extent
the level of protection.
112
Figure5-1. DF50A Broadcast Transmitter, Front View.
113
Figure5-2. Transmitter unit1 Location Diagram.
114
Table 5-1 List of Equipment Required but not supplied.
Name Description Manufacturer
Audio Analyzer HP 8903A Audio Analyzer 20 Hz to 100kHz or equivalent Hewlett-Packard
Spectrum HP 8557A/853A Spectrum analyzer, 0.0l to 350 MHz plug-in Hewlett-Packard

Analyzer and HP853A disp1ay or equivalent
Frequency HP5381A Frequency Counter l0 Hz to 80 MHz, 7 digit LED Hewlett-Packard

Counter display, accuracy l count
Digital 8060A Digital Voltmeter 4- l /2 digit, or equiva1ent Fluke

Vo1tmeter
Impedance Meter HP4l39A Vector Impedance Meter 400 kHz to l10 MHz spot or Hewlett--Packard
sweep frequency or equivalent
RF Voltmeter HP4 l0C with AC probe sweep frequency or equivalent Hewlett-Packard
Electrician Tools One (l) set Any
Lamp Tool Micro-switch, Type l532 A17y
Wrenches Double end, open end/box end 1/4 to l - 1 /4" standard length Any
Mirror Sma1l inspection type Any
Wrenches A1len type, 0 to l0 size Any
Wrenches Box socket with ratchet drive handle 3/8" to l", l/2" drive Any
Ammeter Model 93l or equivalent Weston
Strap No. 2224 static wrist strap witI1 l0 ft. coiled grounding cord. 3M
Bag No. 2 100 static shielding l0 x 12 inch bag 3M
Mat No. 8344 rigid antistatic work surface mat 3M
Table 5-2 List of Consumable Materials.
115
Item Nomenclature Type/Part No. Cage Code
1 Alcohol, Denatured O-E-00760 8l348
2 Grease, Multipurpose 630-2 732l9
3 Grease, High-Temperature 930-AAA 73219
4 Grease, Thermal Heat Sink DC340 71984
5 Handpad, Silicon Carbide (Very 85l 5940l

Fine Grade)
6 Rags, Wiping, Cotton DDD-R-30 8l348
7 Tape, Masking, l" A-A-883 8l348
8 Solder 282 75279
9 Cotton Swabs Any N/A
10 Tape, Thread Sealing 9975260 GT66 06090
11 Cleaning Solution 565 966l3
12 Resin Mixed Bed, De-Ionizer 022-00l l-0l0 52l5l
13 Filter, Particulate, Air L75376- l 52l5l
116
5-3. l General.
The transmitter and modulator include many TMOS, IGBT, and CMOS solid-state
devices. Being MOS devices, damage can be encountered by ESD due to improper
handling or installation. TMOS and IGBT devices are not as susceptible as CMOS
due to their larger input capacitances and are able to absorb more energy before being
charged to the gate-breakdown voltage. Nevertheless, once breakdown begins, there is
enough energy stored in the gate-source capacitance to cause complete perforation of
the gate oxide. With a gate-to-source rating of VGS =20 volts maximum and
electrostatic voltages typically being l00-25,000 volts, it becomes very clear that these
devices require special handling.
5-3.2 Implementation.
The basic method for protecting MOSFETs combines the prevention of static buildup
with the removal of existing charges. The mechanism of charge removal from charged
objects differs between insulators and conductors. Since charge cannot flow through
an insulator, it cannot be removed by contact with a conductor. If the item to be
discharged is an insulator (plastic box, personal clothing, etc.), ionized air is required.
If the object is a conductor (metal tray, conductive bag, personal body, etc.), complete
discharge can be accomplished by grounding.
A static safe work station should include a grounded conductive tabletop or mat, floor
mats, grounded personnel (wrist straps), conductive containers, and ionized air to
remove static charge from nonconductors. All soldering irons should be the grounded
type. All nonconductors such as styrofoam cups, cellophane, paper, plastic bags, etc.
should be removed from the work area. Above a1l, education of all personnel in the
proper handling of static sensitive devices is the key to preventing ESD failures.
The following general guidelines are applicable to the handling of static sensitive
devices.
l. Operations which require human handling should be minimized.
2. Personnel maintaining electrostatic discharge sensitivity equipment, where ground

straps cannot be used, should ground themselves prior to removing sensitive items
from protective packaging.
3. Tools and test equipment used in protected areas should be properly grounded if
possible. Hand tools should not utilize insulation on the handles. If plastic handled
tools must be used, they should be treated with a topical antistat.
4. Assure that all containers, tools, test equipment, and fixtures are grounded before
and during use either directly or by contact with a grounded surface.
Grounding of electrical equipment should be via a grounded plug, not through the
conductive surface of the grounded work station.
5. Work instructions, test procedures, drawings and similar documents used in a

protected area should not be covered in common plastic sheeting or containers.
117
6. Workers clothing should never make contact with the devices, and workers should
avoid friction producing activities in the vicinity of the work station, including putting
on and taking off of smocks, wiping feet, rubbing of hands, etc.
7. Workers should avoid touching device leads or contacts and should handle parts
only by the case.
8. When devices are removed from their protection, they should be kept either:
a. Pin down on a conductive surface; or
b. In a conductive container with the pins in contact with the surface.
9. Periodic continuity and resistivity measurements should be performed. The tests
should include:
a. Worker ground straps
b. Work surfaces
c. Floor mats
d. Other ground connections
l0. Caution should be observed in using solvents such as acetone and alcohol or other
cleaning agents for cleaning ESD protective materials. The use of such solvents can
reduce the effectiveness of some protective materials, especially those employing
detergent type antistats.
5-3.3 Grounding.
Although grounding has thus far been only casually mentioned in conjunction with
ESD protection, it is essentia1. Earth ground rods for ESD protection should be solid
copper or copper jacketed steel and should be driven six to eight feet into the earth
beyond the building slab with
approximately six inches exposed for making connection. Dry soil conditions may
require a copper sulfate drip.E1ectrical grounds should be isolated from static
grounds. Water pipes offer convenient grounds; however, they may not be connected
to ground.
These grounding methods may seem excessive. However, these techniques are for
minimizing the difference of potential between separate grounds, and not for reducing
the ohmic resistance to earth.
5-3.4 Summary.
Transistors and integrated circuits within the transmitter and control systems are
sensitive to electrostatic damage. It is the purpose of this section to broaden the user's
awareness and understanding of the potential danger of failure by electrostatic
discharge (ESD). Continental does not propose to define a program to control the
buildup of static charge but to mention that a static control program is essential to the
reliability of the transmitter and control systems.
118
5-4. ACCESS AND EXIT PROCEDURES
The equipment is housed within unitized enclosures and protective fenced areas.
Access to the enclosures and fenced areas are interlocked for personnel safety. The
interlock system, when properly used, will prevent personnel injury due high voltage
shock.
To gain access to the equipment or fenced areas, fol1ow the procedures in the
following paragraphs.
5-4. l Modulator HV Vault Access.

Access to the modulator high voltage cage is through an access gate. For safe access,
perform the following.
WARNING
HIGH VOLTAGE HAZARD
THE INTERLOCK SYSTEM IS INSTALLED TO PROTECT PERSONNEL FROM
ACCIDENTAL HIGH VOLTAGE SHOCK. FAILURE TO COMPLY WITH THE
USE OF THE INTERLOCK SYSTEM MAY RESULT IN DEATH OR INJURY TO
PERSONNEL.
1. Follow procedures in Section 3 to turn-off the transmitter and modulator. After the
modulator is off, turn-off source power to the HV distribution unit and tag with a
"Maintenance In-Progress" tag.
WARNING
HIGH VOLTAGE AND BURN HAZARDS
THE FOLLOWING STEPS SHALL BE PERFORMED IN THE SEQUENCE
PRESENTED AND AS WRITTEN. FAILURE TO COMPLY MAY RESULT IN
DEATH OR INJURY TO PERSONNEL.
2. Do not defeat the interlock system to gain access to the power vault. Place
"Maintenance In--Progress" warning signs in highly visible areas and on opened
circuit breakers.
3.
WARNING
VOLTAGE HAZARD
l15 AND 230 VAC ARE PRESENT IN THE MODULATOR POWER VAULT, UNIT
4. THIS VOLTAGE IS NOT PROTECTED BY THE INTERLOCK SYSTEM. OPEN
CIRCUIT BREAKER 1CB15 AND 1CB18 BEFORE ENTERING POWER VAULT
AREA. FAILURE TO COMPLY MAY RESULT IN ELECTRICAL SHOCK OR
DEATH TO PERSONNEL.
Open the Plate Control circuit breaker (l CB l 8) and control breaker (1CB15) before
opening the modulator HV vault door.
4.
WARNING
VOLTAGE HAZARD
230 VAC IS PRESENT ON OPEN TERMINAL BOARDS FOR THE MODULATOR
BLOWERS. THIS VOLTAGE IS NOT PROTECTED BY THE INTERLOCK
119
SYSTEM. OPEN THE MAIN BLOWER CIRCUIT BREAKER (1CB12) AFTER
THE HOLDOVER TIMER (1K2) HAS COMPLETED ITS CYCLE. FAILURE TO
COMPLY MAY RESULT IN ELECTRICAL SHOCK OR DEATH TO
PERSONNEL.
Open Main Blower circuit breaker (l CB l2) before opening the modulator HV vault
door.
5. At the Switch Housing Assembly, Unit 4A5:
a. Open the HV POWER SUPPLY circuit breaker (4A5CBl), removing the 480Vac
supply voltage.
b. Rotate the HIGH VOLTAGE GROUND SWITCH to the CLOSED position and
the amber CLOSED lamp will illuminate.
6.
WARNING
VOLTAGE HAZARD
HIGH VOLTAGE IS PRESENT ON THE PRIMARIES AND SECONDARIES OF
THE DISTRIBUTION TRANSFORMER 4T1. IF THE DISTRIBUTION SYSTEM
REQUIRES MAINTENANCE, OPEN THE 230 DISTRIBUTION BREAKER
(4CB2). ALSO REMOVE ALL POWER TO THE TRANSMITTER BY OPENING
THE PRIMARY POWER DISCONNECT. FAILURE TO COMPLY MAY RESULT
IN ELECTRICAL SHOCK OR DEATH TO PERSONNEL.
WARNING
VOLTAGE HAZARD
HIGH VOLTAGE IS PRESENT ON THE SWITCH HOUSING ASSEMBLY, 4A5. IF
ACCESS TO THIS UNIT IS REQUIRED, OPEN THE 230 DISTRIBUTION
BREAKER (4CB2). ALSO REMOVE ALL POWER TO THE TRANSMITTER BY
OPENING THE PRIMARY POWER DISCONNECT. FAILURE TO COMPLY MAY
RESULT IN ELECTRICAL SHOCK OR DEATH TO PERSONNEL.
WARNING
VOLTAGE HAZARD
WAIT A MINIMUM OF 2 MINUTES BEFORE ENTERING THE MODULATOR
CAGE. THIS IS THE TIME REQUIRED TO INSURE THAT CAPACITORS
WITHIN THE MODULATOR SWITCH MODULES ARE DISCHARGED TO A
SAFE LEVEL (BELOW 48 VDC). FAILURE TO COMPLY MAY RESULT IN
INJURY OR DEATH TO PERSONNEL.
WARNING
BURN HAZARD
IF BLOWERS WERE RUNNING WHEN HV AC WAS DISCONNECTED,
COMPONENTS MAY REQUIRE A COOL-DOWN PERIOD. USE CAUTION
WHEN TOUCHING COMPONENT SURFACES. FAILURE TO COMPLY MAY
RESULT IN BURNS TO PERSONNEL.
Use a grounded shorting stick to touch all buses and terminals. Leave stick attached to
the load side of the high voltage bus.
7. Proceed with performance of required tasks.
120
5-4.2 Modulator HV Vault Exit.
CAUTION
EQUIPMENT DAMAGE HAZARD
VERIFY ALL ELECTRICAL CONNECTIONS ARE TIGHT. ACCOUNT FOR ALL
TOOLS, TEST EQUIPMENT AND LOOSE PARTS. FAILURE TO COMPLY MAY
l. Remove grounded stick from high voltage bus, and return it to it's storage clips.
2. Close power vault door and open the ground switch. Return power to a normal
operating condition.
3. Remove the "Maintenance In-Progress" warning signs.
4. Follow turn-on procedures in Section 3 to bring the transmitter to a stand--by mode.
5. Return modulator to operation by following the procedure described in Section 3.
5-4.3 RF Amplifier Cabinet Access.

Access to the RF amplifier cabinet is possible through six interlocked personnel
access doors. For safe access, perform the following:
WARNING
HIGH VOLTAGE HAZARD
PERSONNEL.
1. Follow procedures in Section 3 to shut--down the amplifier.
WARNING
HIGH VOLTAGE, BURN HAZARDS
2. At the Switch Housing Assembly (4A5), open the 480 Vac circuit breaker.
3. Rotate the HIGH VOLTAGE GROUND switch to the CLOSED position. Tag with
a "Maintenance In-Progress" warning sign. Open control breaker (l CB l5) before
opening any doors in the RF amplifier cabinet.
4.
WARNING
VOLTAGE HAZARD
L15 VAC IS PRESENT IN THE RF AMPLIFIER, UNIT 3. THIS VOLTAGE IS NOT
PROTECTED BY THE INTERLOCK SYSTEM. OPEN CIRCUIT BREAKER
1CB15 BEFORE SERVICING THE RF AMPLIFIER. FAILURE TO COMPLY MAY
5. Open Main Blower circuit breaker (lCBl2) before opening before servicing the RF
121
Amplifier.
WARNING
VOLTAGE HAZARD
230 VAC IS PRESENT ON OPEN TERMINAL BOARDS FOR THE MAIN
BLOWER. THIS
VOLTAGE IS NOT PROTECTED BY THE INTERLOCK SYSTEM. OPEN THE
MAIN
BLOWER CIRCUIT BREAKER (1CB12) AFTER THE HOLDOVER TIMER (1K2)
HAS COMPLETED ITS CYCLE. FAILURE TO COMPLY MAY RESULT IN
ELECTRICAL SHOCK OR DEATH TO PERSONNEL.
6. Use a grounded shorting stick to touch all buses, capacitors, and terminals in the
intended work area. Leave stick attached to the load side of the high vo1tage bus.
WARNING
BURN HAZARD
IF BLOWERS WERE RUNNING WHEN HV AC WAS DISCONNECTED,
5-4.4 RF Amplifier Cabinet Exit.

CAUTION
l. Remove grounded sticks from high voltage bus and return it to the storage clips.
2. C1ose doors and return power to a normal operating condition.
3. Remove "Maintenance In-Progress" warning tab and rotate the HIGH VOLTAGE
GROUND switch to the OPEN position.
4. Close the 480 Vac circuit breaker.
5. Follow the procedures in Section 3 to turn--on the transmitter.
5-4.5 Utility Cabinet Access.
Access to the Utility cabinet is possible through two interlocked personnel access
doors. For safe access, perform the following:
WARNING
HIGH VOLTAGE HAZARD
122
PERSONNEL.
l. Follow procedures in Section 3 to shut-down the amplifier.
WARNING
a Maintenance In-Progress warning sign.
4. Open the control breaker (1CB l5) before opening the Utility Cabinet door.
WARNING
VOLTAGE HAZARD
l15 VAC IS PRESENT IN THE UTILITY CABINET, UNIT 3. THIS VOLTAGE IS
NOT PROTECTED BY THE INTERLOCK SYSTEM. OPEN CIRCUIT BREAKER
lCB15 BEFORE SERVICING THE RF AMPLIFIER. FAILURE TO COMPLY MAY
5. Open Boiler Pump circuit breaker (lCB13) before opening the Utility Cabinet door.
WARNING
VOLTAGE HAZARD
230 VAC IS PRESENT ON OPEN TERMINAL BOARDS FOR THE BOILER
PUMP. THIS VOLTAGE IS NOT PROTECTED BY THE INTERLOCK SYSTEM.
OPEN THE BOILER PUMP CIRCUIT BREAKER (lCB13) AFTER THE
HOLDOVER TIMER (1K2) HAS COMPLETED ITS CYCLE. FAILURE TO
COMPLY MAY RESULT IN ELECTRICAL SHOCK OR DEATH TO
PERSONNEL.
intended work area. Leave stick attached to the load side of the high voltage bus.
WARNING
BURN HAZARD
IF THE BOILER PUMP WAS RUNNING WHEN HV AC WAS DISCONNECTED,
123
5-4.6 Utility Cabinet Exit.
CAUTION
2. Close doors and return power to a normal operating condition.
3. Remove "Maintenance In-Progress" warning tab and rotate the HIGH VOLTAGE
5-4.7 Distribution Cabinet Access.
Access to the Distribution cabinet is possible through two interlocked personnel

access doors. For safe access, perform the following:
WARNING
HIGH VOLTAGE HAZARD
PERSONNEL.
l. Follow procedures in Section 3 to shut-down the amplifier.

WARNING
a "Maintenance In-Progress, warning sign.
4. Open the 230 Vac Distribution circuit breaker (4A5CB2) before opening the
Distribution Cabinet door.
WARNING
VOLTAGE HAZARD
ll5 AND 230 VAC IS PRESENT IN THE DISTRIBUTION CABINET, UNIT 1.
124
THIS VOLTAGE IS NOT PROTECTED BY THE INTERLOCK SYSTEM. OPEN
THE 230 VAC DISTRIBUTION CIRCUIT BREAKER (4A5CB2) BEFORE
SERVICING THE RF AMPLIFIER. FAILURE TO COMPLY MAY RESULT IN
ELECTRICAL SHOCK OR DEATH TO PERSONNEL.
intended work area. Leave stick attached to the load side of the high voltage bus.
5-4.8 Distribution Cabinet Exit.

CAUTION
2. Close doors and return power to a normal operating condition.
3. Remove "Maintenance In-Progress warning tab and rotate the HIGH VOLTAGE
5-5 PREVENTIVE MAINTENANCE PROGRAM.
5-5. l General.
The Preventive Maintenance (PM) program establishes systematic inspection and

maintenance that will extend equipment life. A PM works to correct minor defects
before they develop into major problems. Electrical and mechanical parts of this
system shall be maintained by conventional maintenance techniques. Periodic PM
includes inspection, lubrication, cooling system checks, and cleaning of critical parts.
Preventive maintenance must be performed at stated
intervals to minimize equipment failures. Before performing PM routines, personnel

shall become familiar with and observe safety procedures in the front matter of this
manual.
5-5.2 Preventive Maintenance Schedule.
Table 5-3 is the schedule of PM routines for the transmitter system. Preventive
maintenance routines are based on system operation of up to 24 hours a day, 7 days a
week. Environmental conditions or user experience for specific transmitter units may
125
require that PM intervals for routines marked X2 in Table 5-3 be adjusted.
5-5.2. 1 Weekly Maintenance Schedule
Weekly maintenance activities consist of printing an operating parameters log for the
transmitter. The log shall be produced while operating the transmitter at a
predetermined frequency and RF power 1eve1. A log file shall be maintained to aid in
diagnosis of deteriorating transmitter components. The log may be printed from the
integrated computer printer port or a remote site control1er computer.
5-5.2.2.Mothly Maintenance Schedule
Monthly maintenance consist of inspection of Glycol and water coolant reservoirs for
liquid level. The coolant level shall be maintained such that the sight glass is
approximately half full. Add coolant to the respective system when the sight glass
level falls below one-third ful1.
5-5.2.3. Quarterly Maintenance Schedule.
Quarterly maintenance procedures include visual inspection of equipment for wear,
heat damage and loose connections. The interval for these procedures may be adjusted
as a result of site experience or requirements.
5-5.2.3. l. General Inspection Procedures.
The following genera1 inspection procedures should guide the user by identifying
certain areas of the transmitter which can reduce down-time for preventive and
corrective maintenance.
WARNING
SHUTDOWN OR DISCONNECT ALL POWER INPUT TO THE EQUIPMENT

BEFORE PERFORMING THE FOLLOWING OPERATIONS. UPON
COMPLETION RECONNECT POWER AND CHECK FOR SATISFACTORY
OPERATION OF THE SYSTEM. FAILURE TO COMPLY MAY RESULT IN
l. Inspect electron tubes for loose envelopes, connectors, cracked sockets, or

insufficient socket spring tension. Replace faulty tubes.
2. Inspect fixed capacitors for leaks, bulges, or discoloration. Replace faulty

components.
3. Inspect circuit breakers for loose mountings; burned, pitted or corroded contacts;
mis-alignment of contacts and springs; insufficient spring tension; binding of
plungers.
4. Clean the glass envelope of vacuum capacitors and tubes when necessary.
5. Inspect resistors and resistor mountings for cracks, chipping, blistering,

discoloration. Replace faulty resistors or mountings.
6. Inspect terminals of large fixed capacitors and resistors for corrosion, dirt and loose
contacts. Clean, tighten and repair as necessary.
7. Clean and tighten mountings of larger interior equipment.
126
8. Inspect terminal boards for loose connections, cracks and breaks. Replace faulty
terminal boards.
9. Lubricate moving parts, as necessary.
10. Tighten mounting bolts on 1arge transformers and chokes.
11. After the equipment has been in operation, inspect transformers, chokes,
potentiometer, etc., for leakage of overheating. Determine the cause of the trouble and
take corrective measures.
12. Examine sliding or moving coil contacts. Replace any contacts that are worn, bent
or broken.
13. Check all meters for correct zero setting. Adjust as necessary.
14. Check all door inter1ocks. Repair if inoperative.
15. Lubricate each motor drive mechanism when necessary.
16. During long periods of normal service, the character of the emitted signa1s from
the transmitter should be checked periodically. Indication for trouble during these
checks will often lead to the discovery of impending equipment failure before it
occurs.
5-5.2.3.2 Clean & Inspect Switch Housing Assembly.
Perform the following inspection and take corrective action as required. Observe
safety procedures in front matter of this manual while performing the procedures.
WARNING
HIGH VOLTAGE HAZARD
FOLLOW APPROVED ACCESS PROCEDURE AS REQUIRED. FAILURE TO
COMPLY MAY RESULT IN DEATH OR INJURY TO PERSONNEL.
1. Follow the procedure in Paragraph 5-4.l to access the switch housing assembly
2. Use a trouble light and inspect;
a. Wiring for signs of over--heating.
b. Components for signs of overheating or arcing.
c. Grounding switch contacts for a thin film of grease. If necessary, apply

multipurpose grease and wipe off any excess with cotton rag.
CAUTION
FAILURE TO FOLLOW APPROVED EXIT PROCEDURE MAY RESULT IN
EQUIPMENT DAMAGE AND TRANSMITTER DOWN-TIME.
3. Follow the procedure in Paragraph 5-4.2 to exit cabinet.
127
Table 5-3. Preventive Maintenance Schedule
PM Action Maintenance Interval 1 Procedure
W M Q SA A Paragraph
Print Parameters Log X2 Refer to 5-5.2.1
Inspect Coolant System X2 Refer to 5-5.2.2
Clean & Inspect HV Distribution X2 Refer to 5-5.2.3.2

Cabinet
Clean & Inspect Modulator Vault X2 Refer to 5-5.2.3.3
Clean & Inspect RF Amplifier Refer to 5-5.2.3.4
Cabinet
X2
Clean & Inspect PA Cabinet Inlet air X2 Refer to 5-5.2.4.1

fi1ters
Clean & Inspect Cooling System X2 Refer to 5-5.2.4.2
1.Maintenance Interval Codes

W = Weekly M = Monthly Q = Quarterly SA = Semiannually A = Annually
2 Maintenance interval may be adjusted based on environmental conditions and/or experienced
requirements.
5-5.2.3.3 Clean &Inspect Modulator Vault.

WARNING
HIGH VOLTAGE HAZARD
FOLLOW APPROVED ACCESS PROCEDURE AS REQUIRED. FAILURE TO
1. Fo1low the procedure in Paragraph 5-4.l to access modulator vault.

2. Use a trouble light and inspect:
a. Wiring for signs of over-heating.
c. Grounding switch contacts and drive mechanism for a thin film of grease. If
necessary, apply multipurpose grease and wipe off any excess with cotton rag.
d. Remove and clean the two particulate filters located on the intake ports of
blowers 4AlBl and 4A2Bl. The filters may require replacement after 8 to l0
cleaning cycles.
CAUTION
3. Follow the procedure in Paragraph 5-4.2 to exit cabinet
128
5-5.2.3.4 Clean & Inspect RF Amplifier Cabinet
WARNING
HIGH VOLTAGE HAZARD
FOLLOW APPROVED ACCESS PROCEDURE AS REQUIRED, FAILURE TO
1. Follow the procedure in Paragraph 5-4.3 to access RF Amplifier Cabinet.

2. Use a trouble 1ight and inspect;
a. Wiring for signs of over--heating.
c. Grounding switch contacts for signs of arcing. Clean with handpad as
necessary. If cleaning is unsuccessful replace as necessary with cap nut
contact elements.
d. Check spark gaps for evidence of arcing. Clean with handpad or replace as
necessary.
e. Remove and replace the particulate filter located in the RF Amplifier Cabinet.
f. Inspect coolant lines and connections for leaks or bulging flex lines. Take
corrective action as indicated by the condition.
CAUTION
5-5.2.3.5 Clean & Inspect Utility Cabinet.

WARNING
HIGH VOLTAGE HAZARD
1. Follow the procedure in Paragraph 5-4.5 to access Utility Cabinet.
contact elements.
CAUTION
129
5-5.2.3.6 Clean & Inspect Distribution Cabinet.

WARNING
HIGH VOLTAGE HAZARD
1. Follow the procedure in Paragraph 5-4.7 to access Distribution Cabinet.

contact elements.
CAUTION
3. Follow the procedure in Paragraph 5-4.8 to exit cabinet
5-5.2.4 Semiannual Maintenance Procedures.
In addition to the quarterly procedures, the PA cabinet inlet filters requires semiannual
inspection and cleaning. Some semiannual procedures may be changed to quarterly
and quarterly procedures may be changed to semiannual as a result of site experience
and/or requirements.
5-5.2.4.l. Air Filters Inspection and Cleaning.

The transmitter air intake filters will require cleaning or replacement every six
months. In abnormally dusty environments the filter may require more frequent
inspection. In extremely dusty areas a pre-filter will be required to prevent premature
filter failure. If the filter does not contain 1arge amounts of pollutants it can be
cleaned by careful1y blowing low pressure compressed air through the filter in the
reverse direction to normal air flow. If the airflow through the filter is restricted
sufficient1y by dust to reduce the air cooling capabilities of the system, the filter
should be replaced.
5-5.2.4.2. Cooling System Inspection and Cleaning.

The water system must be kept clean at all times. A strainer is provided in the boiler
lines to catch any particulate accumulation which might get into the system. Clean
this strainer more often if an unusual amount of particulate accumulation occurs.
Keep the Pyrex steam lines associated with the boiler clean at all times. Visual
inspection will indicate when these Pyrex lines require cleaning. All water lines that
connect to the boiler are equipped with electrolytic targets which require periodic
130
replacement. The short piece of copper tubing that the water hose attaches to is the
electrolytic target. The operating environment of these targets will determine how
frequently they should be replaced. The target must extend into the hose past the hose
clamp approximately l/8 inch to allow the clamp maintain a water tight connection.
Check the condition of the targets periodically and replace them as necessary. The
separator tank and the cooling reservoir should be checked and cleaned when
necessary to keep the water resistance at a reasonable 1evel.
The flow regulators should be taken apart and cleaned if the water flow is not normal.
There are three valves mounted on the header input lines to inductor 3L12 and its
plungers, and to the PA loading network. Another regulator for the PA boiler input line
is located beside the header in the lower rear portion of rf amplifier cabinet.
Clean the valves by removing the hose and disassembling the valve. Wash the valve
with running water and assemble the valve. Tighten all hoses before turning on the
water.
Clean the heat exchanger to keep it free of dust and other debris. The frequency of the
cleaning must be determined by the prevailing environmental conditions at each site.
5-5.2.5 Annual Maintenance Schedule.

There are no annual maintenance procedures that differ from the quarterly procedures.
Some quarterly procedures may be changed to annual procedures as a result of site
experience and/or requirements.
5-6. CORRECTIVE MAINTENANCE PROGRAM

Corrective maintenance program consist of the trouble-shooting of the transmitter
equipment to fault isolate the defective unit; and systematic fault isolation to the
assembly, or component level; and repair or replacement of the faulty assembly or
component.
5-6.1 Troubleshooting Procedures.

Repair of the Transmitter consists primarily of assembly or component replacement at
the site. The maintainer can use information displayed in the status lamps and meter
reading and perform the maintenance indicated.
5-6.2 Systematic Fault Isolation.

Should troubles exist which are not obvious from the status lamps and meter reading,
the troubleshooting approach shall consists of a systematic fault isolation approach.
And use of standard test equipment and the circuit diagrams located in Section 7 of
this manual to aid in the fault isolation. It is seldom possible to merely observe
symptoms and immediately diagnose system troub1es. Usually, a methodica1
sequence of operational checks, observations, and measurements are required to
isolate faulty circuits. Once a faulty transmitter circuit is isolated an assembly, or, in
1imited instances, components within that circuit must be replaced. Where applicable,
electrical adjustments must then be performed to restore equipment to normal
operation. The following maintenance procedures, outlined in six logical steps,
provide the basis for isolating faults in the amplifier which are not isolated by the
131
status lamps and meters.
1. Symptom recognition is the first step, based on complete understanding of the

transmitter operational characteristics. Equipment troubles are not always a direct
results of component failure. Troubles in the transmitter, therefore, may not be
obvious ones since conditions of less than peak performance do not necessari1y
call attention to themselves. That kind of equipment trouble is usual1y discovered
during preventive maintenance procedures rather than normal operations. It is
important that familiar and unfamiliar troubles be recognized, this part of Section
5 is designed to help achieve that goal.
2. Troubleshooting aids designed into the equipment shall be used to further analyze
trouble symptoms. The local fault indicators and meters will provide valuable
data.
3. Taking note of probable faulty functions is the next step in logical
troubleshooting. This provides a number of logical choices as to likely cause and
location of a fault. Such choices are based on a thorough understanding of the
transmitter operation, fully identified trouble symptoms, and information
contained in this manual.
4. Isolate faulty functional sections by testing 1ogical choices in an order that
consumes the least amount of time. To do that requires deciding which transmitter
section to test first. That selection shall be based on validity of logical choices and
difficulties in making necessary tests. If tests do not isolate a fault the next
selection should be tested, and so on until a faulty section is isolated.
5. After faulty functional sections have been iso1atcd, specific circuits must be
identified. This may involve the making of additional logical choices within
defective functional sections. During circuit analysis, remember to apply the most
basic of techniques. Are trouble symptoms limited to a specific area, or are they
widespread? If all frequencies are affected, for example, look for such common
elements as power supplies, filter stages, etc.
6. Failure analysis shall be conducted after troubles have been located. Prior to
performing corrective actions, maintenance personnel should review fault
isolation procedures to determine exactly why the identified fault affected the
amplifier as it did. This review assures that discovered faults are source failures
rather than resultant, or sympathetic, failures.
5-6.3 Modu1ator Controller, Unit 9.

WARNING
VOLTAGE HAZARD
REMOVE ANY METALLIC JEWELRY FROM PERSON PRIOR TO SERVICING
THE MODULATOR CONTROLLER. FAILURE TO COMPLY MAY RESULT IN
PERSONAL INJURY.
The modulator controller card cage contains circuit cards which plug into the mother--
board and some cards have input and output ribbon type cables to the outer edges of
the card. Some of the cards have LED type indicators along the card edge for
maintenance and trouble shooting purposes. The operation section of this manual,
Figures 3-4 through 3-6 and Tables 3-4 through 3-6 describe the function of each
indicator.
CAUTION
132
USE ELECTROSTATIC HANDLING PROCEDURES WHEN REMOVING OR
INSTALLING CIRCUIT CARD ASSEMBLIES IN THIS TRANSMITTER.
FAILURE TO COMPLY MAY RESULT IN DAMAGE TO CIRCUIT CARDS.
Refer to Figure 5-3 for 1ocation of the cards, and observe the following precautions
when servicing them:
1. Remove all electrical power from the card cage prior to unplugging a card.
2. Place a grounded electrostatic wrist band on your wrist prior to handling circuit
cards in the modulator. Refer to Table 1-3, Equipment Required but not Supp1ied
for identification of a recommended electrostatic wrist band.
3. When a card is removed from the card cage immediately place it in an
electrostatic protective container or on a protective work mat. Refer to Table l -3,
Equipment Required but not Supplied for identification of a recommended
electrostatic container or work mat. If the circuit is to be tested in the controller,
install extender board and insert circuit card into the extender board. Always wear
a grounded e1ectrostatic wrist band when testing circuit cards.
Figure5-3. Modulator Controller Assembly Locator

Diagram.
133
5-6.4 Fault Isolation Using Modu1ator LEDs.
Fault-isolation in the modulator can be facilitated by an understanding of the

interrelationships between the switching module, the switch status card and the ring
modulator card, Refer to Figure 5-4, Simplified Troubleshooting Block Diagram.
Please note the LEDs numbered l through 3 when reading the following explanation.
Three-phase power is applied to each switching module and is rectified and used to
charge a storage capacitor. The voltage across this capacitor is monitored by the "DC
OK LED (#l LED). This LED will be illuminated when there is significant dc
voltage across the storage capacitor. Should the primary 3-phasc power be removed or
switched off, or should the rectifier assembly become defective, the lamp wil1
extinguish as the storage capacitor discharges.
The output of the storage capacitor is applied to the first IGBT. This switch is
normally conducting. Its output is monitored by a voltage-to-frequency (V-F)
converter. This circuit generates a pulse train which is routed to the modulator
controller through a fiber optic cable. If there is no charge on the storage capacitor, or
the first switch is not conducting, the V-F converter generates a repetition rate of a
few hundred Hz. If the storage capacitor has a normal charge, and if the first IGBT is
conducting, the pulse repetition rate will be about 37 kHz. The frequency is
proportional to the voltage across the storage capacitor.
This repetition rate is received at the switch status card. If the repetition rate is
approximately normal (i.e., the voltage on the storage capacitor is normal), and the
first switch is on, then a frequency comparator on the switch status card will
illuminate a second LED (#2 LED). This lamp, on the switch status module, wil1
show that the particular switch is powered and functioning normally. The frequency
comparator output is also routed to the ring modulator card. Here it enables drive
pulses to go from the ring modulator to the switch module.
If the second IGBT switch operates correctly, and its output follows the commands
from the ring modulator, then the phase comparator will allow the first switch to
remain conducting. Should the second switch not follow the incoming command, the
first switch is biased off. This wil1cause the V-F converter frequency to drop to a few
hundred Hz. This is interpreted by the comparator on the switch status card as a fault.
The status LED (#2 LED) on the switch status card will be extinguished and the drive
from the ring modulator to the switch module will be turned off.
The # l LED directly monitors dc present on the storage capacitor. The #2 LED, on
the switch status card, will be on when dc is present on the storage capacitor, the first
dc switch is conducting,
and the fiber optic link return link is satisfactory. The #3 LED directly monitors the
output of the switch module.
Abnormalities in these three LEDs are indications of modulator problems. Use these
LEDs and Figures 5-4, 5-5, and 5--6 to aid in isolation of modulator fau1ts.
134
5-7. REMOVE AND REPLACE PROCEDURES
The illustrations and schematics located in Section 7, show the various units and
components. The components are identified at their location on the assembly by
reference designator numbers. The reference designator numbers correspond to those
used on schematics and parts lists. The figures will be useful for identifying the
components being removed and replaced. Table 6-l is a cross-reference index of the
transmitter unit numbers to parts lists and page numbers.
5-7.1 Lamp Remove and Replacement Procedure.

Use the following procedure to replace the bulbs in the indicator lamp assemblies:
CAUTION
DO NOT INSERT AN EMPTY LAMP EXTRACTOR TOOL INTO AN EMPTY
SOCKET WHEN POWER IS APPLIED. THE BULBS CAN BE REMOVED OR
REPLACED WITH POWER APPLIED BY FOLLOWING STEPS (1) AND (2) OF
THIS PROCEDURE. FAILURE TO COMPLY MAY RESULT IN DAMAGE TO
LAMP SOCKET.
1. Remove the disp1ay screen by gently prying around the top edge with a small
screwdriver or similar instrument. When the display screen is removed the bulbs
and their color filters will be visible.
2. Using the Microswitch Type l532 lamp tool, remove the bulb which is being
replaced by inserting the tool completely down into the socket around the base of
the bulb. Small tabs on the tool will act as stops when the tool is inserted far
enough to spread the prongs which hold the bulb in place. After inserting the tool
around the bulb as close to the socket as possible, withdraw the tool and the bulb
should come out easily.
CAUTION
USE CARE NOT TO STRETCH THE FILTER ON THE BULB. IF THE COLOR
FILTER BECOMES STRETCHED ITS COLOR WILL NOT BE UNIFORM.
FAILURE TO COMPLY MAY RESULT IN DAMAGE TO LAMP FILTERS.
3. Remove the flexible silicone color filter from the old bulb and place it over the
new bulb.
4. Holding the new bu1b in the tool, insert it into the 1amp socket.
5-7.2 Switch Removal and Replacement Procedure.

Under norma1 operating conditions very little maintenance is required for the lamp
modules and their associates switches. If maintenance is required, use the following
procedure to replace module:
1. A single switch/lamp module mounted in a single hole can be removed by pushing
the entire module out through the front of the cabinet.
2. When two or more modules are mounted together in a common hole, all modules
must be pushed out of the common mounting hole together. The faulty module can
then be removed and replaced with a new assembly.
3. The switch can be removed from the assembly after the assembly has been
withdrawn from the mounting hole. Gently pry with a small screwdriver between
the switch housing and the mounting extension on the side where the two
"fingers, of the mounting clip are located.
135
5-7.3 Purification Resin Remove and Replace Procedure.
When the purification resin 1oses its ability to maintain high resistivity coo1ant, it
should be replaced using the following procedure:
1. Use the procedures in Section 3 to turn transmitter off.
2. Close valves to isolated the resin tank for the system water flow.
3. Disconnect the waterlines from the resin tank, using a rag to prevent spilling water
from the lines into the transmitter.
4. Remove resin tank from the transmitter and remove filler cap.
5. Pour old resin beads into a suitable container for proper disposal.
6. Pour new resin beads into the resin tank until it is approximately 2/3 full. Replace
filler cap.
7. Place resin tank into the transmitter and connect the water lines. Use care to
prevent crossing the threads on the water line fittings.
8. Open coolant isolation valves and return the system to normal operation.
Figure5-4 Simplified Troubleshooting Block Diagram.
136
Figure 5-5. Modulator Troubleshooting Logic Diagram(sheet 1 of 5)
137
138
139
140
141
Figure 5-6. Power Switch Troubleshooting Logic Diagram
142
5-7.4 Power Amplifier Tube Remove and Rep1ace Procedure.
2. Remove the 230 Vac distribution voltage by opening circuit breaker 4A5CB2.
3. Loosen coupling nearest grid tuning motor drive shaft using an Allen wrench.
Slide coupling toward motor.(See Figure 5--7.)
4. Loosen resistor assembly and remove 3R l8 and 3Ll1. Use l1/32" wrench.
Remove resistor 3Rl6 and the neutralization paddle 3C34.
5. Remove screws to loosen hinged plate. See Figure 5-8. Use No. 10 Phillips
screwdriver.
6. Remove filament power leads from interface panel. See Figure 5-9.
7. Remove inter and outer air flow cooling flex hose. See Figure 5-l0.
8. Remove coax and control connectors.
9. Slowly raise hinged shelf. See Figure 5- l1.
10. Tie shelf up so tube may be remove.
11. Remove retaining ring. See Figures 5- l2 and 5- 13. Use Phillips type screw driver.
12. Lift up to remove tube from boiler.
13. Apply a non-deteriorating heat-resistant lubricant, DC4 or equivalent, to the o-ring
in the PA tube boiler.
14. Install the type 4CVl00,000C tube (3V3) in its boiler.
15. With the tube centered in the boiler rep1ace the anode ring which was removed in
Step (36) of this procedure. Clamp the tube in place.
16. Carefully lower the low level rf shelf into position making sure that tube 3V3
centers and seats into its socket (3XV3) properly. It may be necessary to
reposition the boiler-blocker assembly slightly.
NOTE
It is critical that the filament contacts are centered and have equal contact pressure.
Watch for over-deflection or under-deflection of the filament contacts.
17. Replace all hardware and components which were removed previously in this
procedure.
18. Follow procedure in Paragraph 5-4.4 to exit RF Amplifier Cabinet.
5-7.5 Fiber Optic Cable Termination.

Use the following instructions when terminating the Motorola fiber optics associated
with the ground fault sensors (wire number 51 and 52). Note that incorrect fiber optic
terminations may result in reduced optical performance and increased modulator
noise.
Termination instructions for the optic cable used with the Hewlett Packard system is
described in the Supplemental Data section of this manual.
1. Cut cable squarely with sharp blade or hot knife.

2. Strip jacket back with l8 gauge wire stripper to expose 0.l0 to 0.l8 inches of bare
fiber core. Avoid nicking the fiber core.
3. Polish the end of the optical core by first using 600 grit abrasive paper and
finishing with 3 m lapping film. When polishing the optical core use a figure
143
eight pattern to insure a proper finish.
4. Loosen the locking nut on the optic device but do not completely remove. Insert
the fiber through the locking nut and into the device until the core tip seats against
the molded lens inside the optic device.
CAUTION
DO NOT OVER-TIGHTEN THE LOCKING NUTS. FAILURE TO COMPLY MAY
RESULT IN DEGRADATION OF OPTIC PERFORMANCE.
5. Tighten the locking nut until it is just finger tight.
144
Loosen Coupling
Remove Nuts Choke

And Resistor
Remove 3R16
Figure 5-7 PA Grid Circuit Component Locator.
145
Figure 5-8 Removing Shelf Screws.
146
Figure5-9 Filament Lead
147
Figure 5-10 Inter and Outer Air Flow Cooling Flex Hose.
148
Figure 5-11 Shelf Assembly Lifted.
149
Figure5-12 Retaining Plate, Screw Removal.
150
Figure 5-13 Retaining Plate Removal
151
5-7.6 Tuning Capacitor Removal and Replacement Procedure.
The following procedure is for the removal and replacement of faulty tuning
capacitors. If the alignment of a tuning capacitor, its motor drive, its follow-pot, or its
limit switch needs adjustment, refer to the Paragraphs 2-8.3 through 2-8.5 in lI1is
manual.
In gcnera1, all tuning capacitors are removed and replaced when the component is at
its high frequency limit. This insures that the tuning component and the servo is
properly aligned. The following procedures describes the removal and replacement of
each tuning capacitors. Refer to Figures5-l4a and 5-l4b for an example of cw and ccw
adjustment of the vacuum capacitors.
5-7.6.l. PA TUNE Capacitors,3C36 and 3C37.
Perform the fol1owing steps to remove and replace tuning capacitors3C36 or 3C37:
1. Note the number on the digital readout of the currently selected PA TUNE
potentiometer. Run the PA TUNE servo to the high frequency limit. This is
accomplished by turning the PA TUNE potentiometer fully clockwise.
4. Remove the l/2" bolt connecting the P1 coil to the coupling of 3C36 and 3C37.
5. Remove the resistor assemblies 3R29 and 3R30.
6. Remove the coupling plate between the capacitors.
7. Remove the six bolts supporting the faulty capacitor to the shelf (requires two
people).
8. Remove the LoveJoy coupling from the faulty capacitor.
9. Install the coupling on the new capacitor.
10. Turn the shaft of the new capacitor clockwise (cw) until the mechanical stop is
reached. Now turn the shaft counterclockwise (ccw) one quarter turn. At this point
the capacitor is set at minimum capacitance. Refer to Figures 5- 14a and 5- l4b for
determining cw and ccw rotation.
11. Mount the capacitor to the shelf. Confirm the servo motor is in the high frequency
limit. Adjust the coupling as necessary and re-tighten the set screw.
procedure.
13. Adjust the PA TUNE potentiometer to the number previously noted. Re-tuning
may be required when the transmitter is returned to operation.
152
14. Follow the procedure in Paragraph 5-4.4 to exit RF Amplifier Cabinet.
5-7.6.2. PA LOAD Capacitors, 3C38 and 3C39
Perform the following steps to remove and replace tuning capacitors3C38 or 3C39.
1. Note the number on the digital readout of the currently selected PA LOAD
potentiometer. Run the PA LOAD servo to the high frequency limit. This is
accomplished by turning the PA LOAD potentiometer fully clockwise.
2. Follow procedure in Paragraph 5-4.3 to access RF Amplifier Cabinet.
4. Remove the l/2" bolt connecting the PI coil to the coupling of 3C38 and 3C39.
Remove the l/4 bolt connecting the output buss to the coup1ing of 3C38
and3C39.
5. Remove the resistor assemblies 3R31 and 3R32.
6. Remove the coupling plate between the capacitors.
7. Remove the six bolts supporting the faulty capacitor to the shelf (requires two
people).
the capacitor is set at minimum capacitance. Refer to Figures 5- l4a and 5-l4b for
11. Mount the capacitor to the shelf. Confirm the servo motor is in the high frequency
limit. Adjust the coupling as necessary and re-tighten the set screw.
procedure.
13. Adjust the PA LOAD potentiometer to the number previously noted. Re-tuning
14. Follow procedure in Paragraph 5-4.4 to exit RF Amplifier Cabinet.
5--7.6.3. IPA TUNE Capacitor, 3C19.
Perform the following steps to remove and rep1ace tuning capacitor 3C l9:
1. Note the number on the digital readout of the currently selected PA TUNE
potentiometer. Run the PA TUNE servo to the high frequency limit. This is
accomplished by turning the PA TUNE potentiometer ful1y clockwise.
153
2. Follow procedure in Paragraph 5-4.3 to access RF Amplifier Cabinet.
4. Remove the insulating shaft between the capacitor 3C l9 and the drive of coil
3L9.
5. Remove the two #l0 screws securing the bracket of 3Cl9 to the two standoff
insulators.
6. Remove the two #8 screws from the clamping bracket that holds 3C l9.
7. Loosen the #l0 screw on the discriminator bracket, located on the end of 3C l9.
8. Remove capacitor 3Cl9.
9. Remove the shaft and remaining bracket from the faulty capacitor and install on
the new capacitor.
the capacitor is set at minimum capacitance. Refer to Figures 5- l4a and 5- l4b for
procedure.
12. Adjust the IPA TUNE potentiometer to the number previously noted. Retuning
13. Fol1ow procedure in Paragraph 5-4.4 to exit RF Amplifier Cabinet.
154
155
5-7.6.4. Harmonic Filter Capacitors.
Refer to Paragraph 5-8.3 for the replacement of capacitors in the Harmonic filter.
5-7.6.5. Balun Capacitors, 7C1 and 7C2.
Perform the fo1lowing steps to remove and replace tuning capacitors 7Cl and 7C2:
1. Note the number on the digital readout of the Currently selected BALUN
potentiometer. Run the BALUN servo to the high frequency limit. This is
accomplished by turning the BALUN potentiometer fully clockwise.
3. Remove Balun Cover.
4. Remove the coupling plate between the capacitors and the connecting strap.
Remove the connecting strap from the outer conductor of the transmission line.
5. Remove the six bolts supporting the faulty capacitor to the balun chassis.
the capacitor is set at minimum capacitance. Refer to Figures 5- l4a and 5- l4b for
9. Mount the capacitor to the balun chassis. Confirm the servo motor is in the high
frequency limit. Adjust the coupling as necessary and retighten the set screw.
procedure.
11. Adjust the BALUN potentiometer to the number previously noted. Retuning may
be required when the transmitter is returned to operation.
12. Fo1low procedure in Paragraph 5-4.4 to exit RF Amplifier Cabinet.
5-8 ALIGNMENT PROCEDURES.
The following alignment procedures are to be performed following maintenance or

when performance of the transmitter indicates an out of tolerance condition.
5-8.l Water Resistivity Meter Calibration.
Should the water resistivity meter need calibration the following procedure should be
used:
156
l. Remove the power from the unit. Remove the cover from the meter assembly by
unscrewing the two screws on the sides.
2. Disconnect the resistance cell wires from the meter terminal board.
3. Connect a 50 K ohm precision resistor across the terminals. App1y power to the
meter and adjust the potentiometer until the meter reads 50 K ohms.
4. Repeat Step 3 using a l meg-ohm resistor, the meter should read 1 meg-ohm.
Remove the resistor and connect the resistive ce1l wires.
5. Install the meter assembly cover and return the system to normal operation.
5-8.2 Audio Path Alignment, 9A4.
CAUT1ON
USE ELECTROSTATIC HANDLING PROCEDURES WHEN REMOVING OR

INSTALLING CIRCUIT CARD ASSEMBLIES IN THIS TRANSMITTER.
FAILURE TO COMPLY MAY RESULT IN DAMAGE TO CIRCUIT CARDS.
The following is the alignment procedure for the Audio Path circuit board, 9A4,
located in the modulator controller assembly. Reference Schematic Diagram
PF2.810.6000DL. Included in this procedure is the alignment of the Clock
Modification circuit card, 9A4Al. Reference Schematic Diagram l8l375.This
procedure assumes the operator has a working knowledge with the circuits associated
with this card. The alignment procedure consists of a low level alignment with zero rf
output power and a high level alignment with l00% rf output power.
5-8.2.l Preliminary Alignment.
Prior to applying power to the circuit card, turn potentiometer R20, R119, Rl20, and
Rl2l fully counterclockwise. Using an extender card, install the audio path card into
the card cage slot for the A4 card. Apply power to the modulator controller but DO
NOT TURN ON HIGH VOLTAGE at this time.
5-8.2.2 Low Level Alignment.
Perform the following steps to achieve a low level alignment:
1. Begin by adjusting the triangle wave frequency and the square wave frequency on
the clock modification card. This is accomplished by measuring the triangle wave
frequency at Al U6-12 and adjusting AlR22 until the frequency is approximately
70 kHz. Verify that the square wave frequency at A1 U l-4 is between 2 and
2.5MHz.
2. Alignment the gain adjustment of the audio path's input stage. Measure the signal
at U28- l with an oscilloscope. This signal should be approximately 5.l volts with
no audio present and CCM set to O dB attenuation.
157
3. The operator should apply a 1 kHz tone to the transmitter audio input. The leve1
of this tone should be set to a value where the user expects to achieve l00%
modulation.
4. Turn the c1ipper switch (S2) to the off position. Jumper J1 and potentiometer R
l06 are used to adjust the gain of the input stage. Jumper J1 is used for course
adjustments and Rl06 is used for fine adjustments. When setting J1, jumper R93
to ground if more gain is desired, or jumper R94 to ground if less gain is desired.
5. Adjust Rl06 until the negative peak of the signal at U28- l reaches zero volts.
After the gain adjustment is completed, continue viewing the signal at U28- l and
turn the clipper switch on.
6. Align the positive and negative peak clipper by adjusting R97 and R112
respectively. After completing this adjustment turn the clipper switch off.
7. Alignment the multiplier chips U1l and U29. Device U11 is invo1ved with the
signal that drives the transmitters' screen power supplies. The offset of its output is
set by R47. Because the negative peak of the triangle wave output (U15-3) is
offset by 5 vo1ts. The signal at U11-8 should also be offset by 5 vo1ts. Adjust R47
until the signal at Ul6-3 is approximately 5 volts.
8. Device U29 processes the signal that drives the modulator's power supply. The
output offset is set by R1l9. Adjust Rll9 until the signal at U30-6 is approximately
300 millivolts. Potentiometer R120 should not be adjusted at this time.
9. Finally, adjust the triangle wave's amplitude at U30-6.Adjust Rl2l until a triangle
appears and has a peak to peak amplitude of approximately 200 millivolts.
This completes the low level alignment of the audio path circuit board. At this time
press the power lower button on the transmitter's front panel and confirm that the
power control signal at Pl-C29 is 0 volts in the following power states: High Power,
Low Power, and Tune Power (if applicable).
5-8.2.3 High Level Alignment
Perform the following steps to achieve a high level alignment of the audio path card:
1. Apply a low level l kHz tone (approximately 20 dB below 100%) to the

transmitter's audio input and turn on the transmitter's high voltage.
NOTE
Both the plate and screen voltage meters should be near 0 volts.
2. Press power raise button until the p1ate voltage is approximately 5 kilovolts.
Adjust R20 until the screen voltage meter reads 250 volts.
NOTE
The transmitter should be properly tuned.
3. With the transmitter properly tuned, raise the plate voltage until it reaches its
158
typical til1 power operating voltage.
4. Adjust R20 until the screen voltage reaches its typical full power operating
voltage. At this point, the transmitter's output power should at l00% rated power.
NOTE
The next stage of the high level alignment involves minimizing total harmonic
distortion (THD).
5. Ca1ibrate the THD measuring equipment to be used. Turn Rl2l fully counter
clockwise. Slowly turn R12l clockwise unti1 the first dip in THD is observed.
After this is completed, check THD at several modulation depths and audio
frequencies. In some cases, the operator may notice a THD problem at high audio
frequencies. This may be improved by adjusting R120. The adjustment of Rl20
injects a second harmonic distortion into the transmitter which is opposite in
phase to the second harmonic distortion inherent to some class C amplifiers.
CAUTION
THE OPERATOR SHOULD TAKE GREAT CARE WHEN ADJUSTING RL20.

FAILURE TO COMPLY MAY RESULT IN DAMAGE TO THE TRANSMITTER.
6. The transmitter's output power should be slightly lowered when adjusting R120
because this potentiometer directly effects the transmitter's plate voltage. Also,
over-adjusting R l20 can cause THD problems at low audio frequencies and
increased positive carrier shift. Therefore, the adjustment of Rl20 should be a
compromise of the following parameters: high audio frequency THD; low audio
frequency THD, and positive carrier shift.
7. After minimizing THD, lower the transmitter's output power to approximately

95% rated power and apply a 1kHz tone at a modulation depth of l00%. Resistor
Rll9 effects the modulation capability of the transmitter but also effects plate
voltage, so great care should be taken when making this adjustment. On an
oscilloscope, observe the negative trough in the envelope of the transmitter's
output. Slowly turn Rll9 clockwise until an increased clipping is noticed in this
trough. Now slow1y turn R l l9 counterclockwise until this clipping is minimized.
8. Remove the audio tone and lower the power to minimum plate voltage. Proper
tracking of the screen voltage and the plate voltage is obtained by adjustingR47.
Adjust R47 until minimum screen voltage and minimum plate voltage occur
simultaneously. This completes the alignment of the audio path circuit card.
5-8.3 Power Control Alignment, 9A5.
The alignment of the power control circuit board effects two modes of modulator
operation. The first adjustment controls what power state the modulator goes to when
a reset command is given. The second adjustment controls the maximum output
voltage of the modu1ator for each of its power states (High, Low, and Tune). Refer to
Schematic l79088 for the following adjustments.
159
5-8.3.l Power Level on Reset Selection.
When a reset command is given to the modulator controller, it wil1 automatically

change to a preselected power state. This power state is selected by using the jumper J
l. If the jumper is placed across pins J1- l and J1 -2, low power will be selected when
a reset command is given. If the jumper is placed across pins J1 -2 and J l -3, high
power will be selected. This option can be defeated by simply removing the jumper
completely.
5-8.3.2 Maximum Power Level Alignment.
Maximum output voltage of the modulator can be adjusted for each power level.
Maximum output voltage for tune power, low power, and high power is set by R29,
R58, and R59 respectively. Install the power control card on the extender card in the
A5 slot. Restore power to the controller and turn the unmodulated transmitter on.
CAUTION
DO NOT ALLOW THE OUTPUT VOLTAGE OF THE MODULATOR TO EXCEED

THE MAXIMUM RATING OF THE TRANSMITTER. MONITOR THE PLATE
VOLTAGE METER WHILE MAKING THIS ADJUSTMENT. FAILURE TO
COMPLY MAY RESULT IN DAMAGE TO EQUIPMENT.
Details of this a1ignment are best explained by example: Assume the maximum
output voltage of the modulator in the high power state is to be set at 13 kV.
1. Turn R59 counterclockwise until the voltage at U2l -7 is approximately one half
volt.
2. Press the power raise button until the plate voltage stops increasing. Turn R59
clockwise until the plate voltage meter reads l3 kV. Confirm that l3 kV is the
maximum output voltage by pressing and holding the power raise button while
observing the plate voltage meter.
3. Repeat the steps l and 2 to set maximum output voltage for low power and tune
power.
5-8.4 Harmonic Filter Alignment, Unit 8.
Use the following procedure if any component in the Harmonic Filter needs
replacement or if the Harmonic Filter needs realignment.
1. Loosen the coupling chain so that the two shorting arms of inductors L1 and L2
can move freely. Adjust the shorting arms so that both are in line and their contact
wheels are pointing the same direction.
2. Re-tighten the coupling chain. Make sure the shorting arms do not move.
3. Remove the access panels to the Harmonic Filter.
4. Remove the interconnecting buss from C1 to L1 and from C3 and L2.
160
5. Loosen and separate the couplings for C1, C2, and C3.
6. Using a vector impedance meter tuned to 20 MHz, set C1 and C3 to an impedance

of 68 ohms.
7. Using a vector impedance meter tuned to 20 MHz, set L1 and L2 so that each
inductor has an impedance of 68 ohms.
8. Install the interconnecting buss from C l to L1 and from C3 and L2.
9. Confirm a resistive 75 ohm load is connected to the output of the Harmonic filter.
10. Isolate the input of the Harmonic filter from the output to the transmitter. Connect
the vector impedance meter to the input of the filter.
11. Adjust C2 until an impedance of 753and an angle of 0 3is measured at the

input of the fi1ter. It may be necessary to slightly adjust L1 and L2 to obtain this
impedance. The relative positions of the shorting arms of L1 and L2 shou1d track
with each other.
12. Reconnect the input of the Harmonic Filter to the output of the transmitter.
13. Engage the couplings for Cl, C2, and C3. Tighten the set screws for each coupling.
14. Disengage the gear for the counter and set the counter to a value of 82.2. Engage
the gear for the counter.
CAUTION
DO NOT LET THE CONTACT WHEELS OF L1 AND L2 COME WITHIN 3

INCHES OF THE END OF THEIR RESPECTIVE COILS. FAILURE TO COMPLY
MAY RESULT IN EQUIPMENT DAMAGE.
15. Run the Harmonic Filter to the low frequency end and set the limit switch (S1) to
engage when the contact wheels of L1 and L2 are 3 inches from the end of their
respective coils.
16. Run the Harmonic Filter to the high frequency and until the high frequency limit
switch (S2) is engaged. The counter shou1d read between 88.0 and 92.0.
17. With the filter at the high frequency limit, set the follow-pot to l,600(between
the slider 2 and cw 3). Run the filter to the low frequency limit, set the follow pot
to l,600(between the slider 2 and ccw l ).
18. Replace the access panels on the Harmonic Filter.
161

50kW TX Operation Manual

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CONTENTS

SECTION1 - GENERAL INFORMATION..................................................................5

1-1.1 Section1 - General Description.

1-l.2 Section 2 -Installation.

l-1.3 Section 3 - Operation.

1-l.4 Section 4 -Theory of Operation.

l-1.5 Section 5 - Maintenance.

l-2.2 Utility Cabinet, Unit 2.

l-2.3 RF Amplifier, Unit 3.

l-2.4 Modulator Power Enclosure, Unit 4.

HIGH VOLTAGES ARE CONTAINED WITHIN THE MODULATOR POWER

l-2.4.l Switch Housing Assembly, 4A5.

l-2.4.2 Solid State Modulator.

1-2.4.2.l Power Switch.

l-2.4.2.2 Power Switch Control.

l-2.5 Cooling System, Unit 5.

l-2.7 Balun, Unit 7 (Optional).

l-2.8 Harmonic Filter, Unit 8.

1-2.9 Modulator Controller, Unit 9.

1-2.9.l SSB Generator, A1(Option).

1-2.9.2 SSB Equalization, A2(Option).

l-2.9.4 Audio Path, A4.

l-2.9.5 Power Control, A5.

l-2.9.6 Flash Converter, A6.

1-2.9.7 Ring Modulator, A7.

l-2.9.8 Status, A8 and A9.

1-2.9.9 Power Supply, A10.

1-2.9.l0 Input Output, A11.

l-2.9.11 Optical Transmitter, A12.

1-2.9.l2 Optical Receiver, A13.

1-2.9.l3 Backplane, A14.

Table 1-2 list of Equipment supplied

Unit2 Utility Cabinet Assembly

Unit3 RF Power Amplifier Assembly

Unit4 50 kW Modulator Assemb1y

Unitl0 Remote Computer (Option 2)

Unit11 Remote Control Assembly

1-6 TUBE COMPLEMENT

Power Amplifier 1 4CVl00,000C

Intermediate Power Amplifier 1 4CX3,000A

2-2. TRANSMITTER BUILDING REQUIREMENTS

In constructing a new building or in using one presently constructed, the method of

If a basement is provided in the transmitter building, the Power Enclosure equipment

2-4. PRELIMINARY INSTALLATION STEPS

2-6. INSTALLATION OF MAJOR UNITS

2-6.2 Utility Cabinet, Unit 2.

Use the following procedure to install the Utility Cabinet.

2-6.3 Control and Low Voltage Distribution, Unit l.

5. If the balun unit is to be mounted externa1 to the transmitter, an extra

40. Install the 4CX3.000A tube in its socket.

44. Install any other components removed for shipment.

46. Confirm the following ball gaps are set as indicated:

Use the fol1owing procedure to install the harmonic filter unit:

2-6.6 Balun, Unit 7.

6. Remove the balun bottom cover plate.

10. Tighten the capacitor mounting bolts.

11. Replace the Balun bottom cover plate.

2-6.8 Assembly Procedure, Unit 4.

Installation of the equipment in Unit 4 should be preceded by proper installation of

Table 2-1 Wire Tray Assignment

Wire # Wire Tray #

#101 through #121 Tray#3

#113 through #124 Tray#1

#125 through #136 Tray#2