TYPE 816R-6C FM TRANSMITTER 3.0 kW, 88-108 MHz Serial No. 89 and Above

237 Pages·2008·23.56 MB·English

816R-6C
TECHNICAL MANUAL
OPERATION AND MAINTENANCE INSTRUCTIONS
TYPE 816R-6C FM TRANSMITTER
3.0 kW, 88-108 MHz
(PIN 180471-2)
Serial No. 89 and Above
COPYRIGHTED©2005BY
CONTINENTALELECTRONICS
4212S.BUCKNERBLVD.
[phone] DALLAS,TEXAS75227 FAX:[phone]
ISSUED - 19 SEPTEMBER 1995
CHANGE 4- 30 June 2005

816R-6C
PREFACE
ThisOperation andMaintenancemanual gives thephysical and functional description, installation, operation, theoryof
operation,maintenance,partslists, and diagramsfor the identified equipment. Operatorandservicepersonnel should
become familiarwith themanual contentsbefore attempting to install, operate, ormaintain the equipment. In addition to the
Safety Summarywhichfollows theTable ofContents, specific WARNINGS, CAUTIONS andNOTES are located
throughoutthis manualwhere they apply. Continental Electronics (CE) manufactured thisequipmentto conformwith I
current electrical,radiation, andsafety codes ofthe United Statesto the extentthat they apply. Itis the user's responsibility
to comply"vith all local andnational codes duringinstallation and operation ofthe equipment.
CEreserves therighttomakeanychanges, withoutnotice, to thisorany ofCE'sproductsto improve reliability, I
performance, function, ordesign.
CE doesnot assume any liabilityresulting from the application oruseofanyproductorcircuitdescribedherein; nordoes CEI
conveyany licenseunderitspatentrights orthe rights ofothers.
The information inthisdocumenthasbeen carefully checked and isbelieved tobe entirelyreliable. While all reasonable
efforts to ensure accuracyhavebeen taken in thepreparation ofthis manual, CEC assumesnoresponsibility resulting from
omissions orerrorsin this manual, orfrom theuse ofinformation containedherein.
Theseinstructionsdonotpurportto coverall details orvariationsin equipmentnortoprovideforeverypossiblecontingency
thatmightbemetduring installation, operation, ormaintenance. Shouldfurtherinformationbedesiredorshouldparticular
problems arisewhicharenotcoveredsufficientlyfor theuser'spurpose, themattershouldbereferredto CEo I
All RightsReserved
This document containsproprietaryinformation of
I
ContinentalElectronics and shall not be duplicated,
norits contents used for anypurpose,
unless express"vrittenpermission is obtained from
ContinentalElectronics. I
CUSTOMERSERVICE
ContinentalElectronicscustomerservice is available for assistance atanytime, 24hoursaday,weekendsandholidays I
included. Call anytimeday ornight:
PartsServices [phone]
Engineering Services [phone]
Main Offices [phone] (8:00am-5:00pmCT)
WebAddress [email protected]
Youmaywrite to anyoftheseservices at4212 S. BucknerBlvd.,Dallas, Texas75227-4299, orFAX [phone].
Change 3 I
816R-6C
INSERTLATESTCHANGEPAGES. DESTROYSUPERSEDEDPAGES
I I
NOTE: Theportionoftextaffectedbythechangesis
indicatedbyachangenumberlocatedinthefooterof
LIST OF EFFECTIVE PAGES eachchangedpage.
Datesoforiginal and changepages are:
OriginaL 0 19 September 1995
Change 1 9July 1996
Change 2 13 July 1998
Change 3 1April2004
Change 4 30June 2005
TOTAL NUMBEROFPAGES INTHIS PUBLICATIONIS 234 CONSISTING OFTHEFOLLOWING:
PageNo. *Change PageNo *Change PageNo. *Change
Title...................... 4 5-5 2 6-86-6-87 .............. 2
Preface.................... 3 5-6 0 6-88-6-89 ... 3
A......................... 4 5-7 2 6-90 2
1- 11 ....................... 3 5-8-5-10 ......... 3 6-91 3
iii........................ 0 5-11 -5-20 ......... 0 6-92 2
iv 2 5-21 3 6-93-6-94 3
v-vi ,............... 3 5-22-5-23 0 6-95Blank................. 3
vii........................ 0 5-24Blank ............. 0 6-96 2
viiiBlank.................. 0 6-1 3 6-97 3
ix-xiii " ... 0 6-2 4 6-98-6-99 .............. 2
xivBlank 0 6-3 -6-6 3 6-100Blank................ 3
1-1 -1-2 3 6-7Blank 2 7-1 3
1-3-1-4 ................... 0 6-8 2 7-2Blank.................. I
2-1 3 6-9 3 7-3 1
2-2-2-3 0 6-10-6-18 2 7-4Blank.................. 1
2-4Blank. ................. 0 6-19 3 7-5 1
2-5 -2-6................... 0 6-20 2 7-6Blank.................. 1
2-7 2 6-21 -6-24 . 3 7-7 1
2-8 -2-9................... 3 6-25Blank ............. 3 7-8Blank.................. 1
2-10-2-15 0 6-26 2 7-9 1
2-16Blank................. 0 6-27-6-29 3 7-10Blank................. 1
3-1 -3-2 3 6-30-6-36 ........... 2 7-11 1
3-3-3-7 ................... 0 6-37-6-39 ...... 3 7-12Blank................. 1
3-8-3-9 3 6-40 2 7-13 3
3-10 0 6-41 3 7-14Blank................. 2
3-11-3-12 3 6-42 2 7-15 1
3-13-3-14 0 6-43-6-49 ........ 3 7-16Blank................. 1
3-15 3 6-50 2 7-17 1
3-16-3-17 1 6-51 -6-53 3 7-18Blank 1
3-18-3-19 0 6-54-6-58 2 7-19 3
3-20Blank................. 0 6-59Blank 3 7-20Blank................. 2
4-1 3 6-60 2 7-21 3
4-2 2 6-61 -6-62 4 7-22Blank................. 2
4-2.1 3 6-63Blank................. 3 7-23 1
4-2.2Blank................. 2 6-64 2 7-24Blank................. 1
4-3-4-5 3 6-65 3 7-25 1
4-6-4-7 ................... 0 6-66 2 7-26Blank ........... 1
4-8 3 6-67 3 7-27 I
4-9 0 6-68 2 7-28Blank .............. 1
4-10-4-11 3 6-69Blank ........ 3 7-29 1
4-12 0 6-70 2 7-30Blank ... 1
4-13 3 6-71 4 7-31 1
4-14 0 6-72 2 7-32Blank................. 1
4-15-4-20 3 6-73 3 7-33 I
5-1 3 6-74-6-76 2 7-34Blank 1
5-2 2 6-77 3 7-35 1
5-3 3 6-78-6-80 2 7-36Blank ................. 1
5-4 0 6-81 3
6-82-6-84 2
6-85 3
*Zerointhiscolumnindicatesanoriginalpage.
A Change 4
816R-6C TABLE OF CONTENTS
Paragraph Title Page
SECTION 1- GENERAL
1-1. Introduction 1-1
1-2. FunctionalDescription ................................................................... 1-1
1-3. PhysicalDescription. .................................................................... 1-1
1-4. Technical Characteristics 1-1
SECTION2-INSTALLATION
2-1. Pre-InstallationInformation '. .................................. 2-1
2-1.1 ACPower 2-1
2-1.2 RFOutputPower 2-1
2-1.3 TransmitterCooling ,'.. 2-1
2-1.3.1 ExhaustFans ........................................................................... 2-1
2-1.3.2 PositivePressure 2-2
2-1.3.3 TransmitterExhaustDuct 2-6
2-2. Unpacking andInspecting 2-6
2-2.1 Domestic Shipments 2-6
2-2.2 International Shipments 2-6
2-3. Assembly 2-7
SECTION3- OPERATION
3-1. General 3-1
3-2. ControlsandIndicators , 3-1
3-3. InitialTurn-OnProcedure 3-1
3-4. Remote Operation - 3-15
3-5. 2ndPowerLevel (LowPwr)Adjustment " 3-15
3-6. AutomaticRecycleResetting 3-15
3-7. NonnalTum-Off(Local) 3-15
3-8. EmergencyTurn-Off 3-15
SECTION 4-THEORYOF OPERATION
4-1. General ................................................................... ............ 4-1
4-2. FunctionalDescription ................................................................... 4-1
4-3. RF Circuits 4-1
4-3.1 Exciter,A4. . 4-1
4-3.2 IPA, A3 4-1
4-3.2.1 MeteringAssemblyA3A1 4-1
4-3.2.2 StatusAssemblyA3A2 4-1
4-3.2.3 AmplifierAssemblyA3A3 4-1
4-3.2.3.1 RFAmplifier 4-2
4-3.2.3.2 ControlAssembly 4-2
4-3.3 RFPowerAmplifier,A12 4-2
4-3.4 Low-PassFilter,A7 4-2.11
4-3.5 DirectionalCoupler,DCl ............................................................... 4-2.1
Change 3 i
TABLE OF CONTENTS 816R-6C
Paragraph Title Page
SECTION 4-THEORY OF OPERATION-Continued
4-4. PowerSuppliesandPowerControl Circuits. .......................................... 4-2.1
4-4.1 General ........... 4-2.1
14-4.2 24 VdcPowerSupply,PIO AlO. 4-2.1
4-4.3 PowerAmplifierBiasPowerSupply,PIO AlO 4-2.1
4-4.4 PAPlate Supply 4.;.10
4-4.5 PowerControlUnit, A9 4-10
4-4.6 PowerControlRegulator,PIO A2A6 4-10
4-4.7 PAScreenPowerSupply 4:-10
4-4.8 DriverPowerSupply,PIO A5 4-10
4-4.9 FilamentVoltageRegulator,A2A4 4-10
4-4.10 FilamentVoltageDistribution 4-13
4-5. PrimaryPowerDistributionControl andOverloadCircuits 4-13
4-5.1 PrimaryPowerDistribution 4-13
4-5.2 TransmitterTum-On. . 4-13
4-5.3 ExciterPowerControl Override. . 4-16
4-5.4 FWD/REFL CalibrateandAuto PowerControlUnit, A2A6. . 4-16
4-5.4.1 Functions 4-16
4-5.4.2 TheoryofOperation. . 4-16
4-5.5 OverloadProtection 4-17
4-5.6 OverloadandRecycleBoard, A2A5 4-17
4-5.7 PowerFailureRecycleBoard,A8Al. . 4-18
4-5.8 Auto-ManualPowerControlLatchingRelayandTransmitterStatusIndicators. . 4-18
4-5.9 PowerControlRelays,PIO Al0A2 4-18
4-5.10 RemoteRelays,PIO AIOA2 4-18
SECTION 5-~1AINTENA1~CE
5-1. RoutineMaintenance 5-1
5-2. Cleaning 5-1
5-2.1 GeneralCleaningProcedures. 5-1
5-2.2 AirFilter. . 5-1
5-2.3 TubeCleaning. 5-1
5-3. Inspection ... .............. ...................................................... 5-1
5-4. Lubrication ...................................................................... 5-1
5-5. PartsReplacement 5-1
5-5.1 PATube,VI 5-2
5-5.2 FuseReplacement. . 5-2
5-6. Troubleshooting 5-2
5-6.1 AccessPanelInterlockSwitch. ....................................................... 5-2
5-6.2 TestEquipment 5-2
5-6.3 TroubleshootingthePowerController. 5-2
5-7. Adjustments 5-3
5-7.1 SwitchAdjustments 5-3
5-7.1.1 AirInterlockSwitch,A12S1 5-3
5-7.1.2 TuningMotorLimitSwitches,A12S11-S14 5-3
ii Change 3
816R-6C TABLE OF CONTENTS
Paragraph Title Page
SECTION5-MAINTENANCE-Continued
5-7.2 FilamentVoltage Adjustment. 5-3
5-7.3 DC OverloadAdjustment. 5-6
5-7.3.1 PAPlate OverloadAdjustment. 5-6
5-7.3.2 PA Screen OverloadAdjustment. 5-6
5-7.4 PAGrid Current. 5-7
5-7.5 High Voltage PowerSupply StaticCheck (nodrive) 5-7
5-7.6 IPA MeteringBoard Calibration. 5-7
5-7.6.1 General Information. . 5-7
5-7.6.2 SetupProcedures. . ,.. 5-7
5-7.6.3 Calibration Procedures. . 5-8
5-7.7 FWD/REFLCAL and PowerControl Card, A2A6 5-9
5-7.7.1 OffsetNulls 5-9
5-7.7.2 ForwardPowerCalibration. . 5-10
5-7.7.3 Reflected Powerand VSWR Protection Calibration 5-10
5-7.7.4 VSWR FoldbackAdjustment. 5-10
5-7.8 Phase MonitorAdjustment. 5-11
5-8. Changing Power ................................................................. 5-11
5-9. Changing Frequency .............................................................. 5-11
5-9.1 Frequency ChangeAdjustments. . 5-11
5-9.1.1 ShortingPlane 5-11
5-9.1.2 PA Neutralization. . 5-12
5-9.1.3 PA GridTuning Slider 5-12
5-9.1.4 PA Grid SwampingCapacitor. 5-12
5-9.1.5 Cathode Return Capacitor. ..................... 5-12
5-9.1.6 Efficiency Capacitor. . 5-12
5-9.1.7 Coupling Capacitor. 5-12
5-9.1.8 PA Bias 5-]2
5-9.1.9 IPA to PACableLength. 5-21
5-9.1.10 PA Grid Circuit. 5-21
5-9.2 PATuning andLoading 5-22
5-9.3 PA Neutralization. . 5-23
SECTION6-PARTSLISTS
6-1. Introduction 6-1
6-2. Reference Designations (RefDes) .................................................... 6-1
6-3. Description ...................................................................... 6-1
6-4. PartNumber 6-1
6-5. Illustrations ...................................................................... 6-1
6-6. Index ofPartsLists ................................................................ 6-1
SECTION7 -DIAGRAMS
7-1. Introduction 7-1
iii
TABLE OF CONTENTS 816R-6C
LIST OFILLUSTRATIONS
Figure Title Page
SECTION 1- GENERAL
1-1. 816R-6C FM Transmitter. 1-2
SECTION 2-INSTALLATION
2-1. FMTransmitterOutline andInstallationDrawing 2-3
2-2. FMTransmitterNominal HeatBalance 2-5
2-3. Remote Control Connections 2-8
2-4. TransmitterController(377D-1 or-2) Connections 2-9
2-5. RemotePlate CurrentSampleCircuit 2-10
2-6. TransformerConnection Schedule 2-12
2-7. DriverTransformer(T3) Connection 2-13
2-8. SecondaryTap Configuration, T2 2-15
SECTION 3- OPERATION
3-1. TransmitterControlPanels. . 3-2
3-2. ControlPanel, AI, Controls (Sheet 1of2) 3-3
3-2. ControlPanel, AI, StatusIndicators (Sheet2of2) 3-4
3-3. Card CageAssembly, A2, Controls and Indicators 3-8
3-4. IPA, A3, Controls andIndicators 3-8
3-5. CircuitBreakerPanel, A6, Controls andIndicators 3-10
3-6. PATuning andLoading 3-14
3-7. AmplifierEfficiencyvs. FrequencyandPower 3-18
3-8. Powerto VSWRConversion Graph 3-19
SECTION4-THEORYOFOPERATION
4-1. FMTransmitter8l6R-6C, BlockDiagram. . 4-3
4-2. RF DrivePath. . 4-4
I
4-3. IPA SimplifiedDiagram,A3 4-5
4-4. SCRPowerControl, SimplifiedDiagram. . 4-6
4-5. PowerAmplifierDCBias CircuitrySimplifiedSchematic 4-7
4-6. PA Cavity, A12 4-8
4-7. PATuningCircuit, Simplified 4-9
4-8. PowerControl Circuits, SimplifiedDiagram. . 4-11
4-9. FilamentVoltage Distribution 4-14
4-10. AC PowerDistribution 4-15
iv Change 2
816R-6C TABLE OF CONTENTS
LIST OFILLUSTRATIONS-Continued
Figure Title Page
SECTION4-THEORY OF OPERATION-Continued
4-11. LatchingRelay SimplifiedSchematic. ................................................ 4-19
4-12. PowerControlRelays SimplifiedSchematic. . 4-20
SECTION 5-l\1AINTENANCE
5-1. PrimaryAC Wiring,PowerControl. 5-4
5-2. PAPlateTuning CavitySlider,CoarseAdjustment. 5-13
5-3. PANeutralizingAdjustment. ' 5-14
5-4. Graphfor CoarseSettingofPA GridTuningInductors. . 5-15
0 • 0 ••••••••••••••• 0 ••••
5-5. PowerAmplifierTube Socket(BottomView), A12A3. ... 5-16
0 ••••••• 0 •••• 0 •••••••••••••••••
5-6. PA GridSwamping Capacitor 5-17
5-7. PA Socket, CathodeReturn Capacitors. ............................................... 5-18
5-8. AdjustmentofCathodeReturn Capacitors. . 5-19
5-9. CathodeReturn CapacitorPositionvs. Frequency. . 5-20
5-10. IPA toPA CableLength. . 5-21
SECTION 6-PARTSLISTS
6-1. 816R-6CFMTransmitter(Sheet 1of2) 6-3
0 •••••••••••••••••••••
6-1. 816R-6CFM Transmitter(Sheet2of2) : 6-4
6-2. ControlPanel,Al ' 6-8
6-3. ControlPanel CircuitCardAssembly, AlAI 6-10
6-4. CardCage,A2 6-18
6-5. FilamentRegulatorCircuitCardAssembly, A2A4 6-20
6-6. Overload/RecycleCircuitCardAssembly, AlA5 6-26
6-7. PowerMonitor/ControlCircuitCardAssembly, AlA6. . 6-30
6-8. CardCageComponentCircuitCardAssembly,A2A? 6-36
6-9. Backplane CircuitCardAssembly,AlA8 6-40
6-10. PowerControlAssembly, A2A9 6-42
6-11. IntermediatePowerAmplifierAssembly,A3 6-44
6-12. IPA Metering CircuitCardAssembly,A3AI 6-46
6-13. IPA StatusAssembly,A3A2 6-49
0 0 • 0 ••••••••••• 0 •••••••••••••••••••
6-14 AmplifierAssembly,A3A3 6-50
0 •••••••• 0 0 ••••••••••• 0 •••••• 0 •••••••••••••••••
6-15 AmplifierModule, A3A3A1-A2 .. o... 6-52
0 ••••••••••••••••••••• 0 •••• 0 •••• 0 ••• 0 •••••••••
6-16 RF CCA,A3A3AI-A2Al 6-54
0 ••••••••••••••••••••••••• 00 ••••••••••••••••••••••
6-17 ControlCCA, A3A3AI-A2A2 6-56
6-18. ComponentShelfAssembly, A5 6-60
6-19. IPAMeteringAssemblyCCA,A5Alo 6-64
6-20. CircuitBreakerAssembly, A6. 6-66
6-21. LowPassFilterAssembly, A7 6-70
6-22. ComponentPanelAssembly, AS 6-72
6-23. PowerFailureRecycleCircuitCardAssembly, ASAI 6-74
6-24. VariacDriverAssembly, ASA2 6-76
Change 3 v
TABLE OF CONTENTS 816R-6C
LIST OF ILLUSTRATIONS- Continued
Figure Title Page
SECTION 6-PARTSLISTS -Continued
6-25. SCRAssembly, A9 6-78
6-26. PowerSupplyAssembly, AID 6-80
6-27. BiasComponentCircuit CardAssembly, AlOAl. 6-82
6-28. RemoteControl CircuitCardAssembly, AIOA2. . 6-84
6-29. PA CavityAssembly(FrontView), A12 (Sheet 1of2) 6-86
t
6-29. PACavityAssembly(RearView), A12. (Sheet2of2) 6-87
6-30. MeteringMultiplierCircuitCardAssembly, A12A1 6-90
6-31. MeteringMultiplierCircuitCardAssembly, A12A2. . 6-92
6-32. PATube SocketAssembly,A12A3. 6-96
6-33. BleederResistorAssembly, AI3 6-98
SECTION7-DIAGRAMS
7-1. ControlPanel (Sht. 1of2) 7-3
7-1. ControlPanel(Sht. 2of2) 7-5
7-2. FilamentRegulatorSchematicDiagram. . 7-7
7-3. OverloadJRecycle SchematicDiagram. . 7-9
7-4. PowerMonitor/ControlSchematicDiagram. . 7-11
7-5. CardCage Components - 7-13
7-6. Backplane SchematicDiagram (Sheet 1of2). .......................................... 7-15
7-6. Backplane SchematicDiagram (Sheet2of2) 7-17
7-7. IntennediatePowerAmplifier(IPA) SchematicDiagram 7-19
7-8. IPAMetering SchematicDiagram 7-21
7-9. IPA StatusSchematicDiagram 7-23
7-10. AmplifierModuleSchematicDiagram 7-25
7-11. ControlCCA SchematicDiagram 7-27
7-12. RFCCASchematicDiagram 7-29
7-13. IPAMeteringCCASchematicDiagram 7-31
7-14. BiasComponentSchematicDiagram 7-33
7-15. RemoteControl SchematicDiagram 7-35
vi Change 3