Broadcast Electronics 4MX 100 User manual

Broadcast Electronics Inc.
4100 North 24th Street, Quincy, Illinois 62305 USA • Phone [phone] • Fax [phone] • www.bdcast.com • [email protected]
4MX 100
100kW AM Transmitter Manual
597-4100, Revision B
3/13/07

4MX 100
100kW AM Transmitter Manual
©2007 Broadcast Electronics Inc. All rights reserved.
The information in this publication is subject to improvement and change without notice. Although
every effort is made to ensure the accuracy of the information in this manual, Broadcast Electronics
Inc. accepts no responsibility for any errors or omissions. Broadcast Electronics Inc. reserves the right
to modify and improve the design and specifications of the equipment in this manual without notice.
Any modifications shall not adversely affect performance of the equipment so modified.
Proprietary Notice
This document contains proprietary data of Broadcast Electronics Inc. No part of this publication may
be reproduced, transmitted, transcribed, stored in a retrieval system, translated into any other
language in any form or by any means, electronic or mechanical, including photocopying or
recording, for any purpose, without the express written permission of Broadcast Electronics Inc.
Trademarks
Broadcast Electronics and the BE logo are registered trademarks of Broadcast Electronics Inc.
All other trademarks are property of their respective owners.

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©2007 Broadcast Electronics Inc.
IMPORTANT INFORMATION
EQUIPMENT LOST OR DAMAGED IN TRANSIT -
When delivering the equipment to you, the truck driver or carrier’s agent will present a receipt for
your signature. Do not sign it until you have:
1) Inspected the containers for visible signs of damage and 2) Counted the containers and compared
with the amount shown on the shipping papers. If a shortage or evidence of damage is noted, insist
that notation to that effect be made on the shipping papers before you sign them.
Further, after receiving the equipment, unpack it and inspect thoroughly for concealed damage. If
concealed damage is discovered, immediately notify the carrier, confirming the notification in
writing, and secure an inspection report. This item should be unpacked and inspected for damage
WITHIN 15 DAYS after receipt. Claims for loss or damage will not be honored without proper
notification of inspection by the carrier.
RF PRODUCT TECHNICAL ASSISTANCE, REPAIR SERVICE, REPLACEMENT
PARTS -
Technical assistance is available from Broadcast Electronics by letter, prepaid telephone, fax, or E-
mail. Equipment requiring repair or overhaul should be sent by common carrier, prepaid, insured,
and well protected. If proper shipping materials are not available, contact the Customer Service
Department for a shipping container. Do not mail the equipment. We can assume no liability for
inbound damage, and necessary repairs become the obligation of the shipper. Prior arrangement is
necessary. Contact the Customer Service Department for a Return Authorization.
Emergency and warranty replacement parts may be ordered from the following address. Be sure to
include the equipment model number, serial number, part description, and part number. Non-
emergency replacement parts may be ordered directly from the Broadcast Electronics stock room by
fax at the number shown below.
RF CUSTOMER SERVICE -
Telephone: [phone]
E-Mail: [email protected]
Fax: [phone]
FACILITY CONTACTS -
Broadcast Electronics, Inc. - Quincy Facility
4100 N. 24th St. P.O. BOX 3606
Quincy, Illinois 62305
Telephone: [phone]
Fax: [phone]
General E-Mail: [email protected]
Web Site: www.bdcast.com
NON-EMERGENCY REPLACEMENT PARTS -
Fax: [phone]

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©2007 Broadcast Electronics Inc.
RETURN, REPAIR, AND EXCHANGES -
Do not return any merchandise without our written approval and Return Authorization. We will
provide special shipping instructions and a code number that will assure proper handling and
prompt issuance of credit. Please furnish complete details as to circumstances and reasons when
requesting return of merchandise. All returned merchandise must be sent freight prepaid and
properly insured by the customer.
WARRANTY ADJUSTMENT -
Broadcast Electronics, Inc. warranty is included in the Terms and Conditions of Sale. In the event of
a warranty claim, replacement or repair parts will be supplied F.O.B. factory. At the discretion of
Broadcast Electronics, the customer may be required to return the defective part or equipment to
Broadcast Electronics, Inc. F.O.B. Quincy, Illinois. Warranty replacements of defective merchandise
will be billed to your account. This billing will be cleared by a credit issued upon return of the
defective item.
PROPRIETARY NOTICE -
This document contains proprietary data of Broadcast Electronics, Inc. No disclosure, reproduction,
or use of any part thereof may be made except by prior written permission.
MODIFICATIONS -
Broadcast Electronics, Inc. reserves the right to modify the design and specifications of the
equipment in this manual without notice. Any modifications shall not adversely affect performance
of the equipment so modified.
FCC NOTICE TO THE EQUIPMENT USER -
FCC Rule 73.1590 mandates that the licensee of each AM station be responsible to make
measurements for spurious and harmonic emissions to show compliance with the transmission
system requirements of Section 73.44 of the Commission’s Rules. It is the broadcast station’s
responsibility to ensure that the audio signal input to the Broadcast Electronics, Inc.’s 4MX 100 AM
Transmitter conform to the audio standard NRSC-1 (published as ANSI / EIA-549-1988). This is a
mandatory requirement to ensure that the equipment complies to Section 73.44 and Section
73.128(C) of the Commission’s Rules.

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©2007 Broadcast Electronics Inc.
TRANSMITTER WARRANTY VOID NOTICE -
THIS PRODUCT WARRANTY WILL BE VOID IF THE TRANSMITTER IS INSTALLED AT A SITE
WITH INADEQUATE LIGHTNING / AC SURGE PROTECTION, DEFECTIVE TRANSMISSION LINE
SYSTEM, OR CONNECTION TO AN IMPROPER AC INPUT.
The transmitter is covered by a two year limited product warranty from Broadcast Electronics, Inc.
However, the transmitter must be properly installed at a site with adequate Lightning / AC Surge
protection, transmission line system or load capable of handling the Transmitter’s RF Output power,
and also be connected to a proper AC Input.
To ensure that the 4MX 100 Transmitter’s Warranty does remain valid:
The transmitter must be installed and setup as described by the installation procedures
presented throughout this manual.
The Lightning / AC Surge Suppressor (supplied with transmitter) must be installed at the AC
Service entrance as described in this manual.
The transmitter’s RF Output must be connected to an adequate transmission line
system or load capable of handing the transmitter’s RF Output power.
The transmitter must be connected to the AC Power Source, with the transformer topology
and voltage, that it was configured for and tested with at the factory. See Section 2.9
regarding “Primary AC Power Source Voltage and Configuration.”
FAILURE TO PROPERLY INSTALL THE AC SURGE SUPPRESSOR WILL VOID THE
TRANSMITTER’S WARRANTY.
If you have any questions regarding the installation of the transmitter or the warranty, please contact
the RF Customer Service Department at Broadcast Electronics, Inc.
Telephone: [phone]
E-Mail: [email protected]
Fax: [phone]

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©2007 Broadcast Electronics Inc.
OPERATING HAZARD
THE TRANSMITTER CONTAINS MULTIPLE CIRCUIT GROUNDS WITH HIGH AC AND DC POTENTIALS
WITH RESPECT TO THE CABINET WHICH IS AT EARTH POTENTIAL. DO NOT ENERGIZE THE
TRANSMITTER WITH TEST EQUIPMENT CONNECTED TO THE TRANSMITTER’S OUTPUT NETWORK,
RF POWER MODULE, RF COMBINER, OR POWER SUPPLY COMPONENTS.
Broadcast Electronics, Inc.’s AM transmitters contain high voltages and currents. If safety precautions are
not practiced, contact with high voltages and currents could cause serious injury or death. The transmitter
is equipped with many built-in safety features, however good judgment, care, and common sense must be
practiced to prevent accidents.
In addition to high voltages and currents, AM transmitters contain multiple circuit grounds with high ac
and dc potentials with respect to the cabinet which is at earth potential. The potentials could cause serious
injury or death if maintenance personnel simultaneously touch a circuit ground and the cabinet. As a
result, operation of the transmitter with test equipment connected to the transmitter’s output network, RF
power module, RF combiner, or power supply components is extremely dangerous and must not be
attempted. Therefore, never energize the transmitter with test equipment connected to the output
network, RF power module, RF combiner, or power supply components.

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SAFETY PRECAUTIONS
PLEASE READ AND OBSERVE ALL SAFETY PRECAUTIONS!!
ALL PERSONS WHO WORK WITH OR ARE EXPOSED TO POWER TUBES, POWER
TRANSISTORS, OR EQUIPMENT WHICH UTILIZES SUCH DEVICES MUST TAKE PRECAUTIONS
TO PROTECT THEMSELVES AGAINST POSSIBLE SERIOUS BODILY INJURY. EXERCISE
EXTREME CARE AROUND SUCH PRODUCTS. UNINFORMED OR CARELESS OPERATION OF
THESE DEVICES CAN RESULT IN POOR PERFORMANCE, DAMAGE TO THE DEVICE OR
PROPERTY, SERIOUS BODILY INJURY, AND POSSIBLY DEATH.
DANGEROUS HAZARDS EXIST IN THE OPERATION OF POWER TUBES AND
POWER TRANSISTORS -
The operation of power tubes and power transistors involves one or more of the following hazards,
any one of which, in the absence of safe operating practices and precautions, could result in serious
harm to personnel.
A. HIGH VOLTAGE - Normal operating voltages can be deadly. Additional information
follows.
B. RF RADIATION - Exposure to RF radiation may cause serious bodily injury possibly
resulting in Blindness or death. Cardiac pacemakers may be affected. Additional
information follows.
C. BERYLLIUM - OXIDE POISONING - Dust or fumes from BeO ceramics used as thermal
links with conduction cooled power tubes and power transistors are highly toxic and can
cause serious injury or death. Additional information follows.
D. HOT SURFACES - Surfaces of air-cooled radiators and other parts of tubes can reach
temperatures of several hundred degrees centigrade and cause serious burns if touched.
Additional information follows.
E. RF BURNS - Circuit boards with RF power transistors contain high RF potentials. Do not
operate an RF power module with the cover removed.

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HIGH VOLTAGE -
Many power circuits operate at voltages high enough to kill through electrocution. Personnel should
always break the primary AC Power when accessing the inside of the transmitter.
RADIO FREQUENCY RADIATION -
Exposure of personnel to RF radiation should be minimized, personnel should not be permitted in the
vicinity of open energized RF generating circuits, or RF transmission systems (waveguides, cables,
connectors, etc.), or energized antennas. It is generally accepted that exposure to “high levels” of
radiation can result in severe bodily injury including blindness. Cardiac pacemakers may be affected.
The effect of prolonged exposure to “low level” RF radiation continues to be a subject of
investigation and controversy. It is generally agreed that prolonged exposure of personnel to RF
radiation should be limited to an absolute minimum. It is also generally agreed that exposure should
be reduced in working areas where personnel heat load is above normal. A 10 mW/cm2per one
tenth hour average level has been adopted by several U.S. Government agencies including the
Occupational Safety and Health Administration (OSHA) as the standard protection guide for
employee work environments. An even stricter standard is recommended by the American National
Standards Institute which recommends a 1.0 mW/cm2 per one tenth hour average level exposure
between 30 Hz and 300 MHz as the standard employee protection guide (ANSI C95.1-1982).
RF energy must be contained properly by shielding and transmission lines. All input and output RF
connections, such as cables, flanges and gaskets must be RF leak proof. Never operate a power tube
without a properly matched RF energy absorbing load attached. Never look into or expose any part
of the body to an antenna or open RF generating tube or circuit or RF transmission system while
energized. Monitor the tube and RF system for RF radiation leakage at regular intervals and after
servicing.
DANGER - BERYLLIUM OXIDE CERAMICS - AVOID BREATHING DUST OR
FUMES -
BeO ceramic material is used as a thermal link to carry heat from a tube or power transistor to the
heat sink. Do not perform any operation on any BeO ceramic which might produce dust or fumes,
such as grinding, grit blasting, or acid cleaning. Beryllium oxide dust or fumes are highly toxic and
breathing them can result in serious personal injury or death. BeO ceramics must be disposed of only
in a manner prescribed by the device manufacturer.
HOT SURFACES -
The anode portion of power tubes is often air-cooled or conduction-cooled. The air-cooled external
surface normally operates at a high temperature (up to 200° to 300°C). Other portions of the tube
may also reach high temperatures, especially the cathode insulator and the cathode/heater surfaces.
All hot surfaces may remain hot for an extended time after the tube is shut off. To prevent serious
burns, take care to prevent and avoid any bodily contact with these surfaces both during and for a
reasonable cooling down period after tube operation.

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Table of Contents
1Preparing for Installation .......................................................................1
1.1 Shipment Inspection.................................................................................... 1
1.2 Unpacking the Transmitter .......................................................................... 1
1.3 Documentation Review................................................................................ 1
1.4 Environmental Requirements ....................................................................... 1
1.5 Cooling Air Requirements ............................................................................ 1
1.6 4MX 100 Physical Information..................................................................... 1
1.7 4MX 100 PA and PS Module Locations........................................................ 3
1.8 Items Required for Installation ..................................................................... 4
1.8.1 Tools / Items Required for Installation (not supplied with 4MX 100)..... 4
1.8.2 Installation Kit Items (977-4101 – supplied with 4MX 100).................. 4
1.8.3 Surge Suppressor (supplied with 4MX 100) ......................................... 4
2Installation and Setup ............................................................................5
2.1 Locate the Transmitter................................................................................. 5
2.2 Remove the 4MX 100 Rear Cabinet Doors ................................................... 5
2.3 Bolt the Main and Auxiliary Cabinets Together............................................. 6
2.4 4MX 100 Output Network Capacitor Banks ................................................. 7
2.4.1 Install the Main Cabinet Capacitor Bank C4.......................................... 8
2.4.2 Install the Main Cabinet Capacitor Bank C3.......................................... 9
2.4.3 Install the Auxiliary Cabinet Capacitor Bank C2................................... 10
2.4.4 Capacitor Bank C1, L1, L2, L3 & L4 Locations..................................... 11
2.4.5 Install Main and Auxiliary Cabinet Capacitor Bank C1......................... 13
2.4.6 Install Inner C1 Cap Bank Sections ..................................................... 14
2.4.7 C1 “Joiner Plate” Detail ..................................................................... 15
2.4.8 Install Outer C1 Cap Bank Sections .................................................... 16
2.4.9 Capacitor Bank C1 to L1, L2, L3, & L4 Connections ............................ 17
2.5 Route / Connect Power and Fan Interconnect Cabling ................................ 19
2.6 Route / Connect the Multiplexer Interconnect Cabling................................ 21
2.7 Earth Ground to 4MX 100 Chassis Connection .......................................... 23
2.8 RF Output Transmission Line Connection ................................................... 24
2.9 Primary AC Power Source Voltage and Configurations ............................... 25
2.10 4MX 100 AC Input Recommended Disconnect Fuse and Wire Sizes.......... 26
2.11 Installing the AC Surge Suppressor .......................................................... 27
2.12 Connecting AC Power To The 4MX 100 Transmitter................................. 29
2.12.1 Install Rear Doors .............................................................................. 31
2.13 Remote INTERLOCK and FAILSAFE I/O Connections .................................. 32
2.13.1 INTERLOCK (TB2-4)............................................................................ 35
2.13.2 FAILSAFE (TB2-2)............................................................................... 35
2.14 Turning on AC Power .............................................................................. 36
2.14.1 Installation Checklist.......................................................................... 36

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2.14.2 Turn ON the Main AC Service Entrance Breaker ................................. 36
2.14.3 Turn ON the 4MX 100 Transmitter AC Breaker .................................. 36
2.15 Initial System Checkout ........................................................................... 37
2.15.1 ON.................................................................................................. 37
2.15.2 OFF ................................................................................................. 37
2.15.3 FAULT RESET ................................................................................... 37
2.15.4 PHASE 1, PHASE 2, and PHASE 3 ...................................................... 37
2.16 Initial RF Output and Connection of the Audio Source ............................. 38
2.16.1 Log into the GUI ............................................................................... 38
2.16.2 Enter the Chief Engineer’s Password.................................................. 38
2.16.3 Set the Initial RF Output Power Level ................................................. 39
2.16.4 Turn the 4MX 100’s RF Output Power ON (without Modulation) ....... 39
2.16.5 PA Diagnostics .................................................................................. 40
2.16.6 Power Supply Diagnostics ................................................................. 41
2.16.7 Turn the Transmitter’s RF Output Power OFF ..................................... 42
2.16.8 Audio Input Connections .................................................................. 42
2.16.9 AUDIO SETUP Menu ......................................................................... 43
2.16.10 Turn the Audio Source ON ............................................................. 45
2.16.11 Audio Tuning Procedure................................................................. 45
2.17 Audio Troubleshooting ........................................................................... 48
2.17.1 Audio Fault (A/D Overdrive)............................................................... 48
2.17.2 Audio Fault (too much gain or over modulation…)............................ 49
2.17.3 Low Modulation Level....................................................................... 49
3Operation ..............................................................................................50
3.1 Overview .................................................................................................. 50
3.2 Switches and Indicators ............................................................................ 51
3.2.1 ON ................................................................................................... 51
3.2.2 OFF................................................................................................... 51
3.2.3 FAULT RESET..................................................................................... 51
3.2.4 PHASE 1, PHASE 2, and PHASE 3 ...................................................... 51
3.3 Graphical User Interface ............................................................................ 52
3.4 Graphical User Interface Sub-Menus.......................................................... 53
3.4.1 Default User Classification and Password........................................... 53
3.4.2 Log In ............................................................................................... 53
3.4.3 Log Out ............................................................................................ 54
3.4.4 Password Protection.......................................................................... 55
3.4.5 Time / Date / IP Setup........................................................................ 57
3.4.5.1 IP Address Entry Menu..................................................................... 57
3.4.5.2 Subnet Mask Entry Menu................................................................. 58
3.4.5.3 Gateway Address Entry Menu .......................................................... 58
3.4.6 Audio Setup...................................................................................... 59
3.4.7 Operating Modes (Analog AM or HD AM)......................................... 61