Crown FM10000 User manual

i
FM10000
RF Transmitter Package
User's Manual
©2006Crown Broadcast, a division of International Radio and Electronics, Inc.
25166 Leer Drive, Elkhart, Indiana, 46514-5425 U.S.A.
[phone]
®

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Revision Control
Revision Print Date
Initial Release (Rev. 1) April 2006
Important Notices
©2006, Crown Broadcast, a division of International Radio and Electronics Corp.
All rights reserved. No part of this publication may be reproduced, transmitted,
transcribed, stored in a retrieval system, or translated into any language in any
form by any means without the written permission of Crown Broadcast.
Printed in U.S.A.
Crown attempts to provide information that is accurate, complete, and useful.
Should you find inadequacies in the text, please send your comments to the
following address:
International Radio and Electronics
P.O.Box 2000
Elkhart, Indiana, 46515-2000 U.S.A.

Contents
Section 1 –Getting Acquainted
1.1 Your Transmitter Package ……………………………………… 1-2
1.2 Transmitter Package Specifications ……………………………. 1-3
1.3 Safety Considerations ………………………………………….. 1-4
1.3.1 Dangers ………………………………………………………. 1-4
1.3.2 Warnings ……………………………………………………… 1-4
1.3.3 Cautions ………………………………………………………. 1-4
Section 2 –Installation
2.1 Operating Environment ………………………………………… 2-2
2.2 Tools Required ………………………………………………… 2-2
2.3 Unpacking ……………………………………………………… 2-2
2.4 Installation ……………………………………………………… 2-3
2.4.1 AC Power Input Block ……………………………………….. 2-3
2.4.2 Voltage Surge Protection Device …………………………….. 2-4
2.4.3 Low Pass Filter ……………………………………………….. 2-4
2.4.4 Audio Input …………………………………………………… 2-4
2.5 Remote I/O Connections ………………………………………… 2-5
Section 3 –Operation
3.1 Initial Power-up Procedures …………………………………….. 3-2
3.2 AC Power Switch for Controller ………………………………… 3-3
3.3 Front Panel Controls and Display ……………………………….. 3-4
3.3.1 Remote/Local Switch ………………………………………….. 3-4
3.3.2 Local Enable Switch ……………………………………………3-4
3.3.3 Transmitter RF Power Control ………………………………… 3-5
3.3.4 Raise/Lower Power Control …………………………………… 3-5
3.3.5 Power Reading ………………………………………………… 3-6
3.4 Rear Panel Connections …………………………………………. 3-7
3.4.1 DB-25 …………………………………………………………. 3-7
3.4.2 DB-37 …………………………………………………………. 3-7
3.4.3 DB-9 …………………………………………………………... 3-7
3.4.4 BNC ……………………………………………………………. 3-8
3.4.5 Chassis Ground ………………………………………………… 3-8

Section 4 –Reference Drawings
4.1 Views ……………………………………………………………. 4-2
4.2 System Block Diagram ………………………………………….. 4-4
4.3 Transmitter Controller Board Component ID …………………… 4-5
4.4 Transmitter Controller Board Schematic ………………………... 4-6
Section 5 –Service and Support
5.1 Service …………………………………………………………… 5-2
5.2 24-Hour Support ………………………………………………… 5-2
5.3 Spare Parts ………………………………………………………. 5-2
Warranty Statement ………………………………………………….. 5-3
Glossary …………………………………………………………… G-2

Getting Acquainted 1–1
I
INFORMATION
Section 1—Getting Acquainted
This section provides a general description of the FM10000
transmitter system and introduces you to safety conventions
used within this document. Review this material before install-
ing or operating the system.

FM10000 User’s Manual
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1–2
1.1 Your Transmitter Package
The FM10000 is a highly efficient transmitter package designed to set a new standard
in FM transmitter design offering modularity, ease of use, and long-term reliabil-
ity. The FM10000 package has five (5) PA2000-10K amplifiers, three (3) 5,600 watt
power supplies, a transmitter controller, a low pass filter and an optional FM250.
The FM10000 transmitter package requires no tuning and typically provides 80% RF
efficiency. The three (3) 5600W power supplies are power factor corrected and
90% efficient. Modern MOSFET technology ensures high AC to RF efficiency
(better than 70% overall typical) and long-term reliability. The unmatched efficiency
of this transmitter significantly improves your bottom line by providing cooler
operation and lower power costs.
These modular units are uniquely designed to be compact for convenient shipping
and simple installation with minimal floor space. Installation is easy with three
connections; AC power in, Audio in, and antenna out. In addition, built in metering
and status indicator capabilities enable intuitive operation to further augment
the user-friendly design.
Economic long-term reliability is ensured through our carefully engineered solid-
state design. Each PA2000 features four field-replaceable 500–watt power modules.
This transmitter delivers 2500 to over 10000 watts of RF power output. Use your
existing exciter or purchase the FM10000T which includes our award-winning FM250
exciter for an unbeatable 10 kW transmitter package.
Illustration 1–1 FM10000 Transmitter Package

Getting Acquainted 1–3
1.2 Transmitter Package Specifications
RF Power Output:2500 to 11000 watts continuous with remote
controlled power adjust
RF Drive Requirement:250 watts for full output
RF Output Impedance: 50 ohms (unbalanced)
Maximum SWR:2.0:1 (With power foldback at high SWR)
Frequency Range:87–108 MHz
RF Harmonics/Spurious Products: Better than –80 dB
Asynchronous AM S/N Ratio:Meets FCC specifications (-50 dB)
(typically > 60 dB)
Synchronous AM S/N Ratio:Meets FCC specifications (-50 dB)
(typically > 60 dB)
Operating Environment:
Temperature Range: 0°–50°C at sea level
Humidity Range: 0–80% at 20°C (noncondensing)
AC Power:240 Volts AC +10/-15%, 50–60 Hz with neutral
Power Consumption:Less than 18000 watts at 11000 watts RF output
typical
Power Factor: .96 typical
Overall Efficiency: 70% typical
RF Output Connector:1 5/8 "EIA flange
Cabinet dimentions : 7 x 17.25 x 23 inches (17.78 x 43.82 x
58.42 cm) exclusive of rack ears, but inclu-
sive of connectors
Overall dimentions : 65 x 24 x 29 (cabinet only)
83 x 27 x 29 (including external filter)
Weight:FM10K cabinet (950 lbs)
FM10K shipping weight (997 lbs)
Note: System performance is specified using Crown Broadcast
Model FM250 Exciter where applicable.

FM10000 User’s Manual
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1–4
1.3 Safety Considerations
Crown Broadcast assumes the responsibility for providing you a safe product and
safety guidelines during its use. “Safety” means protection to all individuals who
install, operate, and service the transmitter as well as protection of the transmitter
itself. To promote safety, we use standard hazard alert labeling on the product and
in this manual. Follow the associated guidelines to avoid potential hazard.
1.3.1 Dangers
DANGER represents the most severe hazard alert. Extreme bodily harm or death
will occur if DANGER guidelines are not followed.
1.3.2 Warnings
WARNING represents hazards which could result in severe injury or death.
1.3.3 Cautions
CAUTION indicates potential personal injury or equipment or property damage if
the associated guidelines are not followed. Particular cautions in this text also
indicate unauthorized radio-frequency operation.
Severe shock hazard!
Turn power off and
wait approximately 1
minute for capacitors
to discharge before
handling them.
WARNING
Type of Hazard
Pictorial Indication
of Hazard Explanation of
Hazard
Illustration 1–2Sample Hazard Alert

2–1
Installation
Section 2—Installation
This section provides important guidelines for installing your
transmitter. Review this information carefully for proper
installation.
®

2–2FM10000 User’s Manual
2.1 Operating Environment
You can install the FM10000 transmitter on any flat surface which should be clean and
well-ventillated as possible.
2.2 Tools Required
To install the FM10000, you will need the following tools:
❑Medium phillips screwdriver
❑Small flat-blade screwdriver
❑/
❑
❑ESD (Electrostatic Discharge) protection grounding strap and/or mat.
2.3 Unpacking

2–3
Installation
2.4 Installation
WARNING
Possible Electric Shock Hazard!
Do not connect AC source until all
other connections are made and
installation is complete.

2-4 FM10000 User's Manual

Installation 2–5
1
25
13
14
Port A
Pin Description
1PA # 5 -# 8 current 1V = 2A of current
2PA # 5 -# 7 current 1V = 2A of current
3System Lock-Out Reset -Momentary to Ground to reset power control to normal
4Remote RF Power RAISE -Momentary to Gnd to raise power 200watts/second
5Cabinet Temperature -0.01 Volts/degrees Celsius reading of internal cabinet temp.
6Ground
7Remote High Voltage ON/OFF -Hold to ground to turn ON High Voltage
8Fault Summary -TTL Logic HIGH (+5 VDC) when any fault light is ON
9Ground
10 PA # 5 -ALC
11 PA # 5 -PA Temperature (Celcius) 1V = 20 degrees C
12 PA # 5 -SWR
13 PA # 5 -RF Output power 1V = 1000 Watts RF power
14 PA # 5 -In Ref.
15 Remote RF Power LOWER -Momentary to Gnd to lower power 20 watts/second
16 PA # 5 -# 6 current 1V = 2A of current
17 PA # 5 -# 5 current 1V = 2A of current
18 Remote RF Power, Forward -1 VDC = 1000 Watts of Forward power
19 PA # 5 -# 4 current 1V = 2A of current
20 PA # 5 -# 3 current 1V = 2A of current
21 Remote RF Power, Reverse -1 VDC = 1000 Watts of Reverse power
22 PA # 5 -# 2 current 1V = 2A of current
23 PA # 5 -# 1 current 1V = 2A of current
24 PA # 5 -PA Total Current 1V = 20 Amps
25 PA # 5 -PA Volts 1V = 10 Volts

2-6 FM10000 User's Manual
Port B
Pin Description
1(PA1) RF Power - 1V = 1000 Watts of power
2(PA1) SWR - Calculated reading of SWR in VDC (1.00 VDC = 1.0 to 1.0 VSWR)
3(PA1) PA Volts - 1V = 10 V on the PA
4(PA1) PA Temperature - 1V = 20 degrees Celsius on the PA
5Ground
6(PA1) PA Total Current - 1V = 20 A on the PA
7(PA1) PA#1 current - 1V = 2A of current
8(PA1) PA#2 current - 1V = 2A of current
9(PA1) PA#3 current - 1V = 2A of current
10 Ground
11 (PA1) PA#4 current - 1V = 2A of current
12 (PA1) PA#5 current - 1V = 2A of current
13 (PA1) PA#6 current - 1V = 2A of current
14 (PA1) PA#7 current - 1V = 2A of current
15 Ground
16 (PA1) PA#8 current - 1V = 2A of current
17 (PA1) ALC - A direct reading of the ALC voltage on the PA
18 (PA1) In Ref - A DC voltage reference representing RF input power to the PA
19 (PA2) RF Power - 1V = 1000 Watts of power
20 (PA2) SWR - Calculated reading of SWR in VDC (1.00 VDC = 1.0 to 1.0 VSWR)
21 Ground
22 (PA2) PA Volts - 1V = 10 V on the PA
23 (PA2) PA Temperature - 1V = 20 degrees Celsius on the PA
24 (PA2) PA Total Current - 1V = 20 A on the PA
25 (PA2) PA#1 current - 1V = 2A of current
26 Ground
27 (PA2) PA#2 current - 1V = 2A of current
28 (PA2) PA#3 current - 1V = 2A of current
29 (PA2) PA#4 current - 1V = 2A of current
30 (PA2) PA#5 current - 1V = 2A of current
31 Ground
32 (PA2) PA#6 current - 1V = 2A of current
33 (PA2) PA#7 current - 1V = 2A of current
34 (PA2) PA#8 current - 1V = 2A of current
35 (PA2) ALC - A direct reading of the ALC voltage on the PA
36 Ground
37 (PA2) In Ref - A DC voltage reference representing RF input power to the PA

2-7
Installation
Port C
Pin Description
1PA # 3 -RF Power -1V = 1000 Watts of power
2PA # 3 -SWR
3PA # 3 -PA Volts -1V = 10 V
4PA # 3 -PA Temperature -1V = 20 degrees Celsius on the PA
5Ground
6PA # 3 -PA Total Current -1V = 20 A on the PA
7PA # 3 -PA#1 current -1V = 2A of current
8PA # 3 -PA#2 current -1V = 2A of current
9PA # 3 -PA#3 current -1V = 2A of current
10 Ground
11 PA # 3 -PA#4 current -1V = 2A of current
12 PA # 3 -PA#5 current -1V = 2A of current
13 PA # 3 -PA#6 current -1V = 2A of current
14 PA # 3 -PA#7 current -1V = 2A of current
15 Ground
16 PA # 3 -PA#8 current -1V = 2A of current
17 PA # 3 -ALC -A direct reading of the ALC voltage on the PA
18 PA # 3 -In Ref -A DC voltage reference representing RF input power to the PA
19 PA # 4 -RF Power -1V = 1000 Watts of power
20 PA # 4 -SWR
21 Ground
22 PA # 4 -PA Volts -1V = 10 V on the PA
23 PA # 4 -PA Temperature -1V = 20 degrees Celsius on the PA
24 PA # 4 -PA Total Current -1V = 20 A on the PA
25 PA # 4 -PA#1 current -1V = 2A of current
26 Ground
27 PA # 4 -PA#2 current -1V = 2A of current
28 PA # 4 -PA#3 current -1V = 2A of current
29 PA # 4 -PA#4 current -1V = 2A of current
30 PA # 4 -PA#5 current -1V = 2A of current
31 Ground
32 PA # 4 -PA#6 current -1V = 2A of current
33 PA # 4 -PA#7 current -1V = 2A of current
34 PA # 4 -PA#8 current -1V = 2A of current
35 PA # 4 -ALC -A direct reading of the ALC voltage on the PA
36 Ground
37 PA # 4 -In Ref -A DC voltage reference representing RF input power to the PA

3–1Operation
Section 3—Operation
This section provides general operating parameters of your
transmitter system and a detailed description of the front panel
displays.

3–2FM10000 User’s Manual
These steps summarize the operating procedures you should use for the initial
operation of the power amplifier and power supply. More detailed information
follows.
1.Ensure that the external remote control unit is properly connected to the
transmitter controller port A (see illustration 2-15, Section 2.5, page 2–5
for proper pin configuration).
2.Connect Antenna feed-line to the output of the Low Pass Filter.
3.1 Initial Power-up Procedures

3–3Operation

3–4FM10000 User’s Manual

Operation 3–5