FM 5CFMi 402 - FM 4CFMi 301 Technical Manual

FM–5C 5 kW FM ONLY,
FMi–402 3.5 kW FM + HD,

1.5 kW HD ONLY
FM–4C 4 kW FM ONLY,
FMi–301 2.8 kW FM + HD,
1.2 kW HD ONLY
BROADCAST TRANSMITTERS
August, 2007 IM No. 597–5001

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 dam-
age is discovered, immediately notify the carrier, confirming the notification in writing, and secure an inspection re-
port. 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. Equip-
ment 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 the
mail 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 Authoriza-
tion.
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.
FACILITY CONTACTS –
Broadcast Electronics, Inc. – Quincy Facility
4100 N. 24th St. P.O. BOX 3606
Quincy, Illinois 62305
Telephone: (217) 224–9600
Fax: (217) 224–9607
E–Mail: General – bdcast@bdcast.com
Web Site: www.bdcast.com
RF PRODUCT TECHNICAL ASSISTANCE – REPAIR – EMERGENCY/WARRANTY REPLACEMENT PARTS –
Telephone: (217) 224–9600
E–Mail: rfservice@bdcast.com
Fax: (217) 224–9607
NON–EMERGENCY REPLACEMENT PARTS –
Fax: (217) 224–9609
RETURN, REPAIR, AND EXCHANGES.
Do not return any merchandise without our written approval and Return Authorization. We will provide special ship-
ping 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 merchan-
dise 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 manu-
al without notice. Any modifications shall not adversely affect performance of the equipment so modified.
WARNING
OPERATING HAZARDS
READ THIS SHEET AND OBSERVE ALL SAFETY PRECAUTIONS
ALL PERSONS WHO WORK WITH OR ARE EXPOSED TO POWER TRANSISTORS MUST TAKE PRECAUTIONS
TO PROTECT THEMSELVES AGAINST POSSIBLE SERIOUS BODILY INJURY. EXERCISE EXTREME CARE
AROUND SUCH PRODUCTS. UNINFORMED OR CARELESS OPERATION OF THESE DEVICES CAN RESULT
IN POOR PERFORMANCE, DAMAGE TO THE DEVICE OR PROPERTY, SERIOUS BODILY INJURY, AND POSSI-
BLY DEATH.
DANGEROUS HAZARDS EXIST IN THE OPERATION OF POWER TRANSISTORS
The operation of power transistors involves one or more of the following hazards, any one of which, in the absence of
safe operating practices and precautions, could result in serious harm to personnel.
A. HIGH VOLTAGE – Normal operating voltages can be deadly. Additional information follows.
B. RF RADIATION – Exposure to RF radiation may cause serious bodily injury possibly resulting in
blindness or death. Cardiac pacemakers may be affected. Additional information follows.
C. BERYLLIUM – OXIDE POISONING – Dust or fumes from BeO ceramics used as thermal links with
power transistors are highly toxic and can cause serious injury or death. Additional information follows.
D. RF BURNS – Circuit boards with RF power transistors contain high RF potentials. Do not operate an RF
power module with the cover removed.
HIGH VOLTAGE
The transmitter operates at voltages high enough to kill through electrocution. Personnel should always break the
primary circuits when access to the transmitter is required.
RADIO FREQUENCY RADIATION
Exposure of personnel to RF radiation should be minimized, personnel should not be permitted in the vicinity of open
energized RF generating circuits, or RF transmission systems (waveguides, cables, connectors, etc.), or energized
antennas. It is generally accepted that exposure to “high levels” of radiation can result in severe bodily injury includ-
ing blindness. Cardiac pacemakers may be affected.
The effect of prolonged exposure to “low level” RF radiation continues to be a subject of investigation and controver-
sy. It is generally agreed that prolonged exposure of personnel to RF radiation should be limited to an absolute mini-
mum. It is also generally agreed that exposure should be reduced in working areas where personnel heat load is
above normal. A 10 mW/cm2 per one tenth hour average level has been adopted by several U.S. Government agen-
cies including the Occupational Safety and Health Administration (OSHA) as the standard protection guide for em-
ployee work environments. An even stricter standard is recommended by the American National Standards Institute
which recommends a 1.0 mW/cm2 per one tenth hour average level exposure between 30 Hz and 300 MHz as the
standard employee protection guide (ANSI C95.1–1982).
RF energy must be contained properly by shielding and transmission lines. All input and output RF connections, such
as cables, flanges and gaskets must be RF leakproof. Never operate a power tube without a properly matched RF
energy absorbing load attached. Never look into or expose any part of the body to an antenna, open RF generating
circuit, or RF transmission system while energized. Monitor the tube and RF system for RF radiation leakage at regu-
lar intervals and after servicing.
DANGER –– BERYLLIUM OXIDE CERAMICS (BeO) – AVOID BREATHING DUST OR FUMES
BeO ceramic material is used as a thermal link to carry heat from a transistor to the heat sink. Do not perform any
operation on any BeO ceramic which might produce dust or fumes, such as grinding, grit blasting, or acid cleaning.
Beryllium oxide dust or fumes are highly toxic and breathing them can result in serious personal injury or death. BeO
ceramics must be disposed of only in a manner prescribed by the device manufacturer.
TABLE OF CONTENTS
PARAGRAPH PAGE NO.
SECTION I GENERAL INFORMATION
1-1. INTRODUCTION 1-1
1-3. RELATED PUBLICATIONS 1-1
1-6. EQUIPMENT DESCRIPTION 1-2
1-7. FM-5C/FM-4C GENERAL 1-2
1-12. FMi 402/FMi 301 GENERAL 1-2
1-17. FM-250C EXCITER 1-5
1-19. FXi 250 DIGITAL EXCITER 1-5
1-21. FXi 250 DIGITAL EXCITER (HD SYSTEM) 1-5
1-22. XPi 10 EXPORTER (HD SYSTEM) 1-5
1-23. POWER SUPPLY 1-5
1-24. RF AMPLIFIER MODULES 1-6
1-25 CONTROLLER 1-6
1-28 COMBINER 1-6
1-29 TRANSMITTER CONFIGURATIONS 1-6
1-32. OPTIONAL EQUIPMENT AND SPARE PARTS 1-8
KITS
1-34. EQUIPMENT SPECIFICATIONS 1-8
SECTION II INSTALLATION
2-3. UNPACKING 2-1
2-6. ENVIRONMENTAL REQUIREMENTS 2-1
2-8. COOLING AIR REQUIREMENTS 2-1
2-12. PRIMARY POWER 2-1
2-16. INSTALLATION 2-2
2-18. EQUIPMENT PLACEMENT 2-2
2-21. EQUIPMENT INSTALLATION 2-2
2-22. COMPONENT INSTALLATION 2-2
2-26. WIRING 2-10
2-27. REMOTE CONTROL 2-10
2-51. EXTERNAL INTERLOCK 2-15
2-52. MODULATION MONITOR RECEPTACLE 2-16
2-53. AUDIO INPUT CONNECTIONS 2-16
2-54. RF OUTPUT TRANSMISSION LINE 2-16
CONNECTION
2-55. GROUND 2-16
2-56. AC POWER CONNECTIONS 2-18
2-62. PRELIMINARY OPERATION 2-23
SECTION III OPERATION

3-3. CONTROLS AND INDICATORS 3-1
3-5. OPERATION 3-7
3-6. TURN-ON 3-7
3-13. TURN-OFF 3-7
Broadcast Electronics 2007

ALL RIGHTS RESERVED -i -
Printed in the U.S.A.
PARAGRAPH PAGE NO.
3-16. MULTIMETER OPERATION 3-7
3-18. SYSTEM PARAMETER DISPLAY 3-8
3-19. MODULE PARAMETER DISPLAY 3-8
3-20. POWER ADJUST 3-9
3-22. EXCITER OPERATION 3-9
3-24. FAULT RESET 3-9
3-28. RF POWER MODULE STATUS AND DRIVE 3-9
INDICATORS
3-31. POWER SUPPLY FAULT INDICATORS 3-9
3-33. THREE-PHASE AC LOSS MONITOR - FOR 3-10
THREE-PHASE DELTA POWER SUPPLY
MODELS ONLY
SECTION IV THEORY OF OPERATION

4-3. OVERALL OPERATION 4-1
4-5. POWER SUPPLY/RF CIRCUITRY OPERATION 4-1
4-7. CONTROLLER CIRCUITRY OPERATION 4-1
4-11. CONTROLLER ON/OFF SWITCH CIRCUIT 4-1
BOARD
4-13. TRANSMITTER ON CONTROL CIRCUIT 4-1
4-15. TRANSMITTER OFF CONTROL CIRCUIT 4-2
4-17. REMOTE CONTROL ENABLE/DISABLE 4-2
CIRCUIT
4-18. REMOTE CONTROL FAILSAFE INPUT 4-2
CIRCUIT
4-21. AFC LOCK INPUT CIRCUIT 4-10
4-22. RESET CIRCUIT 4-10
4-23. EXTERNAL INTERLOCK CIRCUIT 4-10
4-24. TRANSMITTER RAISE POWER CIRCUIT 4-10
4-25. TRANSMITTER LOWER POWER CIRCUIT 4-10
4-26. CONTROLLER CIRCUIT BOARD 4-10
4-28. AUTOMATIC-POWER-CONTROL CIRCUIT 4-13
4-33. METER AMPLIFIER/BUFFER CIRCUITS 4-13
4-35. INLET AIR TEMPERATURE CIRCUIT 4-14
4-36. REFLECTED POWER METER CIRCUIT 4-14
4-37. FORWARD POWER METER CIRCUIT 4-15
4-38. TRANSMITTER FAULT DETECTION 4-15
CIRCUITRY
4-44. CONTROLLER METER SWITCH CIRCUIT 4-16
BOARD
4-46. METER DISPLAY CIRCUIT BOARD 4-16
4-48. RF AMPLIFIER CIRCUITRY OPERATION 4-16
SECTION V MAINTENANCE
5-3. SAFETY CONSIDERATIONS 5-1
5-6. POWER AMPLIFIER EFFICIENCY 5-1
5-8. FIRST LEVEL MAINTENANCE 5-1
5-10. ROUTINE MAINTENANCE 5-2
-ii -
PARAGRAPH PAGE NO.
5-11. INSPECTION AND CLEANING 5-2
5-12. CONTROLLER BATTERY 5-2
5-13. AIR FILTERS 5-2
5-15. FLUSHING FANS 5-4
5-17. SECOND LEVEL MAINTENANCE 5-4
5-20. ELECTRICAL ADJUSTMENTS 5-4
5-21. MULTIMETER DISPLAY CALIBRATION 5-4
5-33. REFLECTED POWER METER, VSWR 5-5
FOLDBACK, AND VSWR OVERLOAD
CALIBRATION
5-54. FORWARD POWER CALIBRATION 5-7
5-66. PAV CALIBRATION 5-8
5-80. TEMPERATURE CALIBRATION 5-9
5-92. PA MODULE FORWARD POWER 5-10
CALIBRATION
5-106. CONTROLLER SQUARING CIRCUIT 5-10
ADJUSTMENTS
5-107. RF POWER AMPLIFIER MODULE 5-11
ADJUSTMENTS
5-108. LOW-PASS FILTER 5-11
5-109. TRANSMITTER FREQUENCY 5-11
RE-PROGRAMMING
5-119. TROUBLESHOOTING 5-12
5-120. TYPICAL METER INDICATIONS 5-12
5-121. POWER AMPLIFIER POWER SUPPLY 5-12
MODULES
5-123. CONTROLLER POWER SUPPLY 5-13
5-131. POWER AMPLIFIER MODULE 5-14
TROUBLESHOOTING/REPAIR
5-132. POWER AMPLIFIER MODULE 5-14
TROUBLESHOOTING/REPAIR
5-135. TRANSMITTER TROUBLESHOOTING 5-15
PROCEDURES
5-136. TRANSMITTER COMPONENT LOCATIONS 5-15
5-138. COMPONENT REPLACEMENT PROCEDURE 5-21
SECTION VI PARTS LIST

SECTION VII DRAWINGS

APPENDIX A MANUFACTURERS DATA

A-1 Introduction A-1
-iii -
LIST OF TABLES
TABLE NO. TITLE PAGE NO.
1-1. FM-5C/FM-4C ELECTRICAL 1-8
SPECIFICATIONS
1-2. FM-5C/FM-4C PHYSICAL AND 1-11
ENVIRONMENTAL SPECIFICATIONS
1-3. FMi 402/FMi 301 ELECTRICAL 1-12
SPECIFICATIONS
1-4. FMi 402/FMi 301 PHYSICAL AND 1-15
ENVIRONMENTAL SPECIFICATIONS
3-1. FM-5C/FM-4C & FMi 402/FMi 301 CONTROLS AND 3-1
INDICATORS
5-1. TROUBLESHOOTING 5-16
6-1. REPLACEABLE PARTS LIST INDEX 6-1
LIST OF ILLUSTRATIONS
FIGURE NO. TITLE PAGE NO.
1-1. FM-5C/FM-4C TRANSMITTERS 1-3
1-2. FMi 402/FMi 301 TRANSMITTERS 1-4
2-1. FM-5C/FM-4C TRANSMITTER 2-3
INSTALLATION DIAGRAM
2-2. FMi 402/FMi 301 TRANSMITTERS 2-4
2-3. ACCEPTABLE AC POWER INPUT 2-5
CONFIGURATIONS
2-4. COMPONENT INSTALLATION 2-6
2-5. FM-250C VERTICAL ALIGNMENT 2-9
2-6. REMOTE CONTROL CONNECTIONS 2-11
2-7. INTERLOCK, REMOTE 2-13
CONTROL, AND MODULATION
MONITOR WIRING
2-8. RF OUTPUT CONNECTIONS 2-17
2-9. FM-5C/FMi 402 SINGLE PHASE AC POWER 2-20
CONNECTIONS
2-10. FM-4C/FMi 301 SINGLE PHASE AC POWER 2-21
CONNECTIONS
2-11. FM-5C/FM-4C & FMi 402/FMi 301 THREE PHASE 2-22
POWER CONNECTIONS
3-1. FM-5C/FM-4C & FMi 402/FMi 301 CONTROLS AND 3-2
INDICATORS
4-1. FM-5C/FM-4C & FMi 402/FMi 301 TRANSMITTER 4-3
BLOCK DIAGRAM
4-2. POWER SUPPLY/RF CIRCUIT 4-5
SIMPLIFIED SCHEMATIC
4-3. FM-5C/FM-4C & FMi 402/FMi 301 TRANSMITTER 4-7
CONTROLLER SIMPLIFIED SCHEMATIC
4-4. CONTROLLER ON/OFF SWITCH CIRCUIT 4-9
BOARD SIMPLIFIED SCHEMATIC
4-5 MULTIPLEXER AND MODULE SELECT 4-11
CIRCUIT BOARD SIMPLIFIED SCHEMATIC
4-6. RF AMPLIFIER MODULE SIMPLIFIED 4-17
SCHEMATIC
-iv -
5-1. FM-5C/FM-4C TYPICAL PA EFFICIENCY 5-2
5-2. AIR FILTER REMOVAL 5-3
5-3. ADJUSTABLE VOLTAGE SOURCE 5-5
5-4. CONTROLLER AND METER DISPLAY 5-6
CIRCUIT BOARD CONTROLS
5-5. COMPONENT LOCATOR 5-23
-v -
SECTION I
GENERAL INFORMATION
1-1. INTRODUCTION.
1-2. Information presented by this section provides a general description of the Broadcast ElecĆ
tronics FM-5C/FM-4C and FMi-402/FMi-301 transmitters and lists equipment specificaĆ
tions.
1-3. RELATED PUBLICATIONS.

1-4. The following list of publications provides data for equipment associated with the FM-5C/
FM-4C transmitters.
PUBLICATION NUMBER EQUIPMENT
597-1004 FM-250C FM Transmitter/Exciter Manual
597-0008-004 FC-30 SCA Generator Manual
597-9900 LYNX Digital Stereo Generator Manual
1-5. The following list of publications provides data for equipment associated with the
FMi-402/FMi-301 transmitters.
PUBLICATION NUMBER EQUIPMENT
597-0541 FXi-60/250 Digital Exciter Manual
597-0542-XM3 FXi & XPi Quick Installation Guide
597-0542-008 XPi-10 Operation Manual
1-1
1-6. EQUIPMENT DESCRIPTION.
1-7. FM–5C/FM–4C GENERAL.
1-8. The Broadcast Electronics FM-5C transmitter is a 5 kW solid-state FM ONLY transmitter
designed for continuous operation in the 87.5 MHz to 108 MHz broadcast band (refer to
Figure 1-1).
1-9. The FM-5C transmitter is equipped with: 1) an FM-250C FM exciter, 2) 6 modular
switching power supply assemblies, 3) 10 modular solid-state broadband plug-in RF power
amplifier modules, 4) a low-pass filter, 5) a combiner, and 6) a CMOS controller. All the
components are housed in a single chassis.
1-10. The Broadcast Electronics FM-4C transmitter is a 4 kW solid-state FM ONLY transmitter
designed for continuous operation in the 87.5 MHz to 108 MHz broadcast band. (refer to
Figure 1-1).
1-11. The FM-4C transmitter is equipped with: 1) an FM-250C FM exciter, 2) 5 modular
switching power supply assemblies, 3) 8 modular solid-state broadband plug-in RF power
amplifier modules, 4) a low-pass filter, 5) a combiner, and 6) a CMOS controller. All the
components are housed in a single chassis.
1–12. FMi–402/FMi–301 GENERAL

1-13. The Broadcast Electronics FMi-402 transmitter is a 3.5 kW solid-state FM+HD and 1.5
kW HD ONLY solid state transmitter based largely on the FM-5C architecture and is deĆ
signed for continuous operation in the 87.5 MHz to 108 MHz broadcast band (refer to FigĆ
ure 1-2).
1-14. The FMi-402 transmitter is equipped with: 1) an FXi-250 Digital FM Exciter, 2) an XPi-10
HD Exporter, 3) 6 modular switching power supply assemblies, 4) 10 modular solid-state
broadband plug-in RF power amplifier modules, 5) a low-pass filter, 6) a combiner, and 7) a
CMOS controller. All the components are housed in a single chassis.
1-15. The Broadcast Electronics FMi-301 transmitter is a 2.8 kW solid-state FM+HD and 1.2
kW HD ONLY solid state transmitter based largely on the FM-4C architecture and is deĆ
signed for continuous operation in the 87.5 MHz to 108 MHz broadcast band (refer to FigĆ
ure 1-2).
1-16. The FMi-301 transmitter is equipped with: 1) an FXi-250 Digital FM Exciter, 2) an XPi
10 HD Exporter, 3) 5 modular switching power supply assemblies, 4) 8 modular solid-state
broadband plug-in RF power amplifier modules, 5) a low-pass filter, 6) a combiner, and 7)
a CMOS controller. All the components are housed in a single chassis.
1-2
FM-5C TRANSMITTER FM-4C TRANSMITTER
COPYRIGHT 2007 BROADCAST ELECTRONICS, INC.
597-5001-1
FIGURE 1-1. FM-5C/FM-4C TRANSMITTERS
1-3
FMi-402 TRANSMITTER FMi-301 TRANSMITTER
597-5001-2
FIGURE 1-2. FMi-402 / FMi-301 TRANSMITTERS
1-4
1-17. FM–250C EXCITER. The FM-250C exciter is a solid-state wideband FM exciter providĆ
ing a continuously variable RF output at any frequency within the 87.5 MHz to 108 MHz
broadcast band in 10 kHz increments. The FM-250C comes standard with an FM-5C/
FM-4C transmitter. The FM-250C is designed to accept multiple wideband composite inĆ
puts from a stereo generator or SCA generator. In addition, the FM-250C is equipped with
a 600 Ohm balanced monaural input. A tapped dual primary power transformer and a
voltage selector allows operation from a wide range of ac input potentials.
1-18. The FM-250C is equipped with a digitally programmed frequency synthesizer which genĆ
erates and maintains the phase and frequency of the carrier. A temperature compensated
reference oscillator and a dual-speed phase-locked-loop control circuit locks the frequency
of a modulated oscillator to a precision frequency oscillator allowing prompt on-frequency
operation. A solid-state broadband 25 to 250 watt RF amplifier provides amplification of
the FM signal. Exciter operating parameters are monitored and displayed by a
front-panel digital LCD multimeter and an LED display.
1-19. FXi–250 DIGITAL EXCITER. The FXi-250 Digital Exciter comes standard with the
FMi-402/FMi-301 transmitters. FM-5C/FM-4C transmitters may also be equipped with
the FXi 250. The FXi-250 is a solid-state wideband digital FM exciter providing a
constant variable RF output at any frequency within the 87.5 to 108 MHz FM broadcast
band in 10 kHz increments. The FXi-250 is divided into several board assemblies. The
assemblies include: 1) DSP (Digital Signal Processor) Modulator, 2) Controller, 3) OscillaĆ
tor/Filter, 4) RF Amplifier, 5) Power Supply, and 6) Color GUI Interface.
1-20. The FXi-250 is highly integrated and comes with the following standard features: 1) AES
Input, 2) L&R Analog Inputs, 3) Balanced and Unbalanced Composite Inputs, 4) Two InĆ
ternal SCA Generators, 5) Internal RDS Generator, 6) External SCA/RDS Input. The FXi
250 also has a buit in stereo generator, compressor, and limiter all of which are software
programmable and defeatable. The digital exciter also provides modulation Directly To
Channel (DTC) 87.5 - 108 MHz, eliminating any analog up converter processes. The chasĆ
sis of the FXi-250 requires 7 inches (height) of a 19 inch (wide) rack cabinet. Refer to pubĆ
lication 597-0541 for a detailed explanation of the FXi 250 features.
1-21. FXi–250 DIGITAL EXCITER (HD SYSTEM). When the FXi-250 Exciter is used in a
FMi-402/FMi-301 transmitter the FXi is equipped with an Exgine Card. Refer to publicaĆ
tion 597-0542-XM3 for detailed instructions for the Installation and Setup of an FXi ExĆ
citer (w/Exgine) and XPi-10 Exporter.
1-22. XPi–10 EXPORTER (HD SYSTEM). FMi-402/FMi-301 transmitters come standard with
an XPi-10 HD Exporter. The XPi works in conjunction with the FXi (w/Exgine) to provide
HD signals to the FMi-402/FMi-301 transmitter. Refer to publication 597-0542-XM3 for
detailed instructions for the Installation and Setup of an FXi Exciter (w/Exgine) and XPi
10 Exporter.
1-23. POWER SUPPLY. FM-5C/FM-4C and FMi-402/FMi-301 transmitters are equipped with
modular switching power supply assemblies. 5 switching power supplies in FM-5C/FMi-
402 models and 4 switching power supplies in FM-4C/FMi-301 models provide dc operatĆ
ing potentials for the transmitter power amplifier circuitry. A separate modular switching
power supply is provided for the controller circuitry. The transmitter power supply circuitĆ
ry is equipped with overload protection, over-voltage protection, high temperature protecĆ
tion, and a soft-start feature which minimizes in-rush currents.
1-5
1-24. RF POWER AMPLIFIER MODULES. FM-5C/FMi-402 is equipped with 10 RF power
amplifier modules. The FM-4C/FMi-301 is equipped with 8 RF power amplifier modules.
Each module consists of a broadband solid-state RF amplifier and a logic circuit board.
The RF amplifier contains two dual MOSFET power transistors operated in a push-pull
configuration. Each module is designed to output 500 watts of RF power. RF amplifier
operations are monitored by the logic circuit board. The logic circuit board is designed to
monitor over-current, over-voltage, high reflected power, and high temperature condiĆ
tions. A limit circuit is designed to limit the RF output during high reflected power, high
temperature, over-current, or high forward power demand conditions. The operating staĆ
tus of the module is displayed by a front panel LED. The LED displays normal, fault, and
limit conditions. A second module status LED displays the presence of RF drive at the
module.
1-25. CONTROLLER. Transmitter control and monitoring operations are performed by a
CMOS logic controller. The controller utilizes extensive RFI filtering and CMOS logic cirĆ
cuitry to ensure maximum reliability. A battery back-up system is incorporated into the
design to maintain the controller memory during ac power interruptions. Operating potenĆ
tials for the controller circuitry are provided by a modular switching power supply. The
supply provides the controller circuitry with a stable +5 and r15 volt dc supply.
1-26. The transmitter RF output power is controlled by a power control circuit. The circuit is
designed to raise or lower the transmitter power in response to the front panel raise and
lower switches. A fault circuit monitors transmitter operations for an RF power amplifier
module fault, a power supply module fault, a high reflected power condition, or a high
temperature condition.
1-27. The controller is also equipped with metering circuitry. Meter amplifier/buffering circuits
are provided for the RF power amplifier module forward power, current, voltage, and temĆ
perature samples. Meter amplifier/buffering circuits are also provided for the transmitter
forward power, reflected power, PA voltage, and air inlet temperature samples. Display of
the samples is provided by an LCD multimeter. Samples are selected for application to the
multimeter by a meter switch circuit board.
1-28. COMBINER. In FM-5C/FM-4C and FMi-402/FMi-301 transmitters, the RF power modĆ

ule outputs are combined using a unique combiner assembly. The FM-5C/FMi-402 is
equipped with a 10 position combiner designed to produce 5 kW of RF output power.
FM-4C/FMi-301 is equipped with an 8 position combiner designed to produce 4 kW of RF
output power. The unique features of the combiner include: 1) very low loss, 2) broadband,
3) no cable connections and 4) operates with open or shorted inputs.
1-29. TRANSMITTER CONFIGURATIONS.
1-30. The FM-5C/FM-4C transmitters can be ordered in the following configurations:
P/N DESCRIPTION
909-5001-204 FM-5C 5 kW FM Transmitter for operation in the 87.5
MHz to 108 MHz broadcast band, 196V to 252V ac
50/60 Hz single phase supply. Includes FM-250C FM
exciter, 196V to 252V ac 50/60 Hz single phase
operation.
909-4001-204 FM-4C 4 kW FM Transmitter for operation in the 87.5
MHz to 108 MHz broadcast band, 196V to 252V ac
50/60 Hz single phase supply. Includes FM-250C FM
exciter, 196V to 252V ac 50/60 Hz single phase
operation.
1-6
P/N DESCRIPTION
909-5001-254 FM-5C 5 kW FM Transmitter with FM-250C for
operation in the 87.5 MHz to 108 MHz broadcast band,
196V to 252V ac 50/60 Hz three phase supply.
909-1250 FM-5C/FM-4C Transmitter Less FM-250C Exciter.
1-31. The FMi 402/FMi 301 transmitters can be ordered in the following configurations:
P/N DESCRIPTION
909-0402-404 FMi-402 3.5 kW FM+HD (1.5kW HD ONLY) Transmit
ter with an FXi 250 Exciter and XPi 10 HD Exporter for
196V to 252V ac 50/60 Hz single phase supply.
196V to 252V ac 50/60 Hz single phase supply.
196V to 252V ac 50/60 Hz three phase delta supply.
196V to 252V ac 50/60 Hz three phase delta supply.
339V to 437V ac 50/60 Hz three phase 4 wire WYE sup
ply.
339V to 437V ac 50/60 Hz three phase 4 wire WYE sup
ply.
1-7
1-32. OPTIONAL EQUIPMENT AND SPARE PARTS KITS.
1-33. The following text presents the optional equipment and spare parts kits available for the
use with FM-5C/FM-4C and FMi-402/FMi-301 transmitters.
P/N DESCRIPTION
909-0051-204 FC-30 FM SCA Generator.
979-0414 Recommended spare parts kit for FM-5C/FM-4C
and FMi-402/FMi-301 solid-state transmitters.
Includes selected switches, relays, etc. Does not
include spare parts for a FM-250C or FXi-250.
979-0415 Recommended semiconductor kit for FM-5C/
FM-4C and FMi-402/FMi-301 solid-state tran-
mitters. Does not include semiconductors for a
FM-250C or FXi-250.
979-0416 100% semiconductor kit for the FM-4C/FMi-301
solid-state transmitter. Does not include semicon-
ductors for a FM-250C or FXi-250.
979-0417 100% semiconductor kit for the FM-5C/FMi-402
solid-state transmitter. Does not include semicon-
ductors for a FM-250C or FXi-250.
907-0016-204 VMC-16 Voice Remote Control Unit, FM-5C/
FM-4C.
1-34. EQUIPMENT SPECIFICATIONS.

1-35. Refer to Table 1-1 for FM-5C/FM-4C electrical specifications, Table 1-2 for FM-5C/
FM-4C Physical and Environmental specifications. Refer to Table 1-3 for FMi-402/FMi-
301 electrical specifications, and Table 1-4 for FMi 402/FMi 301 Physical and EnvironmenĆ
tal specifications.
TABLE 1-1. FM-5C / FM-4C ELECTRICAL SPECIFICATIONS

(Sheet 1 of 3)
PARAMETER SPECIFICATION
RF POWER OUTPUT
FM-5C 2.5 kW to 5 kW (as specified).
FM-4C 2 kW to 4 kW (as specified).
FREQUENCY RANGE 87.5 to 108 MHz (as specified).
Exciter programmable in 10 kHz increments.
RF OUTPUT IMPEDANCE 50 Ohms.
RF OUTPUT CONNECTOR 1 5/8 inch EIA female field flange.
1-8
(Sheet 2 of 3)
MAXIMUM VSWR Rated power into 1.5:1 maximum without output

matching. Capable of operating into high VSWR
conditions with automatic power reduction. Open
and short circuit protected at all phase angles.
EXCITER Model FM-250C, solid-state 250 watt output
with digitally programmed synthesizer. 10 kHz
increment programming. Optional FXi 250
digital exciter, 250 watt output, 10 kHz increment
programming.
AM SIGNAL-TO-NOISE RATIO:
Asynchronous 55 dB below an equivalent reference carrier with
100% AM modulation @ 400 Hz, 75 microsecond
deemphasis (no FM modulation present).
Synchronous
FM-5C 50 dB below an equivalent 5 kW reference car-
rier @ 100% AM modulation @ 400 Hz. 75 uS de-
emphasis with r75 kHz FM modulation @ 400 Hz
and a 5 kW output power.
FM-4C 50 dB below an equivalent 4 kW reference car-
rier @ 100% AM modulation @ 400 Hz. 75 uS de-
emphasis with r75 kHz FM modulation @ 400 Hz
and a 4 kW output power.
RF HARMONIC SUPPRESSION Meets all FCC/DOC requirements and CCIR
recommendations.
FM SIGNAL-TO-NOISE RATIO:
Mono/Composite 85 dB below r75 kHz deviation @ 400 Hz meas-
ured in a 20 Hz to 30 kHz bandwidth with 75
microsecond deemphasis.
Stereo 80 dB below r75 kHz deviation @ 400 Hz meas-
ured in a 20 Hz to 30 kHz bandwidth with 75
microsecond deemphasis.
DISTORTION
Mono/Composite
Harmonic 0.02% or less at 400 Hz.
SMPTE Intermodulation 0.02% or less, 60 Hz/7 kHz, Ratio:
Distortion 4:1 Monophonic, 1:1 Composite.
CCIF Intermodulation 0.02% or less, 15 kHz/14 kHz, 1:1 Ratio.
Distortion
Transient Intermodulation 0.02% or less, sine wave/square wave.
Distortion
1-9
(Sheet 3 of 3)
DISTORTION (CONT'D)
Stereo
Harmonic 0.05% or less at 400 Hz.
SMPTE Intermodulation 0.05% or less, 60 Hz/7 kHz, 4:1 Ratio.
Distortion
CCIF Intermodulation 0.05% or less, 15 kHz/14 kHz, 1:1 Ratio.
Distortion
Transient Intermodulation 0.05% or less, sine wave/square wave.
Distortion
STEREO SEPARATION 50 dB or better, 30 Hz to 15 kHz (sine wave).
DYNAMIC STEREO SEPARATION 40 dB or greater, 30 Hz to 15 kHz (normal
program content).
LINEAR CROSSTALK 45 dB Minimum below 100% modulation,
(Main to Sub/Sub to Main 30 Hz to 15 kHz.
Due to Amplitude and Phase Matching)
NON-LINEAR CROSSTALK 70 dB Minimum below 100% modulation.
(Main to Sub/Sub to Main
Due to Distortion Products)
AC POWER REQUIREMENTS
Standard 196 to 252V ac 50/60 Hz single phase.
Optional 196 to 252V ac 50/60 Hz or 339 to 437V ac 50/60
Hz three phase.
AC POWER CONSUMPTION
FM-5C 10 kW typical at a 5 kW RF power output,
50 Ohm resistive load.
FM-4C 8 kW typical at a 4 kW RF power output, 50
Ohm resistive load.
OVERALL EFFICIENCY 50% or greater (AC line input to RF output)
DISCONNECT FUSE / WIRE SIZE
FM-5C (Single Phase) 80A / #6 AWG COPPER TYPE THHN
FM-5C (Three Phase) 50A / #6 AWG COPPER TYPE THHN
FM-4C (Single Phase) 70A / #6 AWG COPPER TYPE THHN
FM-4C (Three Phase) 50A / #6 AWG COPPER TYPE THHN
1-10
TABLE 1-2. FM-5C / FM-4C PHYSICAL AND ENVIRONMENTAL SPECIFICATIONS
PHYSICAL
DIMENSIONS:
FM-250C Exciter Width: 19.0 inches (48.3 cm).
Height: 7.0 inches (17.8 cm).
Depth: 19.0 inches (48.3 cm).
FXi 250 Exciter Width: 19.0 inches (48.3 cm).
Transmitter Width: 30.6 inches (77.8 cm).
WEIGHT (with Exciter)
FM-5C 575 pounds (261 kg) unpacked.
FM-4C 525 pounds (238 kg) unpacked.
SAFETY Meets IEC 215.
ENVIRONMENTAL
HEAT DISSIPATION
FM-5C (5 kw Output) 5.5 kW (18,805 Btu/H) at a 5 kW RF output, 50
Ohm resistive load.
FM-4C (4 kW Output) 4.5 kW (15,390 Btu/H) at a 4 kW RF output,
COOLING AIR REQUIREMENTS 2200 cubic feet per minute (62.3 m3/min).
AMBIENT TEMPERATURE RANGE +32qF to +122qF (0qC to +50qC).
MAXIMUM ALTITUDE
50 Hz Operation 0 to 7,500 feet above sea level (0 to 2286 meters).
MAXIMUM HUMIDITY 95%, non-condensing.
1-11
TABLE 1-3. FMi-402 / FMi-301 ELECTRICAL SPECIFICATIONS
(Sheet 1 of 3)
RF POWER OUTPUT
FMi-402
HD Only 1,000-1,500W
FM+HD 2,000-3,500W
FM ONLY 2,500-5,000W
FMi-301
HD Only 750-1,200W
FM+HD 1,500-2,800W
FM ONLY 2,000-4,000W
RF OUTPUT IMPEDANCE 50 Ohms.

RF OUTPUT CONNECTOR 1 5/8 inch EIA female field flange.
OVERALL EFFICIENCY
HD Only >25%
FM+HD >50%
FM ONLY >50%
VSWR Rated power into 1.5:1 maximum without output
matching. Capable of operating into high VSWR
conditions with automatic power reduction. Open
and short circuit protected at all phase angles.
FREQUENCY RANGE 87.5 to 108 MHz (as specified).
Exciter programmable in 10 kHz increments.
FREQUENCY STABILITY
INTERNAL 10MHZ REF. +/- 300Hz, 0-50 degrees C
EXTERNAL 10MHZ REF.(GPS) Determined by source
MODULATION CAPABILITY +/- 300kHz FM Mode
MODULATION MODES FM Only, FM+HD, HD Only
ASYNCHRONOUS AM S/N RATIO 55dB below rated power with 100% AM at 400Hz
and 75usec de-emphasis (no modulation present)
SYNCHRONOUS AM S/N RATIO 50dB below rated power with 100% AM modulation
at 400Hz and 75usec de-emphasis
(+/-75kHz modulation)
IMD PROTECTION 20dB or better turn-around loss or mixing loss to
interfering signals.
SPURIOUS AND HARMONIC Meets or exceeds all FCC requirements.
1-12
(Sheet 2 of 3)
AC INPUT
3 PHASE 196 to 252VAC, 50/60Hz, 3-phase, Closed Delta or
339 to 437VAC, 50/60Hz, 3-phase, 4 wire, WYE
SINGLE PHASE 196 TO 252VAC, 50/60Hz, Single Phase
POWER FACTOR .99 @ 230VAC
DISCONNECT FUSE / WIRE SIZES
FMi-402 (Single Phase)
HD Only 35A / #8 AWG COPPER TYPE THHN
FM+HD 45A / #6 AWG COPPER TYPE THHN
FM Only 80A / #3 AWG COPPER TYPE THHN
FMi-402 (Three Phase)
FMi-301 (Single Phase)
FMi-301 (Three Phase)
1-13
(Sheet 3 of 3)
AC POWER CONSUMPTION
FMi 402
HD Only 5,250W @ 1,500W RF Output
FM+HD 7,000W @ 3,500W RF Output
FMi 301
HD Only 4,200W @ 1,200W RF Output
FM+HD 5,600W @ 2,800W RF Output
FM AUDIO PERFORMANCE
AES INPUT FM+IBOC MODE
Input Level -2dBFS for 100% modulation
Input Frequency 32,44.1,48, or 96kHz; 16-24bits
Impedance 110ohms
Connector Wire (XLR), Optical (Toslink)
Amplitude Response +/-0.5dB; 20Hz to 15kHz
IMD Distortion 0.03% or better
THD + Noise
Stereo 0.03% or better
Mono 0.005% or better
S/N Ratio
Stereo 90dB or better below 100% modulation @ 400kHz
Mono 85dB or better below 100% modulation @ 400kHz
INTERNAL SCAs (2)
Frequency 20kHz to 99kHz software programmable
Deviation 2.5kHz to 10kHz
Injection Level 2% to 15%
Pre-Emphasis 0, 50usec, 75usec, or 150usec
1-14
TABLE 1-4. FMi-402 / FMi-301 PHYSICAL AND ENVIRONMENTAL SPECIFICATIONS
PHYSICAL
DIMENSIONS:
FM-250C Exciter Width: 19.0 inches (48.3 cm).
FXi-250 Exciter Width: 19.0 inches (48.3 cm).
Transmitter Width: 30.6 inches (77.8 cm).
WEIGHT (with Exciter)
FMi-402 575 pounds (261 kg) unpacked.
FMi-301 525 pounds (238 kg) unpacked.
SAFETY Meets IEC 215.
ENVIRONMENTAL
HEAT DISSIPATION
FM ONLY:
FMi-402 5.5 kW (18,783 Btu/H) at 5 kW RF output, 50
Ohm resistive load.
FMi-301 4.5 kW (15,368 Btu/H) at 4 kW RF output,
HD ONLY:
FMi-402 4.5 kW (15,368 Btu/H) at 1.5 kW RF output, 50
Ohm resistive load.
FMi-301 3.6 kW (12,295 Btu/H) at 1.2 kW RF output,
FM + HD:
FMi-402 3.5 kW (11,953 Btu/H) at 3.5 kW RF output, 50
Ohm resistive load.
FMi-301 2.8 kW (9,563 Btu/H) at 2.8 kW RF output,
COOLING AIR REQUIREMENTS 2200 cubic feet per minute (62.3 m3/min).
AMBIENT TEMPERATURE RANGE +32qF to +122qF (0qC to +50qC).
MAXIMUM ALTITUDE
MAXIMUM HUMIDITY 95%, non-condensing.
1-15
SECTION II
INSTALLATION
2-1. INTRODUCTION.
2-2. This section contains information required for the installation and preliminary checkout of
the Broadcast Electronics FM-5C/FM-4C and FMi-402/FMi-301 transmitters.
2-3. UNPACKING.
2-4. The equipment becomes the property of the customer when the equipment is delivered to
the carrier. Carefully unpack the transmitter. Perform a visual inspection to determine
that no apparent damage has been incurred during shipment. All shipping materials
should be retained until it is determined that the unit has not been damaged. Claims for
damaged equipment must be promptly filed with the carrier or the carrier may not accept
the claim.
2-5. The contents of the shipment should be as indicated on the packing list. If the contents are
incomplete, or if the unit is damaged electrically or mechanically, notify both the carrier
and Broadcast Electronics.
2-6. ENVIRONMENTAL REQUIREMENTS.

2-7. Tables 1-2 and 1-4 provide environmental conditions which must be considered prior to
transmitter installation. Refer to Table 1-2 and 1-4 in SECTION I, INTRODUCTION and
ensure the transmitter is to be installed in an acceptable environment.
2-8. COOLING AIR REQUIREMENTS.

2-9. FM-5C/FM-4C and FMi-402/FMi-301 transmitters require a source of cooling air to
maintain an acceptable operating temperature. These transmitters require a cooling air
flow of 2200 cubic feet per minute (refer to Figure 2-1 and 2-2). The cooling air source
must be dry and well filtered.
2-10. If the heated transmitter air is to be ducted from the room, the duct system must not introĆ
duce any back-pressure on the equipment. Proper allowances for air flow will ensure that
only a limited amount of heat is dissipated into the equipment interior. The duct system
must allow for a minimum air flow of 2200 CFM (for a FM-5C/FM-4C) and 2700 CFM (for
a FMi-402/FMi-301).
2-11. If an exhaust system is desired, an exhaust hood must be designed. A paper titled
TRANSMITTER COOLING SYSTEMS: DESIGN, OPERATION, AND MAINTENANCE "
provides information on the design and maintenance of transmitter exhaust systems. The
paper can be obtained by contacting the Broadcast Electronics Customer Service DepartĆ
ment.
2-12. PRIMARY POWER.

2-13. The standard FM-5C/FM-4C and FMi-402/FMi-301 transmitters operate from a single
phase ac power source. However, these transmitters may be equipped with a three-phase
power supply option. If the transmitter is equipped with a three phase power supply, the
transmitter must be connected to a closed-delta or wye connected three-phase power
source. Operation from an unsatisfactory power source will void the warranty on the
transmitter as any resultant damage is beyond the control of the manufacturer. Before
attempting installation of the transmitter, assure that the proper power source is installed.
Acceptable power input configurations are shown in Figures 2-2 and 2-3.
2-1
2-14. An open-delta, V to V, T to T, T to L, or Scott connected power source will provide unsatisĆ
factory transmitter performance as transients and unstable power can damage components
of the transmitter and provide degraded specifications. Any of these systems will develop a
considerable imbalance between phases in voltage, phase angle, or both voltage and phase
angle. These problems can result in premature failure of power supply and RF circuit comĆ
ponents.
2-15. It is important that the local electric utility be consulted to ensure that the correct service
is provided before connection of the transmitter to a primary power source. The proper
power source can be readily identified by the use of three transformers with one winding
each or one transformer with three windings instead of the use of two transformers as reĆ
quired for the unacceptable configurations.
2-16. INSTALLATION.
2-17. Each transmitter is wired, operated, tested, and inspected at the factory prior to shipment
and is ready for installation when received. Prior to installation, this publication should be
studied to obtain an understanding of the operation, circuitry, nomenclature, and installaĆ
tion requirements. Installation is accomplished as follows: 1) equipment placement, 2)
equipment installation, 3) wiring, and 4) preliminary operation.
2-18. EQUIPMENT PLACEMENT.
WARNING ENSURE NO PRIMARY POWER IS CONNECTED TO

THE TRANSMITTER BEFORE PROCEEDING.
WARNING
2-19. FM-5C/FM-4C and FMi-402/FMi-301 transmitters are designed with access holes in the
top and bottom of the cabinet to allow for over-head and under-floor ducting of ac power,
control, and ground strap wiring (refer to Figures 2-1 and 2-2). The floor must be capable
of supporting the total transmitter weight.
2-20. Evaluate the installation site and determine the location of the transmitter. Once the locaĆ
tion is determined, use a forklift to move the transmitter to the desired location. After the
transmitter is placed in the desired location, slide the transmitter off the skid. Remove the
shipping skid and slide the transmitter to the exact location.
2-21. EQUIPMENT INSTALLATION.

WARNING
2-22. COMPONENT INSTALLATION. Selected components of the transmitter have been re-
moved to prevent damage during shipment. The components removed from the transmit-
ter are shipped in separate containers. To re-install the FM-5C/FM-4C and
FMi-402/FMi-301 components, refer to Figure 2-4 and perform the following procedures.
2-23. Battery Installation. The transmitter controller is equipped with a battery back-up system
to maintain the controller memory during a power failure. A battery for installation in the
transmitter is provided in the accessory parts kit. Locate the battery in the accessory
parts kit. To install the battery, refer to Figure 2-4 and install the battery in the holder
on the controller circuit board as shown.
2-2
COPYRIGHT ¤ 2007 BROADCAST ELECTRONICS, INC
597-5001-2
FIGURE 2-1. FM-5C/FM-4C TRANSMITTER

(2-3/2-4)
2-4
FIGURE 2-2. FM-402/FMi 301 TRANSMITTER

INSTALLATION DIAGRAM 597-5001-2A
(2-5/2-4)
2-6
¤ 2007 BROADCAST ELECTRONICS, INC
COPYRIGHT
FIGURE 2-3. ACCEPTABLE AC POWER INPUT CONFIGURATIONS 597-0099-11
2-5
597-5001-3
FIGURE 2-4. COMPONENT INSTALLATION (SHEET 1 OF 2)
2-6
597-5001-3A
FIGURE 2-4. COMPONENT INSTALLATION (SHEET 2 OF 2)
2-7
2-24. FM–250C Installation. The exciter is mounted in the transmitter rack. For transmitters
equipped with an FM-250C, perform the following installation procedure. For transmitĆ
ters equipped with the FXi 250 Exciter, the following installation procedure is not reĆ
quired.
1. Locate the FM-250C exciter.
2. Refer to FM-250C exciter manual 597-1004 and perform the PRELIMINARY
INSTALLATION PROCEDURES to unpack and configure the unit. Do not
perform the following preliminary installation procedures: 1) placement, and 2)
slide-rail installation and mounting.
3. If the FM-250C was removed for shipment, proceed as follows:
A. Remove the shipping ties on the slide-rails.
B. Refer to Figure 2-5 and place the unit on the slide-rails.
4. Slide the FM-250C in and out of the rack to check the movement and vertical
alignment. If the FM-250C is to be moved up or down, proceed as follows:
A. Push the FM-250C back in the rack and measure the distance the unit is to be
moved.
B. Remove the FM-250C from the transmitter rack.
C. Adjust the FM-250C as follows:
1. Refer to Figure 2-5 and loosen the vertical alignment bracket hardware.
2. Refer to Figure 2-5 and move the mounting bracket to a notch in the: 1) up
direction to raise the FM-250C or 2) down direction to lower the FM-250C.
Each notch will move the unit 0.015 inches (0.038 cm).
3. Secure the mounting bracket hardware.
4. Repeat the procedure for the opposite side.
D. Replace the FM-250C on the slide-rails.
E. Push the FM-250C back in the rack and observe the alignment. Repeat the
procedure if additional adjustment is required.
5. Refer to Figure 2-4 and connect P22 to J22 on the controller housing rear panel as
shown.
6. Refer to Figure 2-4 and connect cable 300 to the FM-250C RF OUTPUT receptacle.
2-25. RF Power Module Installation. The FM-5C/FMi-402 is equipped with RF power modules 1
through 10. The FM-4C/FMi 301 is equipped with RF power modules 1 through 8. To
install the RF modules, proceed as follows:
CAUTION THE TRANSMITTER MAY BE DAMAGED IF AN RF

POWER MODULE IS NOT SECURELY SEATED
CAUTION INTO THE MOTHERBOARD CONNECTORS.
CAUTION AN RF POWER MODULE IS EQUIPPED WITH REAR-

PANEL MOUNTED CONNECTORS. TO PREVENT
CAUTION DAMAGE TO THE CONNECTORS, INSERT/REMOVE
THE MODULES CAREFULLY AND DO NOT STAND A
MODULE ON THE REAR-PANEL.
1. Locate the RF power modules.

2. Ensure the packing material is removed from the RF output connector on the
module rear-panel.
2-8
2-9
597-5001-4
FIGURE 2-5. FM-250C VERTICAL ALIGNMENT
3. Refer to Figure 2-4 and align an RF power module with the guides in the RF power
module 1 location.
4. Insert and firmly press the RF module into the motherboard connectors.
5. Secure the RF power module mounting hardware. The mounting hardware must
be secure to ensure the module is properly seated in the connectors.
6. For FM-5C/FMi 402 models, repeat the procedure for RF power modules 2 through 10.
7. For FM-4C/FMi 301 models, repeat the procedure for RF power modules 2 through 8.

WARNING
2-26. WIRING.
2-27. REMOTE CONTROL. The FM-5C/FM-4C and FMi-402/FMi-301 transmitters are deĆ
signed for complete remote control operations (refer to Figure 2-6). The transmitters will
interface with almost any remote control unit. The following text presents a description of
the FM-5C/FM-4C and FMi-402/FMi-301 remote control functions and indications. The
remote control connections are located on the transmitter rear-panel (refer to Figure 2-7).
2-28. Remote control connections are interfaced to the transmitter at J20 on the transmitter
rear-panel (refer to Figure 2-7). Remote control commands and indications can be interĆ
faced to the transmitter using: 1) remote control mating connector P20 or 2) the remote
control interface circuit board with remote control terminal strip TB2. The transmitter is
shipped with the remote control interface circuit board installed. If the remote control inĆ
terface circuit board is not desired, refer to Figure 2-7 and remove the interface circuit
board.
2-29. The transmitter controller: 1) provides positive or negative control logic and 2) +4/+2 volt
remote full-scale meter indications. Positive/negative control is determined by jumper J1
on the controller on/off switch circuit board assembly. Positive control requires the use of a
momentary contact to a +5 volt to +15 volt dc signal to activate the function. Negative conĆ
trol requires the use of a momentary contact to ground to activate the function. Remote
indication functions: 1) require current limiting resistors and 2) provide up to 100 mA of
current for indicators. Refer to Figure 2-6 and the following text to connect remote control
equipment to the system. The text describes the connections using remote control interĆ
face circuit board terminal strip TB2. The pin connections for remote control interface conĆ
nector J20 are identical to terminal strip TB2. The transmitter controller is factory proĆ
grammed for positive remote control operations.
2-30. Remote Forward/Reflected Power Meter Indications. Remote transmitter forward/reflected

power meter indications are located at TB2-1 and TB2-2. The indications can be proĆ
grammed for +4 volt dc full-scale or +2 volt dc full-scale meter indications. The transmitĆ
ter is shipped with the remote forward and reflected power meter indications programmed
for +4 volt full-scale meter indications. On FM-5C/FMi-402 models, the following meter
indications will be present: 1) Forward Power - 4V = 5 kW and 2) Reflected Power - 4V =
200W. On FM-4C/FMi-301 models, the following voltages will be present: 1) Forward
Power - 4V = 4 kW and 2) Reflected Power - 4V = 160W. Signal ground recommended for
remote metering ground connections.
2-10
597-5001-5
FIGURE 2-6. REMOTE CONTROL
CONNECTIONS
(2-11/2-12)
2-12
COPYR
597-5001-6
FIGURE 2-7. INTERLOCK, REMOTE CONTROL,
AND MODULATION MONITOR WIRING
2-13
2-31. Remote PA Power Supply Bus Voltage/Inlet Temperature Meter Indications. Remote PA power
supply bus voltage/temperature meter indications are located at TB2-3 and TB2-4. The
PA power supply bus voltage indication monitors a transmitter power supply bus voltage.
The temperature indication monitors the transmitter inlet air temperature. The indicaĆ
tions can be programmed for +4 volt dc full-scale or +2 volt dc full-scale meter indications.
The transmitter is shipped with the remote PA power supply bus voltage/inlet temperature
meter indications programmed for +4 volt full-scale meter indications. The meter indicaĆ
tions are as follows: 1) Power Supply Bus Voltage - 4V = 50V and 2) Temperature - 4V =
60 Degrees Celsius. Signal ground recommended for remote metering ground connections.
2-32. Remote PA Module Forward Power/Current Meter Indications. Remote PA module forward
power/current meter indications are located at TB2-5 and TB2-6. The PA module forward
power/current indications monitor forward power and current of a single module selected
by the PA module select command (refer to PA Module Select Command in the following
text). The indications can be programmed for +4 volt dc full-scale or +2 volt dc full-scale
meter indications. The transmitter is shipped with the remote PA forward power/current
tions are as follows: 1) PA Module Forward Power - 4V = 500W and 2) PA Module Current
- 4V = 20A. Signal ground recommended for remote metering ground connections.
2-33. Remote PA Module Voltage/Temperature Meter Indications. Remote PA module voltage/temĆ

perature meter indications are located at TB2-7 and TB2-8. The PA module voltage/temĆ
perature indications monitor voltage and temperature of a single module selected by the
PA module select command (refer to PA Module Select Command in the following text).
The indications can be programmed for +4 volt dc full-scale or +2 volt dc full-scale meter
indications. The transmitter is shipped with the remote PA module voltage/temperature
tions are as follows: 1) PA Module Voltage - 4V = 50V and 2) Temperature - 4V = 60 DeĆ
grees Celsius. Signal ground recommended for remote metering ground connections.
2-34. Transmitter On Indications. The transmitter on indicator provides a signal to indicate when
the transmitter is enabled. The transmitter on indicator is located at TB2-9. The indicaĆ
tor will go LOW (0 volts dc) to indicate when the transmitter is enabled.
2-35. Transmitter Off Indications. The transmitter off indicator provides a signal to indicate when
the transmitter is disabled. The transmitter off indicator is located at TB2-10. The indiĆ
cator will go LOW (0 volts dc) to indicate when the transmitter is disabled.
2-36. Transmitter Fault Indications. The transmitter fault indicator provides a signal to indicate
when: 1) a PA module fault occurs, 2) a power supply module fault occurs, 3) reflected
power is greater than 200 watts for an FM-5C/FMi 402 or 160 watts for an FM-4C/FMi
301, or 4) the transmitter inlet temperature is greater than 50qC (+122qF). The transmitĆ
ter fault indicator is located at TB2-11. The indicator will go LOW (0 volts dc) to indicate
when a PA module fault, a power supply module fault, a high reflected power, or a high
temperature condition has occurred.
2-37. Remote Transmitter On Control. The transmitter on function is located at TB2-12. The
function can be activated using positive or negative control. Positive control requires the
use of a momentary contact to a +5 volt to +15 volt dc signal to operate the transmitter to
on. Negative control requires the use of a momentary contact to ground to operate the
transmitter to on.
2-38. Remote Transmitter Off Control. The transmitter off function is located at TB2-13. The
function can be activated using positive or negative control. Positive control requires the
use of a momentary contact to a +5 volt to +15 volt dc signal to operate the transmitter to
off. Negative control requires the use of a momentary contact to ground to operate the
transmitter to off.
2-14
2-39. Remote Power Level Raise Control. The transmitter power level raise control is located at
TB2-14. The function can be activated using positive or negative control. Positive control
requires the use of a momentary contact to a +5 volt to +15 volt dc signal to raise the transĆ
mitter power level. Negative control requires the use of a momentary contact to ground to
raise the transmitter power level.
2-40. Remote Power Level Lower Control. The transmitter power level lower control is located at
TB2-15. The function can be activated using positive or negative control. Positive control
requires the use of a momentary contact to a +5 volt to +15 volt dc signal to lower the
transmitter power level. Negative control requires the use of a momentary contact to
ground to lower the transmitter power level.
2-41. Remote Reset Control. The reset control is designed to reset the transmitter fault circuitry.
The reset control is located at TB2-16. The function can be activated using positive or negĆ
ative control. Positive control requires the use of a momentary contact to a +5 volt to +15
volt dc signal to reset the transmitter fault circuitry. Negative control requires the use of a
momentary contact to ground to reset the transmitter fault circuitry.
2-42. Remote Fail–Safe Input. The remote failĆsafe input is designed for the remote control unit
failĆsafe control line. The input is located at TB2-17. The input can be activated using
positive or negative control. Positive control requires the use of a +5 volt to +15 volt dc sigĆ
nal to indicate an enabled remote control unit. Negative control requires the use of a
ground to indicate an enabled remote control unit.
2-43. +5V DC Supply. A +5 volt dc supply is provided for the remote control switches and indicaĆ
tors. The +5 volt dc supply is located at TB2-18 and TB2-19. The supply can provide up
to 20 mA for indicator and switch operations.
2-44. +15V DC Supply. A +15 volt dc supply is provided for coaxial switch control relays. The
+15 volt dc supply is located at TB2-20. The supply can provide up to 50 mA for control
operations.
2-45. PA Power Supply Fault Status Indications. The PA power supply fault indicator provides a
signal to indicate when a PA power supply fault has occurred. The PA power supply fault
indicator is located at TB2-21. The indicator will go LOW (0 volts dc) to indicate the presĆ
ence of a PA power supply fault.
2-46. PA Module Fault Status Indications. The PA module fault indicator provides a signal to indiĆ
cate when a PA RF power module fault has occurred. The PA RF power module fault indiĆ
cator is located at TB2-22. The indicator will go LOW (0 volts dc) to indicate the presence
of a PA RF power module fault.
2-47. Signal Ground. Signal ground is an isolated circuit ground for remote control connections.
Signal ground is to be used to remedy ground loops or to eliminate RFI conditions. Signal
ground is located at TB2-23, TB2-26, and TB2-27.
2-48. Chassis Ground. Chassis ground is designed to be used for remote control connections.
Chassis ground is located at TB2-24 and TB2-30.
2-49. PA Module Select Command. The PA module select command is located at TB2-25. The
command is used to select one PA RF power module for metering operations. The control
requires a momentary contact to ground to select a PA RF power module. A different modĆ
ule is selected each time a momentary contact to ground is applied (refer to SECTION III,
OPERATION for operating information).
2-50. No Connection. No connection at TB2-28 and TB2-29.
2-51. EXTERNAL INTERLOCK. The FM-5C/FM-4C transmitters are equipped with an exĆ
ternal interlock such as for a test load. The interlock will operate the transmitter to off
when opened. The interlock is located at J21 on the transmitter rear-panel (refer to FigĆ
ure 2-6). To connect an external interlock to the transmitter, refer to Figure 2-7 and disĆ
connect external interlock connector P21. Connect the interlock wiring to P21-1 and
P21-2. When wiring is complete, connect P21 to J21 on the transmitter rear-panel.
2-15
2-52. MODULATION MONITOR RECEPTACLE. The FM-5C/FM-4C and FMi-403/FMi-301
transmitters are equipped with a modulation monitor receptacle. The receptacle is located
on the transmitter low-pass filter (refer to Figure 2-7). Refer to Figure 2-7 and connect
the modulation monitor to the modulation monitor receptacle. The receptacle provides a
2V RMS sample in a 50 Ohm load at 5 kW for monitoring operations on FM-5C/FMi-402
models or 2V RMS sample in a 50 Ohm load at 4 kW for monitoring operations on FM-4C/
FMi-301 models.
2-53. AUDIO INPUT CONNECTIONS. Audio input connections for FM-5C/FM-4C and FMi-
402/FMi-301 transmitters are located on the exciter rear panel. For an FM-250C, refer to
FM-250 manual 597-1004 and perform the WIRING procedures in SECTION II, INSTALĆ
LATION. For an FXi 250, refer to manual 597-0541 SECTION II, INSTALLATION.

WARNING
2-54. RF OUTPUT TRANSMISSION LINE CONNECTION. FM-5C/FM-4C and FMi-

402/FMi-301 transmitter RF output connection is located on the transmitter's low-pass
filter (refer to Figure 2-8). The connection requires a 1 5/8 inch male EIA field flange.
Install the RF output transmission line as follows:
1. Insert the RF inner conductor into the bullet conductor on the low-pass filter.
2. Insert the RF outer conductor into the flange on the low-pass filter.
3. Install the 1 5/8 inch flange on the inner and outer conductors. Secure the flange
by tightening the flange clamp hardware.
4. Connect the RF output transmission line to the transmitter using a 1 5/8 inch male
flange as shown.
WARNING ENSURE PRIMARY POWER IS DISCONNECTED

BEFORE PROCEEDING.
WARNING
WARNING ENSURE AN EARTH GROUND CONDUCTOR IS SE-
CURELY CONNECTED TO THE TRANSMITTER
WARNING CHASSIS GROUND LUG.
2-55. GROUND. FM-5C/FM-4C and FMi-402/FMi-301 transmitters are equipped with a chasĆ
sis ground system for operating safety. The ground system requires the connection of an
earth ground. Refer to Figures 2-9 through 2-11 and connect an earth ground to the chasĆ
sis ground lug using a 2 inch (5.08 cm) wide copper strap. For FM-5C/FM-4C and FMi-
402/FMi-301 models configured for a three phase power supply, connect the ground strap
as follows:
1. Remove the ground lug and the hardware from the chassis ground terminal.
2. Connect the strap to the chassis ground terminal.
3. Connect the ground wire to the lug.
4. Replace the ground lug and secure lug to the terminal using the hardware.
2-16
FIGURE 2-8. RF OUTPUT CONNECTIONS 597-5001-7
2-17
BEFORE PROCEEDING.
WARNING
WARNING ENSURE AN EARTH GROUND CONDUCTOR IS SE-
CURELY CONNECTED TO THE TRANSMITTER
WARNING CHASSIS GROUND LUG.
2-56. AC POWER CONNECTIONS. The following text presents power source requirements
for FM-5C/FM-4C and FMi-402/FMi-301 transmitters. For operating safety, the power
source must be routed to the transmitter through a fused power disconnect (refer to FigĆ
ures 2-9 through 2-11).
FM-5C
Single Phase 196V To 252V AC, 50/60 Hz 80 Amperes
(FM Only)
Three Phase 196V To 252V AC or 339V to 437V AC, 50/60 Hz 50 Amperes
(FM Only)
FM-4C
(FM Only)
(FM Only)
FMi-402
(HD Only)
(FM + HD)
(HD Only)
(FM + HD)
FMi-301
(HD Only)
(FM + HD)
(HD Only)
(FM+HD)
2-18
BEFORE PROCEEDING.
WARNING
2-57. Exciter AC Power Connections. The exciter ac power source is provided by the transmitter.
Connect the ac power cord from the transmitter to the exciter as shown. The FM-250C
operates from a 194V to 266V ac source.
2-58. Main AC Input – FM–5C Single Phase. Refer to Figure 2-8 and connect the 80 Ampere single
phase service to the ac input panel through a fused service disconnect as shown. Connect
the utility company ground conductor securely to the ground terminal as shown.
2-59. Main AC Input – FM–4C Single Phase. Refer to Figure 2-9 and connect the 70 Ampere single
phase service to the ac input panel through a fused service disconnect as shown. Connect
2-60. Main AC Input – FM–5C/FM–4C Three Phase. Refer to Figure 2-10 and connect the 50 AmĆ
pere three phase service to the ac input panel through a fused service disconnect as shown.
For 380 volt systems, ensure the neutral conductor is connected to the N terminal. Connect
2-61. Optional Equipment AC Power Connections. The FM-5C/FM-4C and FMi-402/FMi-301
transmitters are designed for the installation of optional equipment such as a stereo generĆ
ator, SCA generator, or a remote control system. If optional equipment is installed in the
transmitter, route the optional equipment line cords through the ac line service hole in the
top of the transmitter to an appropriate power source. Ensure the power source is proĆ
tected by a fuse or circuit breaker.
2-19
2-20
597-5001-8
FIGURE 2-9. FM-5C/FMi 402 SINGLE PHASE AC POWER CONNECTIONS
2-21
597-5001-9
FIGURE 2-10. FM-4C/FMi 301 SINGLE PHASE AC POWER CONNECTIONS
2-22
597-5001-10
FIGURE 2-11. FM-5C/FM-4C & FMi 402/FMi 301 THREE PHASE AC POWER CONNECTIONS
2-62. PRELIMINARY OPERATION.
NOTE DO NOT REDUCE THE EXCITER OUTPUT POWER
PRIOR TO ENABLING THE TRANSMITTER.
NOTE
2-63. The following text presents procedures for the preliminary operation of the FM-5C/FM-4C
and FMi-402/FMi-301 transmitters. The procedures will reference the factory test data
sheets which are shipped with the transmitter. Locate the factory test data sheets. DifferĆ
ences in the values obtained during actual operation may be noted due to differences in
primary power and antenna systems. Refer to the following text and perform the proceĆ
dures to initially operate the FM-5C/FM-4C and FMi-402/FMi-301 transmitters.
2-64. Ensure the appropriate ac power supply is applied to the transmitter.
2-65. Operate the POWER switch to ON. The following events will occur:
1. Each RF power module MODULE STATUS indicator will illuminate yellow.
2. The INTERLOCK indicator will illuminate.
3. The OFF switch/indicator will illuminate.
2-66. If the INTERLOCK indicator does not illuminate, perform the following procedure.
WARNING DISCONNECT ALL TRANSMITTER PRIMARY

POWER BEFORE PROCEEDING.
WARNING
1. Disconnect the ac power.

2. Remove the rear door and filter and observe the three-phase ac line monitor
indicators.
3. If the indicators are illuminated, check the external interlock, the exciter AFC
circuit, and the remote control failsafe. If the indicators are flashing or
extinguished, refer to APPENDIX A for a description of the ac line monitor
indicators and determine the fault condition. Typically, the ac line phasing must be
changed. To change the ac line phasing, perform the following procedure. If the
monitor detects a low or high voltage condition, check the ac line input.
A. Reverse any two ac line phases at the ac input panel.
B. Attempt transmitter operation.
4. Once the problem is located and repaired, continue the preliminary operation
procedure.
2-67. Depress the transmitter SYSTEM FWD POWER switch/indicator. The MULTIMETER
will indicate 0 watts forward power.
2-68. Depress the ON switch/indicator to illuminate the switch/indicator. All RF power module:
1) MODULE STATUS indicators will illuminate green and 2) RF DRIVE indicators will
illuminate.
2-69. For an FM-250C, depress the exciter MULTIMETER FWD switch. The exciter MULTIĆ
METER will indicate the forward power recorded in the factory test data sheets. controlĆ
ler display will indicate the forward power recorded in the factory test data sheets.
2-23
2-70. Depress and hold the transmitter POWER switch until the MULTIMETER indicates the
forward power level recorded in the factory test data sheets. If the RESET switch/indicaĆ
tor illuminates or the MODULE STATUS indicators illuminate yellow during the increase
of transmitter power, proceed as follows:
1. If the RESET switch/indicator illuminates, proceed as follows:
A. Depress the transmitter SYSTEM RFL POWER switch/indicator to
illuminate the switch/indicator.
B. Observe the MULTIMETER reflected power indication. If a reflected power
condition of greater than 200 watts is present for an FM-5C or 160 watts for an
FM-4C, refer to SECTION V, MAINTENANCE and perform the
TROUBLESHOOTING procedures to locate the problem. The transmitter will
operate into a VSWR of 1.5:1.
C. If the reflected power indication is less than 200 watts for an FM-5C or 160
watts for an FM-4C, depress the SYSTEM PS VDC and INLET TEMP switch/
indicators to determine if a power supply or temperature problem is present.
D. If no power supply or temperature problem is present, depress the
MODULE FWD PWR, P.A. CUR, P.A. VDC, TEMP, and the MODULE
SELECT switch/indicators to determine if an RF power module problem is
present.
E. When the problem condition is removed, reset the transmitter fault circuitry by
depressing the RESET switch/indicator.
2. If the RF power MODULE STATUS indicators illuminate yellow, refer to
SECTION V, MAINTENANCE and perform the TROUBLESHOOTING procedures
to locate the problem.
2-71. When the desired transmitter output power is obtained, depress the following switch/indiĆ
cators and compare the indications with the values recorded in the factory test data sheets.
The values should be approximately equal to the values recorded in the test data sheets.
1. RFL PWR 6. MODULE P.A. VDC
2. PS VDC 7. MODULE TEMP
3. EXH TEMP 8. MODULE SELECT
4. MODULE FWD PWR
5. MODULE P.A. CUR
2-24
SECTION III
OPERATION
3-1. INTRODUCTION.
3-2. This section identifies all controls and indicators associated with the FM-5C/FM-4C and
FMi-402/FMi-301 transmitters and provides standard operating procedures.
3-3. CONTROLS AND INDICATORS.

3-4. Figure 3-1 presents the location of all controls and indicators associated with normal opĆ
eration of the FM-5C/FM-4C and FMi-402/FMi-301 transmitters. Table 3-1 presents the
functions of each control or indicator. Refer to Figure 3-1 and Table 3-1 for a description
of the controls and indicators associated with the FM-5C/FM-4C and FMi-402/FMi-301
transmitters.
TABLE 3-1. FM-5C/FM-4C and FMi-402/FMi-301 CONTROLS AND INDICATORS

(Sheet 1 of 4)
INDEX NOMENCLATURE FUNCTION

NO.
1 MODULE TEMP C SWITCH: Configures the MULTIMETER to display
Switch/Indicator RF power amplifier module temperature in degrees
Centigrade.
INDICATOR: A yellow display indicates the MULTI-
METER is configured to present RF power amplifier
module temperature.
2 MODULE P.A. VDC SWITCH: Configures the MULTIMETER to
Switch/Indicator display RF power amplifier module voltage.
module voltage.
3 MODULE P.A. CUR SWITCH: Configures the MULTIMETER to display
Switch/Indicator RF power amplifier module current in amperes.
module current.
4 MODULE FWD PWR SWITCH: Configures the MULTIMETER to display
Switch/Indicator RF power amplifier module forward power in watts.
module forward power.
3-1
597-5001-11
FIGURE 3-1. FM-5C/FM-4C & FMi 402/FMi 301 CONTROLS
AND INDICATORS (SHEET 1 OF 2)
3-2

FIGURE 3-1. FM-5C/FM-4C & FMi 402/FMi 301 CONTROLS 597-5001-11A

AND INDICATORS (SHEET 2 OF 2)
3-3
TABLE 3-1. FM-5C/FM-4C & FMi-402/FMi-301 CONTROLS AND INDICATORS
(Sheet 2 of 4)

NO.
5 SYSTEM INLET SWITCH: Configures the MULTIMETER to display
TEMP the transmitter inlet air temperature in degrees
Switch/Indicator Centigrade.
METER is configured to present the transmitter inlet
air temperature.
6 SYSTEM P. S. VDC SWITCH: Configures the MULTIMETER to
Switch/Indicator display the PA power supply bus voltage.
METER is configured to present the PA power supply
voltage.
7 SYSTEM RFL POWER SWITCH: Configures the MULTIMETER to
Switch/Indicator display the transmitter reflected power in watts.
METER is configured to present the transmitter reflected
power.
8 SYSTEM FWD POWER SWITCH: Configures the MULTIMETER to
Switch/Indicator display the transmitter forward power in kilowatts.
METER is configured to present the transmitter forward
power.
9 MULTIMETER Display Displays forward power, reflected power, power supply
voltage, inlet air temperature, RF power module
forward power, RF power module current, RF power
module voltage, and RF power module temperature as
selected by the MULTIMETER SYSTEM and MODULE
switches.
10 POWER SUPPLY The 1, 2, 3, 4, or 5 indicator will illuminate to indicate
FAULT 1, 2, 3, 4, a power supply module fault in an FM-5C. The
and 5 Indicators 1, 2, 3, or 4 indicator will illuminate to indicate a
power supply fault in an FM-4C. The fault will illuminate
during 1) Low/No RF Drive and 2) Power Supply Failure.
11 TRANSMITTER ON SWITCH: Enables the transmitter RF output by unmut-

Switch/Indicator ing the exciter, power amplifier modules, and the PA
power supplies.
INDICATOR: Illuminates to indicate the transmitter RF
output is enabled.
3-4
(Sheet 3 of 4)

NO.
12 TRANSMITTER OFF SWITCH: Disables the transmitter RF output by muting

Switch/Indicator the exciter, power amplifier modules, and the PA power
supplies.
INDICATOR: Illuminates to indicate the transmitter RF
output is disabled.
13 POWER SWITCH: Instructs the system controller to raise
Switch/Indicator the transmitter output power.
INDICATOR: Illuminates to indicate the POWER
switch is selected.
14 POWER SWITCH: Instructs the system controller to lower
Switch/Indicator the transmitter output power.
INDICATOR: Illuminates to indicate the POWER
switch is selected.
15 FAULT RESET SWITCH: Clears the transmitter fault circuitry if:
Switch/Indicator 1) the switch is depressed and 2) the fault condition
is removed.
INDICATOR: Illuminates to indicate: 1) an RF power
amplifier module fault, 2) a power supply module fault,
3) a high transmitter or module temperature condition, or
4) a high reflected power condition. During a high
temperature condition, the transmitter will foldback the
output power to maintain transmitter operation.
16 INTLK STATUS SWITCH: No Operation.
Switch/Indicator INDICATOR: Illuminates to indicate: 1) the external
interlock is closed, 2) the exciter AFC is locked, 3) the
remote control failĆsafe input is closed if remote control
operation is enabled, and 4) the three-phase ac line
monitor is normal. Extinguishes to indicate: 1) an open
external interlock, 2) the exciter AFC is unlocked, 3) an
open remote control failĆsafe input if remote control
operation is enabled, or 4) the three-phase ac line monitor
has detected the loss of a phase, incorrect ac line phasing,
or a high/low ac line voltage condition.
17 MODULE SELECT Displays the RF power amplifier module selected by the
Display MODULE SELECT switch for the display of forward
power, current, voltage, or temperature parameters on the
MULTIMETER.
3-5
(Sheet 4 of 4)

NO.
18 MODULE SELECT SWITCH: Selects an RF power amplifier module for the

Switch/Indicator display of forward power, current, voltage, or temperature
parameters on the MULTIMETER. For FM-5C models,
the switch will select RF power amplifier modules 1
through 10. For FM-4C models, the switch will select RF
power amplifier modules 1 through 8. The switch is
disabled when the REMOTE CONTROL
ENABLE/DISABLE switch is operated to ENABLE. The
switch is enabled when the REMOTE CONTROL
ENABLE/DISABLE switch is operated to DISABLE.
INDICATOR: Illuminates to indicate the MODULE
SELECT switch is enabled. Extinguishes to indicate the
module select switch is disabled. The MODULE SELECT
switch is controlled by the REMOTE CONTROL
ENABLE/DISABLE switch.
19 REMOTE CONTROL Controls the transmitter remote control operations. When
ENABLE/DISABLE the switch is operated to ENABLE, remote control
Switch operation is enabled. When the switch is operated to
DISABLE, remote control operation is disabled.
20 POWER SWITCH Provides overload protection and primary power control for
the transmitter.
21 MODULE STATUS Displays the operating status of the RF power amplifier
Indicator module.
RED DISPLAY: Indicates an RF power module fault.
RF power module faults include: 1) over-current,
2) over-temperature, 3) high reflected power, and 4) high
forward power demand.
YELLOW DISPLAY: Indicates an RF power module
current limit, VSWR limit, high forward power demand
limit, or transmitter off condition.
GREEN DISPLAY: Indicates normal RF power module
output operation. Will illuminate if no RF drive is present.
22 MODULE DRIVE Illuminates to indicate the presence of RF drive at the RF
Indicator power amplifier module.
23 Exciter For transmitters equipped with an FM-250C, refer to the
FM-250C exciter instruction manual for a description of
the FM-250C controls and indicators. For transmitters
equipped with a PREDATOR, refer to the PREDATOR
instruction manual for a description of the PREDATOR
controls and indicators.
3-6
3-5. OPERATION.
NOTE ENSURE THE TRANSMITTER IS COMPLETELY INĆ

STALLED PRIOR TO PERFORMING THE FOLLOWING
NOTE PROCEDURES.
NOTE THE FM-5C/FM-4C TRANSMITTERS WILL NOT OPERĆ

ATE WITH MORE THAN 3 RF POWER AMPLIFIER MODĆ
NOTE ULES REMOVED FROM THE CHASSIS. ENSURE NO
MORE THAN 3 RF POWER AMPLIFIER MODULES ARE
REMOVED FROM THE TRANSMITTER.
3-6. TURN–ON.
3-7. Operate the POWER switch to ON. The flushing fans will begin operation.
3-8. Observe the transmitter front-panel indicators. The FAULT RESET, INTLK STATUS,
POWER SUPPLY FAULT, MODULE DRIVE, and MODULE STATUS indicators will
display normal operating conditions. If the FAULT RESET indicator displays a fault conĆ
dition, depress the FAULT RESET switch/indicator. If the fault condition is not cleared,
operate the POWER switch to OFF and locate the problem. If the INTLK STATUS indiĆ
cator is not illuminated, operate the POWER switch to OFF and troubleshoot: 1) an open
remote control failĆsafe input, 2) an open external interlock, 3) an unlocked exciter AFC, or
4) the loss of a phase, incorrect ac line phasing, or high/low ac line voltage. If a MODULE
STATUS indicator displays a fault condition, operate the POWER switch to OFF and
troubleshoot the transmitter.
3-9. Depress the ON switch/indicator to activate the transmitter. The ON switch/indicator will
illuminate. The RF power amplifier module MODULE STATUS indicators will illumiĆ
nate green to indicate normal RF power output operation. The RF power amplifier module
DRIVE indicators will illuminate to indicate the presence of RF drive at each module.
3-10. Operate the MULTIMETER to observe the transmitter forward and reflected power indiĆ
cations by performing the MULTIMETER OPERATION procedure in the following text.
3-11. Adjust the transmitter output power by performing the POWER ADJUST procedure preĆ
sented in the following text.
3-12. If remote control operation is desired, operate the REMOTE CONTROL ENABLE/DISĆ
ABLE switch to ENABLE. This will enable both local and remote operation. If remote
control operation is to be disabled, operate the REMOTE CONTROL ENABLE/DISĆ
ABLE switch to DISABLE.
3-13. TURN–OFF.
3-14. Operate the transmitter to OFF by depressing the OFF switch/indicator. The OFF
switch/indicator will illuminate. The transmitter RF output will be disabled. Each RF
power amplifier MODULE STATUS indicator will illuminate yellow and the DRIVE indiĆ
cators will extinguish.
3-15. Operate the POWER switch to OFF to remove ac power from the transmitter.
3-16. MULTIMETER OPERATION.
3-17. The MULTIMETER is designed to display several transmitter operating parameters. To
operate the multimeter, perform the following procedures.
3-7
3-18. SYSTEM PARAMETER DISPLAY. Operate the SYSTEM FWD PWR, RFL PWR, P.S.
VDC, or INLET TEMP switch/indicators as desired to select the parameter to be disĆ
played on the MULTIMETER. The parameter will be displayed on the multimeter.
3-19. MODULE PARAMETER DISPLAY. The display of individual RF power amplifier modĆ
ule parameters on the MULTIMETER display is accomplished by: 1) selecting the desired
RF power amplifier module and 2) selecting the desired parameter. To operate the multiĆ
meter to display individual RF power amplifier module parameters, proceed as follows:
LOCAL OPERATION -
1. Operate the REMOTE CONTROL ENABLE/DISABLE switch to DISABLE.
2. Depress the MODULE SELECT switch until the desired RF power amplifier
module number is displayed on the MODULE SELECT display. For FM-5C/FMi-
402 models, the switch will select RF power amplifier modules 1 through 10. For
FM-4C/FMi-301 models, the switch will select RF power amplifier modules 1 through 8.
3. Depress the MODULE FWD PWR, P.A. CUR, P.A. VDC or TEMP C
switch/indicators as desired to select the parameter to be displayed on the
MULTIMETER. The parameter will be displayed on the multimeter.
4. To display total module P.A. current, proceed as follows:
A. Depress the P.A. CUR. switch/indicator to illuminate the indicator.
B. Depress the MODULE SELECT switch until 0 is displayed on the MODULE
SELECT display.
C. Observe the multimeter display and ignore the decimal point. The display will
present total module P.A. current.
REMOTE OPERATION -
1. Operate the REMOTE CONTROL ENABLE/DISABLE switch to ENABLE.
2. Depress the remote PA module select switch until the meters indicate 0 with the
exception of the P.A. module current meter.
3. Depress the remote PA module select switch once to select PA RF power module 1.
Depress the remote PA module select switch again to select PA RF power module 2.
Repeat the procedure to select PA RF power modules 3 through 10 on FM-5C/
FMi-402 models or PA RF power modules 3 and 8 on FM-4C/FMi-301 models. The
selected module FWD PWR, P.A. CUR, P.A. VDC, and TEMP C parameters will be
displayed on the remote meters.
4. To display total module P.A. current, proceed as follows:
A. Depress the remote PA module select switch until the meters indicate 0 with the
exception of the P.A. module current meter.
B. Observe the multimeter display and ignore the decimal point. The display will
present total module P.A. current.
3-8
3-20. POWER ADJUST.
NOTE THE POWER SWITCH WILL NOT FUNCTION DURĆ

ING A FAULT CONDITION.
NOTE
3-21. The POWER and switches adjust the transmitter output power. The switches adĆ
just the transmitter power using a two-speed control feature. When a switch is depressed,
the switch controls power using a normal control rate. When a switch is depressed and
held, the switch controls power using a fast control rate. To adjust the transmitter output
power, proceed as follows:
1. Depress the POWER switch to increase the transmitter output power. Depress
and hold the POWER switch for fast raise power operation. Observe the
transmitter output power indications on the MULTIMETER.
OR
2. Depress the POWER switch to decrease the transmitter output power. Depress
and hold the POWER switch for fast lower power operation. Observe the
transmitter output power indications on the MULTIMETER.
3-22. EXCITER OPERATION.
3-23. For transmitters equipped with an FM-250C, refer to the FM-250C instruction manual for
a complete description of the FM-250C operating procedures. For transmitters equipped
with an FXi-250, refer to the FXi-250 instruction manual.
3-24. FAULT RESET.
3-25. To reset a transmitter fault condition, depress the FAULT RESET switch/indicator. If the
fault condition is remedied, the FAULT RESET indicator will extinguish.
3-26. If the fault condition is not remedied, operate the POWER switch to OFF and locate the
problem.
3-27. Once the fault condition is remedied, depress the FAULT RESET switch/indicator. The
indicator will extinguish.
3-28. RF POWER MODULE STATUS AND DRIVE INDICATORS.
3-29. The RF power MODULE STATUS indicator monitors the operating status of the power
module. A red display indicates a power module fault. A yellow display indicates a power
module limit or transmitter off condition. A green display indicates normal power module
RF power output operation. If the indicator displays a fault or limit condition, refer to
SECTION V, MAINTENANCE and troubleshoot the transmitter.
3-30. The RF power module DRIVE indicator monitors the status of RF drive from the exciter.
The indicator will illuminate to indicate the presence of RF drive at the module. If an indiĆ
cator is extinguished, refer to SECTION V, MAINTENANCE and troubleshoot the transĆ
mitter.
3-31. POWER SUPPLY FAULT INDICATORS.
3-32. The POWER SUPPLY FAULT 1, 2, 3, 4, and 5 indicators monitor the power supply modĆ
ules in an FM-5C transmitter. The POWER SUPPLY FAULT 1, 2, 3, and 4 indicators
monitor the power supply modules in an FM-4C transmitter. If an indicator illuminates,
refer to POWER AMPLIFIER POWER SUPPLY MODULES in SECTION V, MAINTEĆ
NANCE and troubleshoot the transmitter.
3-9
3-33. THREE–PHASE AC LOSS MONITOR – FOR THREE–PHASE DELTA POWER
SUPPLY MODELS ONLY.
3-34. FM-5C/FM-4C and FMi-402/FMi-301 transmitters configured to operate from a three-
phase Delta power supply are equipped with a three-phase ac line monitor. The monitor
protects the power supplies from damage associated with: 1) the loss of or incorrect ac line
phasing or 2) high/low ac line voltage. The monitor is connected to the transmitter interĆ
lock circuit. In the event of an improper ac line condition, the monitor will open the transĆ
mitter interlock circuit. As a result, the front panel INTERLOCK STATUS switch/indicaĆ
tor will extinguish. If the INTERLOCK STATUS indicator extinguishes during operation,
proceed as follows:
WARNING DISCONNECT ALL TRANSMITTER PRIMARY

POWER BEFORE PROCEEDING.
WARNING
1. Disconnect the ac power.

2. Remove the rear door and filter and observe the three-phase ac line monitor
indicators.
3. If the indicators are illuminated, check the external interlock, the exciter AFC
circuit, and the remote control failsafe. If the indicators are are flashing or
extinguished, refer to APPENDIX A for a description of the ac line monitor
indicators and determine the fault condition. Typically during initial operation, the
ac line phasing must be changed. To change the ac line phasing, perform the
following procedure. If the monitor detects a low or high voltage condition, check
the ac line input.
A. Reverse any two ac line phases at the ac input panel.
B. Attempt transmitter operation.
3-10
SECTION IV
THEORY OF OPERATION
4-1. INTRODUCTION.
4-2. This section presents the theory of operation for the Broadcast Electronics FM-5C/FM-4C
and FMi-402/FMi-301 transmitters.
4-3. OVERALL OPERATION.

4-4. Information on overall FM-5C/FM-4C and FMi-402/FMi-301 transmitter operation is
presented in Figure 4-1.
4-5. POWER SUPPLY/RF CIRCUITRY OPERATION.

4-6. A description of the FM-5C/FM-4C and FMi-403/FMi-301 transmitter power supply and
RF circuitry is presented in Figure 4-2.
4-7. CONTROLLER CIRCUITRY OPERATION.

4-8. FM-5C/FM-4C and FMi-402/FMi-301 transmitter control and monitoring functions are
performed by a CMOS digital controller. The transmitter controller consists of the
following circuit board assemblies: 1) the on/off switch circuit board, 2) the controller
circuit board, 3) the meter switch circuit board, 4) the meter display circuit board, 5) the
multiplexer circuit board, and 6) the module select circuit board. The controller is
designed to provide: 1) on/off control, 2) raise/lower power control, 3) automatic power
control operation, and 4) metering operation.
4-9. Six switch/indicators provide transmitter control functions. An LCD multimeter presents
8 transmitter indications. The controller circuitry is designed to interface to almost any
remote control device. Positive/negative control optical couplers allow the transmitter to
be controlled using positive or negative control logic. DC power for controller circuitry
operation is provided by a modular switching power supply unit. The power supply unit
provides +5 and r15 volt dc supplies for controller circuitry operation.
4-10. A description of the FM-5C/FM-4C and FMi-402/FMi-301 transmitter controller
circuitry is presented in Figures 4-3 through 4-5. Figure 4-3 presents the controller,
meter switch, and meter display circuit board information. Figure 4-4 presents the on/off
switch circuit board information. Figure 4-5 presents the multiplexer and module select
circuit board information.
4-11. CONTROLLER ON/OFF SWITCH CIRCUIT BOARD.
4-12. The controller on/off switch circuit board is equipped with the on/off, raise/lower, and
reset switch/indicator circuitry (refer to Figure 4-4). The circuit board is designed to
output control signals to the controller circuit board, the RF amplifier logic circuit board,
to the exciter, and the remote control interface terminal strip.
4-13. TRANSMITTER ON CONTROL CIRCUIT. The transmitter can be operated to ON
using remote or local control. Local ON control is provided by switch S3. When local on
control is used, a LOW from on switch S3 is applied to relay K1. Remote on control is
performed by optical coupler U4 and inverters U10B and U12A. U4 can be activated
using positive or negative control logic. Jumper J1 programs the optical coupler circuitry
for positive or negative control operation. When U4 is activated, a LOW is routed to
inverters U10B and U12A. U12A will output a LOW to the on control coil of relay K1.
4-1
4-14. Relay K1 is used to: 1) disable the transmitter when the exciter
Automatic-Frequency-Control (AFC) signal is disabled and 2) generate a transmitter on
and a transmitter off command. With a LOW from the on circuitry, K1 will output a
HIGH to transistor Q1 and inverter U11B. A HIGH at K1 will allow the transmitter
on/off circuitry to initiate a transmitter on sequence. U11B will output a LOW to
inverters U11C, U12F, and U11E. U11C will output a HIGH to transistor Q1, inverter
U11D, inverter U12G, and transistor Q2. U12F will output a HIGH to extinguish OFF
indicator S4. Q1 will output a LOW to unmute the power amplifier modules. U12G will
output a LOW to enable on indicator S3. Q2 will output a LOW remote on status signal to
the remote interface terminal strip. U11D will output a LOW to the automatic power
control circuitry on the controller circuit board and unmute the power amplifier power
supplies.
4-15. TRANSMITTER OFF CONTROL CIRCUIT. The transmitter off control circuitry
operates in a similar manner as the on control circuitry. The transmitter off control
circuitry consists of off switch S4, optical coupler U5, and inverters U10C and U12B.
Local OFF control is provided by switch S4. When local off control is used, a LOW from
off switch S4 is applied to relay K1. Remote off control is performed by optical coupler U5
and inverters U10C and U12B. U5 can be activated using positive or negative control
logic. Jumper J1 programs the optical coupler circuitry for positive or negative control
operation. When U5 is activated, a LOW is routed to inverters U10C and U12B. U12B
will output a LOW to the off control coil of relay K1.
4-16. With a LOW from the off circuitry, K1 will output a LOW to transistor Q1 and inverter
U11B. A LOW at K1 will allow the transmitter on/off circuitry to initiate a transmitter off
sequence. U11B will output a HIGH to inverters U11C, U12F, and U11E. U11C will
output a LOW to transistor Q1, inverter U11D, inverter U12G, and transistor Q2. U12F
will output a LOW to enable OFF indicator S4. Q1 will output a HIGH to mute the power
amplifier modules. U12G will output a HIGH to disable on indicator S3. Q3 will output a
LOW remote off status signal to the remote interface terminal strip. U11D will output a
HIGH to the automatic power control circuitry on the controller circuit board and mute
the power amplifier power supplies.
4-17. REMOTE CONTROL ENABLE/DISABLE CIRCUIT. Switch S302 on the controller
meter switch circuit board is designed to enable/disable the remote control circuitry.
When remote control is enabled, S302 will output a HIGH to inverter U12C on the on/off
control circuit board. U12C will output a LOW to U10D. U10D will output a HIGH to
relay K1. A HIGH will allow the transmitter on/off circuitry to generate a transmitter on
sequence. When remote control is disabled, S302 will output a LOW to U12C. U12C will
output a HIGH to U10D. U10D will output a LOW to K1. The LOW prevents the on/off
circuit from generating a transmitter on sequence.
4-18. REMOTE CONTROL FAILSAFE INPUT CIRCUIT. The controller on/off switch
circuit board is equipped with a remote control failsafe input. The input is provided to
configure the transmitter to off if the remote control unit is disabled. The failsafe input is
applied to optical coupler U6. U6 can be activated using positive or negative control logic.
Jumper J1 programs the optical coupler circuitry for positive or negative control
operation.
4-19. When the remote control unit is enabled, an enabled command from the remote control
unit is applied to U6. U6 will output a LOW to U10D. U10D will output a HIGH to K1.
A HIGH will allow the transmitter on/off circuitry to initiate a transmitter on sequence.
4-20. When the remote control unit is disabled, a HIGH is applied to U10D. U10D will output a
LOW to K1. A LOW will configure the transmitter on/off circuitry to initiate a
transmitter off sequence.
4-2
597-5001-12
FIGURE 4-1. FM-5C/FM-4C & FMi 402/FMi 301

TRANSMITTER BLOCK DIAGRAM
(4-3/4-4)
4-4
597-5001-18
FIGURE 4-2. POWER SUPPLY/RF CIRCUIT
(4-5/4-6)
4-6
597-5001-16
FIGURE 4-3. FM-5C/FM-4C & FMi 402/FMi 301
TRANSMITTER CONTROLLER
(4-7/4-8)
4-8
4-9
597-3002-16
FIGURE 4-4. CONTROLLER ON/OFF SWITCH CIRCUIT BOARD SIMPLIFIED SCHEMATIC
4-21. AFC LOCK INPUT CIRCUIT. The Automatic-Frequency-Control status signal from the
exciter is applied to optical coupler U14. When the exciter frequency is locked, a LOW is
applied to U14. U14 will output a LOW to inverter U13C. U13C will output a HIGH to
K1. A HIGH will allow the transmitter on/off circuitry to initiate a transmitter on
sequence. If the exciter frequency becomes unlocked, a HIGH is applied to U13C. U13C
will output a LOW to K1 to configure the transmitter on/off circuitry to initiate a
transmitter off sequence.
4-22. RESET CIRCUIT. A reset circuit is provided to reset the transmitter fault detection
circuitry on the power amplifier modules. The reset circuit can be activated using local or
remote control. Local reset operation is provided by reset switch/indicator S5. S5 will
output a LOW to reset the fault detection circuitry on the RF amplifier modules. Remote
reset commands are generated by optical coupler U7. U7 can be activated using positive or
negative control logic. Jumper J1 programs the optical coupler circuitry for positive or
negative control operation. When a remote reset command is initiated, the command is
applied to U7. U7 will output a LOW to inverters U10E and U12D. U12D will output a
LOW to reset the fault detection circuitry on the RF amplifier modules.
4-23. EXTERNAL INTERLOCK CIRCUIT. An external interlock circuit is provided for the
connection of external equipment such as a test load. External interlock commands are
generated by optical coupler U3. U3 can be activated using positive or negative control
logic. Jumper J1 programs the optical coupler circuitry for positive or negative control
operation. When the external interlock is closed, the signal is applied to U3. U3 will
output a LOW to inverters U10A and U12E. U12E will output a LOW to illuminate
interlock indicator DS1. When the external interlock opens, the signal is applied to U3. A
HIGH is applied through inverters U10A and U11F. U11F will output a HIGH to configure
the transmitter to off. U12E will output a HIGH to extinguish interlock indicator DS1.
4-24. TRANSMITTER RAISE POWER CIRCUIT. The transmitter raise power circuitry
consists of raise switch S6, optical coupler U8, and inverters U10F and U13D. Local raise
control is provided by switch S6. When local raise power control is used, a LOW from
switch S6 is routed to the automatic-power-control circuitry on the controller circuit
board. Remote raise control is performed by optical coupler U8 and inverters U10F and
U13D. U8 can be activated using positive or negative control logic. Jumper J1 programs
the optical coupler circuitry for positive or negative control operation. When U8 is
activated, a LOW is routed to inverters U10F and U13D. U13D will output a LOW to the
automatic-power-control circuitry on the controller circuit board.
4-25. TRANSMITTER LOWER POWER CIRCUIT. The transmitter lower power circuitry
operates in a similar manner as the transmitter raise power circuit. The transmitter lower
power circuit consists of lower switch S7, optical coupler U9, and inverters U11A and
U13E. Refer to TRANSMITTER RAISE POWER CIRCUIT in the preceding text for a
description of the transmitter lower power circuit operation.
4-26. CONTROLLER CIRCUIT BOARD.

4-27. The controller circuit board is equipped with the automatic-power-control circuitry, 8
meter amplifier/buffer circuits, and fault processing circuitry (refer to Figure 4-3). The
automatic-power-control circuitry is designed to control the transmitter output power in
response to local/remote control commands, high reflected power conditions, and high
temperature conditions. The meter amplifier/buffer circuits process transmitter signals for
application to the meter display circuit board. The fault processing circuitry monitors
several transmitter parameters and generates a fault signal when a power amplifier fault,
a high temperature condition, or a high reflected power condition occurs.
4-10
597-5001-17
FIGURE 4-5. MULTIPLEXER AND

MODULE SELECT CIRCUIT BOARD
(4-11/4-12)
4-12
4-28. AUTOMATIC–POWER–CONTROL CIRCUIT. The automatic-power-control circuit
consists of up/down counters U9/U10/U11, latches U12 through U15, digital-to-analog
converter U16, NAND gates U8B/U8C/U8D, inverters U8A/U7C/U7A/U7E, transistors
Q1/Q4, and timer U17. The automatic-power-control circuit controls the transmitter
power output in response to local/remote raise/lower commands, high reflected power
conditions, and high temperature conditions.
4-29. Raise Output Power Operation. When the transmitter is operated to on, a LOW from U10D
on the controller on/off switch circuit board is applied to inverter U7A. When a
local/remote raise command is initiated, a LOW is applied to inverter U7C. U7C will
output a HIGH to NAND gate U8B. U8B will output a HIGH to U8C. With no lower
command present: 1) U8C will output HIGH to U8D and 2) a HIGH is applied to up/down
counters U9/U10/U11 to configure the counters to count up. U8D will output a HIGH to an
oscillator circuit consisting of timer U17, inverter U7E, and transistors Q1 and Q4. The
oscillator is designed to provide slow/fast power level adjustment control as determined by
the operation of the raise switch/indicator. When the raise switch/indicator is depressed
such as during fine output power adjustment, the oscillator output will be 16 Hz. When
the raise switch/indicator is depressed and held such as during coarse output power
adjustment, the oscillator output will be 150 Hz.
4-30. The output of the oscillator is inverted at U7E and applied to each up/down counter clock
input. The counters will respond to the raise command by counting up and routing a
number to latches U12 through U15. The output of latches U12 through U15 are applied
to digital-to-analog converter U16. U16 will convert the numbers to a dc output voltage.
The voltage from U16 is amplified at U6D. U6D will output a dc voltage to summing
amplifier U21D. In FM ONLY mode with no VSWR or over temperature conditions, U21D
will output a dc power control voltage to the power amplifier power supply. The power
supply will respond by routing the appropriate dc voltage to the power amplifier modules
to increase the RF output power.
4-31. In IBOC or FM + IBOC mode jumpers P724 and P725 are moved to position 1 - 2. The
output of U21D is routed to window comparator U22A/B, which generates a control signal
for the FXi Exciter which is buffered through U36A. U22A/B has open collector outputs
with pull up resistors R156, R177, R220 and R221. This output voltage will command the
FXi Exciter power to raise, lower or remain constant. When the forward power sample is
within the window set by R145 the output of U22A/B is 2.5V which commands the FXi
Exciter power to remain constant. The action of the FXi Exciter can be summarized by the
following table:
Control Voltage Range FXi Exciter Response

< 1V Remain Constant
1.0V - 2.0V Lower Power
2V- 3V Remain Constant
> 3V Raise Power
4-32. Lower Output Power Operation. When the transmitter is operated to on, a LOW from U10D
on the controller on/off switch circuit board is applied to inverter U7A. When a
local/remote lower command is initiated, a LOW is applied to NAND gate U8C and
up/down counters U9/U10/U11. The LOW configures the up/down counters to count down.
U8C will respond by routing a HIGH to U8D. U8D will output a HIGH to an oscillator
circuit consisting of timer U17, inverter U7E, and transistors Q1 and Q4. The oscillator is
designed to provide slow/fast power level adjustment control as determined by the
operation of the lower switch/indicator. When a lower switch/indicator is depressed during
fine output power adjustment, the oscillator output will be 16 Hz. When a lower
switch/indicator is depressed and held during coarse output power adjustment, the
oscillator output will be 150 Hz.
4-13
4-33. The output of the oscillator is inverted at U7E and applied to the up/down counters. The
counters will respond to the lower command by counting down and routing a number to
latches U12 through U15. The output of latches U12 through U15 are applied to
digital-to-analog converter U16. U16 will convert the numbers to a dc output voltage.
The voltage from U16 is amplified at amplifier U6D. U6D will output a dc voltage to
summing amplifier U21D. In FM ONLY mode with no VSWR or over temperature
conditions, U21D will output a dc power control voltage to the power amplifier power
supply. The power supply will respond by routing the appropriate dc voltage to the power
amplifier modules to decrease the RF output power.
4-34. METER AMPLIFIER/BUFFER CIRCUITS. The controller circuit board is equipped

with 8 meter amplifier/buffer circuits. The module current, module temperature, module
forward power, module voltage, and the PA voltage meter circuits operate in an identical
manner. Therefore, only the PA voltage amplifier/buffer circuit will be discussed.
4-35. PA Voltage Meter Amplifier/buffer Circuit. A PA voltage sample from the PA motherboard
assembly is applied through potentiometer R133 to amplifier U5D. Potentiometer R133 is
provided to calibrate the PA voltage meter sample. U5D is a non-inverting amplifier with
a gain of approximately 1. The output of U5D is applied to: 1) meter switch S301 on the
controller meter switch circuit board and 2) amplifier/buffer U5A. U5A is a non-inverting
amplifier with a gain determined by resistor R13. R13 is a resistor network designed to be
installed/removed as determined by the desired remote meter voltage indication. For a +4
volt equals 50 V dc remote full-scale PA voltage meter indication, R13 is installed. As a
result, U5A will be programmed for a gain of approximately 2. For a +2 volt remote
full-scale meter indication, R13 is removed. As a result U5A will be programmed for a
gain of approximately 1. The output of U5A is routed to the controller RFI filter circuit
board.
4-36. INLET AIR TEMPERATURE CIRCUIT. A dc sample voltage from the inlet air
temperature sensor circuit board is applied to non-inverting amplifier U21B. The gain of
U21B is controlled by potentiometer R134. R134 is provided to calibrate the inlet air
temperature circuitry. The output of U21B is applied to: 1) the controller meter switch
circuit board, 2) over-temperature comparator U21A, and 3) amplifier/buffer U21C. U21C
is a non-inverting amplifier with a gain determined by resistor R13. R13 is a resistor
network designed to be installed/removed as determined by the desired remote meter
voltage indication. For a +4 volt equals 60 degrees Celsius remote full-scale temperature
meter indication, R13 is installed. As a result, U21C will be programmed for a gain of
approximately 2. For a +2 volt remote full-scale meter indication, R13 is removed. As a
result U21C will be programmed for a gain of approximately 1. The output of U21C is
routed to the controller RFI filter circuit board.
4-14
4-37. REFLECTED POWER METER CIRCUIT. A dc reflected power sample voltage from the
low-pass filter assembly is applied to non-inverting meter amplifier U2A. The gain of
U2A is controlled by potentiometer R64. R64 is provided to calibrate the reflected power
circuitry. The output of U2A is applied to a squaring circuit consisting of integrated
circuits U26 and U24B. U26 and U24B function to convert the voltage sample to a power
sample. The output of the squaring circuit is routed to: 1) amplifier U6B, 2) VSWR
foldback comparator U18D, and 3) amplifier/buffer U2D. U2D is a non-inverting amplifier
with a gain determined by resistor R13. R13 is a resistor network designed to be
installed/removed as determined by the desired remote meter voltage indication. For a +4
volt equals 200W/160W remote full-scale reflected power meter indication, R13 is
installed. As a result, U2D will be programmed for a gain of approximately 2. For a +2
volt remote full-scale meter indication, R13 is removed. As a result, U2D will be
programmed for a gain of approximately 1. The output of U2D is routed to the controller
RFI filter circuit board. U6B is a non-inverting amplifier. The output of U6B is routed to
the controller meter switch circuit board. Jumper P721 selects the feed back path for the
circuit. Position 2-3 of P721 selects a power sample for application to the remote meter
terminal.
4-38. FORWARD POWER METER CIRCUIT. A dc forward power sample voltage from the
low-pass filter assembly is applied to non-inverting meter amplifier U2B. The gain of
amplifier U2B is controlled by potentiometer R49. R49 is provided to calibrate the forward
power circuitry. The output of U2B is applied to a squaring circuit consisting of integrated
circuits U25 and U24A. U25 and U24A function to convert the voltage sample to a power
sample. The output of the squaring circuit is routed to: 1) amplifier U6A, and 2)
amplifier/buffer U2C. U2C is a non-inverting amplifier with a gain determined by resistor
R13. R13 is a resistor network designed to be installed/removed as determined by the
desired remote meter voltage indication. For a +4 volt equals 5 kW/4 kW remote full-scale
forward power meter indication, R13 is installed. As a result, U2C will be programmed for
a gain of approximately 2. For a +2 volt remote full-scale meter indication, R13 is
removed. As a result, U2C will be programmed for a gain of approximately 1. The output
of U2C is routed to the controller RFI filter circuit board. U6A is a non-inverting
amplifier. The output of U6A is routed to the controller meter switch circuit board. The
dc forward power sample voltage is also routed to buffer U5B. The output of U5B is
applied to summing amplifier U21D. The signal is used to determine the transmitter
output power level. Jumper P720 selects the feed back path for the circuit. Position 2-3 of
P720 selects a power sample for application to the remote meter terminal.
4-39. TRANSMITTER FAULT DETECTION CIRCUITRY. The transmitter fault detection

circuit consists of VSWR foldback comparator U18D, over-temperature comparator U21A,
VSWR overload comparator U18A, comparators U18B/U18C, inverters
U19A/U19B/U19C/U19D/U19E/U7F, one shot U20, and transistors Q5/Q2. The circuitry is
designed to monitor the transmitter power amplifier modules, transmitter temperature,
and reflected power for fault conditions. When a fault is determined, the circuitry will
respond by enabling the fault indicator and muting or reducing the transmitter output
power.
4-40. Over–Temperature Comparator. A dc temperature sample from U21B is applied to
over-temperature comparator U21A. U21A compares the dc voltage to a reference voltage.
When the dc temperature sample is above the reference voltage, U21A will:
1) output a +0.7 to +15.0 dc voltage to comparator U18C and 2) output a voltage to
summing amplifier U21D. U21D will respond by reducing the transmitter output power
to: 1) maintain on-air operation and 2) reduce the transmitter temperature. With a
positive voltage at U18C from U21A, the output of U18C will go HIGH. The HIGH is
routed through inverters U19C and U7F to transistors Q5/Q2. Q5/Q2 will output a LOW
to enable the local and remote fault indicators.
4-15
4-41. Module temperature conditions are monitored by circuitry on the multiplexer circuit board
(refer to Figure 4-5). The circuitry consists of temperature comparator circuits for each
module in the transmitter. If a module temperature exceeds the reference, the multiplexer
circuit board will output a HIGH to diode D48 on the controller circuit board. The HIGH is
applied to summing amplifier U21D to foldback the transmitter output power. The HIGH
is also applied through diode D50 to comparator U18C. The output of U18C will go HIGH
to enable both the local and remote fault indicators.
4-42. VSWR Comparator. A dc reflected power sample from U2A is applied to VSWR comparator
U18D. U18D compares the dc voltage to a reference voltage from VSWR foldback calibrate
control R112. When the dc reflected power sample is above the reference voltage, U18D
will: 1) output a +0.7 to +15.0 dc voltage to comparator U18B, 2) output a +0.7 to +15.0 dc
voltage to comparator U18A, and 3) output a voltage to summing amplifier U21D. U21D
will respond by reducing the transmitter output power. With a positive voltage at U18B,
the output of U18B will go HIGH. The HIGH is routed through inverters U19B and U7F
to enable the local and remote fault indicators. The positive voltage routed to U18A is
compared to a reference voltage from VSWR overload calibrate control R94. When the dc
output from U18D is above the reference voltage, U18A will output a HIGH to inverter
U19A. U19A will output a LOW to enable one-shot U20. U20 will output a HIGH to
transistor Q3 to mute the transmitter output.
4-43. PA Module Fault Circuit. A HIGH PA module fault signal from the multiplexer circuit board
is applied to inverter U19E. U19E will output a LOW to inverter U7F. U7F will output a
HIGH to transistors Q5/Q2. Q5/Q2 will output a LOW to enable the local and remote fault
indicators.
4-44. Power Supply Fault. In the event of a power supply fault such as in power supply 1, a LOW
is applied through switch U29A to comparator U30A. U30A will output a LOW to inverter
U7D. U7D will output a HIGH to inverter U19F. U19F will output a LOW to NAND gate
U8B to disable any raise power commands. Jumper P719 allows the selection of a manual
or automatic raise disable. Automatic raise disable allows the controller circuitry to
disable raise power operation in response to reflected power and fault conditions. In the
manual raise disable mode, the controller circuitry is disabled to allow the raise power
function to be controlled manually. Ensure the jumper is placed in the automatic disable
position.
4-45. CONTROLLER METER SWITCH CIRCUIT BOARD.

4-46. The controller meter switch circuit board is equipped with meter switch S301 and remote
control enable/disable switch S302. S301 is an interlocked 8-position switch designed to
route samples to the meter display circuit board when a switch is depressed. When the
module forward power switch section is depressed, the forward power sample is applied
through forward power meter calibrate control R135 to non-inverting amplifier U6C on
the controller circuit board. The output of U6C is routed through R78 to a squaring circuit
consisting of integrated circuits U24C/D and U27. U24C/D and U27 convert the voltage
sample to a power sample. The output of the squaring circuit is returned to switch S301.
S301 routes the forward power sample through meter buffer U5C to the meter display
circuit board. S302 is configured to enable/disable the remote control inputs. A HIGH
enables the remote control inputs. A LOW disables the remote control inputs.
4-47. METER DISPLAY CIRCUIT BOARD.

4-48. The controller meter display circuit board is equipped with an LCD meter display and
meter driver circuitry. Meter samples from U5C on the controller circuit board are routed
to integrated circuit U201. U201 is an LCD display driver. Calibration of U201 is provided
by potentiometer R203. The output of U201 is applied to LCD display DS201. Exclusive
OR gate U202A controls the LCD decimal display.
4-16
4-49. RF AMPLIFIER CIRCUITRY OPERATION.
4-50. A description of the FM-5C/FM-4C and FMi-402/FMi-301 transmitter RF amplifier
circuitry is presented in Figure 4-6.
4-17
597-3002-14
FIGURE 4-6. RF AMPLIFIER MODULE
(4-18/4-18)
4-19
SECTION V
MAINTENANCE
5-1. INTRODUCTION.
5-2. This section provides maintenance information, electrical adjustment procedures, and
troubleshooting information for the Broadcast Electronics FM-5C/FM-4C and
FMi-402/FMi-301 transmitters.
5-3. SAFETY CONSIDERATIONS.
WARNING NEVER OPEN THE EQUIPMENT UNLESS ALL TRANSĆ
MITTER PRIMARY POWER IS DISCONNECTED. ENĆ
WARNING SURE ALL TRANSMITTER PRIMARY POWER IS DISĆ
CONNECTED BEFORE ATTEMPTING MAINTENANCE
ON ANY AREA WITHIN THE TRANSMITTER.
WARNING HIGH RF VOLTAGE IS PRESENT AT THE TYPE N

CONNECTOR WHEN AN RF POWER MODULE IS REĆ
WARNING MOVED FOR SERVICE. NEVER OPERATE THE
TRANSMITTER UNLESS AN RF POWER MODULE OR
A MODULE COVER PANEL IS INSTALLED IN EACH
TRANSMITTER MODULE LOCATION.
5-4. The FM-5C/FM-4C and FMi-402/FMi-301 transmitters contain high voltages and
currents. If safety precautions are not practiced, contact with the high voltages and
currents could cause serious injury or death. Never operate the transmitter unless: 1) all
transmitter safety guards and cover panels are installed and 2) an RF power module or
cover panel is installed in each RF power module location. The transmitter is equipped
with built-in safety features, however good judgement, care, and common sense must be
practiced to prevent accidents. The maintenance procedures contained in this section
should be performed only by trained and experienced maintenance personnel.
5-5. It is dangerous to measure voltages inside the cabinet or replace components with power
energized. Therefore, do not measure voltages inside the cabinet or replace components
with power energized. Always operate the transmitter POWER circuit breaker to OFF
prior to performing any maintenance within the transmitter. Measurements with the
power energized can be performed in the controller enclosure if required.
5-6. POWER AMPLIFIER EFFICIENCY.
5-7. The FM-5C/FM-4C and FMi-402/FMi-301 power amplifier stage consists of solid-state
power amplifier devices. Figure 5-1 presents typical FM-5C/FM-4C PA stage efficiency
values. The PA stage efficiency will vary slightly from the values presented in Figure 5-1
due to component tolerances. Refer to Figure 5-1 as required for typical PA stage
efficiency values.
5-8. FIRST LEVEL MAINTENANCE.
5-9. First level maintenance consists of procedures applied to the equipment to prevent future
failures. The procedures are performed on a regular basis and the results recorded in a
maintenance log. Preventive maintenance of the transmitter consists of good
housekeeping and checking performance levels using the meters and various indicators
built into the equipment.
5-1
WARNING: DISCONNECT POWER PRIOR TO SERVICING
COPYRIGHT
FIGURE 5-1. FM-5C/FM-4C TYPICAL PA EFFICIENCY 597-5001-19
5-10. ROUTINE MAINTENANCE.

5-11. INSPECTION AND CLEANING. On a regular basis, clean the equipment of

accumulated dust using a brush and vacuum cleaner. Inspect the RF amplifier modules
and the power supplies for damage caused by component overheating. Overheated
components are identified by circuit board discoloration near the component leads. Inspect
the circuit boards for loose hardware as required.
5-12. CONTROLLER BATTERY. Periodically, the battery on the controller circuit board
should be checked. If the battery is defective, a good-quality Alkaline battery is
recommended for replacement. Typically, it is recommended the controller battery be
replaced annually.
5-13. AIR FILTERS. The FM-5C/FM-4C and FMi-402/FMi-301 transmitters are equipped
with a screen-type air filter. The air filter is located inside the rear-access panel (refer to
Figure 5-2) and is equipped with an air flow indicator. Ensure the filter is installed with
the air flow indicator pointing towards the flushing fans. The filter can be checked and
cleaned without interrupting transmitter operation.
5-2
597-5001-13
FIGURE 5-2. AIR FILTER REMOVAL

5-14. Check the filter approximately once a week. When dirt is to be removed from the filter,
refer to Figure 5-2 and proceed as follows:
1. Remove the transmitter rear-access panel.
2. Remove the filter from the chassis by lifting the filter from the retaining
hardware.
3. Clean the filter using a: 1) brush and vacuum or 2) brush and soapy water.
4. Replace the filter with the air flow indicator pointing towards the flushing fans.
5. Replace the rear-access panel.
5-3
5-15. FLUSHING FANS. Inspect the transmitter flushing fans for dust accumulation and
periodically clean the fans using a brush and vacuum cleaner. The fans are cooled by air
passing around each motor. If dust is allowed to accumulate on the motors, the ambient
air temperature will increase due to restricted air flow. When the ambient air temperature
increases, the fan motor bearing lubricant will gradually vaporize and bearing failure will
occur.
5-16. It is recommended the flushing fan mounting hardware be periodically checked. The
flushing fans are equipped with sealed bearings which do not permit lubrication. If a
bearing fails, the motor must be replaced.
5-17. SECOND LEVEL MAINTENANCE.

5-18. Second level maintenance consists of procedures required to adjust the transmitter
circuitry or restore the transmitter to operation after a fault has occurred. The procedures
consists of electrical adjustments, troubleshooting, and component replacement
procedures. All electrical adjustments with the exception of the transmitter frequency
re-programming procedure are required only when components are replaced in the
transmitter circuitry.

5-19. The maintenance philosophy for the FM-5C/FM-4C and FMi-402/FMi-301 transmitters
consists of isolating a problem to a specific area. Once the specific area is located,
subsequent troubleshooting using the information in the following text will assist in
problem isolation to a replaceable assembly or component. If required, the replaceable
assembly may be: 1) returned to the factory for repair or exchange or 2) repaired locally.
5-20. ELECTRICAL ADJUSTMENTS.

5-21. MULTIMETER DISPLAY CALIBRATION. Potentiometer R203 on the controller meter

display circuit board calibrates the multimeter display. The following text presents the
procedure to calibrate the multimeter display.
5-22. Required Equipment. The following equipment is required to adjust the multimeter display
calibration control.
1. Insulated adjustment tool.
2. Digital voltmeter (Fluke 77 or equivalent).
5-23. Procedure. To calibrate the multimeter display, proceed as follows:
5-24. Depress the transmitter OFF switch/indicator to illuminate the switch/indicator and
operate the POWER SWITCH to OFF.
5-4
5-25. Open the controller door.
5-26. Remove integrated circuit U5 from the controller circuit board.
5-27. Refer to Figure 5-3 and construct a voltage source for the calibration procedure. Adjust
the voltage source for a 2.000 volt dc output.

COPYRIGHT
FIGURE 5-3. ADJUSTABLE VOLTAGE SOURCE 597-3002-21
5-28. Connect the voltage source between TP204 on the controller meter display circuit board
and TP203 ground.
5-29. Operate the POWER SWITCH to ON.
5-30. Refer to Figure 5-4 and adjust multimeter display calibration control R203 on the meter
display circuit board for a 1000 indication on the transmitter multimeter. Check the
voltage source to ensure the voltage is at 2.000.
5-31. Operate the POWER SWITCH to OFF.
5-32. Remove the test equipment, replace integrated circuit U5, and close the controller door.
5-33. REFLECTED POWER METER, VSWR FOLDBACK, AND VSWR OVERLOAD
CALIBRATION. Potentiometer R64 on the controller circuit board calibrates the
reflected power meter display. Potentiometer R112 on the controller circuit board
determines the VSWR level for foldback operations. Potentiometer R94 on the controller
circuit board determines the VSWR level for overload operations. The following text
presents the procedure to adjust the reflected power meter calibrate, the VSWR foldback,
and the VSWR overload controls.
5-34. Required Equipment. The following equipment is required to adjust the reflected power
meter, VSWR foldback, and VSWR overload calibration controls.
2. Adjustable voltage source.
5-35. Procedure. To adjust the reflected power meter, VSWR foldback, and VSWR overload
calibration controls, proceed as follows:
5-36. The transmitter MULTIMETER must be calibrated prior to adjusting the reflected power
meter, VSWR foldback, and VSWR overload calibration controls. Refer to MULTIMETER
DISPLAY CALIBRATION in the preceding text and perform the procedure to calibrate the
display.
5-37. Depress the transmitter OFF switch/indicator to illuminate the switch/indicator and
operate the POWER SWITCH to OFF.
5-38. Refer to Figure 5-3 and construct a voltage source for the calibration procedure. Adjust
the voltage source for a 2.57 volt dc output for FM-5C/FMi 402 models or a 2.27 volt dc
output for FM-4C/FMi 301 models.
5-39. Disconnect directional coupler input connector J302 on the transmitter rear panel.
5-5
5-6
597-5001-14
FIGURE 5-4. CONTROLLER AND METER DISPLAY CIRCUIT BOARD CONTROLS
5-40. Connect the voltage source between P302-3 (ground) and P302-4 (RFL).
5-41. Depress the transmitter SYSTEM RFL PWR switch/indicator.
5-43. Connect the digital voltmeter between the high signal side of R176 (end of R176 near TP5)
and ground on the controller circuit board.
5-44. Operate the POWER SWITCH to ON. Ensure the transmitter OFF switch/indicator is
illuminated.
5-45. Observe the digital voltmeter and ensure a 2.57 volt dc output for FM-5C/FMi-402 models
or a 2.27 volt dc output for FM-4C/FMi 301 models is present at R176. Adjust the voltage
source if required.
5-46. Refer to Figure 5-4 and adjust reflected power meter calibrate control R64 on the
controller circuit board for: 1) a 200 watt indication on the transmitter multimeter for
FM-5C/FMi-402 models or 2) a 160 watt indication on the transmitter multimeter for
FM-4C/FMi-301 models.
5-47. Connect the digital voltmeter between TP-1 and ground on the controller circuit board.
5-48. Refer to Figure 5-4 and adjust VSWR foldback control R112 on the controller circuit board
for a 4.3 volt indication on the digital voltmeter. The FAULT RESET switch/indicator
may illuminate.
5-49. Connect the digital voltmeter between TP-17 and ground on the controller circuit board.
5-50. Adjust the voltage source to obtain a: 1) 300 watt indication on the transmitter multimeter
for FM-5C/FMi-402 models or 2) 240 watt indication on the transmitter multimeter for
FM-4C/FMi-301 models.
5-51. Refer to Figure 5-4 and adjust VSWR overload control R94 on the controller circuit board
until the voltage at TP-17 goes positive.
5-52. Operate the POWER SWITCH to OFF.
5-53. Remove the test equipment, re-connect P302 on the transmitter rear panel, and close the
controller door.
5-54. FORWARD POWER CALIBRATION. Potentiometer R49 on the controller circuit board
calibrates the forward power detector circuitry. The following text presents the procedure
to calibrate the forward power detector circuitry.
5-55. Required Equipment. The following equipment is required to adjust the forward power
2. Calibrated in-line wattmeter with a 5 kW element for FM-5C/FMi-402 models or a
4 kW element for FM-4C/FMi 301 models (Bird 43 or equivalent).
3. Test load and cable (50 Ohm Non-Inductive, 5 kW minimum for FM-5C/FMi-402
models or 4 kW minimum for FM-4C/FMi-301 models.
5-56. Procedure. To adjust the forward power calibration control, proceed as follows:
5-57. The transmitter MULTIMETER must be calibrated prior to adjusting the forward power
detector circuitry. Refer to MULTIMETER DISPLAY CALIBRATION in the preceding text
and perform the procedure to calibrate the display.
5-7
WARNING DISCONNECT ALL TRANSMITTER PRIMARY POWER
BEFORE PROCEEDING.
WARNING
5-58. Disconnect all transmitter primary power before proceeding.

5-60. Connect the test load and wattmeter to the transmitter output.
5-61. Energize the transmitter primary ac power and operate the transmitter at the desired
output power level as indicated by the in-line wattmeter.
5-62. Depress the transmitter SYSTEM FWD PWR switch/indicator.
5-63. Refer to Figure 5-4 and adjust FORWARD POWER CAL control R49 on the controller
circuit board until the transmitter MULTIMETER display is equal to the value presented
on the in-line wattmeter. Ensure the in-line wattmeter power level and frequency
correction charts are used during this calibration procedure.

BEFORE PROCEEDING.
WARNING
5-64. Disconnect all transmitter primary power.

5-65. Remove the test equipment, close the controller door, and reconnect the transmitter output
to the antenna.
5-66. PAV CALIBRATION. Potentiometer R133 on the controller circuit board calibrates the
PA voltage detector circuitry. The following text presents the procedure to calibrate the PA
voltage detector circuitry.
5-67. Required Equipment. The following equipment is required to adjust the PA voltage
5-68. Procedure. To adjust the PA voltage calibration control, proceed as follows:
5-69. The transmitter MULTIMETER must be calibrated prior to adjusting the PA voltage
5-70. Operate the transmitter to on.
5-71. Depress the LOWER switch/indicator to obtain: 1) a 1 kW indication on the
MULTIMETER display for FM-5C/FMi 402 models and 2) a 500 W indication on the
MULTIMETER display for FM-4C/FMi 301 models.

BEFORE PROCEEDING.
WARNING
5-8
5-74. Remove PA power supply module 1 and connect the voltmeter between TP402 (dc +) and
TP404 (ground) on the power supply motherboard.
5-75. Energize the transmitter primary ac power.
5-76. Depress the transmitter SYSTEM PS VDC switch/indicator.
5-77. Refer to Figure 5-4 and adjust PAV CAL control R133 on the controller circuit board until
the transmitter MULTIMETER display is equal to the value presented on the digital
voltmeter.

BEFORE PROCEEDING.
WARNING

5-79. Remove the test equipment, replace the PA power supply module, close the controller door,
and return the transmitter to the normal output power level.
5-80. TEMPERATURE CALIBRATION. Potentiometer R134 on the controller circuit board
calibrates the temperature detector circuitry. The following text presents the procedure to
calibrate the temperature detector circuitry.
5-81. Required Equipment. The following equipment is required to adjust the temperature
3. Fluke 80T-150 temperature probe or equivalent Celsius indicating temperature
probe.
5-82. Procedure. To adjust the temperature calibration control, proceed as follows:
5-83. The transmitter MULTIMETER must be calibrated prior to adjusting the temperature

BEFORE PROCEEDING.
WARNING

5-86. Locate the temperature sensor circuit board and place the temperature probe near the
transistor temperature sensor.
5-87. Energize the transmitter primary ac power. Allow the transmitter to operate for
approximately 5 minutes.
5-88. Depress the transmitter SYSTEM INLET TEMP switch/indicator.
5-89. Refer to Figure 5-4 and adjust TEMP CAL control R134 on the controller circuit board
until the transmitter MULTIMETER display is equal to the value presented on the digital
voltmeter.
5-9
BEFORE PROCEEDING.
WARNING
5-91. Remove the test equipment and close the controller door.
5-92. PA MODULE FORWARD POWER CALIBRATION. Potentiometer R135 on the

controller circuit board calibrates the PA module forward power detector circuitry. The
following text presents the procedure to calibrate the PA module forward power detector
circuitry.
5-93. Required Equipment. The following equipment is required to adjust the PA module forward
power calibration control.
5-94. Procedure. To adjust the PA module forward power calibration control, proceed as follows:
5-95. The transmitter MULTIMETER must be calibrated prior to adjusting the PA module
forward power detector circuitry. Refer to MULTIMETER DISPLAY CALIBRATION in the
preceding text and perform the procedure to calibrate the display.
5-97. Depress the transmitter OFF switch/indicator to illuminate the switch/indicator.
5-98. Connect the digital voltmeter between TP8 on the controller circuit board and ground.
5-99. Energize the transmitter primary ac power and operate the transmitter.
5-100. Depress the transmitter RAISE or LOWER switch/indicator to obtain a +5.0 volt dc
indication on the digital voltmeter.
5-101. Depress the transmitter MODULE SELECT switch/indicator to select a module. The
module selected will be presented on the MODULE SELECT display.
5-102. Depress the transmitter MODULE PA FWD POWER switch/indicator.
5-103. Refer to Figure 5-4 and adjust PA FWD CAL control R135 on the controller circuit board
until the transmitter MULTIMETER display equals 500 watts.
5-104. Depress the transmitter OFF switch/indicator to illuminate the switch/indicator.
5-105. Remove the test equipment and close the controller door.
5-106. CONTROLLER SQUARING CIRCUIT ADJUSTMENTS. The controller circuit board

squaring circuitry contains calibration controls. The calibration controls consist of:
1) transmitter forward power squaring circuit calibrate control R54, 2) transmitter
reflected power squaring circuit calibrate control R67, and 3) module forward power
squaring circuit calibrate control R78. Due to the critical nature and specialized test
equipment required to adjust the controls, the controls are not considered field adjustable.
If the controls are to be adjusted, contact the Broadcast Electronics Customer Service
Department.
5-10
5-107. RF POWER AMPLIFIER MODULE ADJUSTMENTS. The RF power amplifier module
amplifier circuit board and the power amplifier logic circuit board contain calibration
controls. The power amplifier circuit board is equipped with bias level controls R9 and
R22. The RF amplifier logic circuit board contains current offset control R11, current limit
control R5, forward power calibration control R51, forward power limit control R15, and
reflected power limit control R25. Due to the critical nature and specialized test
equipment required to adjust the controls, the controls are not considered field adjustable.
If the controls are to be adjusted, contact the Broadcast Electronics Customer Service
Department.
5-108. LOW–PASS FILTER. The low-pass filter is equipped with a reflected power null control.
Due to the critical nature and specialized test equipment required to adjust the control, the
control is not considered field adjustable. If the control is to be adjusted, contact the
Broadcast Electronics Customer Service Department.
5-109. TRANSMITTER FREQUENCY RE–PROGRAMMING. The FM-5C/FM-4C and
FMi-402/FMi-301 transmitters are configured for a specific frequency when shipped from
the factory. However, the transmitters can be re-programmed for a different frequency in
the field if required. The following text presents the procedure to change an
FM-5C/FM-4C or FMi-402/FMi-301 transmitter's operating frequency.
5-110. Required Equipment. The following equipment is required to re-program the transmitter
operating frequency.
1. Calibrated in-line wattmeter with 5 kW element for FM-5C/FMi-402 models or a
4 kW element for FM-4C/FMi-301 models (Bird 43 or equivalent).
2. Test load and cable (50 Ohm Non-Inductive, 1 5/8 connector, 5 kW for FM-5C/FMi 402
models or 4 kW for FM-4C/FMi 301 models minimum).
5-111. Procedure. To re-program the transmitter operating frequency, proceed as follows:

BEFORE PROCEEDING.
WARNING

5-113. Connect the test load and wattmeter to the transmitter output.
5-114. For an FM-250C exciter, refer to SECTION 4, AFC/PLL ASSEMBLY in FM-250C
publication 597-1004 and perform the FREQUENCY SELECTION procedure. For an
FXi- 250 refer to publication 597-0541 SECTION 3, CARRIER FREQUENCY
SELECTION. Operate and test the exciter independently from the transmitter.
5-115. Energize the transmitter primary ac power and operate the transmitter at the desired
output power level as indicated by the in-line wattmeter.
5-116. If a difference in values presented on the in-line wattmeter and the transmitter
multimeter is observed, the transmitter forward power display may be calibrated if desired
by performing the following procedure. Typically, the transmitter forward power display
on the multimeter will be more accurate than the in-line wattmeter. Ensure the in-line
wattmeter has been recently calibrated at the factory prior to calibrating the transmitter
multimeter display.
5-11
1. Depress the transmitter SYSTEM FWD PWR switch/indicator.
2. Refer to Figure 5-4 and adjust FORWARD POWER CAL control R49 on the
controller circuit board until the transmitter MULTIMETER display is equal to
the value presented on the in-line wattmeter.

BEFORE PROCEEDING.
WARNING

5-118. Remove the test equipment, close the controller door, and reconnect the transmitter output
to the antenna.
5-119. TROUBLESHOOTING.
5-120. TYPICAL METER INDICATIONS. Typical meter indications for the FM-5C/FM-4C
and FMi 402/FMi 301 transmitters are presented in the factory final test data sheets
shipped with each transmitter. Refer to the factory test data sheets for typical meter
indications.
CAUTION REMOVING OR INSTALLING A POWER AMPLIFIER

POWER SUPPLY WITH THE TRANSMITTER ENERĆ
CAUTION GIZED MAY RESULT IN DAMAGE TO THE SUPPLY.
DO NOT REMOVE/INSERT A POWER AMPLIFIER
POWER SUPPLY WITH THE TRANSMITTER ENERĆ
GIZED.
5-121. POWER AMPLIFIER POWER SUPPLY MODULES. The FM-5C/FM-4C and
FMi-402/FMi-301 transmitters are equipped with modular switching power supply units.
The FM-5C/FMi-402 is equipped with a modular switching power supply for the controller
and 5 modular switching power supplies for the power amplifier circuitry. The
FM-4C/FMi-301 is equipped with a modular switching power supply for the controller and
4 modular switching power supplies for the power amplifier circuitry. Each power
amplifier power supply module contains a fuse and a cooling fan.
5-122. When a power supply module fault indicator illuminates, check the following:
1. The PA power supply modules are equipped with temperature overload protection.
If a power supply module temperature overload occurs, the modules must be reset.
To reset a power supply module, proceed as follows:
A. Depress the transmitter OFF switch/indicator.
B. Wait approximately 1 minute.
C. Depress the transmitter ON switch/indicator. The module will return to
operation if the problem was associated with a temperature overload.
2. If the power supply module does not return to operation, check the following:
A. Depress the SYSTEM P.S. VDC switch/indicator and check the power supply
voltage. During a power supply failure, the voltage will be less than the
normal operating voltage and greater than 0.0 volts dc.
B. Check the rotation of the defective power supply module fan. Ensure the fan is
operating.
3. If system power supply voltage is normal and the fan is not operating, proceed as
follows:
5-12
CAUTION A POWER AMPLIFIER POWER SUPPLY MODULE WILL
BE DAMAGED IF A MODULE IS REMOVED OR
CAUTION INSTALLED WITH POWER ENERGIZED. DISCONĆ
NECT ALL TRANSMITTER POWER PRIOR TO REMOVĆ
ING OR INSTALLING A POWER AMPLIFIER MODULE.
A. Disconnect all transmitter primary power.

B. Loosen the lock knob on the front panel of the defective power supply module.
C. Remove and re-insert the power supply module and secure the lock knob.
D. Apply power and depress the transmitter ON switch/indicator to illuminate the
switch/indicator. The module will return to operation if the problem is
associated with improper module seating.
4. If the power supply module problem remains, refer to APPENDIX A and locate the
Pioneer Magnetics Troubleshooting Guide for the PM3329BP-5 power supply. Use
the guide to locate the problem.
5-123. CONTROLLER POWER SUPPLY. The FM-4C/FM-5Cand FMi-402/FMi-301

transmitter controller power supply is located on a panel behind the air filter (refer to
Figure 5-5). The power supply is equipped with a fuse and should be checked if a failure
occurs. To check the controller power supply module, proceed as follows:

BEFORE PROCEEDING.
WARNING

5-125. Refer to Figure 5-2 and remove the rear door.
5-126. Remove the air filter.
5-127. Refer to Figure 5-5 and remove the access panel.
5-128. Disconnect the wiring, remove the 4 mounting screws, and remove the controller power
supply module.
5-129. Check the power supply fuse. If the power supply fuse has not blown, contact the
Broadcast Electronics Customer Service Department. If desired, refer to APPENDIX A
and the Computer Products power supply schematic diagram for additional power supply
troubleshooting information.
5-130. Once the power supply troubleshooting has been completed, re-install the supply by
reversing the preceding procedure.
5-13
MODULE WITH THE TRANSMITTER ENERGIZED MAY
CAUTION RESULT IN DAMAGE TO THE MODULE. DO NOT
REMOVE/INSERT A POWER AMPLIFIER MODULE
WITH THE TRANSMITTER ENERGIZED.
5-131. POWER AMPLIFIER MODULE TROUBLESHOOTING/REPAIR. Each transmitter

power amplifier module contains circuitry requiring specialized equipment and test
procedures for troubleshooting and repair operations. Therefore, almost all power
amplifier module troubleshooting and repair can not be performed in the field. If a power
amplifier module is determined to be defective, contact the Broadcast Electronics Customer
Service department for: 1) troubleshooting information and 2) information on a power
amplifier module exchange program (refer to the following text).
NOTE THE FM-5C/FM-4C & FMi-402/FMi-301 TRANSMITTERS

WILL NOT OPERATE WITH MORE THAN 3 RF POWER
NOTE AMPLIFIER MODULES REMOVED FROM THE CHASSIS.
ENSURE NO MORE THAN 3 RF POWER AMPLIFIER
MODULES ARE REMOVED FROM THE TRANSMITER.

MODULE WITH THE TRANSMITTER ENERGIZED MAY
CAUTION RESULT IN DAMAGE TO THE MODULE. DO NOT REĆ
MOVE/INSERT A POWER AMPLIFIER MODULE WITH
THE TRANSMITTER ENERGIZED.
5-132. POWER AMPLIFIER MODULE TROUBLESHOOTING/REPAIR. Each transmitter

power amplifier module requires specialized equipment for troubleshooting and repair
operations. Therefore, almost all power amplifier module troubleshooting and repair can
not be performed in the field. If a power amplifier module is determined to be defective,
contact the Broadcast Electronics Customer Service department for: 1) troubleshooting
information and 2) information on a power amplifier module exchange program (refer to
the following text).
WARNING HIGH RF VOLTAGE IS PRESENT AT THE TYPE N

CONNECTOR ON THE PA MOTHERBOARD WHEN AN
WARNING RF POWER AMPLIFIER MODULE IS REMOVED FOR
SERVICE. ENSURE A MODULE COVER PANEL IS
INSTALLED IN THE MODULE LOCATION WHEN A
MODULE IS REMOVED FOR SERVICE.
5-133. Power Amplifier Module Cover Panel Installation. If a power amplifier module is removed
from the transmitter, a module cover panel must be installed in the module location. The
panels are located in the transmitter accessory kit. The installation of the panel will
maintain adequate air flow in the transmitter and prevent access to the RF power at the
Type N connector on the PA motherboard.
5-14
5-134. Power Amplifier Module Exchange Program. If a power amplifier module is determined to be
defective, Broadcast Electronics has established a power amplifier module exchange
program. The program allows the customer to: 1) exchange a defective module for a
reconditioned module or 2) obtain a module on loan during the repair of the defective
module. Terms of the program are available from the Broadcast Electronics Customer
Service Department.

5-135. TRANSMITTER TROUBLESHOOTING PROCEDURES. Table 5-1 presents

troubleshooting information for the FM-5C/FM-4C and FMi-402/FMi-301 transmitters.
Refer to Table 5-1 to isolate the problem to a specific assembly. Once the trouble is
isolated, refer to the theory of operation and schematic diagrams to assist in problem
resolution.
5-136. TRANSMITTER COMPONENT LOCATIONS. Figure 5-5 presents the transmitter
component locations. Refer to Figure 5-5 as required during the troubleshooting
procedures to locate components within the transmitter.
5-137. Transmitter Access Panels. Figure 5-5 presents the transmitter access panels. Refer to
Figure 5-5 and remove the panels as required to access transmitter components.
5-15
TABLE 5-1. FM-5C/FM-4C & FMi-402/FMi-301 TROUBLESHOOTING
(Sheet 1 of 6)
SYMPTOM CIRCUITRY TO CHECK

1. NO OUTPUT POWER 1. FM-250C - AFC is unlocked. FXi-250 exciter fault.
2. INTERLOCK INDICATOR Refer to the exciter manual and troubleshoot the exciter.
EXTINGUISHED
3. MODULE RF DRIVE
INDICATORS EXTINGUISHED
4. FM-250C LOCK INDICATOR
EXTINGUISHED OR FXi 60
FAULT INDICATOR
ILLUMINATED
1. NO OUTPUT POWER 1. Operate the remote control switch to disable.
2. INTERLOCK INDICATOR A. If the interlock indicator is extinguished, check
EXTINGUISHED the external interlock.
B. If the interlock indicator illuminates, check the
remote control unit.
1. LOW OUTPUT POWER 1. Check the exciter forward power. The forward
2. MODULE DRIVE INDICATORS power must be: 1) 220 W for the FM-5C/FMi-402 and 2) 175
W EXTINGUISHED for the FM-4C/FMi-301.
2. If the exciter forward power is low, increase the exciter
output power.
3. If the exciter forward power is normal, ensure the
exciter RF output cable is connected to the splitter on
the motherboard.
1. LOW OUTPUT POWER 1. Defective low-pass filter or combiner.
2. MODULE STATUS INDICATORS
ILLUMINATE YELLOW
5-16
(Sheet 2 of 6)

1. RESET INDICATOR 1. Depress the reset switch.
ILLUMINATED 2. If the reset indicator does not display normal
indications, depress the SYSTEM FWD
POWER switch. The transmitter forward power
must be equal to the TPO.
3. If the transmitter forward power is high,
depress the LOWER switch to lower the output
power to the TPO level.
4. If the transmitter forward power is low or equal to the
TPO, depress the multimeter TEMP switch. The
temperature must be less than 50 qC. The transmitter
will foldback power if the temperature is greater than
50 qC.
5. If the temperature is high, check the flushing fans and
the filter.
6. If the temperature is normal, check each module
temperature. The transmitter will foldback RF output
power when a module temperature exceeds 85qC.
7. If the module temperature is normal, depress the
SYSTEM RFL PWR switch/indicator. The re-
flected power must be less than 300 watts on
FM-5C/FMi-402 models and 240 watts on FM-4C/FMi-301
models.
8. If the reflected power is high, check the output
transmission line and the antenna.
9. If the reflected power is normal, check the low-pass
filter and the reflected power directional coupler.
1. A RED MODULE STATUS 1. Depress the reset switch.
INDICATOR 2. If the module status and reset indicators do not dis-
2. RESET INDICATOR play normal indications, depress the multimeter
ILLUMINATED (SHT 1 OF 2) TEMP switch. The temperature should be less than
50 qC.
3. If the temperature is high, check the flushing fans
and the filter.
4. If the temperature is normal, check the module
temperature. The module temperature must be less
than 95 qC.
5. If the module temperature is normal, label the
defective module and record the location.
Interchange the module with another module in the
transmitter.
5-17
(Sheet 3 of 6)

1. A RED MODULE STATUS 6. If the module inserted into the location recorded in
INDICATOR the preceding step displays a red MODULE STATUS
2. RESET INDICATOR indicator, check the transmitter combiner.
ILLUMINATED (SHT 2 OF 2) 7. If the MODULE STATUS indicator on the
module recorded in the preceding step remains
red, the module is defective. Contact the
Broadcast Electronics Customer Service Department.
1. TRANSMITTER WILL NOT 1. Replace the battery in the controller.
AUTOMATICALLY RETURN TO
RATED POWER AFTER AN
AC POWER LOSS
1. TRANSMITTER OFF 1. Ensure primary ac power is applied to the unit and
WITH NO FRONT PANEL ensure the POWER switch is operated to on.
INDICATIONS 2. If the primary ac power is on, defective controller
power supply.
1. TRANSMITTER OFF 1. Defective controller power supply +15V output.
2. NO OFF INDICATOR
3. NO INTERLOCK INDICATOR
4. NO MODULE STATUS
INDICATORS
1. TRANSMITTER OFF 1. Defective controller power supply +5V output.
WITH FRONT PANEL
INDICATIONS
2. NO MULTIMETER DISPLAY
ILLUMINATE YELLOW
1. TRANSMITTER OFF 1. Defective controller power supply -15V output.
WITH FRONT PANEL
INDICATIONS
ILLUMINATE YELLOW
1. A MODULE STATUS INDICATOR 1. Label the defective module and record the location.
ILLUMINATES YELLOW Interchange the module with another module in the
transmitter.
2. If the module inserted into the location recorded in
the preceding step displays a yellow MODULE
STATUS indicator, check the transmitter combiner.
3. If the MODULE STATUS indicator on the module
recorded in the preceding step remains yellow, the
module is defective. Troubleshoot the module.
5-18
(Sheet 4 of 6)

1. ERRATIC POWER CONTROL 1. Depress the RAISE switch and check for a HIGH at
U7 pin 6 on the controller circuit board.
2. If the HIGH is present, check U6D, U9, U10, U11,
U12, U13, U14, U15, U16, U7E, U17, Q1, Q4,
U8C, U8D, and U8B on the controller circuit board.
3. If the HIGH is not present, check U7C on the
controller circuit board and S7 on the controller on/off
circuit board.
1. NO POWER CONTROL 1. Check for a dc voltage at TP3 on the controller circuit
board.
2. If the voltage at TP3 is present, check U3C, U3A,
U3B, and U4C on each RF power module logic circuit
board.
3. If the voltage at TP3 is not present, check for a 4.4
volt dc signal at U21 pin 12 on the controller circuit
board.
4. If the 4.4 volt signal is present, check U21 on the
controller circuit board.
5. If the 4.4 volt signal is not present, check for a 8.7
volt dc signal at U6 pin 14 on the controller circuit
board.
6. If the 8.7 volt signal is present, check Q3, U20, U19A,
U18A, and U18D on the controller circuit board.
Check U11D, U11C, U11B, K1, U10D, U13C, U6 and
U14 on the controller on/off circuit board.
7. If the 8.7 volt signal is not present, check U6D,
U9, U10, U11, U12, U13, U14, U15, U16, U7E,
U17, Q1, Q4, U8D, U8C, and U7C on the
1. TRANSMITTER OPERATES 1. Depress the SYSTEM P.S. VDC switch/indicator
2. NO MULTIMETER OPERATION and check for a dc voltage at TP204 on the meter
display circuit board.
2. If the voltage at TP204 is present, check for: 1) +5
volts dc at TP201, 2) -5 volts dc at U201 pin 26, and
3) approximately 2.0 volts at U201 pin 36.
3. If the voltages are not present, check the r5 volt
supplies, D201, and R202 on the meter display circuit
board.
4. If the voltages are present, check U201 and
DS201 on the meter display circuit board.
5. If the voltage at TP204 is not present, check U5C
on the controller circuit board.
5-19
(Sheet 5 of 6)

1. TRANSMITTER OPERATES 1. Check for a 7.48 VDC signal for a 5 kW output on
2. NO FORWARD POWER METER FM-5C models or a 6.67 VDC signal for a 4 kW
DISPLAY output on FM-4C models at U2 pin 5 on the controller
circuit board.
2. If the voltage is not present, check the directional
coupler.
3. If the voltage is present, check for a 3 volt dc signal at
TP4 and a 9 volt dc signal at TP14 on the controller
circuit board. Do not adjust R54.
4. If the voltages at TP4/TP14 are not present, check
U2B, U24A, U25A/B/C/D/E, U6A , and D8 on the
5. If the voltages at TP4/TP14 are present, check S301
on the meter switch circuit board.
1. TRANSMITTER OPERATES 1. Check the exciter output power. The forward power
WITH NORMAL INDICATIONS must be: 1) FM-5C/FMi 402 = 220 W
2. RATED POWER CAN NOT BE 2) FM-4C/FMi 301 = 175 W
OBTAINED. 2. If the exciter output power is less than 10 W:
1) Operate the transmitter to OFF, 2) wait
approximately 10 seconds, and 3) operate the
transmitter to ON.
3. If the exciter output power is normal, check U5B
on the controller circuit board.
1. TRANSMITTER OPERATES 1. Check for a voltage at U2 pin 3 on the controller
2. NO REFLECTED POWER METER circuit board.
DISPLAY 2. If the voltage is not present, check the directional
coupler.
3. If the voltage is present, check for a voltage at TP10
and TP15 on the controller circuit board. Do not
adjust R67.
4. If the voltages at TP10/TP15 are not present, check
U2A, U24B, U26A/B/C/D/E, U6B, and D8 on the
5. If the voltages at TP10/TP15 are present, check S301
on the meter switch circuit board.
1. CIRCUIT BREAKER OPERATION 1. Check the MOVs, PA power supply modules,
controller power supply, and the circuit breaker.
1. NO PA MODULE FORWARD 1. Ensure PA module 0 is not presented on the module
POWER METER INDICATION status display.
(SHT 1 OF 2) 2. Check U201 and U205A on the multiplexer circuit
board.
3. Check for the following voltages on the controller
circuit board: 1) approximately 5.0 volts (500W) at
TP8, 2) 3 volts dc at TP11, and 3) 9 volts dc at TP16.
5-20
(Sheet 6 of 6)

NO PA MODULE FORWARD 4. If the voltages at TP8/TP11/TP16 are not present,
POWER METER INDICATION check U4A, U6C, U24C, U27A/B/C/D/E, U24D, and
(SHT 2 OF 2) D8.
5. If the voltages at TP8/TP11/TP16 are present,
check S301 on the meter switch circuit board.
1. NO PA MODULE CURRENT 1. Ensure PA module 0 is not presented on the module
2. Check U202 and U205B on the multiplexer circuit
board.
3. Check U3A on the controller circuit board.
1. NO PA MODULE VOLTAGE 1. Ensure PA module 0 is not presented on the module
2. Check U203 and U205C on the multiplexer circuit
board.
3. Check U4C on the controller circuit board.
1. NO PA MODULE TEMPERATURE 1. Ensure PA module 0 is not presented on the module
2. Check U204 and U205D on the multiplexer circuit
board.
3. Check U3C on the controller circuit board.
1. NO PA MODULE SELECTION 1. Ensure P715 on the controller circuit board is
installed in position 1-2.
2. Check S1 on the module select circuit board.
3. Check U23 and U7B on the controller circuit board.
4. Check U206 and U207 on the multiplexer circuit
board.
5. Check U1 on the module select circuit board.
1. ALL FRONT PANEL INDICATORS 1. Check the controller power supply outputs.
FLASHING
1. NO TRANSMITTER INDICATORS 1. On 220V ac three-phase models, the 3-phase ac
2. NO TRANSMITTER OPERATION voltage monitor has been enabled. Check the 3-phase
supply.
2. On single-phase models, no ac power source. Check
the transmitter ac input.
1. POWER SUPPLY FAULT 1. Check the RF drive to the transmitter. Ensure the
INDICATOR(S) ILLUMINATED exciter output is: 1) FM-5C/FMi 402 = 220W
2) FM-4C/FMi 301 = 175W
2. RESET INDICATOR ILLU-
MINATED 2. Check the Power Supply.
1. NO OUTPUT POWER 1. Refer to APPENDIX A for a description of the ac line
2. INTERLOCK INDICATOR monitor indicators and determine the fault condition.
EXTINGUISHED 2. For incorrect ac line phasing during initial operation,
3. THREE-PHASE AC LOSS disconnect ac power and reverse any two ac line
MONITOR INDICATORS phases at the ac input panel. For high/low voltage
FLASHING/EXTINGUISHED and loss of phase conditions, check the ac input.
5-21
5-138. COMPONENT REPLACEMENT PROCEDURE. Component replacement on printed
circuit boards requires extreme care to avoid damage to the circuit board traces. The
following text describes the procedure to replace components on FM-5C/FM-4C and
FMi-402/FMi-301 circuit boards.
5-139. On all circuit boards, the adhesive securing the copper trace to the board melts at almost
the same temperature at which solder melts. A circuit board trace can be destroyed by
excessive heat or lateral movement during soldering. Use of a small iron with steady
pressure is required for circuit board repairs.
5-140. To remove a component from a circuit board, cut the leads from the body of the defective
component while the device is still soldered to the board.
5-141. Grip each component lead, one at a time, with long-nose pliers. Rotate the circuit board
and touch a soldering iron to the lead at the solder connection. When the solder begins to
melt, push the lead through the back side of the board. Each lead may now be heated
independently and pulled out of each hole. The holes may be cleared of solder by carefully
re-heating each hole with a low wattage iron and removing the residual solder with a
soldering vacuum tool.
WARNING MOST SOLVENTS WHICH WILL REMOVE ROSIN FLUX

ARE VOLATILE AND TOXIC BY THEIR NATURE AND
WARNING SHOULD BE USED ONLY IN SMALL AMOUNTS IN A
WELL VENTILATED AREA, AWAY FROM FLAME SUCH
WARNING
AS FROM A SOLDERING IRON OR SMOKING MATERIĆ
ALS. OBSERVE THE MANUFACTURER'S CAUĆ
WARNING
TIONARY INSTRUCTIONS.
5-142. Install the new component and apply solder from the bottom side of the circuit board.
After soldering, remove flux with a cotton swab moistened with a suitable solvent.
Rubbing alcohol is highly diluted and is not effective.
5-143. The board should be checked to ensure the flux has been removed and not just smeared.
Rosin flux is not normally corrosive, but rosin will absorb enough moisture in time to
become conductive and cause problems.
5-22
597-5001-15
FIGURE 5-5. FM-5C/FM-4C & FMi 402/FMi 301 COMPONENT LOCATOR
(SHEET 1 OF 4)
5-23
5-24
597-5001-15A
FIGURE 5-5. FM-5C/FM-4C & FMi 402/FMi 301 COMPONENT LOCATOR (SHEET 2 OF 4)
5-25
597-5001-15B
5-26
597-5001-15C
SECTION VI
PARTS LIST
6-1. INTRODUCTION.
6-2. This section provides parts lists for the FM-5C/FM-4C and FMi-402/FMi-301 transmitters.
The parts lists provide descriptions and part numbers of electrical components, assemblies,
and selected mechanical parts required for maintenance. Each parts list entry in this section
is indexed by reference designators appearing on the applicable schematic diagrams.
TABLE 6-1. FM-5C/FM-4C & FMi-402/FMi-301 REPLACEABLE PARTS LIST INDEX

(Sheet 1 of 2)
TABLE DESCRIPTION PART NO. PAGE
6-2 FM-5C Transmitter, 220VAC, Single Phase 909-5001-204 6-3

6-3 FM-4C Transmitter, 220VAC, Single Phase 909-4001-204 6-4
6-4 FM-5C Transmitter, 220VAC, Three Phase 909-5001-254 6-5
6-8 FMi 402 Transmitter, 220VAC, Single Phase 909-0402-404 6-9
6-9 FMi 301 Transmitter, 220VAC, Single Phase 909-0301-404 6-10
6-10 FMi 402 Transmitter, 220VAC, Three Phase 909-0402-454 6-11
6-14 Optically Coupled Relay Circuit Board Assembly 919-0096 6-15
6-15 Optically Coupled Relay Circuit Board Assembly 919-0096-001 6-15
6-16 Control Switch Circuit Board Assembly 919-0406-101 6-16
6-17 Display Circuit Board Assembly 919-0406-102 6-17
6-18 Meter Switch Circuit Board Assembly 919-0406-103 6-17
6-19 Temperature Sensor Circuit Board Assembly 919-0406-105 6-18
6-20 RFI Filter Circuit Board Assembly 919-0562 6-18
6-21 Low-pass Filter Input/RFI Filter Circuit Board Assembly 919-0415-003 6-19
6-22 Remote Interface Barrier Strip Circuit Board Assembly 919-0415-005 6-20
6-23 FM-5C/FMi 402 Power Supply Distribution Assembly 919-0415-500 6-20
FM-4C/FMi 301 Power Supply Distribution Assembly 919-0415-400
6-24 FM-5C/FMi 402 Module Select Circuit Board Assembly 919-0415-501 6-21
FM-4C/FMi 301 Module Select Circuit Board Assembly 919-0415-401
6-25 FM-5C/FMi 402 Multiplexer Circuit Board Assembly 919-0415-502 6-22
FM-4C/FMi 301 Multiplexer Circuit Board Assembly 919-0415-402
6-26 FM-5C/FMi 402 Controller Circuit Board 919-0563-500 6-26
6-27 FM-4C/FMi 301 Controller Circuit Board 919-0563-400 6-33
6-28 FM-5C/FMi 402 Motherboard Circuit Board Assembly 919-0513 6-40
FM-4C/FMi 301 Motherboard Circuit Board Assembly 919-0513-001
6-29 Wire Harness 949-0416 6-42
6-30 RF Amplifier Module Assembly, FM-5C/FM-4C 959-0412-013 6-42
6-1
TABLE 6-1. FM-5C/FM-4C & FMi-402/FMi-301 REPLACEABLE PARTS LIST INDEX
(Sheet 2 of 2)
TABLE DESCRIPTION PART NO. PAGE
6-31 RF Amplifier Module Assembly, FMi 402/FMi 301 959-0412-213 6-43

6-32 RF Amplifier Logic Circuit Board Assembly 919-0417-012 6-43
6-33 RF Amplifier Circuit Board Assembly 919-0416-213 6-46
6-34 Low Pass Filter / Directional Coupler Assembly 919-0418-011 6-47
6-35 FM-5C/FMi 402 Low-Pass Filter Circuit Board Assembly 919-0418-012 6-47
6-37 FM-5C/FMi 402 Low-Pass Filter Assembly 959-0414-001 6-48
6-39 FM-5C/FMi 402 Combiner Assembly 959-0418 6-49
FM-4C/FMi 301 Combiner Assembly 959-0418-001
6-2
TABLE 6-2. SINGLE PHASE FM-5C TRANSMITTER, 220VAC - 909-5001-204
REF. DES. DESCRIPTION PART NO. QTY.
B1 Thru B3 Fan, 10.00" Diameter, 230V ac 380-0024 3

CB1 Circuit Breaker, 70A, 250V ac, 2 Pole, E-Frame 341-0067 1
J1 Connector, Male, EDP20891-A 417-0388 1
K1 Optically Coupled Relay Circuit Board Assembly 919-0096-001 1
K2 Contactor, 2 Pole, 75A, 240V, 60 Hz, DP 341-0069 1
MOV1 Thru Metal-Oxide Varistor, B40K275, 275V, 1680 Joules 140-0021 3
MOV3
P1 Connector, Female, EDS10891-A 417-0387 1
P21 Connector Housing, 2-Pin, Male 418-0702 3
---- Air Filter, FXA 17.50"x 26.50"x.86" 407-0172 1
---- Circuit Board Guide, 6 inch 409-0026 50
---- Bulkhead Receptacle, Type N. Jack-to-Jack, UG30/U 418-0035 10
---- Contact, Pin, AMP 350967-1 417-0036 6
---- Adapter, 1 5/8 Inch EIA Flanged to Unflanged 427-0010 1
---- Power Supply, Computer Products, NFS80-7606, r15V, +5%, 540-0015 1
+24 V, 85V to 264V Operation, 80W
---- Power Supply, Pioneer Magnetics, PM33210BP-5 540-0016-001 5
---- 48D40-2F-6B-127-R, 48V Adjustable, 2 kW, Power Factor Corrected
---- FM-250C 250 Watt FM Transmitter/Exciter 909-1251-304 1
---- Control Switch Circuit Board Assembly 919-0406-101 1
---- Display Circuit Board Assembly 919-0406-102 1
---- Meter Switch Circuit Board Assembly 919-0406-103 1
---- Temperature Sensor Circuit Board Assembly 919-0406-105 1
---- RFI Filter Circuit Board Assembly 919-0562 1
---- Low-Pass Filter Input/RFI Filter Circuit Board Assembly 919-0415-003 1
---- Remote Interface Barrier Strip 919-0415-005 1
---- Power Supply Distribution Assembly 919-0415-500 1
---- Module Select Circuit Board Assembly 919-0415-501 1
---- Multiplexer Circuit Board Assembly 919-0415-502 1
---- Controller Assembly 919-0563-500 1
---- Motherboard Circuit Board Assembly 919-0513 1
---- Wire Harness 949-0416 1
---- RF Amplifier Module Assembly 959-0412-013 10
---- Low-Pass Filter Assembly 959-0414-001 1
---- Combiner Assembly 959-0418 1
---- Accessory Parts Kit, FM5C/4C 979-0413 1
---- Battery, 9V Alkaline 350-0002 1
6-3
TABLE 6-3. SINGLE PHASE FM-4C TRANSMITTER, 220VAC - 909-4001-204

MOV3
---- Air Filter, FXA 17.50"x 26.50"x.86" 407-0172 1
---- Contact, Pin, AMP 350967-1 417-0036 6
---- FM-250C 250 Watt FM Transmitter/Exciter 909-1251-304 1
---- Motherboard Circuit Board Assembly 919-0513-001 1
---- Wire Harness 949-0416 1
---- Combiner Assembly 959-0418-001 1
---- Accessory Parts Kit, FM5C/4C 979-0413 1
6-4
TABLE 6-4. THREE PHASE FM-5C TRANSMITTER, 220VAC - 909-5001-254
---- FM-5C, 5 kW Transmitter, 220V, 50/60 Hz 909-5001-204 1

DELETE PARTS
---- Circuit Breaker, 70A, 250V ac, 2 Pole, E-Frame 341-0067 1
---- Contactor, 2 Pole, 75A, 240V, 60 Hz, DP 341-0069 1
ADD PARTS
---- Fuse, AGC, 250V, 1/2 Ampere 330-0050 3
---- Contactor 341-0053 1
Coil: 208/240V ac 60 Hz or 190/220V ac 50 Hz
Contacts: 3-Pole, 600V ac, 40 Amperes
---- Circuit Breaker, 40A, 480VAC, 3 Pole, E-Frame 341-0070 1
---- AC Phase Monitor Relay, EUY C 240 270-0068 1
---- Barrier Strip, 3 Position, 4AWG 412-0049 1
---- Fuse Holder, Single 350329 Littelfuse 415-0004 3
---- Harness, Add-On, FM-5C, Three Phase, Delta, 220V 949-0416-254 1
6-5
---- FM-4C, 4 kW Transmitter, 220V, 50/60Hz 909-4001-204 1

DELETE PARTS
ADD PARTS
---- Fuse, AGC, 250V, 1/2 Ampere 330-0050 3
---- Contactor 341-0053 1
6-6
–––– FM-5C, 5 kW Transmitter, 220V, 50/60 Hz 909-5001-204 1

DELETE PARTS
ADD PARTS
---- Contactor 341-0053 1
---- Terminal, Male, 0.25 Tab 410-0064 1
---- Barrier Strip, 4 Terminal 412-0011 1
---- Add-On Harness, FM-5C, Three Phase, WYE, 380V 949-0416-384 1
6-7
---- FM-4C, 4 kW Transmitter, 220V, 50/60Hz 909-4001-204 1

DELETE PARTS
ADD PARTS
---- Contactor 341-0053 1
6-8
TABLE 6-8. SINGLE PHASE FMi-402 TRANSMITTER, 220VAC - 909-0402-404

MOV3
---- Air Filter, FXA 17.50"x 26.50"x.86" 407-0172 1
---- Contact, Pin, AMP 350967-1 417-0036 6
---- FXi 250 Watt FM Transmitter/Exciter 909-9250 1
---- XPi 10 HD Exporter 909-6027-MB3 1
---- Motherboard Circuit Board Assembly 919-0513 1
---- Wire Harness 949-0416 1
---- Combiner Assembly 959-0418 1
---- Accessory Parts Kit, FMi 402/FMi 301 979-0413-200 1
6-9
TABLE 6-9. SINGLE PHASE FMi-301 TRANSMITTER, 220VAC - 909-0301-404

MOV3
---- Air Filter, FXA 17.50"x 26.50"x.86" 407-0172 1
---- Contact, Pin, AMP 350967-1 417-0036 6
---- FXi 250 Watt FM Transmitter/Exciter 909-9250 1
---- XPi 10 HD Exporter 909-6027-MB3 1
---- Motherboard Circuit Board Assembly 919-0513-001 1
---- Wire Harness 949-0416 1
---- Combiner Assembly 959-0418-001 1
---- Accessory Parts Kit, FMi 402/FMi 301 979-0413-200 1
6-10
TABLE 6-10. THREE PHASE FMi-402 TRANSMITTER, 220VAC - 909-0402-454
---- FM 402 Transmitter, SINGLE PHASE, 220V, 50/60 Hz 909-5001-204 1

DELETE PARTS
ADD PARTS
---- Fuse, AGC, 250V, 1/2 Ampere 330-0050 3
---- Contactor 341-0053 1
6-11
---- FMi 301 Transmitter, 220V, 50/60Hz 909-0301-404 1

DELETE PARTS
ADD PARTS
---- Fuse, AGC, 250V, 1/2 Ampere 330-0050 3
---- Contactor 341-0053 1
6-12
–––– FMi 402 Transmitter, 220V, 50/60 Hz 909-0402-404 1

DELETE PARTS
ADD PARTS
---- Contactor 341-0053 1
6-13
---- FMi 301 Transmitter, 220V, 50/60Hz 909-0301-404 1

DELETE PARTS
ADD PARTS
---- Contactor 341-0053 1
6-14
TABLE 6-14. OPTICALLY COUPLED RELAY CIRCUIT BOARD ASSEMBLY - 919-0096-001
---- Optically Coupled Relay Circuit Board Assembly 919-0096 1

DELETE PARTS
C3 Capacitor, Ceramic Disc, 0.1 uF, 600V 000-1051 1
R2 Resistor, 560 Ohm r5%, 1/2W 110-5633 1
TABLE 6-15. OPTICALLY COUPLED RELAY CIRCUIT BOARD ASSEMBLY - 919-0096
C1 Capacitor, Ceramic, 0.001 uF, 1 kV 002-1034 1

C2 Capacitor, Electrolytic, 47 uF, 35V 020-4773 1
C3 Capacitor, Ceramic Disc, 0.1 uF, 600V 000-1051 1
D1 Diode, 1N4005, Silicon, 600V @ 1 Ampere 203-4005 1
D2 Diode, Zener, 1N5359, 24V r10%, 5W 200-5359 1
D5 Bridge Rectifier, MDA970A3, 4 Amps, 50-200V 239-0003 1
E1 thru E5 Terminal, Male Disconnect 410-0025 5
F1, F2 Fuse, 3 Amps, 250V, Printed Circuit Board Mount 330-0055 2
K1 Relay, Printed Circuit Board Mount 270-0054 1
Coil: 24V dc, 660 Ohm r10%
Contacts: SPST-NO, 0.5 to 15A @ 12 to 240V ac Resistance
MOV1 Varistor, 27V, V27ZA60 140-0023 1
R1 Resistor, 2 k Ohm r3%, 10W, W/W 130-2032 1
R2 Resistor, 560 Ohm r5%, 1/2W 110-5633 1
R3 Resistor, 820 Ohm r5%, 1/2W 110-8233 1
R4 Resistor, 51.1 Ohm r1%, 1/4W 103-5112 1
R5 Resistor, 2 k Ohm r3%, 10W, W/W 130-2032 1
U1 Integrated Circuit, 4N33, Optical Isolator, NPN Photo 229-0033 1
Transistor/Infared Emitting Diode Type, 1500V Isolation,
Response: 30 kHz Maximum, Current: 50 mA Maximum,
6-Pin DIP
XU1 Socket, 6-Pin DIP 417-0600 1
---- Cover, Dust Relay, 35C620A 270-0054-001 1
---- Blank, Optically Coupled Relay Circuit Board 519-0096 1
6-15
TABLE 6-16. CONTROL SWITCH CIRCUIT BOARD ASSEMBLY - 919-0406-101
C8 thru Capacitor, Mica, 470 pF r1%, 500V 040-4721 7

C14
C15, C16 Capacitor, Monolythic Ceramic, 0.1 uF 20%, 50V 003-1054 2
C17 Capacitor, Mica, 470 pF r1%, 500V 040-4721 1
D6, D12, D13, Diode, 1N4005, Silicon, 600V @ 1 Ampere 203-4005 5
D15, D16
DS1 Switch, PB, Momentary, LED Illuminated, Green 340-0140 1
J1 Receptacle, Male, 3-Pin In-line 417-0003 1
J101 Receptacle, 26-Pin Dual In-line 418-2602 1
K1 Relay, 270-0058 1
Coil: 12V dc
Contact: DPDT, 120V ac @ 1 Ampere
P1 Jumper, Programmable, 2-Pin 340-0004 1
Q1 thru Q3 Transistor, 2N7000, Mosfet, TO-92 Case 210-7000 3
R8 Resistor, 3.3 Meg Ohm r5%, 1/4W 100-3373 1
R9, R10 Resistor, 100 k Ohm r1%, 1/4W 103-1062 2
R12 Resistor, 3.01 k Ohm r1%, 1/4W 103-3014 1
R13 Resistor, 100 k Ohm r1%, 1/4W 103-1062 1
R20 thru Resistor, 715 Ohm r1%, 1/4W 100-7132 3
R22
R28, R29 Resistor, 715 Ohm r1%, 1/4W 100-7132 2
S3 Switch, PB, Momentary, LED Illuminated, Green 340-0140 1
S4, S5 Switch, Pushbutton, Momentary, LED Illuminated, Red 340-0143 2
S6, S7 Switch, Pushbutton, Momentary, LED Illuminated, Yellow 340-0139 2
U3 thru Integrated Circuit, H11AA1, Optical Isolator, AC Input 229-0111 7
U9 NPN Phototransistor, 6-Pin Dual In-Line Package.
U10, U11 Integrated Circuit, MC14106BP, Hex Schmitt Trigger, 14-Pin 228-4106 2
U12, U13 Integrated Circuit, ULN2004, 7 NPN Darlington Driver Pack, 226-2004 2
16-Pin DIP
U14 Integrated Circuit, H11AA1, Optical Isolator, AC Input 229-0111 1
NPN Phototransistor, 6-Pin Dual In-Line Package.
XU3 thru XU9 Socket, 6-Pin DIP 417-0600 7
XU10, XU11 Socket, 14-Pin DIP 417-1404 2
XU12, UX13 Socket, 16-Pin DIP 417-1604 2
---- Blank Control Switch Circuit Board Assembly 519-0406-101 1
6-16
TABLE 6-17. DISPLAY CIRCUIT BOARD ASSEMBLY - 919-0406-102
C201 Capacitor, Monolythic Ceramic, 0.1 uF r20%, 50V 003-1054 1

C206 Capacitor, Polyester Film, 0.033 uF r10%, 200V 030-3353 1
C208 thru Capacitor, Monolythic Ceramic, 0.1 uF r20%, 50V 003-1054 6
C213
D1 Integrated Circuit, LM3362Z-2.5, Precision Voltage Reference, 229-0336 1
2.5V r4%, -0 to +70qC, TO-92 Case
DS201 Display, FE0502W-DU LCD 4 Digit, 0.7" High 320-0021 1
J201 Connector, Printed Circuit Board Mounting, 10-PIN (Dual 5) 418-1003 1
R201 Resistor, 1 Meg Ohm r1%, 1/4W 103-1007 1
R203 Potentiometer, 2 k Ohm r10%, 1/2W 178-2044 1
R207 thru Resistor, 100 k Ohm r1%, 1/4W 103-1062 3
R209
U201 Integrated Circuit, ICL7136CPL, 3-1/2-Digit A/D Converter, 220-7136 1
U202 Integrated Circuit, MC14070BCP, Quad Exclusive OR Gate, CMOS 228-4071 1
14-Pin DIP
---- Blank Display Circuit Board 519-0406-102 1
TABLE 6-18. METER SWITCH CIRCUIT BOARD ASSEMBLY - 919-0406-103

R304
S301 Switch, 8 Section, 2PDT Pushbutton, Black/Yellow Indication 340-0124 1
S302 Switch, Toggle, SPDT, 5A @ 125V ac & 28V dc 348-0123 1
---- Blank, Meter Switch Circuit Board 519-0406-103 1
6-17
TABLE 6-19. TEMPERATURE SENSOR CIRCUIT BOARD ASSEMBLY - 919-0406-105

J501 Socket, 4-Pin 418-0255 1
U501 Integrated Circuit, LM35DZ, Celsius Temperature Sensor, 220-0035 1
TO-92 Case
---- Blank, Temperature Sensor Circuit Board 519-0406-105 1
TABLE 6-20. RFI FILTER CIRCUIT BOARD ASSEMBLY - 919-0562

(Sheet 1 of 2)

C218
C228
D1 thru D8 Bidirectional Zener Transient Voltage Suppressor, Motorola SA13CA, 201-0039 8
+/-13V
D9 thru D17 Bidirectional Zener Transient Voltage Suppressor, Motorola SA18C, 201-0040 9
Or SA18CA, +/-18V
D18 Bidirectional Zener Transient Voltage Suppressor, Motorola SA13CA, 201-0039 1
+/-13V
D19 thru D25 Bidirectional Zener Transient Voltage Suppressor, Motorola SA18C 201-0040 7
Or SA18CA, +/-18V
FL1 thru EMI Suppression Filter, 10,000 pF r30%, 3-Pin 411-0001 25
FL25
J19 Connector, PC 26 Positions, ANSLEY 609-2624 418-2602 1
J20 Receptacle, 25-Pin 417-2500 1
J21 Connector, 2-Pin 417-0700 1
J22 Socket, 4-Pin 418-0255 1
R201 thru Resistor, 51.1 Ohm r1%, 1/4W 103-5112 11
R211
R217
R220
R223
R224, R225 Resistor, Power, 47 Ohm r5%, 3 1/4W, W/W 132-4721 2
R226, R227 Resistor, 51.1 Ohm r1%, 1/4W 103-5112 2
6-18
TABLE 6-20. RFI FILTER CIRCUIT BOARD ASSEMBLY - 919-0435
(Sheet 2 of 2)

---- Blank, RFI Filter Board Circuit Board 519-0435 1
TABLE 6-21. LOW-PASS FILTER INPUT/RFI FILTER CIRCUIT BOARD ASSEMBLY -

919-0415-003
C301, C302 Capacitor, Mica, 390 pF r5%, 100V 042-3922 2

J301 Socket, 4-Pin 418-0255 1
J302 Receptacle, 6-Pin 417-0677 1
---- Blank, Low Pass Filter Input/RFI Filter Circuit Board 519-0415-003 1
6-19
TABLE 6-22. REMOTE INTERFACE BARRIER STRIP CIRCUIT BOARD ASSEMBLY -
919-0415-005

P20 Plug, 205737-1 AMP, Printed Circuit Board Mount, 25-PIN 417-2501 1
TB2 Barrier Strip, 30 Position, BEAU61-5-30-50 412-3000 1
---- Label, Remote Interface Circuit Board FM-5C 594-0415 1
TABLE 6-23. FM-5C/FMi 402 POWER SUPPLY DISTRIBUTION ASSEMBLY - 919-0415-500

FM-4C/FMi 301 POWER SUPPLY DISTRIBUTION ASSEMBLY - 919-0415-400
For 919-0415-500 ASSEMBLY

C401 thru Capacitor, Monolythic Ceramic, .47 uF r10%, 50V 003-4743 7
C407

C401 thru Capacitor, Monolythic Ceramic, .47 uF r10%, 50V 003-4743 4
C404
C406, C408 Capacitor, Monolythic Ceramic, .47 uF r10%, 50V 003-4743 2

J401 thru Connector For Pioneer Power Supplies, 29-Pin 417-2900 5
J405

J401 thru Connector For Pioneer Power Supplies, 29-Pin 417-2900 4
J404
J406 Connector, 20-Pin, MR Series, PCB 417-0230 1

R402 thru Resistor, 10 Ohm r1%,1/4W 103-1021 5
R406

R402 thru Resistor, 10 Ohm r1%,1/4W 103-1021 4
R405
TP401 thru Terminal, Test Point, Oval, Red 413-0106 4

TP404
---- Busbar, Power Supply, FM-5C 471-5031 2
---- Blank Power Supply Motherboard, Main, FM-4C/FM-5C 519-0415-504 1
---- Blank, Power Supply Motherboard, SUB, FM-4C/FM-5C 519-0415-505 1
6-20
TABLE 6-24. FM-5C/FMi-402 MODULE SELECT CIRCUIT BOARD ASSY - 919-0415-501
FM-4C/FMi-301 MODULE SELECT CIRCUIT BOARD ASSEMBLY - 919-0415-401
(Sheet 1 of 2)

C1 thru C3 Capacitor, Monolythic Ceramic, 0.1 uF r20%, 50V 003-1054 3

C2, C3 Capacitor, Monolythic Ceramic, 0.1 uF r20%, 50V 003-1054 2

DS1 thru DS5 Led, Red Diffused Chimney, P424, 70 mW, 20 mA, 4V 320-0037 5

DS1 thru DS4 Led, Red Diffused Chimney, P424, 70 mW, 20 mA, 4V 320-0037 4
DS6, DS7 LED, HD1107G, Green, 7-Segment High Efficiency Common Cathode 320-0022 2
J1 Connector, Header, 16-Pin, Printed Circuit Board Mount 417-1606 1
Q1 Transistor, 2N27000, FET, N-Channel, TO-92 Case 210-7000 1
R1 thru R20 Resistor, 1 k Ohm r5%, 1/2W 110-1043 20



S1 Switch, Pushbutton, Momentary, LED Illuminated, Yellow 340-0139 1

TP1 thru TP3 Terminal, Test Point, Oval, Red 413-0106 3

TP1, TP3 Terminal, Test Point, Oval, Red 413-0106 2

U1, U2 Integrated Circuit, MC14511BCP, Seven Segment Driver 220-4511 2
6-21
TABLE 6-24. FM-5C/FMi-402 MODULE SELECT CIRCUIT BOARD ASSY - 919-0415-501
FM-4C/FMi-301 MODULE SELECT CIRCUIT BOARD ASSEMBLY - 919-0415-401
(Sheet 2 of 2)

U2 Integrated Circuit, MC14511BCP, Seven Segment Driver 220-4511 1
U3 Integrated Circuit, CD4081B, Quad 2-Input AND Gate, CMOS, 225-0008 1

14-Pin DIP


---- Blank Module Select Circuit Board 519-0415-501 1
TABLE 6-25. FM-5C/FMi-402 MULTIPLEXER CIRCUIT BOARD ASSY - 919-0415-502

FM-4C/FMi-301 MULTIPLEXER CIRCUIT BOARD ASSEMBLY - 919-0415-402
(Sheet 1 of 4)

C208
C218
C219 Capacitor, Monolythic Ceramic, .47 uF r10% 50V 003-4743 1
C221, C222 Capacitor, Electrolytic, 100 uF, 35V 020-1084 2
C233
C234 Capacitor, Electrolytic, 100 uF r10%, 35V 023-1085 1
D201 thru Diode, 1N4148, Silicon, 75V @ 0.3 Amperes 203-4148 34
D234

D208
D218
D232
6-22
(Sheet 2 of 4)
D235, D236 Diode, 1N4148, Silicon, 75V @ 0.3 Amperes 203-4148 2

J201 thru Connector, Printed Circuit Board Mounting, 10-PIN(DUAL 5) 418-1003 10
J210

J201 thru Connector, Printed Circuit Board Mounting, 10-PIN(DUAL 5) 418-1003 8
J208
J211 Connector, Header, 34-Pin, Male Printed Circuit Board Mount 417-3402 1
J212 Connector, Header, 16-Pin, Printed Circuit Board Mount 417-1606 1
J213 Receptacle, Male, 3-Pin In-line 417-0003 1
J214 Connector, Header, 2-Pin 417-4004 1
P213, P214 Jumper, Programmable, 2-Pin 340-0004 2
Q201 Transistor, 2N7000, Mosfet, TO-92 Case 210-7000 1
R201, R202 Resistor Network, 10 k Ohm r2%, 1W Resistors, 8-Pin Single 226-1051 2
In-Line Package
R216
R214

R223 Resistor, 634 Ohm r1%, 1/4W 103-6343 1
R228 Resistor, 10 Ohm r1%, 1/4W 103-1021 1
R229 Resistor, 10 M Ohm r5%, 1/4W 100-1083 1
R230 Resistor, 10 Ohm r1%, 1/4W 103-1021 1
6-23
(Sheet 3 of 4)

R232 Resistor, 10 Ohm r1%, 1/4W 103-1021 1
R234 Resistor, 10 Ohm r1%, 1/4W 103-1021 1
R239
R240, R241 Resistor Network, 7-6.8 k Ohm 1% Resistors, 8-Pin Single 226-6800 2
In-Line Package
R247


R271 thru Resistor, 1 M Ohm r1%, 1/4W 103-1007 10
R280
R271 thru Resistor, 1 M Ohm r1%, 1/4W 103-1007 8
R278
R282 Resistor, 5.1 M Ohm r5%, 1/4W 100-5173 1
6-24
(Sheet 4 of 4)
R283 Resistor, 100 Ohm r1%, 1/4W 100-1031 1

U201 thru Integrated Circuit, MC14067, 16 Channel Analog Multiplexer 228-4067 4
U204
U205 Integrated Circuit, TLO74CN, Quad JFET-Input Operational 221-0074 1
Amplifier, 14-Pin DIP
U206 Integrated Circuit, MC14082B, Dual, 4-Input, And Gate 220-4082 1
U207 Integrated Circuit, MC14516B, Binary Up/Down Counter, CMOS, 228-4516 1
16-Pin DIP
U208 Integrated Circuit, ULN2004, 7 NPN Darlington Driver Pack, 226-2004 1
16-Pin DIP
U209 Integrated Circuit, LM324N, Quad Operational Amplifier, 14-Pin DIP 220-0324 1
16-Pin DIP
U211 thru Integrated Circuit, TLO74CN, Quad JFET-Input Operational 221-0074 3
U213 Amplifier, 14-Pin DIP
XU201 thru Socket, 24-Pin DIP 417-2404 4
XU204
XU205, Socket, 14-Pin DIP 417-1404 2
XU206
XU207, Socket, 16-Pin DIP 417-1604 2
XU208
XU213
---- Blank, Multiplexer Circuit Board 519-0415-502 1
6-25
TABLE 6-26. FM-5C/FMi-402 CONTROLLER CIRCUIT BOARD - 919-0563-500
(Sheet 1 of 7)

C36 Capacitor, Poly, 0.33uF r10%, 63V 030-3300 1
C50,C51 Capacitor, Electrolytic, 1 uF, 50V 024-1064 1
C52,C53 Capacitor, Monolythic Ceramic, 0.1 uF r20%, 50V 003-1054 2
C59 thru C61 Capacitor, Mica, 330 pF rq%, 500V 042-3322 3
C73,C74 Capacitor, Monolythic Ceramic, 0.47uF, r10%, 50V 003-4743 2
D1, D2 Diode, Zener, 1N4733A, 5.1V r5%, 1W 200-4733 2
D3 Diode, 1N4148, Silicon, 75V @ 0.3 Amperes 203-4148 1
D4, D5 Diode, 1N4005, Silicon, 600V @ 1 Ampere 203-4005 2
D8 Diode, Volt Ref, LM336Z-2.5 229-0336 1
D9 thru D11 Diode, 1N4148, Silicon, 75V @ 0.3 Amperes 203-4148 3
D21 Diode, Zener, 1N4733A, 5.1V r5%, 1W 200-4733 1
D42 thru D46 Diode, Schotky, 20V, 1N5817 200-0019 5
J701 Connector, Printed Circuit Board Mounting, 10-PIN(DUAL 5) 418-1003 1
J703 Connector, Header, 34-Pin, Male, Printed Circuit Board Mount 417-3402 1
6-26
(Sheet 2 of 7)
J704 Socket, 4-Pin 418-0255 1

J705 Connector, Printed Circuit Board, MR, Male, 24-Pin 417-2401 1
J706, J707 Receptacle, 26-Pin Dual In-line 418-2602 2
J710 thru Receptacle, Male, 3-Pin In-line 417-0003 8
J717
J722
J723 Receptacle, Header, Dual In-Line 8-Pin 417-1603 1
J725
J726 Connector, 2 Pin 417-0700 1
J727, J728 Receptacle, Header, Dual In-Line 8-Pin 417-1603 2
P710 thru Jumper, Programmable, 2-Pin 340-0004 8
P717
P725
Q1 thru Q10 Transistor, 2N27000, FET, N-Channel, TO-92 Case 210-7000 10
Q16, Q17 Field Effect Transistor, J270, P-Channel J-FET, TO-92 Case 210-0270 2
R1 Resistor, 470 Ohm r5%, 1/2W 110-4733 1
R13 Resistor Network, 8-10 k Ohm r1%, 1/4W, 16-Pin DIP 226-1055 1
6-27
(Sheet 3 of 7)

R49 Potentiometer, 10 k Ohm, 12 Turn 177-1058 1
R62 Resistor, 499 Ohm r5%, 1/4W 103-4993 1
6-28
(Sheet 4 of 7)

R94 Potentiometer, 5 k 177-5044 1
R104, R105 Resistor, 1 Meg Ohm r1%, 1/4W 103-1007 2
R108 Resistor, 715 Ohm r1%, 1/4W 100-7132 1
R118 Resistor, 576 Ohm r1%, 1/4W 103-5761 1
R121 Resistor, 34k Ohm r1%, 1/4W 103-3405 1
R133 thru Potentiometer, 10 k Ohm r10%, 1/2W 177-1054 3
R135
R137 Resistor, 4.02 k Ohm, r1%, 1/4W 103-4024 1
6-29
(Sheet 5 of 7)

R142 Resistor, 100 Ohm r1%, 1/4W 100-1031 1
R144 Resistor, 100 Ohm r1%, 1/4W 100-1031 1
R145, R146 Potentiometer, 5 k Ohm, 20 Turn 178-5045 2
R151 thru Resistor, 82.5 k Ohm r1%, 1/4W 103-8255 5
R155
R156 Resistor, 4.99 k Ohmr1%, 1/4W 100-5041 1
R162 Resistor, 140 Ohm r1%, 1/4W 103-1403 1
R163,R164 Resistor, 100 k Ohm r1%, 1/4W 103-1062 2
R178 Resistor, 10 Ohm r5%, 1/4W 100-1024 1
R187
R192
R203 Resistor, 1 Ohm r5%, 1/4W 100-1013 1
R205 Resistor, 1 Ohm r5%, 1/4W 100-1013 1
6-30
(Sheet 6 of 7)

R214
R222 Resistor, 51.1 Ohm r1%, 1/4W 103-5112 1
R226 Resistor, 51.1 Ohm r1%, 1/4W 103-5112 1
RN1, RN2 Resistor, Network, 100 K, 8-Pin Single-In-Line Package 226-1061 2
TP1 thru TP18 Terminal, Test Point, Oval Red 413-0106 17
U1 Integrated Circuit, Low Power OP Amp, 17 uA, 8-Pin DIP 220-0078 1
U2 thru U6 Integrated Circuit, TLO74CN, Quad JFET-Input Operational 221-0074 5
U7 Integrated Circuit, MC14106BCP, Hex Schmitt Trigger, 14-Pin 228-4106 1
U8 Integrated Circuit, MC14011BCP, Quad 2-Input NAND Gate, CMOS, 228-4011 1
14-Pin DIP
U9 thru U11 Integrated Circuit, MC14516B, Binary Up/Down Counter, CMOS, 228-4516 3
16-Pin DIP
U12, U13 Integrated Circuit, MC14503B, Hex Non-Inverting 3-State Buffer, 228-4503 2
CMOS, 16-Pin DIP
U14, U15 Integrated Circuit, 14505, Hex Level Shifter, TTL to CMOS, 228-4504 2
16-Pin DIP
U16 Integrated Circuit, AD565AJ, 12-Bit Digital/Analog Converter, 220-0565 1
24-Pin DIP
U17 Integrated Circuit, NE555N, Timer, 8-Pin DIP 229-0555 1
16-Pin DIP
U22 Integrated Circuit, LM339AN, Quad Comparator, 14-Pin DIP 221-0339 1
Response: 30 kHz Maximum, Current: 50 mA Maximum, 6-Pin DIP
U25 thru U27 Integrated Circuit, CA3183E, Five Transistor Array, NPN, 220-3183 3
16-Pin DIP
6-31
(Sheet 7 of 7)
U28, U29 Integrated Circuit, CD4066BE, Quad Bilateral Switch, CMOS, 225-0004 2
14-Pin DIP
U30, U31 Integrated Circuit, LM339AN, Quad Comparator, 14-Pin DIP 221-0339 2
U32, U33 Voltage Comparator, LM393N 221-0393 2
U34 Voltage Regulator, 7805, r5V, TO-92 Package 227-7805-1 1
U35 Integrated Circuit, Voltage Regulator, -12V, MC79L05, T0-92 CASE 227-7905-A 1
U36 Operational Amplifier, TL072CP 221-0072 1
XBT1 Battery Holder, 9 Volt Rectangular 415-0002 1
XR13 Socket, 16-Pin DIP 417-1604 1
XU15
XU27
XU31
XU32, XU33, Socket, 8-Pin DIP 417-0804 1
XU36
---- Blank, Controller Circuit Board 519-0563 1
6-32
(Sheet 1 of 7)

C36 Capacitor, Poly, 0.33uF r10%, 63V 030-3300 1
C50,C51 Capacitor, Electrolytic, 1 uF, 50V 024-1064 1
C52,C53 Capacitor, Monolythic Ceramic, 0.1 uF r20%, 50V 003-1054 2
C59 thru C61 Capacitor, Mica, 330 pF rq%, 500V 042-3322 3
C73,C74 Capacitor, Monolythic Ceramic, 0.47uF, r10%, 50V 003-4743 2
D1, D2 Diode, Zener, 1N4733A, 5.1V r5%, 1W 200-4733 2
D4, D5 Diode, 1N4005, Silicon, 600V @ 1 Ampere 203-4005 2
D8 Diode, Volt Ref, LM336Z-2.5 229-0336 1
D43 thru D46 Diode, Schotky, 20V, 1N5817 200-0019 4
J701 Connector, Printed Circuit Board Mounting, 10-PIN(DUAL 5) 418-1003 1
6-33
(Sheet 2 of 7)
J703 Connector, Header, 34-Pin, Male, Printed Circuit Board Mount 417-3402 1
J704 Socket, 4-Pin 418-0255 1
J705 Connector, Printed Circuit Board, MR, Male, 24-Pin 417-2401 1
J706, J707 Receptacle, 26-Pin Dual In-line 418-2602 2
J717
J722
J723 Receptacle, Header, Dual In-Line 8-Pin 417-1603 1
J724, J725 Receptacle, Male, 3-Pin In-line 417-0003 2
J726 Connector, 2 Pin 417-0700 1
J727, J728 Connector, 26-Pin 417-2600 2
P717
P725
Q1 thru Q10 Transistor, 2N27000, FET, N-Channel, TO-92 Case 210-7000 10
Q16, Q17 Field Effect Transistor, J270, P-Channel J-FET, TO-92 Case 210-0270 2
R1 Resistor, 470 Ohm r5%, 1/2W 110-4733 1
R13 Resistor Network, 8-10 k Ohm r1%, 1/4W, 16-Pin DIP 226-1055 1
6-34
(Sheet 3 of 7)

R62 Resistor, 499 Ohm r5%, 1/4W 103-4993 1
6-35
(Sheet 4 of 7)

R94 Potentiometer, 5 k 177-5044 1
R108 Resistor, 715 Ohm r1%, 1/4W 100-7132 1
R118 Resistor, 576 Ohm r1%, 1/4W 103-5761 1
R121 Resistor, 34k Ohm r1%, 1/4W 103-3405 1
R133 thru Potentiometer, 10 k Ohm r10%, 1/2W 177-1054 3
R135
6-36
(Sheet 5 of 7)

R142 Resistor, 100 Ohm r1%, 1/4W 100-1031 1
R144 Resistor, 100 Ohm r1%, 1/4W 100-1031 1
R145, R146 Potentiometer, 5 k Ohm, 20 Turn 178-5045 2
R154
R156 Resistor, 4.99 k Ohmr1%, 1/4W 100-5041 1
R162 Resistor, 140 Ohm r1%, 1/4W 103-1403 1
R163,R164 Resistor, 100 k Ohm r1%, 1/4W 103-1062 2
R178 Resistor, 10 Ohm r5%, 1/4W 100-1024 1
R186
R191
R203 Resistor, 1 Ohm r5%, 1/4W 100-1013 1
R205 Resistor, 1 Ohm r5%, 1/4W 100-1013 1
6-37
(Sheet 6 of 7)

R214
R222 Resistor, 51.1 Ohm r1%, 1/4W 103-5112 1
R226 Resistor, 51.1 Ohm r1%, 1/4W 103-5112 1
RN1, RN2 Resistor, Network, 100 K, 8-Pin Single-In-Line Package 226-1061 2
TP1 thru TP18 Terminal, Test Point, Oval Red 413-0106 17
U1 Integrated Circuit, Low Power OP Amp, 17 uA, 8-Pin DIP 220-0078 1
U2 thru U6 Integrated Circuit, TLO74CN, Quad JFET-Input Operational 221-0074 5
U7 Integrated Circuit, MC14106BCP, Hex Schmitt Trigger, 14-Pin 228-4106 1
U8 Integrated Circuit, MC14011BCP, Quad 2-Input NAND Gate, CMOS, 228-4011 1
14-Pin DIP
U9 thru U11 Integrated Circuit, MC14516B, Binary Up/Down Counter, CMOS, 228-4516 3
16-Pin DIP
U12, U13 Integrated Circuit, MC14503B, Hex Non-Inverting 3-State Buffer, 228-4503 2
CMOS, 16-Pin DIP
U14, U15 Integrated Circuit, 14505, Hex Level Shifter, TTL to CMOS, 228-4504 2
16-Pin DIP
U16 Integrated Circuit, AD565AJ, 12-Bit Digital/Analog Converter, 220-0565 1
24-Pin DIP
16-Pin DIP
U22 Integrated Circuit, LM339AN, Quad Comparator, 14-Pin DIP 221-0339 1
Response: 30 kHz Maximum, Current: 50 mA Maximum, 6-Pin DIP
U25 thru U27 Integrated Circuit, CA3183E, Five Transistor Array, NPN, 220-3183 3
16-Pin DIP
6-38
(Sheet 7 of 7)
U28, U29 Integrated Circuit, CD4066BE, Quad Bilateral Switch, CMOS, 225-0004 2
14-Pin DIP
U30, U31 Integrated Circuit, LM339AN, Quad Comparator, 14-Pin DIP 221-0339 2
U34 Voltage Regulator, 7805, r5V, TO-92 Package 227-7805-1 1
U35 Integrated Circuit, Voltage Regulator, -12V, MC79L05, T0-92 CASE 227-7905-A 1
U36 Operational Amplifier, TL072CP 221-0072 1
XBT1 Battery Holder, 9 Volt Rectangular 415-0002 1
XR13 Socket, 16-Pin DIP 417-1604 1
XU15
XU27
XU31
---- Blank, Controller Circuit Board 519-0563 1
6-39
TABLE 6-28. FM-5C/FMi-402 MOTHERBOARD CIRCUIT BOARD ASSEMBLY - 919-0513
FM-4C/FMi-301 MOTHERBOARD ASSEMBLY - 919-0513-001
(Sheet 1 of 2)
C601 Capacitor, Mylar, 0.1 uF r10%, 100V 030-1053 1

C621 Capacitor, Ceramic Chip, 68 pF r5%, 500V 009-6813 1

C622 Capacitor, Trimmer, Ceramic, 5.5-18 pF, NPO, 350V 096-0011 1
For 919-0513 ASSEMBLY

C623 thru Capacitor, Ceramic Chip, 56 pF r5%, 500V 009-5613 10
C632
C630
J601 thru Connector, Printed Circuit Board Mounting, 10-Pin (Dual 5) 418-1003 10
J610
J601 thru Connector, Printed Circuit Board Mounting, 10-Pin (Dual 5) 418-1003 8
J608
J611 thru Connector, PCB D, RF/Logic/Power 417-0322 10
J620
6-40
TABLE 6-28. FM-5C/FMi-402 MOTHERBOARD CIRCUIT BOARD ASSEMBLY - 919-0513
FM-4C/FMi-301 MOTHERBOARD ASSEMBLY - 919-0513-001
(Sheet 2 of 2)

J611 thru Connector, PCB D, RF/Logic/Power 417-0322 8
J618
R602 Resistor, .005 Ohm r3%, 5W, 139-0007 1
R606 Resistor, .005 Ohm r3%, 5W 139-0007 1
R610 Resistor, .005 Ohm r3%, 5W 139-0007 1
R614 Resistor, .005 Ohm r3%, 5W 139-0007 1
R618 Resistor, .005 Ohm r3%, 5W 139-0007 1
R622 Resistor, .005 Ohm r3%, 5W 139-0007 1
R626 Resistor, .005 Ohm r3%, 5W 139-0007 1
R630 Resistor, .005 Ohm r3%, 5W 139-0007 1

R634 Resistor, .005 Ohm r3%, 5W 139-0007 1
R638 Resistor, .005 Ohm r3%, 5W 139-0007 1
R641 thru Resistor, 50 Ohm r5% , 40W, Flange Mount 131-5029 10
R650
R641 thru Resistor, 50 Ohm r5% , 40W, Flange Mount 131-5029 8
R648
---- Blank, Motherboard, Main, Circuit Board 519-0513 1

---- Blank, Motherboard, SUB, Circuit Board 519-0513-001 1
---- Blank, Motherboard Input Circuit Board 519-0513-002 1
---- Motherboard Cable Assembly 949-0418 1
6-41
TABLE 6-29. WIRE HARNESS - 949-0416
---- Wire Harness 949-0416 1
TABLE 6-30. RF AMPLIFIER MODULE ASSEMBLY - 959-0412-013
C13, C16, Capacitor, Ceramic Chip, 470 pF r5%, 200V 009-4723 4

C27, C30
C28, C29
C41, C42 Capacitor, Ceramic Chip, 15 pF r5%, 500V 009-1513 2
Q1, Q2 Transistor, RF Power, SD2932 210-2932 2
R1 Resistor, 50 Ohm r1%, 20W 132-5002 1
R201 Resistor, 50 Ohm, 250W 131-5030 1
T1, T2 Transformer, RF Amplifier Output 370-0052 2
---- RF Amplifier Module Logic Circuit Board Assembly 919-0417-012 1
---- RF Amplifier Circuit Board Assembly 919-0416-213 1
---- RF Amplifier Module Low Pass Filter/Directional Coupler Circuit 919-0418-011 1
Board Assembly
---- RF Amplifier Module Low-Pass Filter Circuit Board Assembly 919-0418-002 1
---- Blank, Module Combiner Shield Circuit Board 519-0419 1
---- Blank, Module Combiner Circuit Board 519-0420 2
6-42
TABLE 6-31. RF AMPLIFIER MODULE ASSEMBLY - 959-0412-213

C27, C30
C28, C29
Q1, Q2 Transistor, RF Power, SD2932 210-2932 2
R1 Resistor, 50 Ohm r1%, 20W 132-5002 1
R201 Resistor, 50 Ohm, 250W 131-5030 1
T1, T2 Transformer, RF Amplifier Output 370-0052 2
---- RF Amplifier Module Logic Circuit Board Assembly 919-0417-012 1
---- RF Amplifier Circuit Board Assembly 919-0416-213 1
---- RF Amplifier Module Low Pass Filter/Directional Coupler Circuit 919-0418-011 1
Board Assembly
---- RF Amplifier Module Low-Pass Filter Circuit Board Assembly 919-0418-002 1
---- Blank, Module Combiner Shield Circuit Board 519-0419 1
---- Blank, Module Combiner Circuit Board 519-0420 2
TABLE 6-32. RF AMPLIFIER LOGIC CIRCUIT BOARD ASSEMBLY - 919-0417-012

(Sheet 1 of 3)
C1 Capacitor, Ceramic Disc, 20 pF r10%, 1kV 002-2013 1

C5, C6 Capacitor, Monolythic Ceramic, .047 uF r5% 50V 003-4733 2
C10
C12 thru Capacitor, Ceramic Disc, 20 pF r10%, 1kV 002-2013 3
C14
C16 thru Capacitor, Electrolytic, 10 uF, 50V 023-1076 3
C18
C25, C26 Capacitor, Ceramic Disc, 20 pF r10%, 1kV 002-2013 2
D17 Diode, Zener, 1N4742A, 12V r5%, 1W 200-4742 1
D21
D22, D23 Diode, HP5082-2800, High Voltage, Schottky Barrier Type, 201-2800 2
70V, 15 mA
6-43
(Sheet 2 of 3)
P801 Receptacle, 40-Pin Dual In-line 417-4041 1

Q1, Q2, Q5 Transistor, MPSA06, NPN, TO-92 Case 211-0006 5
thru Q7
Q8 Transistor, 2N3906, PNP, Silicon, TO-92 Case 210-3906 1
R1 Resistor Network, 5 k Ohm r1%, 1/4W, 16-Pin DIP 226-0500 1
R2 Resistor, 499 k Ohm, r1%, 1/4W 103-4996 1
R5 Potentiometer, 10 k Ohm r10% 1/2W 178-1054 1
R6 thru R8 Resistor, 22.1 k Ohm r1%, 1/4W 103-2211 3
R11 Potentiometer, 200 Ohm r10%, 1/2W 177-2035 1
R19 Resistor, 240 Ohm r1%, 1/4W 103-2431 1
R31, R32 Resistor, 499 k Ohm, r1%, 1/4W 103-4996 2
R35 Resistor Network, 8-22 k Ohm 1/4W Resistors, 16-Pin DIP 226-2250 1
R44, R45 Resistor, 22.1 k Ohm r1%, 1/4W 103-2211 2
6-44
(Sheet 3 of 3)

R67 Resistor, 2.2 M Ohm r5%, 1/4W 100-2273 1
TP1, TP2, Terminal, Test Point, Oval Red 413-0106 3
TP3
U1 Integrated Circuit, MPQ3799, Quad Amplifier, PNP, 14-Pin DIP 220-3799 1
U2 thru Integrated Circuit, TLO74CN, Quad JFET-Input Operational 221-0074 5
U6 Amplifier, 14-Pin DIP
U7 Integrated Circuit, LM317LZ, Adjustable Positive Voltage 220-0317 1
Regulator, 1.2 to 37V @ 0.1 Ampere, TO-92 Case
---- Blank RF Amplifier Logic Circuit Board 519-0417-012 1
6-45
TABLE 6-33. RF AMPLIFIER CIRCUIT BOARD ASSEMBLY - 919-0416-213

C3, C4 Capacitor, Ceramic, Variable, 4 to 25 pF, 100V 090-0004 2
C5, C8 Capacitor, Ceramic Chip, 470 uF, 63V 013-4784 2
C10 Capacitor, Ceramic, Variable, 4 to 25 pF, 100V 090-0004 1
C17 Capacitor, Mica, Feedthru, 1000 pF r10%, 350V 046-1030 1
C18 thru C21 Capacitor, Ceramic Chip, 1000 pF r5%, 100V 009-1032 2
C24 Capacitor, Ceramic, Variable, 4 to 25 pF, 100V 090-0004 1
C31 Capacitor, Mica, Feedthru, 1000 pFr10%, 350V 046-1030 1
C43 Capacitor, Ceramic Chip, 1000 pFr5%, 100V 009-1032 1
D1, D2 Diode, Switching, MMBD914LT1, TO-236AB 204-0914 2
D3 Diode, MMBD701LT1, High Voltage, Schottky Barrier Type, 201-2801 1
70V, Surface Mount
DS1, DS2 LED, Tri-Color, Common Cathode 320-0031 2
F1 Fuse, ATC, 25A 334-2500 1
L3, L4 Inductor, 17.5NH 366-0017 2
J1 thru J4 Receptacle, Male, 3-Pin In-Line 408-0300 4
J801 Connector, Header, 40-Pin Dual-In-Line 417-4040 1
P1 thru P4 Jumper, Programmable, 2-Pin 340-0004 4
R2 Resistor, Chip, 2.2 k Ohm r5%, 1/4W 101-2243 1
R5 thru R8 Resistor, Chip, 22 Ohm r5%, 1/2W 111-2223 4
R14 Resistor, Chip, 499 k Ohm r1%, 1/4W 101-4990 1
R18 thru R21 Resistor, Chip, 22 Ohm r5%, 1/2W 111-2223 4
R23, R26 Resistor, Chip, 2.2 k Ohm r5%, 1/4W 101-2243 2
R27, R28 Resistor, 22 Ohm r5%, 4W 130-2243 2
U1, U2 Integrated Circuit, LM35DZ, Celsius Temperature Sensor, 220-0035 1
TO-92 Case
---- Blank RF Amplifier Circuit Board 519-0416 1
---- RF Amplifier Circuit Board Wire Harness 949-0405 1
---- Fuse Holder, ATC Type, PCB Mount 415-0015 2
6-46
TABLE 6-34. MODULE LOW PASS FILTER/DIRECTIONAL COUPLER CIRCUIT BOARD
ASSEMBLY -919-0418-011
---- Assembly, PCB, Low Pass Filter/Directional Coupler 919-0418-012 1

---- Assembly, PCB, Module Low Pass Filter 919-0418-013 1

ASSEMBLY -919-0418-012

C103 Capacitor, Ceramic Chip, 6.8 pF, 500V 009-6810 1
C107 Capacitor, Ceramic, 47 pF r5%, 50V 003-4712 1
C109 Capacitor, Ceramic, 47 pF r5%, 500V 009-5613
C114
C117, C118 Capacitor, Ceramic, 47 pF r2%, 50V 007-4702-500 2
C119, C120 Capacitor, Ceramic, 0.1uF r10%, 50V 007-1044 2
C121 Capacitor, Ceramic Chip, 0.001 uF r10%, 50V 007-1024 1
C122 Capacitor, Ceramic Chip, 10 uF, 10V 007-1075-100 1
C123 Capacitor, Ceramic Chip, 0.001 uF r10%, 50V 007-1024 1
C124, C125 Capacitor, Ceramic, 0.1uF r10%, 50V 007-1044 2
70V, 15 mA
L101 Coil, Molded, .11 uH, 1A 364-0011 1
L103, L104 Inductor, Molded, 68 uH 360-0106 2
L105 Coil, Molded, 100NH 366-0100 1
R111 Resistor, 64.9 Ohm r1%, 1/10W 102-6409 1
R112 Resistor, 130 Ohm r1%, 1/10W 102-1300 1
R115 Resistor, 15 Ohm r1%, 1/10W 102-1510 1
R117, R118 Resistor, 0 Ohm 102-0000 2
U101 Integrated Circuit, True Average Power Detector 221-8361 1
U102 Voltage Regulator, 78LO5AC 231-7805 1
---- Blank RF Amplifier Directional Coupler Circuit Board 519-0418-012 1
6-47
ASSEMBLY -919-0418-013
C201 Capacitor, Ceramic Chip, 10 pF r5% 500V 009-1013 1

C203 Capacitor, Ceramic Chip, 6.8 pF, 500V 009-6810 1
---- Blank RF Amplifier Module Low-Pass Filter Circuit Board 519-0418-013 1
TABLE 6-37. LOW PASS FILTER ASSEMBLY - 959-0414-001
---- Receptacle, BNC 417-0016 1

---- Connector, Anchor Insulator, Bullet, Silver Plated For 1 5/8 Line 427-0009-1 1
---- Low Pass Filter Assembly 919-0421-001 1
TABLE 6-38. LOW-PASS FILTER CIRCUIT BOARD ASSEMBLY - 919-0421-001

C11 Capacitor, Ceramic, 27 pF r2%,100V 003-2753 1
C14, C15 Capacitor, Ceramic, 2.2 pF, 100V, +/-0.25 pF 003-2201 2
70V, 15 mA
J23 Receptacle, Male, Right Angle, 20-Pin In-Line 417-0214 1
L1 Coil 360-0145 1
L2 Coil, Molded, .023 uH, 22 AWG 364-0023 1
---- Inductor, Low Pass Filter 471-5035 1
---- Low Pass Filter 519-0421 1
6-48
TABLE 6-39. FM-5C/FMi 402 COMBINER ASSEMBLY - 959-0418
FM-4C/FMi 301 COMBINER ASSEMBLY - 959-0418-001
---- Coil, Shunt Indicator, Combiner, FM-5C 360-0155 10

---- Connector, N" Type, Male To Pin, No Nut 417-0384 10
---- Blank, Output Combiner Circuit Board 519-0431 2
6-49
SECTION VII
DRAWINGS
7-1. INTRODUCTION.
7-2. This section provides schematic and assembly diagrams as indexed below for the
Broadcast Electronics FM-5C/FM-4C & FMi 402/FMi 301 transmitters.
FIGURE TITLE NUMBER
7-1 OVERALL SCHEMATIC DIAGRAM, FM-5C/FM-4C SD909 -/5001-204

& FMi-402/FMi-301 TRANSMITTER -/4001-204
7-2 OVERALL SCHEMATIC DIAGRAM, THREE PHASE SD909 -/5001-254
220V AC FM-5C/FM-4C & FMi-402/FMi-301 TRANSMITTER -/4001-254
7-3 OVERALL SCHEMATIC DIAGRAM, THREE PHASE SD909 -/5001-384
380V AC FM-5C/FM-4C & FMi-402/FMi-301 TRANSMITTER -/4001-384
7-4 SCHEMATIC DIAGRAM, MOTHERBOARD SB919-0513/-001
7-5 ASSEMBLY DIAGRAM, MOTHERBOARD AD919-0513/-001
7-6 SCHEMATIC DIAGRAM, CONTROLLER CIRCUIT BOARD SB919-0432-400
/-500
7-7 ASSEMBLY DIAGRAM, CONTROLLER CIRCUIT BOARD AD919-0432-400
/-500
7-8 SCHEMATIC DIAGRAM, RFI FILTER CIRCUIT BOARD SB919-0435
7-9 ASSEMBLY DIAGRAM, RFI FILTER CIRCUIT AB919-0435
BOARD
7-10 SCHEMATIC DIAGRAM, CONTROLLER ON/OFF SWITCH SB919-0406-101
CIRCUIT BOARD
7-11 SCHEMATIC DIAGRAM, CONTROLLER METER DISPLAY SB919-0406-102
7-12 SCHEMATIC DIAGRAM, CONTROLLER METER SWITCH SB919-0406-103
7-13 SCHEMATIC DIAGRAM, TEMPERATURE SENSOR SA919-0406-105
7-14 ASSEMBLY DIAGRAM, CONTROLLER CIRCUIT BOARDS AD919-0406-101
thru -105
7-15 SCHEMATIC DIAGRAM, REMOTE INTERFACE BARRIER SB919-0415-005
STRIP
7-16 ASSEMBLY DIAGRAM, REMOTE INTERFACE BARRIER STRIP AB919-0415-005
7-17 SCHEMATIC DIAGRAM, MODULE SELECT CIRCUIT BOARD SB919-0415-501
/-401
7-18 ASSEMBLY DIAGRAM, MODULE SELECT, MULTIPLEXER, AB919-0415-501
LPF RFI INPUT, PS MOTHERBOARD, AND RMT /-401
INTERFACE BARRIER STRIP CIRCUIT BOARDS
7-19 SCHEMATIC DIAGRAM, MULTIPLEXER CIRCUIT BOARD SB919-0415-502
/-402
7-20 ASSEMBLY DIAGRAM, MULTIPLEXER BOARD AC919-0415-502
/402
7-21 SCHEMATIC DIAGRAM, LOW-PASS FILTER INPUT RFI SA919-0415-003
FILTER CIRCUIT BOARD
7-22 ASSEMBLY DIAGRAM, LPF RFI INPUT AA919-0415-003
7-1
FIGURE TITLE NUMBER
7-23 SCHEMATIC DIAGRAM, POWER SUPPLY MOTHERBOARD SB919-0415-500

FILTER CIRCUIT BOARD /-400
7-24 ASSEMBLY DIAGRAM, PS MOTHERBOARD AD919-0415-500
/400
7-25 SCHEMATIC DIAGRAM, RF POWER MODULE SB959-0412
7-26 SCHEMATIC DIAGRAM, RF AMPLIFIER LOGIC CIRCUIT SB919-0417
BOARD
7-27 ASSEMBLY DIAGRAM, RF AMPLIFIER LOGIC CIRCUIT AB919-0417
BOARD
7-28 ASSEMBLY DIAGRAM, RF AMPLIFIER CIRCUIT BOARD AD919-0416
7-29 ASSEMBLY DIAGRAM, RF AMPLIFIER MODULE AC919-0418-001
LOW-PASS FILTER/DIRECTIONAL COUPLER CIRCUIT /-002
BOARDS
7-30 SCHEMATIC DIAGRAM, LOW-PASS FILTER SB959-0414/-001
7-31 ASSEMBLY DIAGRAM, LOW-PASS FILTER CIRCUIT BOARD AC919-0421/-001
7-32 SCHEMATIC DIAGRAM, OPTICALLY-COUPLED-RELAY (OCR) SB919-0096/-001
CIRCUIT BOARD
7-33 ASSEMBLY DIAGRAM, OPTICALLY-COUPLED-RELAY (OCR) AB919-0096/-001
CIRCUIT BOARD
7-34 ASSEMBLY DIAGRAM, POWER AMPLIFIER MODULE 597-3002-23
7-2
blank
597-3002-23
FIGURE 7-34. POWER AMPLIFIER MODULE
ASSEMBLY DIAGRAM
(SHEET 1 OF 2)
28
597-3002-23A
FIGURE 7-34. POWER AMPLIFIER MODULE
ASSEMBLY DIAGRAM
(SHEET 2 OF 2)
30
APPENDIX A
MANUFACTURERS DATA
A-1. INTRODUCTION.
A-2. This appendix provides technical data associated with the operation and maintenance of
the FM-5C/FM-4C transmitters. The information contained in this appendix is presented
in the following order.
A. Technical data, Electromatic 3-Phase AC Voltage Monitor.
B. Pioneer Magnetics, Troubleshooting Guide For The PM3329BP-5.
C. Computer Products Schematic Diagram, Model NFS 80-7606/7606 HM Power
Supply.
A-1
TECHNICAL DATA
ELECTROMATIC 3-PHASE AC VOLTAGE MONITOR
A-3. INTRODUCTION.
A-4. The FM-5C/FM-4C 220V ac 3-phase transmitters are equipped with a 3-phase ac line
voltage monitor. The following text presents the standard operating adjustments and operĆ
ating information.
UPPER VOLTAGE LIMIT (upper set 250V
of voltage controls on the unit)
LOWER VOLTAGE LIMIT (lower set 192
of voltage controls on the unit)
ASYMMETRY 12%
TIME 0.1 SEC.
A-2

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FM–5C 5 kW FM ONLY,

FMi–402 3.5 kW FM + HD,

August, 2007 IM No. 597–5001

READ THIS SHEET AND OBSERVE ALL SAFETY PRECAUTIONS

SECTION III OPERATION

Broadcast Electronics 2007

SECTION IV THEORY OF OPERATION

SECTION VI PARTS LIST

SECTION VII DRAWINGS

APPENDIX A MANUFACTURERS DATA

1-3. RELATED PUBLICATIONS.

1–12. FMi–402/FMi–301 GENERAL

COPYRIGHT  2007 BROADCAST ELECTRONICS, INC.

COPYRIGHT  2007 BROADCAST ELECTRONICS, INC.

1-28. COMBINER. In FM-5C/FM-4C and FMi-402/FMi-301 transmitters, the RF power modĆ

1-34. EQUIPMENT SPECIFICATIONS.

TABLE 1-1. FM-5C / FM-4C ELECTRICAL SPECIFICATIONS

MAXIMUM VSWR Rated power into 1.5:1 maximum without output

RF OUTPUT IMPEDANCE 50 Ohms.

2-6. ENVIRONMENTAL REQUIREMENTS.

2-8. COOLING AIR REQUIREMENTS.

2-12. PRIMARY POWER.

2-18. EQUIPMENT PLACEMENT.

WARNING ENSURE NO PRIMARY POWER IS CONNECTED TO

2-21. EQUIPMENT INSTALLATION.

WARNING ENSURE NO PRIMARY POWER IS CONNECTED TO

FIGURE 2-1. FM-5C/FM-4C TRANSMITTER

FIGURE 2-2. FM-402/FMi 301 TRANSMITTER

FIGURE 2-3. ACCEPTABLE AC POWER INPUT CONFIGURATIONS 597-0099-11

FIGURE 2-4. COMPONENT INSTALLATION (SHEET 2 OF 2)

CAUTION THE TRANSMITTER MAY BE DAMAGED IF AN RF

CAUTION AN RF POWER MODULE IS EQUIPPED WITH REAR-

1. Locate the RF power modules.

WARNING ENSURE NO PRIMARY POWER IS CONNECTED TO

2-30. Remote Forward/Reflected Power Meter Indications. Remote transmitter forward/reflected

2-33. Remote PA Module Voltage/Temperature Meter Indications. Remote PA module voltage/temĆ

WARNING ENSURE NO PRIMARY POWER IS CONNECTED TO

2-54. RF OUTPUT TRANSMISSION LINE CONNECTION. FM-5C/FM-4C and FMi-

WARNING ENSURE PRIMARY POWER IS DISCONNECTED

2. Connect the strap to the chassis ground terminal.

3. Connect the ground wire to the lug.

FIGURE 2-8. RF OUTPUT CONNECTIONS 597-5001-7

WARNING DISCONNECT ALL TRANSMITTER PRIMARY

1. Disconnect the ac power.

3-3. CONTROLS AND INDICATORS.

TABLE 3-1. FM-5C/FM-4C and FMi-402/FMi-301 CONTROLS AND INDICATORS

INDEX NOMENCLATURE FUNCTION

FIGURE 3-1. FM-5C/FM-4C & FMi 402/FMi 301 CONTROLS 597-5001-11A

INDEX NOMENCLATURE FUNCTION

11 TRANSMITTER ON SWITCH: Enables the transmitter RF output by unmut-

INDEX NOMENCLATURE FUNCTION

12 TRANSMITTER OFF SWITCH: Disables the transmitter RF output by muting

INDEX NOMENCLATURE FUNCTION

18 MODULE SELECT SWITCH: Selects an RF power amplifier module for the

NOTE ENSURE THE TRANSMITTER IS COMPLETELY INĆ

Broadcast Electronics 2007

COPYRIGHT 2007 BROADCAST ELECTRONICS, INC.

COPYRIGHT 2007 BROADCAST ELECTRONICS, INC.