Broadcast Electronics 4100 North 24th Street, Quincy, Illinois 62305 USA • Phone (217) 224-9600 • Fax (217) 224-9607 • www.bdcast.com • bdcast@bdcast.
STXe – 60 Watt FM Exciters Installation and Maintenance Guide ©2013 Broadcast Electronics all rights reserved. The information in this publication is subject to improvement and change without notice. Although every effort is made to ensure the accuracy of the information in this manual, Broadcast Electronics accepts no responsibility for any errors or omissions. Broadcast Electronics reserves the right to modify and improve the design and specifications of the equipment in this manual without notice.
i Broadcast Electronics Product Warranty (Two-Year Limited) BE hereby warrants all new products manufactured by BE against any defects in material or workmanship at the time of delivery thereof, or that develop under normal use within a period of two (2) years from the date of shipment. BE reserves the right to repair equipment under warranty with new or refurbished equipment or parts.
ii this warranty. If the equipment is described as “used” equipment, it is sold as is and where is and no warranty applies unless authorized in writing.
iii IMPORTANT INFORMATION EQUIPMENT LOST OR DAMAGED IN TRANSIT When delivering the equipment to you, the truck driver or carriers’ 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.
iv RETURN, REPAIR, AND EXCHANGES Do not return any merchandise without our written approval and Return Authorization. We will provide special shipping instructions and a code number that will assure proper handling and prompt issuance of credit. Please furnish complete details as to circumstances and reasons when requesting return of merchandise. All returned merchandise must be sent freight prepaid and properly insured by the customer.
v SAFETY PRECAUTIONS PLEASE READ AND OBSERVE ALL SAFETY PRECAUTIONS ALL PERSONS WHO WORK WITH OR ARE EXPOSED TO POWER TUBES, POWER TRANSISTORS, OR EQUIPMENT WHICH UTILIZES SUCH DEVICES MUST TAKE PRECAUTIONS TO PROTECT THEMSELVES AGAINST POSSIBLE SERIOUS BODILY INJURY. EXERCISE EXTREME CARE AROUND SUCH PRODUCTS. UNINFORMED OR CARELESS OPERATION OF THESE DEVICES CAN RESULT IN POOR PERFORMANCE, DAMAGE TO THE DEVICE OR PROPERTY, SERIOUS BODILY INJURY, AND POSSIBLY DEATH.
vi HIGH VOLTAGE Many power circuits operate at voltages high enough to kill through electrocution. Personnel should always break the primary AC Power when accessing the inside of the transmitter. RADIO FREQUENCY RADIATION Exposure of personnel to RF radiation should be minimized, personnel should not be permitted in the vicinity of open energized RF generating circuits, or RF transmission systems (waveguides, cables, connectors, etc.), or energized antennas.
vii Table of Contents 1 2 3 4 5 Overview............................................................................................................................ 11 Preparing to Install ............................................................................................................ 16 2.1 Verify Contents of Shipment .............................................................................................. 16 2.2 Items Sold Separately or Not Supplied ...................................
viii Figures Figure 1 – STXe 60 ...................................................................................................................... 12 Figure 2 –Rear Panel ................................................................................................................... 18 Figure 3 - Standard D-Sub 37 Connector Numbering .................................................................. 19 Figure 4 – Rack Mounting .........................................................................
ix Figure 52 – PA Assembly on Chassis............................................................................................ 54 Figure 53 – PA Chassis 1 ............................................................................................................. 54 Figure 54 – PA Chassis 2 ............................................................................................................. 55 Figure 55 – PA Chassis 3 .............................................................................
11 1 Overview The STXe FM exciter series is designed to provide a cost effective solution for FM broadcast. Selected exciter settings such as frequency, expected output power, Ethernet settings, etc. can be communicated at the time of purchase. After preliminary testing of all systems in the transmitter, technicians use customer settings and verify full system operation under closer conditions compared to the intended installation. IP network interfacing features are optional, and thus not included.
12 Figure 1 – STXe 60 ©2013 Broadcast Electronics
13 Table 1 - Specifications Parameter Specification Physical Height Width Depth Weight Outlet Size 2 RU 3.5” (8.89 cm) 19” (48.3 cm) EIA Rack Mount 22.5” (57 cm) including connectors 19lbs (8.6 kg) unpacked 30 in2 (194 cm2), rear of unit Environmental Temperature Altitude Humidity Air Capacity Heat Dissipation BTU -10°C to +50°C 10,000ft (3048M) maximum 95% maximum, non-condensing 80 CFM (2.
14 Capability Maximum Overshoot 300 kHz 150% RF Harmonics Suppression FCC; DOC; CCIR Meets all requirements/recommendations Composite Input Connector Impedance Level Amplitude Response Phase Response THD + Noise IMD SNR BNC 10k ohms, un-balanced 3.5V p-p for 100% modulation +/-0.03 dB 20 Hz to 53 kHz; +/-0.1 dB 53 kHz to 100 kHz +/-0.1 degree 53kHz to 100kHz 0.005% 0.005% -90dBr below 100% modulation @ 400 Hz SCA1 & 2 Inputs Connectors(2) Impedance Level Response BNC 10k ohms, un-balanced 3.
15 10 MHz Input Connector Level SMA un-balanced 1 to 3 V p-p, nominal 2.
16 2 Preparing to Install STXe systems come with installation kits tailored to standard BE transmitter installations. Standard C and T series transmitters require an adapter board and some alternate cabling. Ensure that the appropriate kit is received, checked, and installed. 2.
17 2.2 Items Sold Separately or Not Supplied Remote station interface controller and solderable wiring for desired connections Networking cable(s) and switch(s) for Ethernet connectivity 2.3 Tools and Materials Small flat blade screwdriver (about 5/32” blade or smaller) Large Phillips screwdriver Tie-wraps Remote Station Interface Connections Wire strippers Soldering iron and solder 2.4 Estimated Time for Installation Installation and initial setup should take approximately 30 minutes.
18 3 Rear Panel Connections Before assembling the system, please take some time to familiarize yourself with all of the connectivity features included in STXe Systems. Note that “low” logic in the context of machine interface connections refers to a connection to logic ground pins. “High” logic is a connection to +5V (supplied by GPIO pin 32). Active edge refers to a transition from the inactive state to the active state.
19 Figure 3 - Standard D-Sub 37 Connector Numbering Table 2 – GPIO Pins 1 Pin Direction Input Name Fault Reset 2 Input Failsafe 3 4 5 Input Input Input Transmitter On Transmitter Off Mute 6 Input 7 Input 8 9 Input Input Raise Transmitter Power Lower Transmitter Power Reserved Controller Reset 10 11 12 Input Input Input Reserved FM Only Mode Ground 13 14 15 Input Input Output Reserved Reserved Reflected Power 16 Output PA Total Current 17 Output PA Temperature 18 19 Input N/A
20 Pin 21 Direction Output Name VSWR Fault 22 23 24 25 Output Output Output Output Transmitter On Transmitter Off Mute Status AFC Lock 26 Output Power Supply Fault 27 28 29 30 31 32 Output Output Output Output Input Output Reserved PA Fault Reserved Reserved Reserved +5V 33 Output Forward Power 34 Output PA Voltage 35 36 37 Output Output N/A Reserved Reserved Ground 3.1.
21 3.1.5 ETHERNET Standard 10/100 Mbps RJ45 IP network communications input/output. Connect to a local area network switch and/or to a gateway for access through the internet. This interface automatically negotiates hardware interfacing, and a crossover cable is not required. Direct connections to a PC or other network controller can be made with either a crossover or straight Ethernet cable.
22 3.1.13 PA RF IN Power Amplifier RF Input connector. For 1kW systems this is cabled from EXC RF OUT. For combined systems, this should be connected to one of the splitter RF outputs on the combiner module designated A, B, C, D, or E using phase matched cables. 3.1.14 RF SAMPLE Power amplifier RF sample connector. This BNC carries a coupled RF signal from the module’s PA. This is intended to be used in 1kW systems in optional monitoring of RF output.
23 4 Installation and Initial Setup This section covers standard installation requirements. Non-standard installations or optional features and equipment may be covered in other technical documents. Be sure to check the Operation Manual or http://www.bdcast.com/information-center/ for details. ENSURE ALL AC POWER INPUT IS COMPLETELY DISCONNECTED BEFORE ACCESSING ANY SYSTEM COMPONENTS 4.1 Install in Rack The STXe60 fits in two EIA rack units.
24 Figure 5 – Exciter RF Jumper 4.3 RF Output Connect STXe60 RF OUT to the transmitter RF in. Use provided N-type to BNC adapter if necessary. Figure 6 – 1C Transmitter RF Example For standalone installations simply connect RF out to the antenna transmission line. 4.4 AC Power Connect AC power from the transmitter. Alternatively, one of the provided power cables can be plugged into a building power socket.
25 Figure 7 – 1C AC Power Example ©2013 Broadcast Electronics
26 4.5 Active Stub Connect the provided exciter activation stub and secure it with a small screwdriver. Figure 8 – Active Stub 4.6 Exciter to Transmitter Interface Exciter interface cables included in STXe60 kits, 949-4144 or 949-4150, are built using solder pot D-subminiature connectors that can be accessed by opening the shell. These can be modified to suit the requirements of the transmission system.
27 1. Use two of the provided Phillips screws in the screw holes shown to attach standoffs to the bottom of the board. Note that the side of the board shown is important to avoid interference with the rail. Figure 10 – Adapter Standoffs 2. Use a small screwdriver and/or the thumb screws to attach the provided D-Subminiature cable harnesses. Figure 11 – Adapter Cables 3. Screw hole spacing is exactly 5 Rack units, so the board can be positioned anywhere vertically.
28 4. Connect the existing EXCITER INTERFACE cable to the 25 pin D- Subminiature cable from the adapter assembly and tighten the thumb screws. Figure 13 – Exciter Interface Cable 5. Connect the 37 pin D- Subminiature cable from the adapter assembly to the 37-pin GPIO interface on the STXe60. Figure 14 – GPIO Connection Secure all loose cabling with ty-wraps.
29 4.7 Turn on AC 1. Unlock AC main breaker on the service line and turn the switch to the on position. 2. Turn on all transmitter circuit breakers. 3. Flip the Power Switch to the on position on the STXe unit. 4.8 Ethernet/IP Network IP network features are entirely optional.
30 2. Use the transmitter control center on the front panel of the main assembly to navigate to the ETHERNET/IP menu. Because of the way all network adapters function, the actual address, mask, and gateway address utilized are displayed in the second menu layer. TRANSMITTER CONTROL CENTER IP ADDRESS 192.168.1.2 TRANSMITTER CONTROL CENTER SUBNET MASK 255.255.000.000 TRANSMITTER CONTROL CENTER GATEWAY ADDRESS 192.168.1.1 3.
31 4.9 Set Time and Date The internal real time clock holds the current time and date for use in the event log. This is a rudimentary device that supports 24-hour format and does not adjust for daylight saving. If installing during summer in a daylight saving region, following standard non-daylight time is recommended instead. 1. Use the transmitter control center on the front panel of the main assembly to navigate to the Date and Time menu. TRANSMITTER CONTROL CENTER < 2000-01-01 > 00:00:00 2.
32 4.10 Primary Program Services The STXe 60 provides built-in injection of one primary audio source – AES, Composite, or Analog L/R. 4.10.1 AES 1. Connect an XLR cable from the desired AES audio source. 2. Navigate to the audio input screen. TRANSMITTER CONTROL CENTER < AUDIO INPUT > COMPOSITE 3. Select AES as the primary audio source and return. TRANSMITTER CONTROL CENTER AUD IN->AES ^ 4. Set the stereo injection reduction (to allocate injection budget for secondary services).
33 4. Set the stereo injection reduction (to allocate injection budget for secondary services). Leave this at 100% if there are no secondary services. Return when finished adjusting. TRANSMITTER CONTROL CENTER 100.0% ANLG L/R ^ 5. Enter the audio level menu. TRANSMITTER CONTROL CENTER < AUDIO LEVEL > 6. Select L and adjust until the displayed left channel peak hold is 100% within a few percent. TRANSMITTER CONTROL CENTER AUDIO LEVEL L->-03.00dB TRANSMITTER CONTROL CENTER L->-03.00dB 99.8% ^ 7.
34 4.10.3 Composite 1. Connect a BNC cable from the desired unbalanced composite audio source. Activate the source with reference tones for level calibration. 2. Navigate to the audio input menu. TRANSMITTER CONTROL CENTER < AUDIO INPUT > AES 100.0% 3. Select composite as the primary audio source. TRANSMITTER CONTROL CENTER AUD IN->COMPOSIT ^ 4. Navigate to the audio level menu. TRANSMITTER CONTROL CENTER < AUDIO LEVEL > 5.
35 2. Navigate to the SCA/RDS menu. TRANSMITTER CONTROL CENTER < SCA/RDS > 3. Select the desired SCA/RDS input and change the setting to ON. TRANSMITTER CONTROL CENTER SCA/RDS SCA1 OFF TRANSMITTER CONTROL CENTER SCA1 ->ON ^ 4. Navigate to the audio level menu. TRANSMITTER CONTROL CENTER < AUDIO LEVEL > 5. Select the desired input and adjust until the displayed composite peak hold is approximately 10%.
36 5 Maintenance These sections detail steps to maintain or replace STXe60 system modules. 5.1 Clean the Air Filter STXe60 systems come standard with snapped washable air filters. Air filter cleaning should be a part of regular system maintenance. To remove the filter from the front of the exciter, use the opening on the bottom to pry the snaps by hand. Figure 15 – Air Filter Removal Remove the filter material from the case for thorough cleaning. Use compressed air or water to remove debris.
37 Figure 17 – Re-insertion of Air Filter 5.2 Remove the Top Cover To perform remaining module replacement actions in this section, the top cover must be removed. Full precautions should be taken against electrostatic discharge. Any such shocks may cause permanent damage to any electronic components. ENSURE AC POWER INPUT IS COMPLETELY DISCONNECTED BEFORE ACCESSING ANY INTERNAL MODULES Use a Phillips screwdriver to unscrew the 15 top cover screws and lift the cover.
38 Figure 18 – Top Cover Screws 5.3 Main Power Supply 540-4048 Tools Phillips Screwdriver 1 Power Supply Board Assembly, 48VDC 240W POWER SUPPLY PARTS MAY HOLD THIER CHARGE FOR MINUTES AFTER AC POWER IS DISCONNECTED. SHOCKS AND BURNS MAY RESULT IF JACKS OR PART LEADS ARE TOUCHED, ESPECIALLY ON THE BOTTOM OF MODULES! 1. Start by unlatching and pulling three cable plugs. To unlatch the cables, pinch the top of the connector at the points indicated in Figure 19.
39 3. Lift the board assembly from the chassis by holding the edges of the board and the heat sinks. Note that heat sinks carry AC when the system is powered. When holding by the edge avoid curling fingers around to the bottom. Figure 21 – Safe Power Supply Removal With the replacement power supply module, repeat the previous three steps in reverse. The cable latches should engage themselves when the cables are fully plugged. Ensure solid latching on all cables is made.
40 5.4 Fan Power Supply 540-5024 Tools Phillips Screwdriver 1 Power Supply Board Assembly, 24VDC 50W POWER SUPPLY PARTS MAY HOLD THIER CHARGE FOR MINUTES AFTER AC POWER IS DISCONNECTED. SHOCKS AND BURNS MAY RESULT IF JACKS OR PART LEADS ARE TOUCHED, ESPECIALLY ON THE BOTTOM OF MODULES! 1. Disengage the latch on the DC cable harness and pull the plug. Simply pull the plug on the AC cable harness. Figure 22 – Fan Power Supply Cable Removal 2.
41 3. Hold the board assembly by the edges of the board and the heat sinks. When holding by the edge avoid curling fingers around to the bottom. Remove both of the top screws and lift the module out of the chassis. Figure 24 – Safe Fan Power Supply Removal With the replacement power supply module, repeat the previous steps in reverse. The cable latches should engage themselves when the cables are fully plugged. Ensure solid latching on all cables is made. 5.
42 2. Note the front/back and wire orientations highlighted in Figure 26 relative to the case cutout. Use a Phillips screwdriver to remove the four screws and nuts securing the fan to the case. NOTE ORIENTATION Figure 26 – Fan Assembly Detail With the replacement fan, repeat the previous steps in reverse. Again, ensure fan direction and orientation in the case is proper to avoid improper airflow or strain on cables.
43 5.6 Front Panel Display 919-4070-100 Tools Phillips Screwdriver 1 STX CPE Display Board Assembly 1. Use a Phillips screwdriver to remove the front panel handle screws. Be careful not to let the handles spin and scratch the front panel. Slide the front panel off. Figure 27 – Front Handle Screws 2. Disengage the latch on the cable harness and disconnect it from the display board.
44 3. Use a Phillips screwdriver to remove the two screws securing the board assembly. Figure 29 – Front Panel Display Screws 4. Pop the board out of the four snaps in the corners. Figure 30 – Front Panel Display Snaps With the replacement front panel display board assembly, repeat the previous steps in reverse.
45 5.7 DC Regulator 919-4206 Tools Phillips Screwdriver 1 DC Regulator Board Assembly 1. Disengage latches on the blue connector and pull it. Pull the three white cable connectors. Set the cables aside. Figure 32 – DC Regulator Cables 2. Use a Phillips screwdriver to remove the three screws.
46 3. Pop the board assembly off the four corner snaps. Set the board about an inch to the side to the position shown in Figure 35. Figure 34 – DC Regulator Snaps 4. Pinch the latches on the now easily accessed red connector and pull the cable. Figure 35 – DC Regulator Cable Latch With the replacement DC regulator board assembly, repeat the previous steps in reverse. Note that step 4 can be performed when plugging in the other cables in step 1 when assembling.
47 5.8 Controller Exciter 919-4200-100 1 STX Controller Exciter Board Assembly Tools Phillips Screwdriver 3/16” Nut Driver 9/16” Wrench (or machine-thinned 9/16” deep-well nut driver) 1. Use a 3/16” nut driver to unscrew the four total D-Subminiature jackscrews that secure the GPIO and BE INTERFACE jacks. Figure 36 – CPE D-Subminiature Jackscrews 2. Use a Phillips screwdriver to remove the six total screws that secure the XLR jacks. Figure 37 – CPE XLR Screws 3.
48 4. Disconnect all cables from the Controller Exciter board. Unseat the cables from the notch in the chassis wall and set them out of the way. Figure 39 – CPE Cables 5. Use a Phillips screwdriver to remove the screw securing the board.
49 6. Insert fingers under the board next to the two snaps and pop them up to free the board. Figure 41 – CPE Snaps 7. Angle the back of the board up and slide cables underneath the corner of the board.
50 8. Carefully support the board by the XLR jacks as shown and ensure that the XLR push tabs clear the chassis, especially the RIGHT tab. Lift the board assembly and Figure 43 – XLR Jack Tabs With the replacement controller exciter board assembly, repeat the previous steps in reverse. Figure 44 – Controller Exciter Outside Chassis Cable harnesses should be neatly arranged in the notch in the chassis as shown.
51 5.9 Power Amplifier 959-4210 1 60W PA Board Assembly Tools Phillips Screwdriver Extra-Long/Short Phillips Screwdriver 1. Set the STXe60 unit on its side and use a Phillips screwdriver to remove the two screws shown. Figure 46 – Bottom PA Screws 2. Set the STXe60 unit back down. Use a Phillips screwdriver to remove the five screws on the side.
52 3. Insert an extra-long Phillips screwdriver through the hole in the back of the chassis and unscrew the front PA screw. An extra-short Phillips screwdriver that can fit inside the cavity is also valid. Figure 48 – Front PA Screw 4. Move the heavy RF out cable to the side and lift all of the cable harnesses out of the notch in the chassis as shown.
53 5. Disconnect the highlighted cables from the CPE and DC regulator boards and disconnect the RF out BNC connector. Figure 50 – Disconnected Cables 6. Slide the PA assembly to the side in order to clear the top lip of the main chassis.
54 7. Carefully lift the PA assembly and set it on the main chassis as shown. Figure 52 – PA Assembly on Chassis 8. Use a Phillips screwdriver to unscrew the two screws and remove the back chassis section.
55 9. Use a Phillips screwdriver to unscrew the three screws and remove the front chassis piece. Figure 54 – PA Chassis 2 10. Use a Phillips screwdriver to unscrew the two screws on the remaining chassis section.
56 11. Cut the ty-wrap holding the SMA cables together. Unscrew both SMA connectors. Feed the RF sample SMA connector through the hole in the chassis section. Figure 56 – SMA Connections 12. Feed the remaining three cables through the chassis section as well. Figure 57 – Cable Extraction 1 13. Disconnect the cables from the PA board.
57 With the replacement PA module, repeat the previous steps in reverse.
