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IFR FM/AM-500 Service Manual

IFR FM/AM-500
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MAINTENANCE
MANUAl
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Table of Contents

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IFR FM/AM-500 Specifications

General IconGeneral
Resolution1 Hz
Frequency Accuracy±1 ppm
Modulation TypesFM, AM
Display TypeLCD
Power Supply50/60 Hz

Summary

MAINTENANCE MANUAL

FM/AM-500/A Communications Service Monitors

Overview of the FM/AM-500/A communications service monitors.

WARNING: HIGH VOLTAGE EQUIPMENT

Shock Victim Rescue and First Aid Procedures

Procedures for rescuing shock victims and essential first aid steps.

CAUTION: COMPONENT HANDLING PRECAUTIONS

Electrostatic Discharge Prevention Measures

Precautions for handling ICs and solid-state devices to prevent ESD damage.

PREFACE

Manual Scope, Applicability, and Organization

Covers the manual's purpose, scope, applicability of terminology, and its overall structure.

SECTION 4 - CALIBRATION

4-1 GENERAL CALIBRATION INFORMATION

Introduces calibration procedures for FM/AM-500A indicators and internal modules.

SECTION 1 - INTRODUCTION

1-1 GENERAL AND ELECTRICAL DESCRIPTION

General overview and electrical description of the FM/AM-500A, including front panel controls.

1-2-1 FREQUENCY SELECTORS

Describes tone generators and RF frequency selection methods.

1-2-2 METERS

Explains the dual analog DC milliammeters and their functions.

1-2-3 MODE/BANDWIDTH CONTROL

Details how operating modes and bandwidths are selected.

SECTION 2 - THEORY OF OPERATION

2-1 INTRODUCTION AND MODULE OVERVIEW

Provides an introduction to the theory of operation and an overview of modules.

2-2 MODULE DESCRIPTIONS

Details open PC boards, enclosed PC boards, and block modules.

2-3 SIMPLIFIED THEORY OF OPERATION

Explains the unit's operation as a receiver and generator.

2-4 INTERMODULE SYSTEMS THEORY

Explains system-oriented theory for functions involving multiple modules.

SECTION 3 - PERFORMANCE EVALUATION

3-1 GENERAL EVALUATION PROCEDURES

Provides step-by-step test procedures for assessing FM/AM-500A performance.

MOBILE VS. LABORATORY CHECKS

Differentiates between quick mobile checks and detailed laboratory procedures.

TEST SETUP AND INITIAL CONTROL SETTINGS

Details test setup diagrams and initial control settings required for procedures.

3-1-1 TEST EQUIPMENT REQUIREMENTS

Refers to Appendix B for a comprehensive list of required test equipment.

3-2 MOBILE PERFORMANCE EVALUATION PROCEDURES

1 kHz Tone Generator and Variable Tone Generator Tests

Procedures for evaluating the performance of the 1 kHz and variable tone generators.

Procedure Steps and Notes

Step-by-step instructions and notes for performing test procedures.

3-2-2 VARIABLE TONE GENERATOR PERFORMANCE EVALUATION

Test Equipment, Setup, Controls, and Steps

Lists required test equipment, setup diagrams, initial controls, and step-by-step instructions.

3-2-3 RECEIVER PERFORMANCE EVALUATION

Required Equipment, Setup, and Controls

Lists required equipment, setup diagrams, and initial control settings for receiver testing.

STEP PROCEDURE

Step-by-step instructions for performing the receiver performance evaluation.

3-2-4 RF FREQUENCY ERROR METER PERFORMANCE EVALUATION

Required Equipment, Setup, and Controls

Lists required equipment, setup diagrams, and initial control settings for the RF error meter test.

STEP PROCEDURE

Step-by-step instructions for performing the RF error meter performance evaluation.

3-2-5 AUDIO FREQUENCY ERROR METER PERFORMANCE EVALUATION

Required Equipment, Setup, and Controls

Lists required equipment, setup diagrams, and initial control settings for the audio error meter test.

STEP PROCEDURE

Step-by-step instructions for performing the audio error meter performance evaluation.

3-2-6 GENERATE MODE AND MODULATION METER PERFORMANCE EVALUATION

Required Equipment, Setup, and Controls

Lists required equipment, setup diagrams, and initial control settings for the generate mode and modulation meter test.

STEP PROCEDURE

Step-by-step instructions for performing the generate mode and modulation meter evaluation.

3-3 LABORATORY PERFORMANCE EVALUATION PROCEDURES

3-3-1 1 kHz Tone Generator Lab Evaluation

Detailed procedure for evaluating the 1 kHz tone generator in a lab setting.

Test Equipment, Setup, Controls, and Steps

Lists required test equipment, setup diagrams, initial controls, and step-by-step instructions.

3-3-2 VARIABLE TONE GENERATOR LAB TEST SET-UP

Test Equipment, Setup, Controls, and Steps

Lists required test equipment, setup diagrams, initial controls, and step-by-step instructions.

3-3-3 RECEIVER LAB TEST SET-UP

Equipment, Setup, Controls, and Steps

Lists required equipment, setup diagrams, initial controls, and step-by-step instructions for receiver testing.

STEP PROCEDURE

Step-by-step instructions for performing the lab test.

3-3-4 GENERATE SYSTEM PERFORMANCE EVALUATION

Equipment, Setup, Controls, and Steps

Lists required test equipment, setup diagrams, initial controls, and step-by-step instructions.

3-3-5 FREQUENCY ERROR METER PERFORMANCE EVALUATION - RF AND SSB

Equipment, Setup, and Controls

Lists required equipment, setup diagrams, and initial control settings for the RF error meter test.

3-3-6 FREQUENCY ERROR METER PERFORMANCE EVALUATION - AUDIO

Equipment, Setup, and Controls

Lists required equipment, setup diagrams, and initial control settings for the audio error meter test.

3-3-7 MODULATION AND POWER METER PERFORMANCE EVALUATION

Equipment, Setup, and Controls

Lists required equipment, setup diagrams, and initial control settings for the modulation and power meter test.

3-3-8 SINAD METER

Equipment, Setup, and Procedures

Lists required equipment and procedures for testing SINAD using distortion analyzer or oscilloscope.

3-3-9 POWER METER

Equipment, Setup, and Procedures

Lists required test equipment and procedures for power meter calibration.

SECTION 4 - CALIBRATION

4-1 GENERAL CALIBRATION INFORMATION

Introduces calibration procedures for FM/AM-500A indicators and internal modules.

4-1-1 SAFETY PRECAUTIONS DURING CALIBRATION

Lists critical safety precautions to observe during calibration procedures.

4-1-2 DISASSEMBLY AND 4-1-3 CALIBRATION SEQUENCE

Specifies case removal requirements and the recommended order for calibrating interactive modules.

4-1-4 TEST EQUIPMENT AND 4-1-5 CONTROLS/POINTS

States test equipment needs and identifies controls and calibration points.

4-2 CALIBRATION PROCEDURES

4-2-1 MECHANICAL ZEROING OF MODULATION AND FREQUENCY ERROR METERS

Procedure for mechanically zeroing the Modulation and Frequency Error Meters.

4-2-2 POWER SUPPLY CALIBRATION PROCEDURE

Prerequisites, Equipment, and Battery Charger Circuit

Lists prerequisites, required equipment, and calibration steps for the battery charger circuit.

Optional Power Supply and Distributed Voltages

Calibration steps for optional power supply and distributed voltages.

4-2-3 10 MHz OSCILLATOR CALIBRATION PROCEDURE

Prerequisites, Equipment, and Coarse Calibration

Lists prerequisites, equipment, and coarse calibration steps for the 10 MHz oscillator.

Fine Calibration Methods

Procedures for fine calibration to WWV and external counter standards.

4-2-4 VARIABLE TONE GENERATOR CALIBRATION PROCEDURE

Prerequisites, Equipment, and Controls

Lists prerequisites, required equipment, and initial control settings for calibration.

4-2-5 FREQUENCY ERROR METER CALIBRATION PROCEDURE

Prerequisites, Equipment, and Controls

Lists prerequisites, required equipment, and initial control settings for frequency error meter calibration.

4-2-6 MODULATION METER CALIBRATION PROCEDURE

Prerequisites, Equipment, and Test Setups

Lists prerequisites, required equipment, and test setup diagrams for modulation meter calibration.

4-2-7 SINAD METER CALIBRATION (FM/AM-500A ONLY)

Prerequisites, Equipment, and Distortion Analyzer Procedure

Lists prerequisites, equipment, and steps for SINAD calibration using a distortion analyzer.

Oscilloscope Procedure for SINAD Calibration

Procedure for calibrating the SINAD meter using an oscilloscope.

4-2-8 POWER METER CALIBRATION (FM/AM-500A ONLY)

Prerequisites, Equipment, and Calibration Points

Lists prerequisites, required equipment, and calibration points for the power meter.

4-2-9 GENERATE OUTPUT LEVEL CALIBRATION PROCEDURE

Prerequisites, Equipment, and Controls

Lists prerequisites, required equipment, and initial control settings for output level calibration.

SECTION 5 - TROUBLESHOOTING

5-1 GENERAL AND FLOWCHART USAGE

Introduces troubleshooting flowcharts and explains how to use them effectively.

5-1-2 TROUBLESHOOTING HINTS AND PRECAUTIONS

Provides initial checks, visual inspection guidance, and safety precautions.

5-1-3 SAFETY PRECAUTIONS AND TEST EQUIPMENT

Lists critical safety precautions and refers to Appendix B for test equipment.

5-1-5 DISASSEMBLY AND 5-1-6 TROUBLESHOOTING INDEX

Specifies case removal requirements and provides an index of troubleshooting flowcharts.

5-2 TROUBLESHOOTING POWER SUPPLY

5-2-1 INCORRECT OUTPUT VOLTAGES

Troubleshooting procedure for incorrect power supply output voltages.

5-2-2 INCORRECT BATTERY CHARGING RATE

Required Test Equipment

Lists required test equipment like Battery Load Simulator and Digital Multimeter.

5-3 TROUBLESHOOTING RECEIVER

5-3-1 SENSITIVITY LOW AT CERTAIN FREQUENCIES

Troubleshooting steps for low sensitivity at specific frequencies.

5-3-2 SENSITIVITY LOW AT ALL FREQUENCIES

Required Test Equipment

Lists required test equipment like Spectrum Analyzer and Signal Generator.

5-3-3 IMPROPER DEMODULATION

Special Accessory Equipment Required

Lists required test equipment like Signal Generator and Oscilloscope.

5-4 TROUBLESHOOTING GENERATOR

5-4-1 INCORRECT CARRIER AMPLITUDE

Troubleshooting steps for incorrect carrier amplitude in the generator.

Special Accessory Equipment Required

Lists required test equipment like Digital Multimeter, Spectrum Analyzer, and Signal Generator.

5-4-2 INCORRECT CARRIER FREQUENCY

Special Accessory Equipment Required

Lists required test equipment like Digital Multimeter and Frequency Counter.

5-4-3 INADEQUATE RESPONSE TO VARIABLE GENERATOR CONTROL

Special Accessory Equipment Required

Lists required test equipment like Digital Multimeter.

5-5 TROUBLESHOOTING PHASE LOCK SYSTEM

5-5-1 LOCK LIGHT INDICATOR SYSTEM NOT PHASE LOCKED

Troubleshooting steps for when the phase lock indicator light is not functioning correctly.

5-5-2 HIGH LOOP DOES NOT PHASE LOCK

Troubleshooting Steps for High Loop Phase Lock Issues

Troubleshooting steps when the High Loop does not phase lock.

5-5-3 LOW LOOP DOES NOT PHASE LOCK

Troubleshooting Steps for Low Loop Phase Lock Issues

Troubleshooting steps when the Low Loop does not phase lock.

SECTION 6 - DISASSEMBLY/REASSEMBLY PROCEDURES

6-1 GENERAL DISASSEMBLY/REASSEMBLY INFORMATION

General information on removing and disassembling modules within the FM/AM-500A.

6-1-2 PRELIMINARY CONSIDERATIONS

Lists required tools and important precautions before starting disassembly.

6-1-3 MODULE DISASSEMBLY/REASSEMBLY INDEX

An index listing modules with their corresponding disassembly and reassembly page numbers.

6-2 REMOVAL AND DISASSEMBLY

6-2-1 CASE REMOVAL PROCEDURE

Step-by-step procedure for removing the FM/AM-500A case.

6-2-2 BATTERY AND 6-2-3 OVEN OSCILLATOR REMOVAL

6-2-4 FREQUENCY STANDARD AND 6-2-5 POWER SUPPLY PC BOARD REMOVAL

Procedures for removing the Frequency Standard and Power Supply PC Boards.

6-2-6 FILTER, 6-2-7 SPEAKER, AND 6-2-8 MOTHER BOARD REMOVAL

6-2-9 AUDIO PC BOARDS REMOVAL

Procedure for removing the Audio PC Boards.

6-2-10 ENCLOSED MODULES REMOVAL/DISASSEMBLY

Procedures for Enclosed Module Removal and Disassembly

Procedures for removing and disassembling enclosed modules.

6-2-11 OUTPUT AMPLIFIER (S/N 1001 THRU 3224) REMOVAL/DISASSEMBLY

6-2-11a OUTPUT AMPLIFIER (S/N 3225 ON) REMOVAL/DISASSEMBLY

Procedures for removing and disassembling the Output Amplifier for later serial numbers.

6-2-12 IF MODULE REMOVAL/DISASSEMBLY

Procedures for IF Module Removal and Disassembly

Procedures for removing and disassembling the IF Module.

6-2-13 DUAL VCO REMOVAL/DISASSEMBLY

Procedures for Dual VCO Removal and Disassembly

Procedures for removing and disassembling the Dual VCO module, with caution about realignment.

6-2-14 REAR PANEL REMOVAL

Procedure for Rear Panel Assembly Removal

Procedure for removing the Rear Panel assembly.

6-2-15 FRONT PANEL REMOVAL

Procedure for Front Panel Assembly Removal

Procedure for removing the Front Panel assembly.

6-2-16 GENERATE AMPLIFIER

A. Removal Procedure

Procedure for removing the optional Generate Amplifier.

6-3 ASSEMBLY

6-3-1 RF LEVEL ATTENUATOR ASSEMBLY

Procedure for positioning and installing the RF Level Attenuator.

SECTION 7 - MODULE TESTING

7-1 GENERAL MODULE TESTING INFORMATION

Provides detailed testing procedures for modules to determine if faulty.

7-1-1 MODULES RECOMMENDED FOR FACTORY REPAIR

Identifies modules that are not field repairable and must be returned to the factory.

7-1-2 DISASSEMBLY REQUIREMENTS

States that case and module removal are usually required for testing.

7-1-3 TEST EQUIPMENT REQUIREMENTS

Refers to Appendix B for a list of suitable test equipment.

7-1-4 SAFETY PRECAUTIONS

Safety Precautions During Module Testing

Lists critical safety precautions for troubleshooting live circuits.

7-1-5 INDEX OF MODULE TESTING PROCEDURES

Module Testing Index by Paragraph

An index listing modules with their corresponding testing procedure page numbers.

7-2 POWER SUPPLY

7-2-1 THEORY OF OPERATION

Explains the theory of operation for the Power Supply unit.

Power Supply Circuits Overview

Details the general, voltage supply, battery charger, and transformer driver circuits.

7-2-2 PREPARATION FOR TESTING

Instructions for preparing the unit for power supply testing.

Test Equipment and Preparation Steps

Lists required test equipment and details preparation steps including initial switch settings.

7-2-3 TESTING PROCEDURES

Power Supply Testing Steps

Step-by-step testing procedures for the power supply.

7-3 IF MODULE

7-3-1 THEORY OF OPERATION

Explains the theory of operation for the IF Module in Generate and Receive modes.

Module Operation and Signal Paths

Describes RF signal path, static protect, mixer, and filter circuits.

Module Circuit Details

Details mixer/amplifier circuits, VCO circuits, and preparation for testing.

Test Equipment and Preparation

Lists test equipment and details preparation steps including connecting test equipment.

7-4 DUAL VCO

7-4-1 THEORY OF OPERATION

Explains the theory of operation for the Dual VCO module.

Module Overview and VCO Circuits

Describes the Dual VCO's general function and its first and second VCO circuits.

VCO Buffer Amplifiers and Divider Network

Details buffer amplifier circuits and the programmable divider network.

7-4-2 PREPARATION FOR TESTING

Preparation instructions for testing the Dual VCO module.

7-4-3 TESTING: VCOs and Mixer Output

Testing Procedures for First VCO

Testing procedures for the first VCO.

Testing Procedures for Second VCO

Testing procedures for the second VCO.

Testing Procedures for Mixer Output

Testing procedures for the mixer output.

7-5 HIGH LOOP SYNTHESIZER MODULE

7-5-1 THEORY OF OPERATION

Explains the theory of operation for the High Loop Synthesizer.

Module Overview and Circuits

Describes the High Loop's general function and its analog/divider circuits.

7-5-2 PREPARATION FOR TESTING

Instructions for removing and disassembling the High Loop Synthesizer for testing.

Test Equipment and Preparation

Lists test equipment and details preparation steps including connecting test equipment.

7-6 LOW LOOP SYNTHESIZER

7-6-1 THEORY OF OPERATION

Explains the theory of operation for the Low Loop Synthesizer.

Module Overview and Circuits

Describes the Low Loop's general function and its VCO, buffer, and divider circuits.

7-6-2 PREPARATION FOR TESTING

Instructions for removing and disassembling the Low Loop Synthesizer for testing.

Test Equipment and Preparation

Lists test equipment and details preparation steps including connecting test equipment.

7-7 RECEIVER/GENERATOR

7-7-1 THEORY OF OPERATION

Explains the theory of operation for the Receiver/Generator module.

Module Modes and Signal Paths

Describes operation in Generate and Receive modes and signal paths.

Bandpass Filters and Signal Amplifiers

Details bandpass filters and amplifier circuits for received signals.

Demodulator Circuits and VCO

Details AM/FM demodulator circuits and the 21.4 MHz VCO.

7-7-2 PREPARATION FOR TESTING

Module Circuits: AM Modulator, Mode Power, and Phase Lock Logic

Details AM modulator, mode power control, and phase lock indicator logic.

7-9 DIGITAL MODULE

7-9-1 THEORY OF OPERATION

Explains the theory of operation for the Digital Module.

Module Circuits Overview

Describes the frequency divider, timing, and counter system circuits.

Timing and Signal Selector Circuits

Details the timing and signal selector circuits.

Counter System Details

Details the counter system, including latches, DAC, and error detection.

7-9-2 PREPARATION FOR TESTING

Test Equipment and Preparation Steps

Lists required test equipment and details preparation steps including control settings.

7-9-4 REASSEMBLY

Reassembly of Digital Module

Instructions for reassembling the Digital Module after testing.

7-10 RECEIVE AUDIO MODULE

7-10-1 THEORY OF OPERATION

Explains the theory of operation for the Receive Audio Module.

Module Operation and Signal Paths

Describes how demodulated audio signals are processed and routed.

Audio AGC and Filter Circuits

Explains the audio AGC circuit and lowpass filters.

Audio AGC, SINAD, and Distortion Circuits

Details audio AGC, SINAD, and distortion circuits.

7-10-2 PREPARATION FOR TESTING

Test Equipment and Preparation Steps

Lists required test equipment and details preparation steps including control settings.

7-10-4 REASSEMBLY

Reassembly of Receive Audio PC Board

Instructions for reassembling the Receive Audio PC Board.

7-11 GENERATE AUDIO MODULE

7-11-1 THEORY OF OPERATION

Explains the theory of operation for the Generate Audio Module.

Module Function and Signal Switching

Describes the module's function in processing audio signals and signal switching.

Signal Switching, AM Modulator, and Mode Power

Details signal switching, AM modulator/leveler, and mode power control circuits.

Phase Lock Indicator Logic

Describes the logic controlling the phase lock indicator LED.

7-11-2 PREPARATION FOR TESTING

Test Equipment and Preparation

Lists test equipment and outlines preparation steps.

7-11-4 REASSEMBLY

Reassembly of Generator Audio PC Board

Instructions for reassembling the Generator Audio PC Board.

7-12 OUTPUT AMPLIFIER MODULE

7-12-1 THEORY OF OPERATION (THRU S/N 3224)

Explains the theory of operation for the Output Amplifier module for specific serial numbers.

Module Operation and Circuits

Describes the module's function in amplifying and attenuating RF signals.

Circuit Details and Protection

Details level detector, receive enable, and power detector circuits.

7-12-2 THEORY OF OPERATION (S/N 3225 AND ON)

Module Modes of Operation

Describes operation in Receive and Generate modes, including signal path and amplification.

7-13 VARIABLE TONE GENERATOR

7-13-1 THEORY OF OPERATION

Explains the theory of operation for the Variable Tone Generator.

Module Components and Function

Describes the module's components like crystal oscillator, ROM/DAC, and adder system.

Adder System Details

Explains the adder system using chained adders and thumbwheel inputs.

Audio Signal Generator, Filters, and Detectors

Details audio signal generation, lowpass filters, and frequency selection detectors.

7-13-2 PREPARATION FOR TESTING

Test Equipment and Preparation

Lists test equipment and details preparation steps including connecting test equipment.

7-13-4 REASSEMBLY

Reassembly of Variable Tone Generator

Instructions for reassembling the Variable Tone Generator.

7-14 OPTIONAL GENERATE AMPLIFIER

7-14-1 THEORY OF OPERATION

Explains the theory of operation for the optional Generate Amplifier accessory.

General Function and Circuit Description

Describes the accessory's function in boosting output signal and its circuit components.

SECTION 8 - PREVENTIVE MAINTENANCE

8-1 PREVENTIVE MAINTENANCE (POWER "OFF")

Routine maintenance instructions for cleaning and inspecting the FM/AM-500A.

External and Internal Cleaning Procedures

Procedures for cleaning external and internal parts of the unit.

Visual Inspection Guidelines

Guidelines for visually inspecting the chassis, capacitors, connectors, and components.

SECTION 9 - PC BOARD ASSEMBLIES

9-1 GENERAL INFORMATION

Explains that this section contains component layout drawings for all PC Boards.

9-2 PC BOARD ASSEMBLY DRAWINGS INDEX

An index listing PC Board assembly drawings alphabetically.

SECTION 10 - CIRCUIT SCHEMATICS

10-1 GENERAL SCHEMATIC INFORMATION

Explains that this section contains module interconnect drawings and circuit schematics.

10-2 INDEX OF SCHEMATICS

An index listing circuit schematics by module title, figure, and page.

APPENDICES

APPENDIX A: FM/AM-500A SPECIFICATIONS

Lists detailed specifications for the FM/AM-500A.

A-1 RF SIGNAL GENERATOR SPECIFICATIONS

Provides specifications for the RF signal generator functions.

AUDIO GENERATOR, GENERATE AMPLIFIER, AND RECEIVER/MONITOR SPECS

Lists specifications for audio generator, optional generate amplifier, and receiver/monitor functions.

OSCILLATOR, FREQUENCY ERROR, MODULATION, AND SINAD METER SPECS

Provides specifications for master oscillator, frequency error meter, modulation meter, and SINAD/distortion meter.

APPENDIX B: TEST EQUIPMENT REQUIREMENTS

B-1 GENERAL INFORMATION

States that this appendix lists suitable test equipment for maintenance procedures.

B-2 RECOMMENDED TEST EQUIPMENT

Lists recommended test equipment with manufacturer, model, and specifications.

APPENDIX C: SPECIAL TEST EQUIPMENT

C-1 BATTERY LOAD SIMULATOR

Provides circuit schematic and diagram for the Battery Load Simulator.

C-2 ATTENUATOR KNOB SPACER

Describes the material and fabrication of an attenuator knob spacer.

APPENDIX D: ABBREVIATIONS & SYMBOLS

D-1 GENERAL ABBREVIATIONS

States that the following defines common abbreviations and symbols used in the manual.

APPENDIX E: REPACKING FOR SHIPMENT

E-1 SHIPPING INFORMATION

Provides conditions for returning test sets for service or repair, including contact information.

E-2 REPACKING PROCEDURE

Step-by-step procedure for repackaging the test set for shipping.

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