TM-11-5820-921-40-1 Power Amplifier AM-6545A/GRC-193A (NSN 5820-01-186-3699) Manual

Section 0. GENERAL
Figure 1-1. Power Amplifier AM-6545/GRC-193
Chapter 1. GENERAL INSTRUCTIONS
Figure 1-2. Radio Set AN/GRC-193 Components and System Relationships
Figure 1-3. Radio Set AN/MRC-138, Components and System Relationships
PA control circuits
PHYSICAL DESCRIPTION
TABLE 1-1. POWER AMPLIFIER AM-6545/GRC-193 CHARACTERISTICS
Figure 1-4. Power Amplifier AM-6545 /GRC-193 Major Assemblies and Components
Figure 1-5. Powe Amplifier Am/6545/GRC-193 Assemblies and Interconnection
TABLE 1-2. POWER AMPLIFIER AM-6545/GRC-193 SEMICONDUCTORS
TABLE 1-2. POWER AMPLIFIER AM-6545/GRC-193 SEMICONDUCTORS - continued - TM-11-5820-921-40-10032
TABLE 1-2. POWER AMPLIFIER AM-6545/GRC-193 SEMICONDUCTORS - continued - TM-11-5820-921-40-10033
TABLE 1-2. POWER AMPLIFIER AM-6545/GRC-193 SEMICONDUCTORS - continued - TM-11-5820-921-40-10034
Section II. PREPARATION FOR USE
INSTALLATION AS A SEPARATE COMPONENT
Table 1-3. Power Amplifier Am-6545/GRC-193 Mating Connector and Cable Identification Data
Figure 1-6. Power Amplifier Mount MT-4497/GRC-193
Figure 1-7. Power Amplifier Mount MT-4497/GRC-193 Lower tray Assembly Dimensional Data
TABLE 1-4. POWER AMPLIFIER INTERFACE CABLE FABRICATION DETAILS
TABLE 1-4. POWER AMPLIFIER INTERFACE CABLE FABRICATION DETAILS - continued
INITIAL CHECKOUT AND ADJUSTMENT
DEMOLITION TO RENDER POWER AMPLIFIER INOPERATIVE
Chapter 2. THEORY OF OPERATION
Figure 2-1. Power Amplifier AM-6545/GRC-193 Overall Funtional Diagram
TUNING CONTROL CIRCUITS
POWER SUPPLY CIRCUITS
RF AMPLIFIER DETAILED DESCRIPTION
Figure 2-2. RF Signal Path Receive Mode
Figure 2-3. RF Signal Path Transmit Mode
OUTPUT AMPLIFIER
TUNE MODE RF SIGNAL PATH
Figure 2-4. +26.5 Vdc Direct Distribution
Figure 2-5. +26.5 Vdc Switched Distribution
RECEIVE-TRANSMIT (RX-TX) SWITCHING
FAULT PROTECTION
SYSTEM CONTROL TUNE CYCLE OPERATION DESCRIPTION
Figure 2-6. System Tune Cycle Detail
TUNE CYCLE OPERATION-DETAILED DESCRIPTION
BAND CODE GENERATION-DETAILED DESCRIPTION
TABLE 2-1. BAND CODE GENERATION
BAND SWITCH INHIBIT-DETAILED DESCRIPTION
SERVO AMPLIFIER 1A5
TABLE 2-3. LMAX FORCE CONDITION
PHASE AND LEVEL DETECTOR
Figure 2-8. RF Output Voltage Sampling Network Simplified Schematic
TUNE CYCLE CONTROL
TABLE 2-5. TUNE CONTROL PWB GATE STATUS DURING TUNE OPERATION SEQUENCE
DC POWER SUPPLIES. DETAILED DESCRIPTION
+26.5 VDC SWITCHED POWER
Figure 2-9. +19 Vdc Distribution
Figure 2-10. - -14Vdc Distribution
+1600 VDC HIGH VOLTAGE POWER SUPPLY
Figure 2-11. +1600V Generation and distribution
+1600 VDC HIGH VOLTAGE POWER SUPPLY - continued
FILAMENT REGULATORS
Chapter 3. MAINTENANCE INSTRUCTIONS - TM-11-5820-921-40-10080
Figure 3-1. Special Setup For testing Power Amplifier
TABLE 3-1. POWER AMPLIFIER AM-6545/GRC-193 MAINTENANCE INSTRUCTION INDEX
TABLE 3-3. POWER AMPLIFIER AM-6545/GRC-193 MAINTENANCE-CLEANING SOLVENTS REQUIRED BUT NOT SUPPLIED
SAFETY PRECAUTIONS
POWER AMPLIFIER INSPECTION, CLEANING AND TOUCHUP - EXTERNAL
Figure 3-2. Power Amplifier AM-6545/GRC-193 Disassembly/Reassembly Diagram (Sheet 1 of 4)
Figure 3-2. Power Amplifier AM-6545/GRC-193 Disassembly/Reassembly Diagram (Sheet 2 of 4)
Figure 3-2. Power Amplifier AM-6545/GRC-193 Disassembly/Reassembly Diagram (Sheet 3 of 4)
Figure 3-2. Power Amplifier AM-6545/GRC-193 Disassembly/Reassembly Diagram (Sheet 4 of 4)
REMOVAL OF DC CONTROL PWB ASSEMBLY 1A2
REMOVAL OF PLATE ASSEMBLY 1A9
REMOVAL OF HIGH VOLTAGE MODULE ASSEMBLY 1A13
ACCESS TO INTERCONNECTION PCB ASSEMBLY 1A14A1
ACCESS AND/OR REMOVAL OF DC-TO-DC CONVERTER ASSEMBLY 1A14A3
ACCESS AND/OR REMOVAL OF CONNECTOR 1A14J13
TABLE 3-6. POWER AMPLIFIER AM-6545/GRC-193 ASSEMBLY AND/OR COMPONENT INSPECTION PROCEDURES - TM-11-5820-921-40-10097
TABLE 3-6. POWER AMPLIFIER AM-6545/GRC-193 ASSEMBLY AND/OR COMPONENT INSPECTION PROCEDURES - continued
TABLE 3-6. POWER AMPLIFIER AM-6545/GRC-193 ASSEMBLY AND/OR COMPONENT INSPECTION PROCEDURES - TM-11-5820-921-40-10099
DAMAGED CONNECTOR THREADS; BENT, LOOSE, OR MISSING PINS; OR CORRODED CONTACTS
LOOSE CASE ASSEMBLY (1A14) COMPONENTS, ASSEMBLIES, AND CONNECTORS
Figure 3-3. Tank Circuit Module Assembly 1A8 lubrication Points
BROKEN OR DAMAGED (OVERHEATED) INDUCTOR 1A14L1
LOGICAL APPROACHES TO POWER AMPLIFIER TROUBLESHOOTING
TABLE 3-7. POWER AMPLIFIER AM-6545/GRC-193 TROUBLESHOOTING INDEX
TABLE 3-8. POWER AMPLIFIER AM-6545/GRC-193 RELAY INDEX
MAINTENANCE TURN-ON PROCEDURE
Figure 3-4. PA Test Points and Indicators (Sheet 1 of 3)
Figure 3-4. PA Test Points and Indicators (Sheet 2 of 3)
Figure 3-4. PA Test Points and Indicators (Sheet 3 of 3)
Table 3-11. Power Amplifier AM-6545/GRC-193 Test Point/Indicator/Operation Correlation
Table 3-11. Power Amplifier AM-6545/GRC-193 Test Point/Indicator/Operation Correlation - continued
Figure 3-5. DC Power Fault Logic Diagram
Figure 3-6. HV Fault (DC-to-DC Converter 1A13 Won't Start) Logic Diagram
Figure 3-7. HV Fault (DC to DC Converter Starts but No. +1600V) Logic Diagram - TM-11-5820-921-40-10115
Figure 3-8. +19 Vdc Fault Logic Diagram
Figure 3-9. -14 Vdc Fault Logic Diagram
Figure 3-10. Bandswitching (Any Frequency) Fault Logic Diagram
Figure 3-11. Bandswitching (Running Motor) Fault Logic Diagram
Figure 3-12. Bandswitching (Incorrect) Fault Logic Diagram
Figure 3-13. L MAX Force Fault Logic Diagram
Figure 3-14. LM I N Force Fault Logic Diagram
Figure 3-15. Servo Tune Fault Logic Diagram
Figure 3-16. Heat Sink Blower fault Logic Diagram
Figure 3-17. Power Amplifier Tube Filament Fault Logic Diagram
Figure 3-18. T/R Line Fault Logic Diagram
Figure 3-19. Transmit RF Fault Logic Diagram
Figure 3-20. +1600 Vdc Overload Fault Logic Diagram
Figure 3-21. PA Fault Logic Diagram
Figure 3-23. Antenna Coupler fault Logic Diagram
HV OVERLOAD THRESHOLD ADJUSTMENT
Figure 3-24. HV Overload Threshold Adjustment Setup - DC Control PWB Assy 1A2
Figure 3-25. Over Voltage (+26.5 Vdc) Adjustment Setup - System Control PWB Assy 1A3
Figure 3-26. Ip ALC and RC ALC Adjustment Setup
RF ALC ALIGNMENT
Figure 3-27. 400 Hz Zero Beat Adjustment Setup
Figure 3-28. Tank Circuit Module Assy 1A8 Adjustment Detail Views
POWER AMPLIFIER REPAIR
DISASSEMBLY OF TUNE DETECTOR MODULE ASSEMBLY 1A10
DISASSEMBLY OF HIGH VOLTAGE MODULE ASSEMBLY 1A13
TABLE 3-12. COMPONENT LOCATION/SCHEMATIC DIAGRAM ILLUSTRATION CROSS-REFERENCE
REPLACEMENT OF CONNECTORS
REPLACEMENT OF CAPACITOR 1A14C1 AND 1A14C2
Section VI. CARE AND PREPARATION FOR STORAGE
Figure 3-29. Power Amplifier AM-6545/GRC-193 Component Location Diagram (Sheet 1 of 3)
Figure 3-29. Power Amplifier AM-6545/GRC-193 Component Location Diagram (Sheet 2 of 3)
Figure 3-29. Power Amplifier AM-6545/GRC-193 Component Location Diagram (Sheet 3 of 3)
Figure 3-30. Meter Board PWB Assembly 1A1, P/N 755017A4210, Component Location Diagram
Figure 3-31. DC Control PWB Assembly 1A2, P/N 755017A4220, Component Location Diagram
Figure 3-32. System Control PWB Assembly 1A3, P/N 755017A4230, Component Location Diagram
Figure 3-33. Tune Control PWB Assembly 1A4, P/N 75507A4240, Component Location Diagram
Figure 3-34. Servo Amplifier PWB Assembly 1A5, P/N 755017A4250, Component Location Diagram
Figure 3-35. Band Control PWB Assembly 1A6, P/N 755017A4260, Component Location Diagram
Figure 3-36. ALC Module Assembly 1A7, P/N 755017A4600, Component Location Diagram
Figure 3-37. Tune Load PWB Assembly 1A7A1, P/N 755017A4620, Component Location Diagram
Figure 3-38. ALC PWB Assembly 1A7A2, P/N 755017A4610, Component Location Diagram
Figure 3-39. Tank Circuit Module Assembly 1A8, P/N 755017A4500, Component Location Diagram
Figure 3-40. Input CAP PWB Assembly P/N 755017A4510, Component Location Diagram
Figure 3-41. Output CAP PWB Assembly 1A8A2, P/N 755017A4520, Component Location Diagram
Figure 3-42. Coil Gear Assembly 1A8A3, P/N 75507A4550, Component Location Diagram
Figure 3-43. Bandswitch Gear Assembly 1A8A4, P/N 755017A4540, Component Location Diagram
Figure 3-44. Coil Assembly 1A8A5, P/N 755017A4530, Component Location Diagram
Figure 3-45. Plate Assembly 1A9, P/N 75501A3900, Component Location Diagram
Figure 3-46. Plate Choke "A" PCB Assembly 1A9A1, P/N 755017A3910, Component Location Diagram
Figure 3-47. PWB "B" Assembly 1A9A2, P/N 755017A3920, Component Location Diagram
Figure 3-48. PWB "C" Assembly 1A9A3, P/N 755017A3930, Component Location Diagram
Figure 3-49. Tune Detector Module Assembly 1A10, P/N 755017A4800, Component Location Diagram
Figure 3-50. Tune Detector PWB Assembly 1A10A1, P/N 755017A4810, Component Location Diagram
Figure 3-51. RF Driver Module Assembly 1A11, P/N 755017A4700, Component Location Diagram
Figure 3-52. Driver Module PWB Assembly 1A11A1, P/N 755017A4710, Component Location Diagram
Figure 3-53. Static Power Inverter Assembly 1A12, P/N 755017A4900, Component Location Diagram
Figure 3-54. Inverter Module PWB Assembly 1A12A1, P/N 755017A4910, Component Location Diagram
Figure 3-55. High Voltage Module Assembly 1A13, P/N 755017A4300, Component Location Diagram
Figure 3-56. High Voltage Module PWB Assembly 1A13A1, P/N 755017A4310, Component Location Diagram
Figure 3-57. Interconnection PCB Assembly 1A14A1, P/N 755017A4270, Component Location Diagram
Figure 3-59. DC to DC Converter Assembly 1A14A3, P/N 755017A4100, Component Location Diagram
Figure 3-60. Indicator Assembly 1A14A4, P/N 755017A3800, Component Location Diagram
Figure 3-61. Junction Block PWB 1A14A5, P/N 755017A4041, Component Location Diagram
Figure 3-62. Regulator Assembly 1A14A6, P/N 755017A4031, Component Location Diagram
Figure 3-63. Component Bracket Assembly P/N 755017A4064, Component Location Diagram
Figure 3-64. Harmonic Filter Assembly 1A15, P/N 755017A4070, Component Location Diagram
Figure 3-65. Meter Board PWB Assembly 1Al, P/N 755017A4210, Schematic Diagram
Figure 3-66. DC Control PWB Assembly 1A2, P/N 755017A4220, Schematic Diagram
Figure 3-67. System Control PWB Assembly 1A3, P/N 755017A4230 Schematic Diagram
Figure 3-68. Tune Control PWB Assembly 1A4, P/N 755017A4240, Schematic Diagram
Figure 3-69. Servo Amplifier PWB Assembly 1A5, P/N 755017A4250, Schematic Diagram
Figure 3-70. Band Control PWB Assembly 1A6, P/N 755017A4260, Schematic Diagram
Figure 3-71. ALC Module Assembly 1A7, P/N 755017A4600, Schematic Diagram
Figure 3-72. Tank Circuit Module Assembly 1A8, P/N 755017A4500, Schematic Diagram
Figure 3-73. Plate Assembly 1A9, P/N 755017A3900, Schematic Diagram
Figure 3-74. Tune Detector Module Assembly 1A10, P/N 755017A4800, Schematic Diagram
Figure 3-75. RF Driver Module Assembly 1A11, P/N 755017A4700, Schematic Diagram
Figure 3-76. Static Power Inverter Assembly 1A12, P/N 755011A4900, Schematic Diagram
Figure 3-77. High Voltage Module Assembly 1A13, P/N 755017A4300, Schematic Diagram
Figure 3-78. Case Assembly 1A14, P/N 755017A400 Schematic Diagram - TM-11-5820-921-40-10199
Figure 3-78. Case Assembly 1A14, P/N 755017A400 Schematic Diagram - TM-11-5820-921-40-10200
Figure 3-79. Harmonic Filter Assembly 1A15, P/N 755017A4070, Schematic Diagram
Appendix A. REFERENCES - TM-11-5820-921-40-10202
TM-11-5820-921-40-1 Power Amplifier AM-6545A/GRC-193A (NSN 5820-01-186-3699) Manual

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