Pineapple Technology UTX2-5KULTRA Analog 2.5 kW TV Transmitter User Manual

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UTX2.5K ULTRA
INSTRUCTION MANUAL
PINEAPPLE TECHNOLOGY, INC
PINEAPPLE TECHNOLOGY, INC.
UTX2.5K ULTRA Operating and Service Manual
TABLE OF CONTENTS
Section l --- SAFETY NOTICES ………………………………………………………………………… 2
** READ THIS SECTION BEFORE INSTALLATON **
Secton ll --- TRANSMITTER SPECIFICATIONS …………………...…………………………………
Section lll --- TRANSMITTER INSTALLATION ………………………………………………………
Section lV --- TRANSMITTER TURN-ON ……………………………………………………………… 6
Section V --- THEORY OF OPERATION
A. Introduction ……………………………………………………………………………… 7
B. ACDIS2 AC Main Distribution …………………………………………………………
C. AC2008 Power Supply ………………………………………………………………… 7
D. PAS3 and ADP500 Performance Monitor …………………………………………… 8
E. RC8 Remote Monitor and Control W/ABS …………………………………………… 9
F. MA5000 Modulator ……………………………………………………………………… 10
G. UDR100AC Driver ……………………………………………………………………… 10
H. S3 3-Way Splitter ………………………………………………………………………… 10
I. MFA2PA Dual Power Amplifier ………………………………………………………… 10
J. UC3KW 3-Way Combiner ……………………………………………………………… 11
K. DC3KW Directional Coupler ……………………………………………………………… 11
L. BPU3K Bandpass Filter ………………………………………………………………… 11
SECTION Vl --- SCHEMATIC AND PARTS LISTS
A. UTX2.5K ULTRA ………………………………………………………….................... 12
B. ACDIS2 AC Main Distribution ………………………………………………………… 14
C. UDR100AC Driver ……………………………………………………………………… 16
D. MFA2PA Dual Power Amplifier ………………………………………………………… 18
1. 1A0035 Status Board ………………………………………………………… 20
2. PA1K 1KW Power Module …………………………………………………… 21
a. U500LDA 500 W Amplifier ………………………………………… 21
b. U250LD 250 W Amplifier ………………………………………… 21
c. 1A0025 Power Distribution Monitor ……………………… 21
d. 1A0018 Gain and Phase Matching Network …………… 21
E. UC200-3 3-Way Splitter ………………………………………………………………… 24
F. UC2KW3NDC 3-Way Combiner with Directional Coupler…………………………… 26
G. BPU3KW Bandpass Filter ……………………………………………………………… 27
H. PAS10 and ADP500 Performance Monitor ………………………………………… 28
SECTION Vll --- RECOMMENDED ROUTINE MAINTENANCE …………………………………… 30
SECTION Vlll --- ADJUSTMENTS AND TUNING ……………………………………………………
32
SECTION lX --- PROBLEM SOLVING / TROUBLESHOOTING …………………………………… 34
SECTION X --- WARRANTY ……………………………………………………………………………
SECTION Xl --- EXTENDED WARRANTY …………………………………………………………… n
37
Section I
Safety
Notices
PINEAPPLE TECHNOLOGY, INC.
UTX2.5K ULTRA Operating and Service Manual
l --- SAFETY NOTICES
l ---SAFETY NOTICES
** READ THIS SECTION BEFORE INSTALLATION **
SEVERE ELECTRICAL SHOCK OR BURNS MAY OCCUR
IF THIS EQUIPMENT IS USED IMPROPERLY.
NEVER WORK ON THIS EQUIPMENT ALONE. ALWAYS HAVE ANOTHER PERSON PRESENT
WHILE WORKING ON ELECTRICAL CIRCUITS OR MOVING EQUIPMENT. COMMUNICATIONS
TO EMERGENCY SERVICES SHOULD BE AVAILABLE AT ALL TIMES.
BEFORE CONNECTING THIS EQUIPMENT TO ANY AC ELECTRICAL SOURCE READ THE
SECTION ON INSTALLATION. ALL ELECTRICAL WIRING FOR THIS EQUIPMENT MUST BE
PERFORMED BY QUALIFIED ELECTRICIANS. ALL WIRING MUST BE COMPLIANT WITH
LOCAL ELECTRICAL CODES.
POWER AMPLIFIERS AND SUPPLIES ARE HEAVY. TO INSTALL THIS EQUIPMENT IN RACKS
USE TWO (2) PERSONS TO AVOID POSSIBLE INJURIES.
NEVER OPEN THE CABINET ENCLOSURE OR UNPLUG CABLES OR WIRES WHILE THIS
EQUIPMENT IS OPERATING.
ALL SERVICE WORK MUST BE PERFORMED BY QUALIFIED TECHNICIANS ONLY.
IF ONE IS NOT AVAILABLE LOCALLY, CONTACT PINEAPPLE TECHNOLOGY, INC. FOR
A LIST IN YOUR AREA.
Page 2
Section II
Transmitter
Specifications
PINEAPPLE TECHNOLOGY, INC.
UTX2.5K ULTRA Operating and Service Manual
II – TRANSMITTER SPECIFICATIONS
II – UTX2.5K ULTRA SPECIFICATIONS
OPERATING
Power Output ………………………… 2.5 kW Peak Sync
125 Watts Aural
RF Output Impedance………………… 50 ohms
Frequency Range……………………… 470 – 806 MHz
Frequency Stability…………………… 1 PPM or better
Harmonic and Spurious………………... -60 dB or better ref to P-sync
Power Consumption…………………… 14 kW maximum
AC Line Voltage……………………… 208 – 240 VAC Single Phase
VIDEO PERFORMANCE
Visual Frequency Response…………… +/- 1 dB across the TV channel -1.25 MHz to 4.75 Mhz
relative to visual carrier.
Differential Gain…………………………… .< 7%
Differential Phase…………………………...< 10 degrees
ICPM………………………………………..< 5 degrees
Low Frequency Linearity………………….. < 15%
Group Delay……………………………….. Meets FCC Part 73 Rule
Video Input Impedance……………………. 75 ohms
Video Input Level………………………….. 1 volt p-p
Variation of Output Power…………………. < 5%
Regulation of Output Power……………….. < 5% typical
Video Signal to Noise Ratio……………….. < 45 dB un-weighted
THESE SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.
Page 3
PINEAPPLE TECHNOLOGY, INC.
UTX2.5K ULTRA Operating and Service Manual
II – TRANSMITTER SPECIFICATIONS
AUDIO PERFORMANCE
Audio Response…………….…………. Meets FCC Pre-emphasis curve
Distortion…………………………………….< 1% THD
FM Noise…………………………............... < 50 dB or better
AM Noise……………………………………< 40 dB or better
AM Synchronous Noise……………………. < 40 dB typical
GENERAL
Operating Temperature…………………….. -10 to +35 Degrees Celsius Ambient
+14 to +95 Degrees Fahrenheit Ambient
Altitude…………………………………….. 5,000 ft without additional cooling
Cooling Requirement………………………. Unobstructed air flow to internal cooling system should
be 2,000 CFM minimum
RF Output Connectors………………………1 5/8” EIA Flange
Weight………………………………………450 lbs
Dimensions Overall…………………………23” x 77” x 32” (W x H x D)
THESE SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.
Page 4
Section III
Transmitter
Installation
PINEAPPLE TECHNOLOGY, INC.
UTX2.5K ULTRA Operating and Service Manual
lll -- TRANSMITTER INSTALLATION
lll -- TRANSMITTER INSTALLATION
To ensure long and reliable trouble-free service from the UTX2.5K ULTRA transmitter the following steps
for installation are recommended:
1.
MECHANICAL INSTALLATION: The UTX2.5K ULTRA was designed to be installed in a building
protected from the weather. The building should have a hard-surface floor such as concrete with a
moisture barrier. This barrier could be pressure-treated wood sub flooring which could be anchored
to the concrete and to the transmitter to make the installation earthquake resistant.
Allow a minimum of three feet around the transmitter cabinet for service access. The top of the
transmitter should be clear for three feet above to allow the air to exhaust from the transmitter.
Air flow thru the transmitter is approximately 2,000 CFM. Provisions for air inlet and exhaust from
the room must allow air flow with minimal obstruction. In the event that the room temperature
exceeds 35º Celsius (95º F), cooling air must be provided so that the room temperature will not
exceed 35 degrees Celsius under worse case conditions.
Notice: This equipment is HEAVY and must be handled by professional movers with proper
equipment. Any damage caused by the installers is not covered under warranty. Check to ensure
that installing crews have proper insurance coverage.
2.
GROUNDING: Transmitter grounding is VERY IMPORTANT and must be done correctly for
safety and operational reasons. A typical installation may be done as follows:
Use a heavy gauge wire such as #2 AWG stranded copper or solid copper buss one (1) inch wide
by 1/8 inch thick for connections. The bonding between the transmitter and the ground rods must
be good quality and protected from corrosion. The ground wires should run over the floor and be
connected to the ground rods located outside the building. The wire should not go thru the concrete
floor but over and around it.
3.
AC WIRING: Wiring to the house electrical sub-panel will be routed to the AC terminal
block mounted in the back of the rack.
Connections to the AC Main should be made as follows:
--- RED and BLACK are connected to the 220 VAC.
--- WHITE WIRE is connected to NEUTRAL.
---GREEN WIRE is connected to SAFETY GROUND.
NOTICE: All wiring of this type must be done by a QUALIFIED ELECTRICIAN and must
conform to LOCAL and NATIONAL wiring CODES.
Consult with your electrician to ensure that the proper breaker size is selected for the main circuit.
4.
ANTENNA CONNECTION: The transmitter is equipped with 1 5/8" EIA flange connectors
located at the top of the rack. Conditions vary from site to site so some engineering may be
required to ensure that the antenna is receiving the correct amount of power to comply with FCC
licenses and to ensure safety from lightning, etc.
Page 5
Section IV
Transmitter
Turn-On
PINEAPPLE TECHNOLOGY, INC.
UTX2.5K ULTRA Operating and Service Manual
lV -- TRANSMITTER TURN-ON PROCEDURE
lV --- TRANSMITTER TURN-ON PROCEDURE
Before applying AC Power to the transmitter for initial turn-on and check out, the installation should
be approved by a qualified broadcast engineer. The turn-on procedure that follows is recommended by
Pineapple Technology, Inc. engineering staff:
1.
Check transmitter load or antenna for proper installation and connection to the transmitter.
2.
Open the transmitter and inspect all cables and wires for loose connections or broken wires in the
rack assembly.
3.
Check for damage to the equipment mounted in the rack.
4.
Check all AC breakers and on/off switched to ensure that they are all in the OFF position.
5.
Turn-on Main AC breaker located in the house service sub-panel.
6.
Turn-on the Main AC breaker located on the two (2) ACDIS2 Power Distribution panel located
on the front of Transmitter. A green light should come on indicating power is on.
7.
Turn-on the AC Switch located on the front of the ADP500. The indicating lights should be on
and ready for operation.
8.
Turn-on the AUX Breaker located on the ACDIS2 front panel. The PA fans and rack exhaust
fans should come on.
9.
Turn-on the AC Power breakers located on the front panel of the ACDIS2. Check the AC2009
power modules, three (3) each, to see if the green lights are lighted indicating normal operation.
10.
Using the ADP500 and PAS3, check the idling currents on each PA to ensure that the
currents are in the correct range. Typical range is 0.5 to 2.5 amps. See ADP500 Operating
Section for details.
NOTICE: The Modulator has been set at the factory so that the output power indication on the
ADP500 will show 100% or 2 KW p-sync power level. It is important to read the instruction
manual supplied with the modulator to locate key adjustment devices on the front panel. The
output level adjustment will be necessary for the next step in the turn-on procedure.
11.
Locate the output level adjustment on the modulator and turn the level down to minimum or CCW.
12.
Turn-on the power switch located on the modulator rear panel.
13.
Apply a video signal (1 volt P-P) to the video input terminal.
14.
Slowly increase the output level adjustment while watching the RF Output level on the
APD500 meter until it reads to 50%.
15.
Using the ADP500 reflected power indication, check the LOAD reflected power. This should be
less than 5% reflected.
16.
Return to the PA current readings on the ADP500 to verify that all the currents are approximately
the same.
17.
With successful performance to Step 17, the transmitter output power can be increased using the
output level adjustment on the modulator to achieve 100%. The aural power can be added at this
time not exceeding 5% of output p-sync power as indicated on the ADP500.
Page 6
Section V
Theory
of
Operation
PINEAPPLE TECHNOLOGY, INC.
UTX2.5K ULTRA Operating and Service Manual
V -- THEORY OF OPERATION
V --- THEORY OF OPERATION (Page 1 of 5)
A. INTRODUCTION
The UTX2.5K ULTRA transmitter was designed to meet or exceed all FCC applicable specifications for
TV broadcast equipment. Special attention was given to the selection of sub-assemblies and components
to achieve maximum reliability and minimum down time. The construction of the UTX2.5K ULTRA is
BASIC and MODULAR with most components field replaceable. Special emphasis was placed on
"KEEPING IT SIMPLE" and returning to more traditional transmitter layouts and instrumentation.
This transmitter was designed for Analog (NTSC) transmission with provisions and options available to
convert to Digital Service at a later date if necessary.
Refer to the UTX2.5K ULTRA block diagram in for an overview of the transmitter architecture. This will
give the technician basic information needed to understand the operation of the transmitter and the function
of each subassembly.
SEE SECTION Vl.A FOR PARTS LIST AND BLOCK DIAGRAM.
B. ACDIS2 AC & DC DISTRIBUTION
The ACDIS2 is the primary AC power inlet module. The UTX2.5K ULTRA transmitter was designed to accept
208 to 240 VAC Single Phase using a four (4) wire connection. The four wires are:
--- 2 wires for 208 -230 VAC Single Phase
--- 1 wire for neutral connection
--- 1 wire for safety ground connection
CAUTION: Connection to the AC Primary source must be made using all four wires listed above. Follow
the wiring instruction given in TRANSMITTER INSTALLATION Section lll.3. If not followed, severe damage to
the transmitter and, or, electrical shock could result.
The ACDIS2 performs the following functions:
1. Provides a primary AC power breaker point to shutdown the transmitter
2. Provides 208 VAC power to each of the 2 KW DC power supplies with individual breaker points for
added safety.
3. Provides 110 VAC circuits for Modulator, ADP500, ABS (as necessary) and AUX Power where
needed.
4. Analog metering is provided to monitor the Power Supply voltage and current being applied to the
RF Amplifier states.
5. Power supply current sharing test points are provided for checking current sharing between
power supply modules.
SEE SECTION VI.B FOR SCHEMATIC AND PARTS LIST
C. AC2008 2KW POWER SUPPLY MODULE
The UTX2.5K ULTRA transmitter is designed with over 4 KW of DC power. To achieve this level, the power supply
in each transmitter rack is made up of two (2) TWRI6004 (PTI Part # AC2008) power modules mounted into
one (1) main frame assembly (PTI Part # AC2009) which are capable of managing three (3)
2 KW modules each.
Page 7
PINEAPPLE TECHNOLOGY, INC.
UTX2.5K ULTRA Operating and Service Manual
V -- THEORY OF OPERATION
(CONTINUED) (Page 2 of 5)
The power modules are "HOT PLUGGABLE" and can be removed or installed without turning off the
transmitter.
Each power supply module has OVER VOLTAGE, OVER CURRENT AND OVER TEMPERATURE
protection as well as a fault signal in the event of a failure.
REFER TO MANUFACTURER'S MANUAL FOR MODEL # TWRI6004 PROVIDED WITH THE UTX2.5K ULTRA.
D. ADP500 AND PAS3 PERFORMANCE MONITOR
The ADP500 AND PAS3 Performance Monitor provides the following functions:
1.
Monitors FORWARD AND REFLECTED POWER to the antenna and presents it as a percentage
of power rating. The transmitter comes set to 100% P-Sync power based on the ratings of the
transmitter.
2.
Monitors Aural Power as a percentage of P-Sync rating (5% typical).
3.
Provides a HIGH ANTENNA VSWR MONITOR in the event of an antenna or coax failure where
the reflected power exceeds 25% the transmitter will shut down. The front panel LED will change
from green to red in case of a fault.
4.
Provides current monitoring of all the pallets used in the three (3) PA1K power amplifier assemblies.
The current levels can be read directly from the multi-meter on the front panel. Individual pallets are
selectable on the ADP500 and the PA assemblies are selected using the PAS3. In normal operation, a
PA FAULT is indicated by going from green to read. RED indicates that the current level is below 500 ma
and a transistor may have failed. To read the actual current, select the appropriate PA Bank using the
PAS3. The ADP500 will display status of each pallet in that PA. The multi-meter will read the actual
current.
5.
A PA INHIBIT switch is provided for failure diagonostic purposes. When activated, this switch allows
the technician to monitor the bias currents for each pallet. These readings were recorded at the factory
and are found on the Transmitter Test Report, DC Test Report Section. This is the best way to
troubleshoot possible transistor problems. When in the PA INHIBIT mode, the RF PWR OFF LED will
change from green to red indicating that the "SHUTDOWN LINE" is at TTL 0 state and the output power
has been reduced to near zero.
6.
An RF MONITOR port (BNC) is available to connect a spectrum analyzer for monitoring the
output signal.
7.
METER SELECTION SWITCHES
The PAS3 is used to select the appropriate PA module (PA1K) for performance display on the ADP500.
PA designations are PA1 starting from the top row left (there is no PA located in the top row right
position) with PA3 and 4 located on the bottom row left to right.
The rotary switch on the ADP500 is the detail selector for the multi-meter. The various positons are
defined as follows:
PA1 thru PA5……………………………………
Reads PA Pallet currents as selected
Typical reading in INHIBIT MODE 1.5 to 2.5 A
Typical reading SMPTE BARS 5-7 A for PA1 thru PA4 with normal picture
Typical reading SMPTE BARS 2-3 A for PA5 with normal picture
Page 8
PINEAPPLE TECHNOLOGY, INC.
UTX2.5K ULTRA Operating and Service Manual
V -- THEORY OF OPERATION
(CONTINUED) (Page 3 of 5)
7.
METER SELECTION SWITCHES (Continued)
PA6………………………………………… No Connection
PS VOLTS………………………………… Reads DC voltage applied to PA stages
Typical reading would be +29 to 33 VDC
P FWRD…………………………………… Reads PA output power in P-Sync percentage of rating
Full power reading would be 100%
P RFLD………………………………………
Reads PA output power being returned from the load and
displayed as a percentage of forward power. Typical
reading would be < 5% indicated.
P AURAL……………………………………Reads the AURAL POWER component as a percentage
of forward power. Typical reading would be 5%
AUX 1 & AUX 2……………………………Not used in this configuration.
REFER TO SECTION VI.H FOR SCHEMATICS AND PARTS LIST
E. RC8 REMOTE MONITOR AND CONTROL WITH ABS
This equipment is OPTIONAL and can be used to satisfy FCC remote control requirements.
The Remote Monitor is used to monitor the operational status of the transmitter and will allow the operator
to turn RF on or off and adjust power levels remotely. The following items are monitored or controlled:
1.
Transmitter on/off function
2.
Power output level monitor and adjust
3.
AC Line Voltage status - With ABS you can be notified if there is a power failure at the site.
4.
Various other custom options afe available. Specify these at the time the transmitter is
purchased and they will be included if possible.
Remote monitoring requires a phone line connection. Information can be accessed via a PC Terminal.
The Auxiliary power unit requires a battery connection. A common car battery (12 VDC) can be used
with a charger as an ABS. This will run the Monitor and provide access to transmitter status for several
hours.
A manual for this equipment is provided by the Manufacturer and is included in the UTX2.5K ULTRA
package shipped with the transmitter. The manual is only included if this option was purchased for
delivery with the transmitter.
REFER TO INSTRUCTION MANUAL PROVIDED WITH THIS PACKAGE.
Page 9
PINEAPPLE TECHNOLOGY, INC.
UTX2.5K ULTRA Operating and Service Manual
V -- THEORY OF OPERATION
(CONTINUED) (Page 4 of 5)
F. MA5000 MODULATOR
The heart of any TV Transmitter is the MODULATOR. This equipment receives the video and audio
signals was well as any control signals needed. The base band signals are converted to RF with
an output on the desired operating channel.
Detail operation of the Modulator with schematics and parts list are provided by the equipment
manufacturer and included in the UTX2.5K ULTRA package shipped with the transmitter.
REFER TO INSTRUCTION MANUAL PROVIDED WITH THIS PACKAGE.
G. UDR100AC 100 WATT DRIVER AMPLIFIER
The RF output from the MA1000 modulator is accepted by the UDR100AC DRIVER AMPLIFIER.
This amplifier increases the drive level to that required for each of the PAK1 power amplifiers
to make rated power. The UDR100AC is powered by 110 VAC.
H. US200-3 3-WAY SPLITTER
The US200-3 3-Way Splitter receives the output from the UDR100AC Driver Amplifier
and splits it into 3 parts with phase and power levels equal. This unit is an isolated
in-phase splitter and will provide some isolation in the event one PA fails.
SEE SECTION VI.F FOR PARTS LIST
I. MFA2PA POWER AMPLIFIER HOUSING
The MFA2PA is the main RF Power Amplifier housing which accommodates two (2) PA1K
Amplifiers. The housing includes the following:
2 each
2 each
2 each
1 each
2 each
1 each
330 CFM cooling fans
Air filter assemblies
Front panel status PC boards
Main chassis
Mechanical slide assemblies
AC Filtered inlet for cooling fans
SEE SECTION Vl.D FOR SCHEMATICS AND PARTS LIST
I-1. PA1K POWER AMPLIFIER
The PA1K is the main RF Power Amplifier Assembly used in the UTX2.5K ULTRA.
Each amplifier assembly is made up of one (1) U250LD power pallet and two (2) U500LDA power
pallets. These amplifiers are operated in Class A/AB or sometimes referred to as "HARD AB". This
refers to the bias levels to achieve best linerarity.
Page 10
PINEAPPLE TECHNOLOGY, INC.
UTX2.5K ULTRA Operating and Service Manual
V -- THEORY OF OPERATION
(CONTINUED) (Page 5 of 5)
Each PA1K amplifier assembly includes the following:
1 each
2 each
U250LD power pallets
U500LDA power pallets
1 each Phase and gain matching circuit
1 each 2-Way gain & in-phase splitter
1 each 2-Way in-phase combiner
1 each Circulator
1 each Power distribution module (1A0025)
2 each Thermal sensors
1 each Remote monitor port (DB9)
1 each Front panel status port (Molex)
1 each Filtered DC input port
1 each Type N Panel mounted RF Input port
1each DIN 7/16 Panel mounted RF Output port
SEE SECTION Vl.E. FOR SCHEMATICS AND PARTS LIST
J. UC2KW3NDC COMBINER/ DIRECTIONAL COUPLER
The UC2KW3NDC is a 3-Way in-phase combiner. The combiner is specifically designed
for the channel designated transmitter frequency. This is a closed unit and cannot be serviced.
SEE SECTION Vl.G. FOR PARTS LIST
K. BPU3KW UHF BAND PASS FILTER
This Band Pass filter was designed to meet FCC Certification requirements with minimum loss of
RF Power. The BPU3KW comes tuned and tested to the operating frequency of the transmitter
and should no be adjusted without proper equipment. Replacement filters are available as
P/N BPUKW UHF (+CHANNEL NUMBER).
Page 11
Section VI
Schematic
and
Parts List
PINEAPPLE TECHNOLOGY, INC.
UTX2.5K ULTRA Operating and Service Manual
A.
Vl -- SCHEMATICS AND PARTS LIST
UTX2.5K ULTRA Parts Assy
Item Qty Type P/N
Title
Detail
Top
CAT UTX2K ULTRA
UHF TV XMTR 2 KW P-SYNC
STD 19 IN RACK 6 FT
PS
BPU3KW
BP FITER 3 KW BAND IV
COM-TECH FC4E110C
PS
HL200
1 5/8 U-LINK 6.5 IN FLANGED
UNPAINTED
PS
HL201
1 5/8 LINE SECTION FLG-FLG
12 INCHES UN PAINTED
PS
HL202
1 5/8 ANCHOR PLATE
UN PAINTED
PS
MFR40RU
40 RU ASSEMBLIED RACK
BLACK CONTEMPRA 2 WELDED
PL
AC2009
6KW 3EA PWR SUPPLY MAIN
FRAME
UNIPOWER RRS2U
PS
AC2008
2 KW 31 VDC PWR SUPPLY
UNI-PWR TRS6000-406
1 X 4 OUTLETS 6 FT CORD
PS
AC8100
AC WIREMOLD 120 VAC 19 IN
RACK MTG
PS
AC8220
AC WIRE MOLD 220 VAC
19 IN RACK MT
10
CAT ADP500
DISPLAY PANEL, ANALOG
SEL SW AND METER
11
PL
ACDIS2
AC & DC DISTRIBUTION
UTX2KWA TRANSMITTERS
MFA2PA
2KW MAIN FRAME W/U500LD
AMPS
UHF/VHF ASSEMBLIES
PA SEL SW FOR ADP500
3 POSITIONS W/1 OUTPUT
BNC-M TO N-M 52 INCHES LONG
12
1.5 PL
13
CAT PAS3
14
PS
1A7052
CABLE ASSEMBLY RG-223
15
PS
PAC0005
DB9 MALE TO MALE 6 FT LONG PA MONITOR CABLE
16
PL
1A6003
DC CABLE SET 5KW
HIGH CURRENT ASSEMBLY
17
CAT UDR100AC
UHF DRIVER AMP 100W W/AC
SUPPLY
U250LD AND UDR100 AMPS
18
PS
MFR44RU-BB
GROUNDING BAR CU
19
.5
PS
MFR44RU-HP5
10-32 MTG SCREWS
BLACK
20
PL
1A7065
CABLE ASSEMBLY LDF4-50
UTX SERIES XMTR 7/16 DIN TO N M
21
PS
MA5000
SCREEN SERVICE
MODIFIED TO PTI SPECS
23
25 PS
INHOUSE_LABOR
PTI LABOR
LOADED
24
12 PS
INHOUSE-ENG TEST ENG TESTING AND FIXIT
LOADED
26
PS
MFS102
RU24/40 RACK TOP COVER
HOLDS 2 FANS AND OUTPUT CONN.
27
PS
851040
FAN, AC 220 V
CARAVEL CLE 3T2 W/O FG
28
PS
MF9283
EQUIPMENT SUPPORT
14 GA GAL-XC (LEFT & RIGHT)
29
CAT US200-3
UHF 3 WAY SPLITTER
TYPE N I/O
Page 12
MIDDLE ATLANTIC BB-44-1
A
220 VAC
AC
Out
AC
Inlet
RF Output
110 VAC
220 VAC
Aural
Visual
IF
AC Inlet
MA5000
Modulator
DC Amps
DC Volts
AC Inlet
220 VAC
10
AUX
Main AC
220 V
100 mv FS
Meter
Shunt
125A
125A
125A
+32 VDC
DC Distribution Panel
AC2009
4 KW
Power
Supply
AC Inlet
UDR100AC
100 W Driver
ACDIS2
AC Main Distribution
110VAC
RC8
Remote Control
(Optional)
220VAC
Xmtr On/Off
Po Level
220VAC
Phone Line
+12 VDC
220VAC
Page 13
FAN B
US200-3
3-Way
Splitter
PAS3
Fwrd Pwr
Xmtr On/Off
Po Level ADP500
Rfld Pwr
AC Inlet
+DC
PA3
PA2
PA3
MFA2PA
PA2
SCALE
SIZE
MFA2PA
RF IN
+DC
PA1
MFA2PA
RF IN
+DC
PA Fans
MFA2PA
PA1
RF IN
FSCM NO.
FIT
SHEET
UTX2.5K ULTRA
BLOCK
DIAGRAM
DWG NO.
REV
1 of 1
UC2KW3NDC
3-Way Combiner
with
Directional
Coupler
Directional Coupler
Pineapple Technology, Inc.
Rocklin, CA
Rack Fan
3-Way
Combiner
BPU3KW
Bandpass
Filter
CAL
ATT
FAN A
CAL
ATT
DC Output
+32 VDC
SECTION VI – SCHEMATICS AND PARTS
SUB-SECTION A - UTX2.5K ULTRA
PINEAPPLE TECHNOLOGY, INC.
UTX2.5K ULTRA Operating and Service Manual
B.
Vl -- SCHEMATICS AND PART
ACDIS2 Assy Tree
Item Qty Type P/N
Top
Title
Detail
PL
ACDIS2 AC & DC DISTRIBUTION
UTX2KWA TRANSMITTERS
PS
660110 DC PANEL METER 50 V FS
HOYT MODEL 3115 1-1/2 ANA PANEL
PS
660113 DC AMP METER 300 A FS
HOYT 3115 100mv FS
PS
670300 SHUNT, METER 100 mv FS
Lightweight shunt, 100 Millivolt, 300 amp.
PS
AC3110 AC CKT BREAKER
115 VAC 10 AMPS RS TYPE
PS
AC8000 AC POWER DISTRIBUTION BLOCK 3 POLE 840 A 60O VAC
PS
AC5105 AC PANEL MTG OUTLET
4 POSITION "GANGED" 15A 115VAC
PS
AC4111 AC POWER PLUG 220AC 16A
POWER INLET SCHURTER 4300.0922
PS
480461 MOLEX CRIMP TERM PLUG
PLUG HOUSING 6 POLE
10
PS
480462 MOLEX CAP STRAIN RELIEF
ACDIS SUBASSEMBLIES
11
PS
480460 MOLEX CRIMP TERM 6 POLE
CAP HOUSING PANEL MTG
12
12 PS
480463 MOLEX PIN CONTACTS LRG
CONN PIN 14-20 AWG TIN CRIMP
13
12 PS
480464 MOLEX SOCKET CONTACTS
CONN SOCKET 14-20 AWG TIN CRIMP
14
PS
480465 MOLEX PLUG HOUSING
9 POLE MATE-LOC
15
PS
480466 MOLEX CAP HOUSING
9 POLE
16
PS
480467 MOLEX STRAIN RELIEFS
9 POLE
17
PS
471380 FUSE FAST ACTING 80 AMP
USE WITH LFFB0001 HOLDER
18
PS
460190 FUSE HOLDER 400A
LITTELFUSE LFFB001
19
PS
AC3315 AC CKT BKR ELUMINATED
U600LPA 220 15 A 2 POLE
20
PS
MF9312 ACDIS MAIN CHASSIS
AL 090 MATERIAL ALODYNE/W SILK
21
PS
MF9313 ACDIS MAIN COVER
1 & 2 KW 090 AL ALODYNE
23
PS
MF9311 PLATE, FRONT ACDIS2
24
PS
AC3250 AC CKT BRKR
25
PS
453000 HW, TIP JACK
RED, Insulated standard TIP JACK
26
PS
453001 HW TIP JACK
WHITE, Insulated standard TIP JACK
27
PS
453002 HW, TIP JACK
BLACK, Insulated standard TIP JACK
28
PS
453003 HW, TIP JACK
BLUE, Insulated Standard TIP JACK
29
PS
AC4302 AC CORD GRIP
0.98 OD CABLE 1.3 HOLE MTG
50 AMP 2-POLE 220V
Page 14
SECTION VI - SCHEMATIC AND PARTS LISTS
AC MAIN
Page 15
JC
2/15/2006
.5 ULTRA
FAN
CABINET
FAN
SUB-SECTION B - UTX2.5K ULTRA
PINEAPPLE TECHNOLOGY, INC.
UTX2.5K ULTRA Operating and Service Manual
C.
Vl -- SCHEMATICS AND PARTS LIST
UDR100AC Assy Tree
Item Qty Type P/N
Title
Detail
Top
CAT UDR100AC
UHF DRIVER AMP 100W W/AC
SUPPLY
U250LD AND UDR100 AMPS
470-810 MHz ZINGER COMBINER
CAT U250LD
UHF TV 250 W P-SYNC PALLET
CAT UDR25A
DRIVER, 25W LINEAR 470-815 MHz LDMOS DUAL PACKS PALLET MTG
PS
MF9337B
PANEL, FRONT
DRV100DC
PS
MF9338F
CHASSIS
DRV100-3
PS
MF9339B
DIVIDER AIR FLOW
DRV100DC
PS
MF9340B
TOP COVER DRV100DC
PS
MF9341
DRV100 HEAT SINK
ALL DRV TYPES
PS
851005
FAN DC 24 V 80X25mm
COMAIR-ROTRON
PS
990201
FILTER & FINGER GUARD
80X25mm FAN 30 PPI
10
PS
631001
INDICATOR LAMP LED
GREEN 24 VDC 1/2 IN MTG HOLE
11
PS
484001
SW, ON/OFF ROCKER AC
CW IND. NAA-211-B121-00
12
PS
AC1003
FILTER, AC LINE
110/220 AC PLUG
13
PS
AC3110
AC CKT BREAKER
115 VAC 10 AMPS RS TYPE
14
PS
451004
HW TER BLOCK
#6 2X6 ROW
15
PS
451010
TERM BLOCK JUMPERS
2 POLE
16
PS
AC2010
DC POWER SUPPLY 115/220 VAC 320 WATTS 27-31 VDC
17
PS
CC316-NPF-PT-21
CABLE ASSEMBLY RG316/
1 N-FM PANEL MT WITH PIGTAIL
18
PS
481100
CON 9 P D-SUB MALE
MALE 9P SOLDER CUP
19
PS
140010
RES 2W 10 OHM
10 OHM
20
PS
140012
RES AXIAL TH 2 WATT
75 OHM METAL OXIDE
Page 16
Page 17
GROUND
110 VAC
RF IN
P1
P2
P3
P4
P5
P6
P7
P8
P9
Optional
Remote
Interface
DB9
CB
On/Off Sw
DC
Power
Supply
GND
75 OHM
+28 VDC
UDR25A
Air Inlet Filters
DC FANS
U250LD
SIZE
SCALE
1:1
SHEET
REV
1 of 1
UDR100AC AMP/DRIVER
BLOCK
DIAGRAM
DWG NO.
FSCM NO.
Pineapple Technology, Inc.
Rocklin, CA
LAMP
RF OUT
SECTION VI-PARTS AND VENDORS
SUB-SECTION C - UTX2.5K ULTRA
Filter
PINEAPPLE TECHNOLOGY, INC.
UTX2.5K ULTRA Operating and Service Manual
D.
Vl -- SCHEMATICS AND PARTS LIST
MFA2PA Parts Assy
Item Qty Type P/N
Title
Detail
Top
UHF/VHF ASSEMBLIES
PL
MFA2PA
2KW MAIN FRAME W/U500LD
AMPS
PS
MF9100E
MAIN CHASSIS
MFA1KW
PS
MF9101D
DIVIDER, PLENUM
MFA1KW
PS
MF9102C
DIVIDER, FAN
MFA1KW
PS
MF9104B
COVER, TOP
MFA1KW
10
PS
MF9139
SLED GUIDE
U600LP & MFA1KW
11
PS
MF9123D
FRONT PANEL, PAINTED
MFA1KW
14
PS
990199
FILTER, AIR DRY
FF-5 MFA/PS FP
16
PS
MF9127
MTG BRACKET, MOLEX FMALE
MFA1KW
17
PS
480472
MOLEX CRIMP TERM MFA1KW
MOLEX MFG 39-00-0041
18
PS
480400
MOLEX PLUG 6 TERM MFA1KW
MOLEX 15-06-0065 MINI-FIT BMI
19
PS
460150
FUSE HOLDER PANEL MTG
3AG TYPE QC CON
20
PL
1A0035
PA STATUS BOARD
PC9061H
22
PS
INHOUSE_LABOR PTI LABOR
LOADED
24
PS
MF9308
FAN FINGER GUARD
MFA1KW & U600LPA
25
PS
MF9310
AC FAN INLET HOLDER
MFA1KW
27
PS
MF9258
BRACKET FILTER MTG PAINTED U600LPA & MFA1KW
28
PS
MF9197B
DIVIDER PA
MFA1KW
29
PS
851025
FAN, AC 220 V
COMAIR ROTRON TN3A2
30
PS
AC5110
AC FAN PLUG & CORD
FMALE PLUG 24 IN CORD
31
PS
451080
TERM BLOCK EU STYLE
4 POLE 12-24 GAGE
32
0.1 PS
H-TAPE_TFE
TEFLON TAPE, SLIDES
1 INCH X 56 INCHS
33
PL
PA1K
UHF 1KW PA ASSEMBLY U500LD DIN OUTPUT W/CAPTOR FILTERS
34
.2
PS
INHOUSE-ENG TESENG TESTING AND FIXIT
Page 18
LOADED
SECTION VI - SCHEMATICS AND PARTS
SUB-SECTION D - UTX2.5K ULTRA
MFA2PA ASSY
+32 VDC
J1
GND RTN
RF IN
PA1, PA2
PA1K
DB9
PA1B
PA2A
PA5
GND
SD
PA1A
PA2B
+VDC
NA
P1
P2
P3
P4
P5
P6
P7
P8
P9
RF OUT
J5
220 AC Fan
330 CFM
Fan Power
Status Display
Assy
+28 VDC
1A0035
Ground
HS Mon
P3
J3
3A
Fuse
L1
L2
Filter
GND
220 VAC
Note: One of the MFA2PA’s in the UTX2.5K ULTRA only
houses one power amp, PA1. The second
MFA2PA houses PA2 and PA3.
+32 VDC
J1
GND RTN
RF IN
PA3
PA1K
DB9
P1
P2
P3
P4
P5
P6
PA1B
PA2A
PA5
GND
SD
PA1A
P7 PA2B
P8 +VDC
P9 NA
RF OUT
J5
220 AC Fan
330 CFM
Fan Power
Status Display
Assy
+28 VDC
1A0035
Ground
HS Mon
P3
J3
3A
Fuse
Pineapple Technology, Inc.
Rocklin, CA
SIZE
Page 19
MFA2PA
BLOCK
DIAGRAM
FSCM NO.
DWG NO.
SCALE
FIT
SHEET
REV
1 of 1
PINEAPPLE TECHNOLOGY, INC.
UTX2.5K ULTRA Operating and Service Manual
D.
Vl -- SCHEMATICS AND PARTS LIST
MFA2PA POWER AMPLIFIER
1. 1A0035 STATUS BOARD PARTS LIST
Item Qty Type P/N
Title
Detail
Top
PL
1A0035
PA STATUS BOARD
PC9061H
PS
114330
RES ARRAY, SMT
330 OHMS
PS
115103
RES CHIP 0805
10K OHM SMT 0805
PS
115334
RES CHIP 0805
330 K OHM SMT
PS
115563
RES CHIP 0805
56K OHM 0805 SM
PS
115682
RES CHIP 0805
6.8 K OHM SMT
PS
21X005
CAP CHIP 0805
100NF 10% XTR 0805 CASE
PS
21X008
CHIP CAP 0805
10NF 50 V 0805 SM
PS
240109
CAP TH POLYPROPYLENE
3N3 600 WVDC .033UF
PS
240110
CAP TAN SMD
3.3 UFD 35 V
10
PS
240111
CAP TAN SMD
47 UF 10 V TAN
11
PS
241300
CAP RADIAL TH
330 UF 35 VDC
12
PS
241301
CAP RADIAL TH
680 UF 10 V ELECTROLYTIC
13
PS
27022N
FT CAP 22N SM
AVX OR MURRATA PART
14
PS
480500
CON MICRO-FIT HEADER 3.0
8 PIN PC MTG
15
PS
520230
SEMI DIODE SHOTTKEY
1.5 A 60 VDC D-64
16
PS
520275
SEMI, DIODE DUAL
SW CC 70V SOT-23
17
PS
530350
HEX SCHMITH TRIG
74HD14
18
PS
538150
IC SWITCHER SIMPLE
SO8 PAK
19
PS
630200
IND LED DUAL COLOR
RED/GREEN T1-3/4 CLR
20
PS
750001
FERRITE BEAD SMT
0805 EMI FERRITE BEAD
21
PS
830510
IND, W/W
82 UH .58A PWR SMD
22
PS
PC9061H
PA STAUS BRD
FR4 060 1/1 CBR
23
PS
115331
RES CHIP 0805
33O OHM SMT
24
PS
520120
SEMI ZENER
5.6 V MELF
25
PS
115683
RES CHIP 0805
68K SM
26
0.2 PS
OS_AES_1A0025
OUTSIDE ASS'Y 1A0025
ASS'Y WORK
27
0.1 PS
INHOUSE_LABOR
PTI LABOR
28
0.1 PS
INHOUSE-ENG TEST ENG TESTING AND FIXIT
29
PS
480510
RECEPTACLE
8 CKT RECEPT MOLEX
30
PS
115333
RES CHIP 0805
33K OHM SMT
31
PS
1155112
RES 0805 CASE
51.1 K OHM 1%
Page 20
SECTION VI - SCHEMATICS AND PARTS
SUB-SECTION D.1 - UTX2.5K ULTRA
C:\\PTI Folders\PTI Block Diagrams\S10-6 5KW Block Diagram
Pineapple Technology, Inc.
Rocklin, CA
SIZE
Page 21
SCALE
1A0035 STATUS BOARD
CIRCUIT
DIAGRAM
FSCM NO.
DWG NO.
SHEET
REV
PINEAPPLE TECHNOLOGY, INC.
UTX2.5K ULTRA Operating and Service Manual
D.
Vl -- SCHEMATICS AND PARTS LIST
MFA2PA POWER AMPLIFIER
2.
PA1K ASSEMBLY TREE
Item Qty Type P/N
Title
Top
Detail
PL
PA1K
UHF 1KW PA ASSEMBLY U500LD
PAs
DIN OUTPUT W/CAPTOR FILTERS
PL
MF9525
HS RT SIDE U500LD ASSEMBLY
BLF872 LDMOS
PL
MF9526
HS LEFT SIDE U500LD
BLF872 DEVICES
PL
MF9539
ISOLATOR & 2-WAY COMB PLATE U1KWPA ASSEMBLY W/BLF872A
PL
U500LDA
500W 470-810 MHz POWER PALLE RGR 4003 032 MATERIAL BLF872
PL
1A0025
DC ISO/MONITOR CKT
REPLACED CB99
PS
CT-1326A
CIR W/TABS CH 26 TO 44
Circulator 542-656 MHz
PS
270600
FT CAP CAPTOR 9 NF 500V
5/16 TERMINALS
PS
MF9126C
MOLEX BRACKET MTG PLATE
U600LD ALL
PS
MF9309
REAR PANEL WITH SILK
090 AL ALODYNE
10
PS
MF9203 B1
1A0025 PCB MTG PLATE
SM 09 AL W/MTG
11
PS
MF9137E
SLED
U500L AL
12
PS
454001
HANDLE, REAR
BLK NYLON
13
CAT U250LD
UHF TV 250 W P-SYNC PALLET
470-810 MHz ZINGER COMBINER
14
PS
PC9022A_B2
2-WAY INPHASE 060 1/1 RG
15
PL
PC9518A
PC BOARD COMB
PCB SET OF (3) BRDS OUTPUT
COMB
16
PS
17
.4
PS
18
PS
INHOUSE_LABOR PTI LABOR
INHOUSE-ENG
TEST
ENG TESTING AND FIXIT
COAXIAL ASSEMBLY W/7_16 DIN
CON
CA4000
COAX IS SUPPER FLEX
Page 22
U1KWPA ASS'Y
P1 PA1B
P2 PA2A
P3 PA5
P4 GND
P5 SD
P6 PA1A
P7 PA2B
P8 +VDC
P9 NC
J31
DB9
Power
Distribution
Module
1A0025 Assy
Page 23
J29
J26
J25
J24
J23
J22
+32 VDC
Shutdown Line (SD)
U250LD
PA
U500LDA
PA1
U500LDA
PA2
+32 VDC
+32 VDC
+32 VDC
+32 VDC
SIZE
SCALE
TS3
TS2
FIT
SHEET
Pineapple Technology, Inc.
Rocklin, CA
Heat Sink R
Heat Sink L
400 W
50 ohm
Circulator
PA1K Amplifier Assy
BLOCK
DIAGRAM
DWG NO.
FSCM NO.
2-Way In-phase
Combiner
RF OUT
1 of 1
REV
MFA2PA
Front
Panel
Interface
SUB-SECTION D.2 - UTX2.5K ULTRA
GROUND
+32 VDC
RF IN
Gain
and
Phase
Network
2-Way Input
Splitter
SECTION VI
SCHEMATICS AND PARTS
PINEAPPLE TECHNOLOGY, INC.
UTX2.5K ULTRA Operating and Service Manual
E.
Vl -- SCHEMATICS AND PARTS LIST
US200-3 Assy Tree
Item Qty Type P/N
Title
Top
UHF 3 WAY SPLITTER
CAT US200-3
Detail
Page 24
SECTION VI - SCHEMATICS AND PARTS
SUB-SECTION E - UTX2.5K ULTRA
RF OUT TO PA1
RF OUT TO PA2
RF IN
RF OUT TO PA3
50 OHM
TERMINATION
Pineapple Technology, Inc.
Rocklin, CA
SIZE
Page 25
SCALE
US200-3 3-WAY SPLITTER
BLOCK
DIAGRAM
FSCM NO.
DWG NO.
REV
SHEET
SECTION V1 - SCHEMATICS AND PARTS
SUB-SECTION F - UTX2.5K ULTRA
No Serviceable Parts
Pineapple Technology, Inc.
Rocklin, CA
UC2KW3NDC 3-WAY COMBINER
& DIRECTIONAL
COUPLERREV
SIZE
FSCM NO.
DWG NO.
Page 26
SCALE
SHEET
SECTION VI - SCHEMATICS AND PARTS
SUB-SECTION G - UTX2.5K ULTRA
NO SERVICEABLE PARTS
Pineapple Technology, Inc.
Rocklin, CA
SIZE
Page 27
SCALE
BPU3KW BANDPASS FILTER
CIRCUIT
DIAGRAM
FSCM NO.
DWG NO.
REV
SHEET
PINEAPPLE TECHNOLOGY, INC.
UTX2.5K ULTRA Operating and Service Manual
Vl -- SCHEMATICS AND PARTS LIST
H-1 PAS3 SELECTOR SWITCH ASSY
Item Qty Type P/N
Title
Detail
Top
CAT PAS10
PA SEL SW FOR ADP500
10 POLE INPUT 1 OUTPUT
PS
PC9501
PA SELECTER SWITCH
10 POLE ADP500
PS
483010
SW 10 POLE
ADP500 PA SELECTOR PAS10
PS
481250
CON DB9 SUB RT ANGLE FM
METAL CASE AMP7457814
PS
481260
CON DB9 2 SECTION RT ANG
PCB MTG 0.9 SPACING
PS
MF9342X1
PLATE, FRONT PAS10
W/ PAINT & SILKSCREEN
PS
MF9343X1
CHASSIS, PAS10
W/ ALODINE & SILKSCREEN
PS
MF9344X1
COVER, TOP PAS10
W/ ALODINE & SILKSCREEN
H-2 APD500 PERFORMANCE MONITOR
Item Qty Type P/N
Title
Detail
Top
CAT ADP500
DISPLAY PANEL, ANALOG
SEL SW AND METER
PL
1A0029
ADP1000 LOGIC PCB
LOGIC BRD PARTS
PL
1A0030
ADP1000 FP PCB
FP PCB AND PARTS
PS
471306
FUSE 3AG
6 AMP
PS
460150
FUSE HOLDER PANEL MTG
3AG TYPE QC CON
10
11
12
13
PS
PS
PL
PS
PS
PS
PS
PS
PS
484001
660103
1A0027
PS2527
484020
MF9214
MF9011
MF9209B
MF9208
SW, ON/OFF ROCKER AC
METER, 2 VOLTS FS
PWR MONITOR CK
POWER SUPPLY OPEN/FRAME
TOGGEL SW MOMENTARY/ON
FRONT PANEL
Cover, Top
DIVIDER
CHASSIS
CW IND. NAA-211-B121-00
SELCO 39M-0-2VDC
PC9052B CBR
110/220 VAC 27 V 25 W
2 POLE
PANEL FRONT ADP500
ADP1000
ADP1000
ADP500/1KW
Page 28
SECTION VI - SCHEMATICS AND PARTS
SUB-SECTION H - UTX2.5K ULTRA
PAS3 PA SELECTOR
PA3 Input
PA2 Input
PA1 Input
DB9
REFL PWR 20 dbm
SEL
SW
FWD PWR 20 dbm
PA(N)
DB9
PA(N)
NOTE: PA6, AUX1 AND AUX2 ARE N/C
PA6
PS VOLTS
PA5
P FWD
PA4
SUB
ASSY
SW
PA3
RF Sample
METER
P RFL
P AURAL
AUX1
PA2
PA1
AUX2
110 VAC
N/A
ADP500 MONITOR
REMOTE STATUS AND CONTROL
P1
P2
P3
P4
P5
P6
P7
P8
P9
FWD PWR
NOT USED
NOT USED
GND
SHUTDOWN
RFLD PWR
AURAL PWR
NC
NC
DC VOLTAGE
DC CURRENT
PHONE LINE
Pineapple Technology, Inc.
Rocklin, CA
SIZE
Page 29
SCALE
PAS3 AND ADP500
BLOCK
DIAGRAM
FSCM NO.
DWG NO.
SHEET
REV
Section VII
Recommended
Routine
Maintenance
PINEAPPLE TECHNOLOGY, INC.
UTX2.5K ULTRA Operating and Service Manual
VII -- ROUTINE MAINTENANCE
VII --- ROUTINE MAINTENANCE (Page 1 of 2)
The following KEY MAINTENANCE AND PERFORMANCE CHECKS should be made monthly or more
frequently in some environments where dust and rodents are problems. Pineapple Technology, Inc.
recommends that the station provide a data log book to maintain these records.
DANGER: SOME OF THE RECOMMENDED TESTS REQUIRE THAT THE TRANSMITTER BE
OPERATING IN NORMAL MODE. THIS PROCEDURE MUST BE PERFORMED BY A
BROADCAST ENGINEER. MORE THAN ONE PERSON SHOULD BE PRESENT IN CASE OF AN
ACCIDENT REQUIRING ASSISTANCE. COMMUNICATIONS TO EMERGENCY SERVICES SHOULD
BE AVAILABLE.
TRANSMITTER
●
This is an integrated 2.5kW transmitter and is built around three (3) PA1K amplifier assemblies
located in two MFA2PA mainframes. (One mainframe only holds one (1) PA1K)
●
Record the transmitter forward and reflected power on the watt meter provided with the transmitter.
This measured value will vary with picture content.
●
Using the ADP500 and PAS3 record currents for each power LDMOS device in the transmitter.
The absolute measured value will vary with picture content so this is best performed with a fixed
signal such as SMPTE BARS, however, relative measurements are adequate to indicate a
problem at the power device stage. (See operating instructions for ADP500 and PAS3 for more
details).
●
(OPTIONAL) When the transmitter is first put into service it is a good idea to go through each PA
stage and record the static bias level (NO RF DRIVE). This is done by selecting the desired
PA and using the PA INHIBIT switch. When this switch is activated, the PA drive is turned off
and the bias current can be measured. This is a momentary switch because when it is
activated, the PA drive is removed from all the PA's in one half of the transmitter and the output
power will be reduced to nearly zero (0) watts. THIS IS THE BEST METHOD TO USE WHEN
TROUBLESHOOTING A POSSIBLE BAD POWER TRANSISTOR.
●
Record the voltage and current measurements displayed on the AUX meter.
●
Carefully inspect RF Output coaxial cables for excessive heating or discoloration.
●
Check DC Power connections on shunt panels and power supplies for over heating which
could indicate the hardware needs attention.
●
Check DC Connections on the PA rear panel.
●
Remove and clean the air filters located on the front panel of each MFA2PA mainframe assembly.
It is safe to remove the filter while the transmitter is operating. The filters may be cleaned with
a light detergent and dried completely before re-installing. Spare filters are available from
Pineapple Technology, Inc. Request Part Number P/N 990199 when ordering.
Page 30
PINEAPPLE TECHNOLOGY, INC.
UTX2.5K ULTRA Operating and Service Manual
VII -- ROUTINE MAINTENANCE
VII --- ROUTINE MAINTENANCE (Page 2 of 2)
FACILITIES
●
Clean all air inlet filters and exhaust outlets to ensure that the transmitter is getting clean
unobstructed airflow.
●
Perform recommended service on air condition systems.
●
Rodent traps or baits should be renewed to keep the facilities clear of these pests which can
cause damage to the transmitter.
Page 31
Section VIII
Adjustments
and
Tuning
PINEAPPLE TECHNOLOGY, INC.
UTX2.5K ULTRA Operating and Service Manual
VIII -- ADJUSTMENTS AND TUNING
VIII --- ADJUSTMENTS AND TUNING (Page 1 of 2)
The UTX2.5K ULTRA is a new series of transmitters offered by Pineapple Technology, Inc. The
latest in LDMOS device and circuit technology are employed to ensure reliable and serviceable
operation for many years.
There are very few adjustments necessary to maintain full service condition. The following will
give the technician a general overview of locations for locating these adjustments:
1.
MODULATOR - See details for all adjustments in the Manufacturer's Instruction Manual
provided with your transmitter. Should you have any questions, contact the Pineapple
Technology, Inc Engineering staff for assistance.
2.
BPU3KW - The bandpass filter provided with your transmitter has been tuned at the factory
and adjustments should not be necessary and are not recommended. Any attempt to tune
or modify this filter will void manufacturer's warranty.
3.
U500LD - This is the main PA board in the transmitter. Under normal operation, no adjustments
are necessary. In the unlikely event that a power transistor has to be replaced, the bias
adjustments should be reset to insure optimum operation of the transmitter. The following
procedure should be followed when making bias adjustments:
a.
Remove the PA1K amplifier assembly from the transmitter and set it up on a
sturdy work bench. The bench should be equipped with a 32 VDC power supply with
current capacity of 10 Amps. A VOM will be required to measure the voltage drop
across the precision resistors located on the monitor board.
b.
Attach 50 ohm load resistors to the input port and one to the output port.
If this is not done, severe damage to the PA is possible resulting in costly repair.
c.
Connect the 32 VDC supply to the DC ± terminals. DO NOT TURN THE POWER SUPPLY
ON AT THIS TIME.
d.
Locate the circuits where bias adjustments are necessary. Adjust only those circuits
where service was performed. Turn the bias adjustment POT's fully counter clockwise
You will find two (2) POT's for each power device with one on each gate. These are
small SMT components and require gentle handling.
e.
Locate the current sense resistors on the monitor board. This is a 2 watt .01 ohm
precision resistor. There is one for each device.
f.
Turn the power supply on and measure the +DC to ensure that it reads +32 VDC.
g.
Measure the voltage drop across the precision resistor. This should read zero (0) VDC.
Increase one of the bias POT's slowly till the meter reads 0.009 volts. Increase the
second POT until the reading is 0.018 volts. This completes the adjustment.
h.
Repeat the adjustment above as necessary to set all circuit that have been serviced.
NOTICE: DO NOT USE THE BIAS CURRENT INDICATED ON THE MONITOR PANEL
OF THE ADP500 TO MAKE BIAS ADJUSTMENTS.
Page 32
PINEAPPLE TECHNOLOGY, INC.
UTX2.5K ULTRA Operating and Service Manual
VIII -- ADJUSTMENTS AND TUNING
VIII --- ADJUSTMENTS AND TUNING (Page 2 of 2)
4.
PA PALLETS - These circuits are "FIXED TURNED" and do not require any field adjustment.
Any questions regarding pallet adjustments should be referred to the factory.
5.
PHASE MATCHED CABLES - If it becomes necessary to replace one of the phase matched
cables, contact Pineapple Technology, Inc. for replacements. These cables are the ones
connected to the input and output ports on the PA1K.
6.
OUTPUT POWER - The transmitter output power measurement is made using a calibrated
wattmeter provided with the transmitter. No adjustments are necessary here.
7.
GAIN & PHASE MATCHING - Under normal conditions it is not necessary to make any gain
or phase adjustments in the transmitter. This transmitter is equipped with provision to adjust
phase and gain to ensure minimum power loss in the dump load and maximum forward
transfer power to the antenna. Contact Pineapple Technology, Inc. for details if this becomes
necessary.
Page 33
Section IX
Problem
Solving
Troubleshooting
PINEAPPLE TECHNOLOGY, INC.
UTX2.5K ULTRA Operating and Service Manual
IX -- PROBLEM SOLVING/TROUBLE SHOOTING
IX - PROBLEM SOLVING & TROUBLE SHOOTING (Page 1of 3)
The UTX2.5K ULTRA is a "MODULAR ASSEMBLY" where most of the sub-assemblies can be
removed and or replaced as necessary to maintain full service. To service this transmitter,
it is best to become familiar with the various sub-assemblies by reviewing the transmitter block diagram
and it's associated subs shown in the introduction. Any work performed on a transmitter licensed by
the FCC must be performed by qualified personnel.
FAILURE ANALYSIS STARTS WITH THE FOLLOWING ASSUMPTIONS:
1. The transmitter is connected to an AC source which is within the specified voltage range
and has ample power to run the transmitter.
2. The antenna has been checked out and a proper match has been verified.
3. The room temperature is < +35 degrees Celsius (+95 degrees Fahrenheit)
4. There are no restrictions in the air flow in or out of the building.
5. The video and aural signals to the modulator comply with stated specifications.
CHECKING THE WARNING LIGHTS
There are several warning signals visible on the front of the transmitter that will alert the technician
of possible problems. When viewed from the front, all the lights should be GREEN indicating normal
operation. An alert signal is indicated by a RED light. We will focus on RED alert signals in this section.
MFA2PA ASSEMBLY
FAN FAULT
RED indicates that the fuse supplying AC to the fan has failed. The fuse
is located just inside the front panel near the top.
CHECK: FUSE AND/OR FAN
DC SUPPLY
RED indicates a loss of +32 VDC to PA
CHECK: DC supply voltage to the rear of the PA1K
CHECK: DC supply fuse located on the Fuse panel located at the bottom
of the rack in the rear.
CHECK: AUX panel location in the bottom half of the rack being checked
for proper voltage and current readings
NOTE: If all the ALERT lights are on in a given rack, this could indicate
that a breaker has tripped
CHECK: Circuit breakers located on the front of the ACDIS2 or the
sub-panel breaker located at the MAIN AC supply.
Page 34
PINEAPPLE TECHNOLOGY, INC.
UTX2.5K ULTRA Operating and Service Manual
IX -- PROBLEM SOLVING/TROUBLE SHOOTING
IX - PROBLEM SOLVING & TROUBLE SHOOTING (Page 2of 3)
SHUTDOWN
RED indicates that the PA has been "SHUTDOWN". There are two
possible reasons for this:
1. Heat Sink over temperature thermostat has tripped protecting the PA
CHECK: Air inlet filter for possible restrictions to air flow
CHECK: Fan air flow for possible fan fault
CHECK: Room temperature
Note: Heat sink over temperature fault is indicated by the RED alert light going
ON/OFF in cycles varying in duration depending on air flow. The PA
returns to normal operation automatically when the problem is corrected.
2. Remote Shutdown by external signals coming from other protection circuits.
CHECK: Transmitter global protection circuits.
ADP500 MONITOR
The ADP500 is a general purpose test instrument used to display PA status and measure voltage,
current and RF power levels. When combined with the PAS3 it is possible to measure the current
being drawn by each PA RF Device. In addition to its measurement features, it serves to integrate
fault signals for PA Assemblies, High VSWR alarms and provides an interface to the RM8 Remote
Control Unit. The ADP500 is a diagnostic tool for troubleshooting the transmitter.
With normal operating conditions, all the LED's on the front panel are GREEN. Red LED's could
indicate a fault in the transmitter that require attention.
RF PWR OFF LED is RED
Will occur anytime the "SHUTDOWN LINE" (SD) is set to zero (0)
volts. The following conditions will pull the set SD to zero volts:
1. Antenna VSWR HIGH
2. PA INHIBIT SWITCH actuated.
ANT VSWR HIGH LED is RED
This indicates that the antenna reflected power exceeded the set
trip point. This is an internal setting performed at the factory and is
normally set to 10% of the RF OUTPUT POWER set point.
CHECK: The transmitter output connections and antenna for
possible faults. The fault condition will automatically reset when
the problem is corrected.
Page 35
PINEAPPLE TECHNOLOGY, INC.
UTX2.5K ULTRA Operating and Service Manual
IX -- PROBLEM SOLVING/TROUBLE SHOOTING
IX - PROBLEM SOLVING & TROUBLE SHOOTING (Page 3 of 3)
PA1 - PA5 LED's are RED
This will indicate that the PA Pallet currents are below the 500 ma
set point. This can occur when the PA Power device has failed.
CHECK 1: Select the PA device in question for current display
on the multi-meter. Compare the reading to the station log. If
abnormal, it is possible that a power transistor has failed.
NOTICE: PA5 will go RED when the INHIBIT SWITCH is
actuated.
CHECK2: To confirm a failed device, it is necessary to shutdown
the transmitter and remove the PA1K power amplifier assembly
and check the device in question. Use a VOM to check the
resistance from the gate of each 1/2 of the device to ground. If
either reading is below 1K ohm it is likely that the device has
failed.
POWER SUPPLY MODULE LED RED
The Power Supply Module has two warning LED's located on the front panel. Normally these LED's are
GREEN indicating that the AC Line voltage and the OVER VOLTAGE circuits are operating properly.
If either LED turns RED the module is question will be turned off and is no longer supplying power
to the transmitter. These modules are "HOT PLUGGABLE" and can be removed from active service
by simply removing it from the main frame. Pineapple Technology, Inc. does not recommend any
attempt to service these modules. Any attempt to service may void factory warranties. Return the
module to Pineapple Technology, Inc. or to the manufacture for service.
NOTICE: If it becomes necessary to operate the transmitter with a missing supply module, very
little if any performance degrading will be experienced. Check the AUX volt meter for any indication
of a drop in voltage (normally 32 VDC). This drop is caused by the power supply modules going into
"CURRENT LIMIT". It is important that the voltage be around 32 volts ±0.5. If the voltage falls below
this point, it can be recovered by reducing the RF Drive level a small amount in most cases. This
should be done only with the DUMP LOAD MONITOR on and indicating that the maximum power
is not exceeded.
Page 36
Section X
Warranty
PINEAPPLE TECHNOLOGY, INC.
UTX2.5K ULTRA Operating and Service Manual
X -- WARRANTY
X -- WARRANTY
The WARRANTY provided by Pineapple Technology, Inc. (PTI) on this transmitter is detailed below.
It should be noted that some of the equipment sub-systems have warranty coverage by the orginal
manufacture that differs from the standard warranty provided by PTI Warrantydetails on equipment falling
into this category may be found in the Manufacturers instruction manual provided with the transmitter.
In all cases, replacement units of this equipment are normally in stock at PTI for quick turn service
support to our customers during the PTI Standard Warranty period.
STANDARD WARRANTY
Seller warrants that each Product sold by it is free of defects in materials and workmanship. Seller's
obligation under said warranty continues for a period of one (1) year from date of shippment. Repairs or
replacement of defective parts shall be the sole and exclusive remedy under waranty, at Seller option,
provided that Seller may, as an alternative, elect to refund an equitable portion of the purchase price
of the product. THIS WARRANTY IS EXPRESSLY IN LIEU OF AND EXCLUDES ALL OTHER
EXPRESS OR IMPLIED WARRANTIES, INCLUDING BUT NOT LIMITED TO WARANTIES OF
FITNESS FOR A PARTICULAR PURPOSE, USE, OR APPLICATION, AND ALL OTHER OBLIGATIONS
OR LIABILITIES ON THE PART OF THE SELLER, UNLESS SUCH OTHER WARRANTIES
OBLIGATIONS OR LIABILITIES ARE EXPRESSLY AGREED TO IN WRITING BY SELLER.
WARRANTY REPLACEMENT AND REPAIRS
All claims under warranty must be made promptly after occurrence of circumstances giving rise to thereto
and must be received within the applicable warranty period by seller or its authorized representatives.
Such claims must be documented on a PTI* Field Failure Report with a full description of the circumstances
giving rise to the claim. Before any products are returned for repair and/or adjustment, written authorization
form seller or its authorized representative for the return and instructions as to how and where these
products should be shipped must be obtained. This is to include a Return Authorization (RA) number
provided by the seller or authorized representative, this must accompany ALL returns. Any product
returned to the seller for the examination shall be sent prepaid via the means of transportation indicated as
acceptable by seller. Seller reserves the right to reject any warranty claim not promptly reported and any
claim on any item that has been altered, i.e. circuit modifications, components removed, or has been shipped
by non acceptable means of transportation . When a product has been returned for examination and inspection,
or for any other reason, customer shall be responsible for all damage resulting from improper packaging or
handling, and for loss in transit, notwithstanding any defect or nonconformity in the product. In all cases the
seller has sole responsibility for determining the cause and nature of the failure, and the Seller's
determination with regard thereto shall be final. If it is found that Seller's Product has been returned without
cause and is still serviceable, customer will be notified and the Product returned at its expense, in addition,
a charge for testing and examination may, in Sellers sole discretion be made on Products so returned.
* A field Failure Report is included at the end of this manual - Additional Field Failure Reports can be obtained by calling
Pineapple Technology, Inc. at (916) 652-1116 or you may download one from our website at www.ptibroadcast.com
in the Warranty section.
Page 37

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