UTX5K ULTRA-2 INSTRUCTION MANUAL PINEAPPLE TECHNOLOGY, INC
PINEAPPLE TECHNOLOGY, INC. UTX5K ULTRA-2 Operating and Service Manual TABLE OF CONTENTS Section l --- SAFETY NOTICES ………………………………………………………………………… 2 ** READ THIS SECTION BEFORE INSTALLATON ** Secton ll --- TRANSMITTER SPECIFICATIONS …………………...………………………………… 3 Section lll --- TRANSMITTER INSTALLATION ……………………………………………………… 5 Section lV --- TRANSMITTER TURN-ON ……………………………………………………………… 7 Section V --- THEORY OF OPERATION A. Introduction ……………………………………………………………………………… 8 B.
Section I Safety Notices
PINEAPPLE TECHNOLOGY, INC. UTX5K ULTRA - 2 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.
Section II Transmitter Specifications
PINEAPPLE TECHNOLOGY, INC. UTX5K ULTRA - 2 Operating and Service Manual II – TRANSMITTER SPECIFICATIONS II – UTX5K ULTRA - 2 SPECIFICATIONS OPERATING Power Output ………………………… 5KW Peak Sync 500 Watts Aural RF Output Impedance………………… 50 ohms Frequency Range……………………… 470 – 806 MHz Frequency Stability…………………… 1 PPM or better Harmonic and Spurious………………...
PINEAPPLE TECHNOLOGY, INC. UTX5K ULTRA - 2 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……………………………………..
Section III Transmitter Installation
PINEAPPLE TECHNOLOGY, INC. UTX5K ULTRA - 2 Operating and Service Manual lll -- TRANSMITTER INSTALLATION lll -- TRANSMITTER INSTALLATION Page 1 of 2 To ensure long and reliable trouble-free service from the UTX5K ULTRA-2 transmitter the following steps for installation are recommended: 1. MECHANICAL INSTALLATION: The UTX5K ULTRA-2 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.
PINEAPPLE TECHNOLOGY, INC. UTX5K ULTRA -2 Operating and Service Manual lll -- TRANSMITTER INSTALLATION lll -- TRANSMITTER INSTALLATION Page 2 of 2 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.
Section IV Transmitter Turn-On
PINEAPPLE TECHNOLOGY, INC. UTX5K ULTRA-2 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.
Section V Theory of Operation
PINEAPPLE TECHNOLOGY, INC. UTX5K ULTRA-2 Operating and Service Manual V -- THEORY OF OPERATION V --- THEORY OF OPERATION (Page 1 of 5) A. INTRODUCTION The UTX5K ULTRA-2 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 UTX5K ULTRA-2 is BASIC and MODULAR with most components field replaceable.
PINEAPPLE TECHNOLOGY, INC. UTX5K ULTRA-2 Operating and Service Manual V -- THEORY OF OPERATION (CONTINUED) Page 2 of 5 D. ADP500 AND PAS6 PERFORMANCE MONITOR The ADP500 and PAS6 Performance Monitor provides the following functions: 1. Monitors FORWARD AND REFLECTED POWER to the hybrid combiner 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.
PINEAPPLE TECHNOLOGY, INC. UTX5K ULTRA-2 Operating and Service Manual V -- THEORY OF OPERATION (CONTINUED) Page 3 of 5 7. METER SELECTION SWITCHES 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. E.
PINEAPPLE TECHNOLOGY, INC. UTX5K ULTRA-2 Operating and Service Manual V -- THEORY OF OPERATION (CONTINUED) Page 4 of 5 G. UDR100AC 100 WATT DRIVER AMPLIFIER The RF output from the MA2000 Modulator is applied to the input of the UDR100AC driver amplifier. This amplifier increases the drive level to that required for each of the six (6) PA1K power amplifiers to make rated power. The UDR100AC is powered by 110 VAC. REFER TO SECTION Vl.C. FOR SCHEMATIC DIAGRAM AND PARTS LIST. H.
PINEAPPLE TECHNOLOGY, INC. UTX5K ULTRA-2 Operating and Service Manual V -- THEORY OF OPERATION (CONTINUED) Page 5 of 5 J. UC6KWN 6-WAY COMBINER The UC6KW is an 6-Way in-phase combiner. The combiners are 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. BPU10K UHF BAND PASS FILTER This Band Pass filter was designed to meet FCC Certification requirements with minimum loss of RF Power.
Section VI Schematic and Parts List
PINEAPPLE TECHNOLOGY, INC. UTX5K ULTRA-2 Operating and Service Manual A.
A D A B 208 VAC 1P 110 VAC 208 VAC 3-Phase Page 14 AC Main Distribution ACDIS4 Xmtr On/Off Po Level Remote Control (Opt) RC8 208 VAC 3P Main AC Breaker Phone Line +12 VDC AC Inlet RF Output Mod & Driver Aural Visual IF AC Inlet MA2000 A AC Inlet DC Output AUX FP6 100 mv FS Meter Shunt DC Volts DC Amps PS12KW 12 KW Power Supply AC Inlet UDR100AC 100 W Driver DC Distribution Panel 125A 125A 125A 125A 125A 125A +32 VDC Shutdown Emergency To PA6 To PA5 To PA4 To PA3
PINEAPPLE TECHNOLOGY, INC. UTX5K ULTRA-2 Operating and Service Manual B.
Page 16 SECTION VI--SCHEMATICS AND PARTS (UTX5K ULTRA() VERSION) 1 BB MA2000 UDR100AC ADP500 FITFIT DWG DWG NO.NO. SHEET SHEET AC Distribution Panel ACDIS4 FSCM SIZESIZE FSCM NO.NO. SCALE SCALE 110VAC Power Strip } AUX PANEL RECEPTICALS PineappleTechnology, Technology,Inc. Inc.
PINEAPPLE TECHNOLOGY, INC. UTX5K ULTRA-2 Operating and Service Manual C.
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 Page 18 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.
PINEAPPLE TECHNOLOGY, INC. UTX5K ULTRA-2 Operating and Service Manual D.
SECTION VI - SCHEMATICS AND PARTS SUB-SECTION D - UTX5K ULTRA-2 MFA2PA ASSY +32 VDC J1 GND RTN RF IN PA1, PA3, PA5 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 +32 VDC J1 GND RTN RF IN PA2, PA4, PA6 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 A
PINEAPPLE TECHNOLOGY, INC. UTX5K ULTRA-2 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 1 2 PS 114330 RES ARRAY, SMT 330 OHMS 2 5 PS 115103 RES CHIP 0805 10K OHM SMT 0805 3 1 PS 115334 RES CHIP 0805 330 K OHM SMT 4 1 PS 115563 RES CHIP 0805 56K OHM 0805 SM 5 3 PS 115682 RES CHIP 0805 6.
SECTION VI - SCHEMATICS AND PARTS SUB-SECTION D.1 - UTX5K ULTRA-2 Pineapple Technology, Inc. Rocklin, CA SIZE Page 22 SCALE 1A0035 STATUS BOARD CIRCUIT DIAGRAM FSCM NO. DWG NO.
PINEAPPLE TECHNOLOGY, INC. UTX5K ULTRA-2 Operating and Service Manual D. Vl -- SCHEMATICS AND PARTS LIST MFA2PA POWER AMPLIFIER 2.
Page 24 GROUND +32 VDC RF IN J31 DB9 P1 PA1B P2 PA2A P3 PA5 P4 GND P5 SD P6 PA1A P7 PA2B P8 +VDC P9 NC Power Distribution Module 1A0025 Assy Gain and Phase Network J29 J26 J25 J24 J23 J22 +32 VDC Shutdown Line (SD) U250LD PA 2-Way Input Splitter U500LDA PA1 U500LDA PA2 +32 VDC B A +32 VDC +32 VDC B A +32 VDC B SCALE SIZE TS3 TS2 Pineapple Technology, Inc. Rocklin, CA Heat Sink R Heat Sink L 400 W 50 ohm Circulator FIT SHEET PA1K Amplifier Assy BLOCK DIAGRAM DWG NO. FSCM NO.
PINEAPPLE TECHNOLOGY, INC. UTX5K ULTRA-2 Operating and Service Manual E. Vl -- SCHEMATICS AND PARTS LIST S6 6-WAY SPLITTER -- Assy Tree Item Qty Type P/N Title Detail Top PL S6 6-WAY INPHASE SPLITTER PHASE AND GAIN ADJUSTMENTS 1 1 PS MF9333A FRONT PANEL S10 SPLITTER PAINTED 2 1 PS MF9334A S10 TOP COVER AL 0.
SECTION VI - SCHEMATICS AND PARTS SUB-SECTION E - UTX5K ULTRA-2 S6 SPLITTER G&P RF OUT TO PA1 G&P RF OUT TO PA2 G&P RF OUT TO PA3 G&P RF OUT TO PA4 G&P RF OUT TO PA5 G&P RF OUT TO PA6 RF IN 50 Ohm Term 50 Ohm Term Pineapple Technology, Inc. Rocklin, CA SIZE Page 26 SCALE S6 SPLITTER BLOCK DIAGRAM FSCM NO. DWG NO.
SECTION VI - SCHEMATIC AND PARTS LISTS SUB-SECTION F - UTX5K ULTRA-2 No Serviceable Parts Pineapple Technology, Inc. Rocklin, CA SIZE Page 27 SCALE UC6KWN 6-WAY COMBINER CIRCUIT DIAGRAM FSCM NO. DWG NO.
SECTION VI - SCHEMATIC AND PARTS LISTS SUB-SECTION G - UTX5K ULTRA-2 No Serviceable Parts Pineapple Technology, Inc. Rocklin, CA SIZE Page 28 SCALE DC7KW Directional Coupler CIRCUIT DIAGRAM FSCM NO. DWG NO.
SECTION VI - SCHEMATICS AND PARTS SUB-SECTION H - UTX5K ULTRA-2 NO SERVICEABLE PARTS BPU10KW Bandpass Filter Pineapple Technology, Inc. Rocklin, CA SIZE Page 29 BPU10KW BANDPASS FILTER CIRCUIT DIAGRAM FSCM NO. DWG NO.
PINEAPPLE TECHNOLOGY, INC. UTX5K ULTRA-2 Operating and Service Manual Vl -- SCHEMATICS AND PARTS LIST I-1 PAS6 SELECTOR SWITCH ASSY Item Qty Type P/N Title Detail Top CAT PAS10 PA SEL SW FOR ADP500 10 POLE INPUT 1 OUTPUT 1 1 PS PC9501 PA SELECTER SWITCH 10 POLE ADP500 2 1 PS 483010 SW 10 POLE ADP500 PA SELECTOR PAS10 3 1 PS 481250 CON DB9 SUB RT ANGLE FM METAL CASE AMP7457814 4 5 PS 481260 CON DB9 2 SECTION RT ANG PCB MTG 0.
SECTION VI - SCHEMATICS AND PARTS SUB-SECTION I - UTX5K ULTRA-2 PAS6 PA SELECTOR PA6 Input PA5 Input PA4 Input 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 VOLT
PINEAPPLE TECHNOLOGY, INC. UTX5K ULTRA-2 Operating and Service Manual J.
SECTION VI - SCHEMATICS AND PARTS SUB-SECTION J - UTX5K ULTRA-2 N/C Emergency Shutdown ACDIS5 N/C PS1 P1 P2 P3 P4 P5 P6 POWER SUPPLY CURRENT SHARING MONITORS 1A 1B 1C 2A 2B 2C 3A 3B 3C Voltage Current P7 P8 P9 PS2 P1 P2 P3 P4 P5 P6 P7 Power Supply Shunt P8 P9 P1 P2 N/C P3 Ref P4 P5 P6 110 VAC Receptacle P7 P8 P9 Lamp 110 VAC { 2A Fuse Pineapple Technology, Inc. Rocklin, CA SIZE Page 33 SCALE AUX PANEL BLOCK DIAGRAM FSCM NO. DWG NO.
PINEAPPLE TECHNOLOGY, INC. UTX5K ULTRA-2 Operating and Service Manual K. Vl -- SCHEMATICS AND PARTS LIST FP6 Fuse and Shunt Panel --- Assembly Tree Item Qty Type P/N Title Detail Top CAT FP-6 FUSE PANEL UTX5K ULTRA INC FUSE, SHUNT, SHIELD 2 6 PS 471380 FUSE FAST ACTING 80 AMP USE WITH LFFB0001 HOLDER 3 6 PS 460190 FUSE HOLDER 400A LITTELFUSE LFFB001 5 1 PS MF9330A CURRENT MONITOR, REAR PANEL SHUNT AND FUSE MTG PLATE 6 1 PS 7 .5 PS 8 .
SECTION VI - SCHEMATICS AND PARTS SUB-SECTION K - UTX5K ULTRA-2 AUX Panel Current Voltage +32VDC 125 A Fuses Meter Shunt PA2 PA4 PA6 PA5 100 mv FS PA3 PA1 +32VDC PS12KW GND +32VDC PA2 PS12KW GND PA4 PA6 PA5 GND PA3 PA1 FP6 Fuse and Shunt Assy Pineapple Technology, Inc. Rocklin, CA SIZE Page 35 SCALE FP6 Fuse and Shunt Panel BLOCK DIAGRAM FSCM NO. DWG NO.
Section VII Recommended Routine Maintenance
PINEAPPLE TECHNOLOGY, INC. UTX5K ULTRA-2 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.
PINEAPPLE TECHNOLOGY, INC. UTX5K ULTRA-2 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.
Section VIII Adjustments and Tuning
PINEAPPLE TECHNOLOGY, INC. UTX5K ULTRA-2 Operating and Service Manual VIII -- ADJUSTMENTS AND TUNING VIII --- ADJUSTMENTS AND TUNING (Page 1 of 2) The UTX5K ULTRA-2 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.
PINEAPPLE TECHNOLOGY, INC. UTX5K ULTRA-2 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.
Section IX Problem Solving & Troubleshooting
PINEAPPLE TECHNOLOGY, INC. UTX5K ULTRA-2 Operating and Service Manual IX -- PROBLEM SOLVING/TROUBLE SHOOTING IX - PROBLEM SOLVING & TROUBLE SHOOTING (Page 1of 3) The UTX5K ULTRA-2 is a "MODULAR ASSEMBLY" where most of the sub-assemblies can be removed and or replaced as necessary as necessar 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.
PINEAPPLE TECHNOLOGY, INC. UTX5K ULTRA-2 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.
PINEAPPLE TECHNOLOGY, INC. UTX5K ULTRA-2 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.
Section X Warranty
PINEAPPLE TECHNOLOGY, INC. UTX5K ULTRA-2 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.
Section XI Extended Warranty
