Harris 994 9202 002, 994 9203 002, 994 9204 002, 994 9205 002 Technical Manual

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Page 1

TECHNICAL MANUAL

GATES ONE - 994 9202 002

GATES TWO - 994 9203 002

GATES FIVE (1-PHASE) - 994 9204 002

GATES Series™

AM TRANSMITTERS

GATES FIVE (3-PHASE) - 994 9205 002

T.M. No. 888-2314-001

2000, 2001, 2002

Printed: 1990

Rev. AF: 06-21-02

Page 2

Returns And Exchanges

Damaged or undamaged equipment should not be returned unless written approval and a Return Authorization is received from HARRIS CORPORATION, Broadcast Systems Division. Special shipping instructions and coding will be provided to assure proper handling. Complete details regarding circumstances and reasons for return are to be included in the request for return. Custom equipment or special order equipment is not returnable. In those instances where return or exchange of equipment is at the request of the customer, or convenience of the customer, a res tocking fee will be charged. All returns will be sent freight prepaid and properly insured by the customer. When communicating with HARRIS CORPORATION, Broadcast Systems Div ision, specify the HARRIS Order Number or Invoice Number.

Unpacking

Carefully unpack the equipment and preform a visual inspection to determine that no apparent damage was incurred during shipment. Retain the shipping materials until it has been determined that all received equipment is not damaged. Locate and retain all PACKING CHECK LISTs. Use the PACKING CHECK LIST to help locate and identify any components or assemblies which are removed for shipping and must be reinstalled. Also remove any shipping supports, straps, and packing materials prior to initial turn on.

Technical Assistance

HARRIS Technical and Troubleshooting assistance is available from HARRIS Field Service during normal business hours (8:00 AM - 5:00 PM Central Time). Emergency service is available 24 hours a day. Telephone 217/222-8200 to contact the Field Service Department or address correspondence to Field Service Department, HARRIS CORPORATION, Broadcast Systems Division, P.O. Box 4290, Quincy, Illinois 62305-4290, USA. Technical Support by e-mail: tsupport@harris.com. The HARRIS factory may also be contacted through a FAX facility (217/221-7096).

Replaceable Parts Service

Replacement parts are available 24 hours a day, seven days a week from the HARRIS Service Parts Department. Telephone 217/222-8200 to contact the service parts department or address correspondence to Service Parts Department, HARRIS CORPORATION, Broadcast Systems Division, P.O. Box 4290, Quincy, Illinois 62305-4290, USA. The HARRIS factory may also be contacted through a FAX facility (217/221-7096).

NOTE

The # symbol used in the parts list means used with (e.g. #C001 = used with C001).

Page 3

MANUAL REVISION HISTORY

GATES Series™ AM Transmitters

888-2314-xxx

Rev. A April 1990 None Replaced the following pages: Title Page, v, vii, 2-1 thru 2-6, 3-3, 3-4, 4-3, 4-4, 5-1 thru 5-6, J-3, & J-4

B Aug. 1990 None Replaced the following pages: Title Page, v, 3-5, 3-6, 4-1 thru 4-4, A-1, B-1, B-2, C-2, E-3, F-1 thru F-3,

C Aug. 1990 35969 Replaced the following pages: Title Page, MRH-1/MRH-2, C-4, & C-5 D Aug. 1990 Field

E Sept. 1990 36322 Replace the following pages: Title Page, MRH-1/MRH-2, & all of Section VI F Oct. 1990 36415 Replace the following pages: Title Page, MRH-1/MRH-2, & all of Section A G Jan. 1991 Errata

H June 1991 FS

I July 1991 36962 Replace the following pages: Title Page, MRH-1/MRH-2, and K-3 J Aug. 1991 36963 Replace the following pages: Title Page, MRH-1/MRH-2, 6-9 to 6-12, & J-9 TO J-11 K Jan. 1992 37611 &

L June 1992 37442 Replaced Title Page, MRH-1/MRH-2 and pages 6-14 to 6-17 M Jan. 1994 38809 Replaced Title Page, MRH-1/MRH-2, page K-3, and all of section VI N Feb. 1994 38895 Replaced Title Page, MRH-1/MRH-2, and pages F-4 & F-5 P July 1994 39302 Replaced Title Page, MRH-1/MRH-2, and all of section VI R Dec. 1994 39223 Replaced Title Page, MRH-1/MRH-2, and pages F-4 & F-5 S July 1995 39125 Replaced Title Page, MRH-1/MRH-2, and all of section VI T Jan. 1996 41051R Replaced Title Page, MRH-1/MRH-2, Table of Contents, 1-2 to 1-4, all of sections 2, 4, & 5 U Jan. 1996 41051R Replaced Tit le Page, MRH-1/MRH-2, and pages 6-15 to 6-19 V Mar. 1996 TBD Replaced Title Page, MRH-1/MRH-2, and page 2-9 X Dec. 1996 41575 Replaced Title Page, MRH-1/MRH-2, iv thru vi, and all of Section C Y May 1998 42198 Replaced Title Page, MRH-1/MRH-2, and page 2-4 Y1 10-02-98 42359 Replaced Title Page, MRH-1/MRH-2, page G-6 and all of Section VI Z 12-22-98 38895A Replaced Title Page, MRH-1/MRH-2, and all of Section F Z1 2-15-99 42544 Replaced Title Page, MRH-1/MRH-2, and pages C-4 & C-5. Z2 2-25-99 42636 Replaced Title Page, MRH-1/MRH-2, and all of Section VI AA 08-18-99 45024 Replaced Title Page, MRH-1/MRH-2, and all of Section H AB 12-10-99 45544 Replaced Title Page, MRH-1/MRH-2 and pages 2-4 and 2-5 AC 02-20-00 45748 Replaced Title Page, MRH-1/MRH-2 and all of Section II AD 10-04-01 47730 Replaced Title Page, MRH-1/MRH-2 and page 3-6 AD1 01-15-02 47924 Replaced Title Page, MRH-1/MRH-2, and all of Section VI AE 03-05-02 48100 Replace Title Page, MRH1/MRH2, all parts lists and chapter B. AF 06-21-02 48426 Replace Title Page, MRH1/MRH2, and page C-3

Date ECN

Service Request

FS Request

Request

Misc

Pages Affected

Added MRH-1/MRH-2

G-1 thru G-4, J-1, J-2, J-3, J-4, J-9 thru J-11, & K-3

Replace the following pages: Title Page, MRH-1/MRH-2, & 2-5

Replace the following pages: Title Page, MRH-1/MRH-2, & all of Section VI

Replace the following pages: Title Page, MRH-1/MRH-2, 2-6, G-2, & J-3

Replaced Title Page, MRH-1/MRH-2 and all part lists in manual

888-2314-001 MRH-1/MRH-2

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Page 5

Guide to Using Harris Parts List Information

The Harris Replaceable Parts List Index portrays a tree structure with the major items being leftmost in the index. The example below shows the Transmitter as the highest item in the tree structure. If you were to look at the bill of materials table for the Transmitter you would find the Control Cabinet, the PA Cabinet, and the Output Cabinet. In the Replaceable Parts List Index the Control Cabinet, PA Cabinet, and Output Cabinet show up one indentation level below the Transmitter and implies that they are used in the Transmitter. The Controller Board is indented one level below the Control Cabinet so it will show up in the bill of material for the Control Cabinet. The tree structure of this same index is shown to the right of the table and shows indentation level versus tree structure level.

Example of Replaceable Parts List Index and equivalent tree structure:

The part number of the item is shown to the right of the description as is the page in the manual where the bill for that part number starts.

Inside the actual tables, four main headings are used:

Table #-#. ITEM NAME - HARRIS PART NUMBER -this line gives the information that corresponds to the Replaceable Parts List Index entry;

HARRIS P/N column gives the ten digit Harris part number (usually in ascending order); DESCRIPTION column gives a 25 character or less description of the part number; REF. SYMBOLS/EXPLANATIONS column 1) gives the reference designators for the item (i.e., C001, R102, etc.) that

corresponds to the number found in the schematics (C001 in a bill of material is equivalent to C1 on the schematic) or

2) gives added information or further explanation (i.e., “Used for 208V operation only,” or “Used for HT 10LS only,” etc.).

Inside the individual tables some standard conventions are used:

A # symbol in front of a component such as #C001 under the REF. SYMBOLS/EXPLANATIONS column means that this item is used on or with C001 and is not the actual part number for C001.

In the ten digit part numbers, if the last three numbers are 000, the item is a part that Harris has purchased and has not manufactured or modified. If the last three numbers are other than 000, the item is either manufactured by Harris or is purchased from a vendor and modified for use in the Harris product.

The first three digits of the ten digit part number tell which family the part number belongs to - for example, all electrolytic (can) capacitors will be in the same family have a 9xx xxxx xxx part number (a number outside of the normal family of numbers), it has probably been modified in some manner at the Harris factory and will therefore show up farther down into the individual parts list (because each table is normally sorted in ascending order). Most Harris made or modified assemblies will have 9xx xxxx xxx numbers associated with them.

The term “SEE HIGHER LEVEL BILL” in the description column implies that the reference designated part number will show up in a bill that is higher in the tree structure. This is often the case for components that may be frequency determinant or voltage determinant and are called out in a higher level bill structure that is more customer dependent than the bill at a lower level.

(524 xxxx 000). If an electrolytic (can) capacitor is found to

Rev. X 888-2314-001 iii

WARNING: Disconnect primary power prior to servicing.

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iv 888-2314-001 Rev. X

WARNING: Disconnect primary power prior to servicing.

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WARNING

THE CURRENTS AND VOLTAGES IN THIS EQUIPMENT ARE DANGEROUS. PERSONNEL MUST AT ALL TIMES OBSERVE SAFETY WARNINGS, INSTRUCTIONS AND REGULATIONS.

This manual is intended as a general guide for trained and qualified personnel who are aware of the dangers inherent in handling potentially hazardous electrical/electronic circuits. It is not intended to contain a complete statement of all safety precautions which should be observed by personnel in using this or other electronic equipment.

The installation, operation, maintenance and service of this equipment involves risks both to personnel and equipment, and must be performed only by qualified personnel exercising due care. HARRIS CORPORATION shall not be responsible for injury or damage resulting from improper procedures or from the use of improperly trained or inexperienced personnel performing such tasks.

During installation and operation of this equipment, local building codes and fire protection standards must be observed. The following National Fire Protection Association (NFPA) standards are recommended as reference:

- Automatic Fire Detectors, No. 72E

- Installation, Maintenance, and Use of Portable Fire Extinguishers, No. 10

- Halogenated Fire Extinguishing Agent Systems, No. 12A

WARNING

ALWAYS DISCONNECT POWER BEFORE OPENING COVERS, DOORS, ENCLOSURES, GATES, PANELS OR SHIELDS. ALWAYS USE GROUNDING STICKS AND SHORT OUT HIGH VOLTAGE POINTS BEFORE SERVICING. NEVER MAKE INTERNAL ADJUSTMENTS, PERFORM MAINTENANCE OR SERVICE WHEN ALONE OR WHEN FATIGUED.

Do not remove, short-circuit or tamper with interlock switches on access covers, doors, enclosures, gates, panels or shields. Keep away from live circuits, know your equipment and don’t take chances.

WARNING

IN CASE OF EMERGENCY ENSURE THAT POWER HAS BEEN DISCONNECTED.

WARNING

IF OIL FILLED OR ELECTROLYTIC CAPACITORS ARE UTILIZED IN YOUR EQUIPMENT, AND IF A LEAK OR BULGE IS APPARENT ON THE CAPACITOR CASE WHEN THE UNIT IS OPENED FOR SERVICE OR MAINTENANCE, ALLOW THE UNIT TO COOL DOWN BEFORE ATTEMPTING TO REMOVE THE DEFECTIVE CAPACITOR. DO NOT ATTEMPT TO SERVICE A DEFECTIVE CAPACITOR WHILE IT IS HOT DUE TO THE POSSIBILITY OF A CASE RUPTURE AND SUBSEQUENT INJURY.

Rev. X 888-2314-001 v

WARNING: Disconnect primary power prior to servicing.

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vi 888-2314-001 Rev. X

WARNING: Disconnect primary power prior to servicing.

Page 9

FIRST-AID

Personnel engaged in the installation, operation, maintenance or servicing of this equipment are urged to become familiar with first-aid theory and practices. The following information is not intended to be complete first-aid procedures, it is a brief and is only to be used as a reference. It is the duty of all personnel using the equipment to be prepared to give adequate Emergency First Aid and thereby prevent avoidable loss of life.

Treatment of Electrical Burns

1. Extensive burned and broken skin a. Cover area with clean sheet or cloth. (Cleanest available cloth article.)

b. Do not break blisters, remove tissue, remove adhered particles of clothing, or apply any salve or ointment.

c. Treat victim for shock as required.

d. Arrange transportation to a hospital as quickly as possible.

e. If arms or legs are affected keep them elevated.

NOTE

If medical help will not be available within an hour and the victim is conscious and not vomiting, give him a weak solution of salt and soda: 1 level teaspoonful of salt and 1/2 level teaspoonful of baking soda to each quart of water (neither hot or cold). Allow victim to sip slowly about 4 ounces (a half of glass) over a period of 15 minutes. Discontinue fluid if vomiting occurs. (Do not give alcohol.)

REFERENCE:

2. Less severe burns - (1st & 2nd degree) a. Apply cool (not ice cold) compresses using the cleanest available cloth article.

b. Do not break blisters, remove tissue, remove adhered particles of clothing, or apply salve or ointment.

c. Apply clean dry dressing if necessary.

d. Treat victim for shock as required.

e. Arrange transportation to a hospital as quickly as possible.

f. If arms or legs are affected keep them elevated.

ILLINOIS HEART ASSOCIATION

AMERICAN RED CROSS STANDARD FIRST AID AND PERSONAL SAFETY MANUAL (SECOND EDITION)

Rev. X 888-2314-001 vii

WARNING: Disconnect primary power prior to servicing.

Page 10

TABLE OF CONTENTS

SECTION I

GENERAL INFORMATION

Introduction......................................1-1

ScopeAndPurpose..............................1-1

Specifications....................................1-1

SECTION II

INSTALLATION/OPERATION

Introduction......................................2-1

Unpacking.......................................2-1

ReturnsandExchanges.............................2-1

GeneralInstallationInformation .....................2-1

Power Distribution for Optimum Transmitter Perform-

ance .........................................2-1

OverheatingfromLineUnbalance..............2-1

TransmitterNoisePerformance ................2-1

TheCausesofLineUnbalance.................2-1

ThreePhaseDeltaDistributionTransformers..... 2-2

ThreePhaseWyeDistributionTransformers...... 2-2

General Installation

Requirements ...................................2-2

EquipmentPlacement............................2-2

Pre-InstallationInspection ........................2-2

EquipmentPositioning...........................2-3

Ground Strap Installation ......................... 2-3

ElectricalInstallation ..............................2-3

PowerRequirements.............................2-3

Procedure. .................................2-3

RFOutputConnection........................... 2-4

BatteryInstallation.............................. 2-4

Audio Input .................................... 2-4

RemoteControl.................................2-4

AirflowSensorStatus............................ 2-5

FailsafeConnection..............................2-5

Modulation Monitor Sample ......................2-5

InitialTurnOnProcedure...........................2-5

InitialTurnOn .................................2-5

Modulation Monitor Carrier Level.................. 2-6

ApplicationofAudio ............................2-7

RemoteMeterCalibration ........................2-7

SECTION III

MAINTENANCE

Introduction......................................3-1

StationRecords...................................3-1

Maintenance Logbook ........................... 3-1

PreventiveMaintenance............................3-1

Maintenance Of Components ...................... 3-1

AirSystem.....................................3-2

GATES Series™ Top Removal

Procedure ....................................3-2

LowVoltageSupplyAdjustment...................3-2

High Voltage Supply Adjustment ..................3-4

RFDriveMeasurement........................... 3-4

IPATuning.................................... 3-5

PAVoltageElectricalZero ....................... 3-5

PAVoltMeterCalibration........................3-5

PACurrentCalibration........................... 3-5

Power Supply Current Calibration .................. 3-5

viii 888-2314-001 Rev. X

WARNING: Disconnect primary power prior to servicing.

PowerOutputCalibration........................ 3-5

OverloadAdjustmentProcedures.................. 3-6

Power Supply Current Overload ............... 3-6

UnderdriveFault............................ 3-6

VSWRDetector............................ 3-6

Replacing Boards and

ReplacingBoardComponents ..................... 3-6

SECTION IV

TROUBLESHOOTING

Introduction ..................................... 4-1

Definition of

FrontPanelIndicators ............................ 4-1

Symptom: Transmitter Will Not Turn On - None of

the Green LED’s on the Power Level Switches are Il-

luminated....................................... 4-1

PossibleCauses................................ 4-1

LossofACPower .......................... 4-1

ControlSupplyFailure....................... 4-1

Symptom: Green Power Level Status LED’s Illumi-

nate, but the Primary Contactors Do Not Energize and

NoOverloadLED’sIlluminate..................... 4-1

PossibleCauses................................ 4-1

Phase Monitor (3∅ FIVEonly)................ 4-1

Blownfuse................................ 4-1

OpenInterlock............................. 4-1

FailsafeInterlockOpen ...................... 4-1

InterfaceboardOutput....................... 4-1

OpenContactorCircuit ...................... 4-1

ContactorControlSignal..................... 4-1

Symptom: One or Both Primary Contactors Energize,

ButThereIsNoPowerOutput ..................... 4-1

HighVoltageSupplyFailure...................... 4-1

Symptom: High Voltage Is Present, But There Is No

PowerOutput ................................... 4-2

PDMKillCondition ............................ 4-2

PDMLevel.................................... 4-2

PossibleCausesForOverloads...................... 4-2

Supply Voltage Overload ........................ 4-2

Supply Voltage Too High .................... 4-2

Power Supply Current Overloads- At Turn On ....... 4-2

Supply Short ............................... 4-2

Power Supply Current Overloads, Continuous Cycling

andAutomaticCutback......................... 4-2

PDMSystemProblem....................... 4-2

PDMGeneratorOutputsHigh................. 4-2

PDMAmplifierShorts....................... 4-2

Supply Current Calibration ................... 4-2

Random Supply Current Overloads With Modulation. . 4-2

Sub-audibleSignals......................... 4-2

UnderdriveFault ............................... 4-2

Low/NoDrive.............................. 4-2

IPAandPATransistors...................... 4-2

VSWR Overload- Continuous VSWR Cycling ....... 4-2

BadLoadImpedance........................ 4-2

AntennaProblem........................... 4-3

OutputNetwork............................ 4-3

Page 11

VSWR Trips With High Levels Of Modulation and

HighPower................................... 4-3

ImproperTuningandLoading................. 4-3

Antenna .................................. 4-3

OutputNetwork............................ 4-3

Symptom:RemoteControlFunctionsDoNotWork .... 4-3

PossibleCauses................................ 4-3

Remote/LocalSwitch........................ 4-3

RemoteControlImproperlyWired............. 4-3

RemoteControlUnitNotFunctioning.......... 4-3

RibbonConnectorsLoose.................... 4-3

CausesforaPAVolts/PAAmpsRatioChange ........ 4-3

No+20VoltstoPDMAmplifier.................. 4-3

ImpedanceChange ............................. 4-3

PAFailure.................................... 4-3

Troubleshooting AM Noise......................... 4-4

50/60Hz...................................... 4-4

AudioLinesareNormallyBalanced ............... 4-4

100/120Hz.................................... 4-4

300/360Hz.................................... 4-4

60kHz....................................... 4-4

RFINoiseonAudio ............................ 4-4

SECTION V

TRANSMITTER OVERALL

Introduction..................................... 5-1

Personnel Protection .............................. 5-1

PrinciplesOfOperation............................ 5-1

FET’SintheGATESSeries™.................... 5-1

PDMTheoryInBrief ........................... 5-1

PolyphaseTheory .............................. 5-1

Audio/PDMSignalFlow......................... 5-1

PDMLoop.................................... 5-3

RFPowerFlow................................ 5-3

Failsafe....................................... 5-3

ACPowerFlow................................ 5-3

High Voltage Power Supply ...................... 5-3

Introduction ............................... 5-3

Description................................ 5-3

Low Voltage Power Supply and IPA Power Supply. . . 5-6

Introduction ............................... 5-6

Description................................ 5-6

AirflowSensor................................. 5-6

Introduction ............................... 5-6

Description................................ 5-6

Section VI

Parts List

Introduction..................................... 6-1

SECTION A

OSCILLATOR (A16)

PrinciplesOfOperation............................ A-1

Replacement/Alignment ........................... A-1

FrequencyAdjustment........................... A-1

Troubleshooting the

RFOscillator ................................... A-1

Symptom:NoOutput ........................... A-1

OpenFuse/Lossof+20V..................... A-1

RFKILL.................................. A-1

Q1,Q2,CR1................................ A-1

U1,CR4...................................A-1

U2.......................................A-1

U3.......................................A-1

SECTION B

IPA (A5)

PrinciplesofOperation.............................B-1

IPATuningNetwork............................B-1

Replacement/Alignment............................B-1

IPA Tuning and Testing

Procedure......................................B-1

IPATuning................................B-1

OhmmeterTestingtheIPA .......................B-1

HandlingMOSFET’s..............................B-1

TestingMOSFET’s ...............................B-2

SECTION C

POWER AMPLIFIER A1 through A4

PrinciplesofOperation.............................C-1

PAToroids......................................C-1

Replacing a PA Module............................C-1

TroubleshootingthePABoards......................C-1

OhmmeterTesting..............................C-1

HandlingMOSFET’s..............................C-2

TestingMOSFET’s ...............................C-2

ReplacingPATransistors.........................C-2

ScopingtheRFDrive..............................C-2

RFDrivePhasingMeasurement .....................C-2

SECTION D

OUTPUT NETWORK

PrinciplesofOperation.............................D-1

AdjustmentProcedures.............................D-1

TuningAndLoadingControls.....................D-1

OutputNetworkColdTuning .....................D-1

ThirdHarmonicTrapL7-C4 ..................D-1

Bandpass Filter L2-C2 .......................D-1

TEENetwork-LoadandTune................D-1

L2SlidingTap .............................D-1

L1Tap....................................D-2

SECTION E

OUTPUT MONITOR (A18)

PrinciplesofOperation.............................E-1

Replacement/Alignment............................E-1

Troubleshooting..................................E-1

Symptom: Detector Null Reading Is High and Cannot

BeAdjustedToZero............................E-1

BadLoadImpedance ........................E-1

SampleSignalMissing.......................E-1

SECTION F

PDM GENERATOR (A15)

PrinciplesOfOperation............................ F-1

Replacement/Alignment............................F-1

TroubleshootingPDMGenerator..................... F-1

Symptom: No Pulses At J4, Causing Zero Power Out-

putfromtheTransmitter......................... F-1

PowerSetting ..............................F-1

LossofPlusandMinus15Volts............... F-1

PDMInterrupt.............................. F-1

DC/AudioFailure........................... F-1

Rev. X 888-2314-001 ix

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Page 12

Symptom:ImbalanceInOutputPulseWidths ........F-2

AudioImbalance............................F-2

TriangleWaveImbalance.....................F-2

Symptom: Output(s) At J2 Always In A High State,

Causing One or More Pdm Amplifiers to Conduct

FullTime.....................................F-2

Symptom:OnlyOneOutputHigh..................F-3

Symptom:TwoOutputsAreHigh..................F-3

Symptom:AllFourOutputsAreHigh ..............F-3

SECTION G

PDM AMPLIFIER/PULL-UP (A6-A9)

PrinciplesofOperation............................ G-1

PDMAmplifier................................ G-1

PDMPull-UpBoard............................ G-1

Maintenance .................................... G-1

PDMAmplifiers............................... G-1

GateDriveChecks............................. G-1

In-Circuit Ohmmetering the PDM Amp Module (A6

thruA9)MOSFET’s........................... G-2

CheckingGateDrive........................ G-4

HandlingMOSFET’s............................. G-4

TestingMOSFET’s............................... G-4

SECTION H

PDM FILTER (A10 and A11)

PrinciplesofOperation............................ H-1

SECTION J

CONTROLLER BOARD (A12)

PrinciplesofOperation............................. J-1

CoarsePowerLevelControl ...................... J-1

ContactorControl............................... J-1

FinePowerControl.............................. J-1

Metering ...................................... J-1

OverloadCircuitry .............................. J-1

OtherFaultDetection............................ J-2

ControllerSupplyVoltages........................J-2

Replacement/AlignmentProcedures...................J-2

PAVoltageElectricalZero........................J-2

PAVoltMeterCalibration ........................J-2

Power Supply Current Calibration ..................J-2

PowerOutputCalibration.........................J-3

OverloadAdjustmentProcedures.....................J-3

Power Supply Current Overload ....................J-3

UnderdriveFault ................................J-3

VSWRDetector.................................J-3

Troubleshooting the Controller .......................J-3

Symptom: Will Not Respond To An On Command ....J-3

Controller Supply Failure ......................J-3

Failedflipflopcircuitry.......................J-3

Symptom: PDM Power Level Signal Cannot Be Con-

trolled ........................................J-3

Symptom:MultimeterIsPinnedFarLeftorRight .....J-3

Symptom: Some Remote Control Functions Do Not

Work.........................................J-3

SECTION K

INTERFACE BOARD (A24)

PrinciplesofOperation............................ K-1

Replacement/Alignment............................ K-1

Troubleshooting .................................. K-1

Symptom: Green Power Level Status LED’s Light On

Controller,ButTheContactorsDoNotEnergize.....K-1

OpenInterlock............................. K-1

24VACMissing............................ K-1

ONCommandMissing ...................... K-1

BadTriacorOpticalIsolator..................K-1

APPENDIX L

TEST EQUIPMENT

Introduction ..................................... L-1

x 888-2314-001 Rev. X

WARNING: Disconnect primary power prior to servicing.

Page 13

SECTION I

GENERAL INFORMATION

1.1. Introduction

1.1.1. Scope And Purpose

This technical manual contains the information necessary to install and maintainthe GATES Series™ AM Transmitters. The various sections of this technical manual provide the following types of information.

Section I, General Information, provides introduction to technical manual contents. Section II, Installation/operation, provides detailed installation and operation procedures. Section III, Maintenance, provides preventive and corrective maintenance as well as tuning procedures (alignment procedures).

Section IV, Troubleshooting, provides a listing of the protection devices in the transmitter as well as troubleshooting procedures. Section V, Transmitter Overall, provides theory of operation of the various sections of the transmitter not covered in later sections. Section VI, Parts List, provides parts list for the transmitter.

The following sections provideprinciples of operation, maintenance information, troubleshooting,and parts lists forboardsin GATES Series™ transmitter:

Section A, Oscillator Section B, IPA Section C, Power Amplifier Section D, Output Network

Section E, Output Monitor Section F, PDM Generator Section G, PDM Amplifier/Pull-Up Section H, PDM Filter Section J, Controller Section K, Interface Board Appendix L, Test Equipment, provides a list of the test equipment provided and recommended to perform maintenance on the transmitter.

1.2. Specifications

Table 1-1, 1-2, and 1-3 list the specifica-

tions of the GATES Series™ transmitters.

NOTE

Specifications subject to change without notice.

Rev. T: Jan. 1996 888-2314-001 1-1

WARNING: Disconnect primary power prior to servicing.

Page 14

Table 1-1. GATES ONE Specifications

POWER OUTPUT: 1000 watts (Rated). Six power levels adjustable between 100-1100 watts. Capable

of lower power PSA/PSSA operation. RF FREQUENCY RANGE: 531 kHz through 1705 kHz. Supplied to one frequency as ordered. CARRIER FREQUENCY STABILITY: Crystal control oscillator meets FCC specifications. +/-4 Hz in typical operating

environment. RF OUTPUT IMPEDANCE: 50 ohms unbalanced. RF OUTPUT TUNING: Integral network will match a VSWR of 1.5:1 to 1.0:1 at carrier. RF OUTPUT TERMINAL: Type N female connector. CARRIER SHIFT: Less than 1% at 100% modulation at 1000 Hz. RF HARMONICS AND SPURIOUS EMISSIONS: Exceeds FCC and CCIR specifications. OTHER EMISSIONS: Meets FCC NRSC 2 when presented with audio signal conforming to NRSC 1

standard. TYPE OF MODULATOR: Patented Polyphase PDM. AUDIO FREQUENCY RESPONSE: +/-0.5 dB, from 20 to 10,000 Hz (with Bessel filter out). AUDIO HARMONIC DISTORTION: Less than 1.0% at 1 kW, 20 to 10,000 Hz @ 95% modulation. AUDIO INTERMODULATION DISTORTION: Less than 1.0%, 60/7000 Hz 1:1. Less than 1.5%, 60/7000 Hz 4:1, SMPTE

standards at 1 kW operation at 95% modulation. SQUAREWAVE OVERSHOOT: Less than 3.5% at 400 Hz. SQUAREWAVE TILT: Less than 3% at 20 Hz, 90% modulation.

Less than 1.5% at 40 Hz, 90% modulation. NOISE (UNWEIGHTED) Better t han 60 dB below 100% modulation, 1000 Hz at 1kW. POSITIVE PEAK CAPABILITY: Greater than 130% positive peak program modulation capability at 1100 watts. INCIDENTAL QUADRATURE MODULATION

30 dB typical below 95% modulation of L+R channel at 1 kHz. (IQM):

AUDIO INPUT: Continuously adjustable from -10 to +10 dBm, transformer-less active 600 ohms

input. ACVOLTAGE INPUT: 197-251 VAC, 50/60 Hz, single phase. OVERALL EFFICIENCY: Better than 65% at 1000W. POWER CONSUMPTION: At 1000 watts carrier, 1538 watts or less at 0% modulation, 2307 watts or less at

100% sine wave modulation, 1923 watts during typical programming. MONITOR PROVISIONS: Adjustable to 5 volts nominal RMS modulated output sample at 50 ohms for six

power levels from 100 watts to 1100 watts. REMOTE CONTROL/MONITORING: Self-contained interface for most remote control systems TTL compatible. AMBIENT TEMPERATURERANGE: -10°Cto+50°C AMSL (derate upper limit 2°C per 1000 feet altitude). AMBIENT HUMIDITY RANGE: To 95%, non condensing. AIR FLOW: 500 CFM HEAT GENERATED: 2756 BTU per hour at 1 KW 100% tone modulation. ALTITUDE: Up to 13,000 feet (4000 meters). SIZE: 72"H X 28"W X 30"D (1830mm X 712 mm X 762 mm). WEIGHT: (Unpacked) 400 lbs. (181 kg) - approximate. Domestic packed, 600 lbs. (275 kg)

- approximate. Export packed, 700 lbs. (320 kg) - approximate. CUBAGE: 68.7 cubic feet (2 cubic meters) packed. NOTE: ALL SPECIFICATIONS TAKEN WITH TRANSMITTER CONNECTED TO TEST LOAD. SPECIFICATIONS SUBJECT

TO CHANGE WITHOUT NOTICE.

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Page 15

Table 1-2. GATES TWO Specifications

POWER OUTPUT: 2500 watts (Rated). Six power levels adjustable between 250-2750 watts. Capable of

lower power PSA/PSSA operation. RF FREQUENCY RANGE: 531 kHz through 1705 kHz. Supplied to one frequency as ordered. CARRIER FREQUENCY STABILITY: Crystal control oscillator meets FCC specifications. +/-4 Hz in typical operating

environment. RF OUTPUT IMPEDANCE: 50 ohms unbalanced. RF OUTPUT TUNING: Integral network will match a VSWR of 1.5:1 to 1.0:1 at carrier. RF OUTPUT TERMINAL: 7/8" EIA male/female flange connector. CARRIER SHIFT: Less than 1% at 100% modulation at 1000 Hz. RF HARMONICS AND SPURIOUS EMIS-

Exceeds FCC and CCIR specifications. SIONS:

OTHER EMISSIONS: MeetsFCCNRSC2whenpresentedwithaudiosignalconformingtoNRSC1standard. TYPE OF MODULATOR: Patented Polyphase PDM. AUDIO FREQUENCY RESPONSE: +/-0.5 dB, from 20 to 10,000 Hz (with Bessel filter out). AUDIO HARMONIC DISTORTION: Less than 1.0% at 2500 watts, 20 to 10,000 Hz @ 95% modulation. AUDIO INTERMODULATION DISTORTION: Less than 1.0%, 60/7000 Hz 1:1. Less than 1.5%, 60/7000 Hz 4:1, SMPTE standards

at 2500 watts operation at 95% modulation. SQUAREWAVE OVERSHOOT: Less than 3.5% at 400 Hz. SQUAREWAVE TILT: Less than 3% at 20 Hz, 90% modulation.

Less than 1.5% at 40 Hz, 90% modulation. NOISE (UNWEIGHTED): Better than 60 dB below 100% modulation, 1000 Hz at 2500 watts. POSITIVE PEAK CAPABILITY: Greater than 130% positive peak program modulation capability at 2750 watts. INCIDENTAL QUADRATURE MODULA-

30 dB typical below 95% modulation of L+R channel at 1 kHz. TION (IQM):

AUDIOINPUT: Continuouslyadjustablefrom-10to+10dBm,transformer-lessactive600ohmsinput. AC VOLTAGE INPUT: 197-251 VAC, 50/60 Hz, single phase. OVERALL EFFICIENCY: Better than 65% at 2500W. POWER CONSUMPTION: At 2500 watts carrier,3846 watts or less at 0%modulation, 5769 watts or less at 100%

sine wave modulation, 4807 watts during typical programming. MONITOR PROVISIONS: Adjustable to5 volts nominal RMSmodulated output sample at50 ohms for sixpower

levels from 250 watts to 2750 watts. REMOTE CONTROL/MONITORING: Self-contained interface for most remote control systems TTL compatible. AMBIENT TEMPERATURERANGE: -10°Cto+50°C AMSL (derate upper limit 2°C per 1000 feet altitude). AMBIENT HUMIDITY RANGE: To 95%, non condensing. AIR FLOW: 500 CFM HEAT GENERATED: 6895 BTU per hour at 2500 watts, 100% tone modulation. ALTITUDE: Up to 13,000 feet (4000 meters). SIZE: 72"H X 28"W X 30"D (1830 mm X 712 mm X 762 mm). WEIGHT: (Unpacked) 450 lbs. (204 kg) - approximate. Domestic packed, 650 lbs. (298 kg) -

approximate. Export packed, 750 lbs. (343 kg) - approximate. CUBAGE: 68.7 cubic feet (2 cubic meters) packed. NOTE: ALL SPECIFICATIONS TAKEN WITH TRANSMITTER CONNECTED TO TEST LOAD. S PECIFICATIONS SUBJECT

TO CHANGE WITHOUT NOTICE.

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WARNING: Disconnect primary power prior to servicing.

Page 16

Table 1-3. GATES FIVE Specifications

POWER OUTPUT: 5000 watts (Rated). Six power levels adjustable between 500-5600 watts. Capable of

Exceeds FCC and CCIR specifications. SIONS:

OTHER EMISSIONS: Meets FCC NRSC 2 when presented with audio signal c onforming to NRSC 1

standard. TYPE OF MODULATOR: Patented Polyphase PDM. AUDIO FREQUENCY RESPONSE: +/-0.5 dB, from 20 to 10,000 Hz (with Bessel filter out). AUDIOHARMONIC DISTORTION: Less than 0.8% at 5000 watts, typically less than 1.5% at 1 kW, 20 to 10,000 Hz @

95% modulation. AUDIO INTERMODULATION DISTORTION: Less than 1.0%, 60/7000 Hz 1:1. Less than 1.5%, 60/7000 Hz 4:1, SMPTE standards

at 5000 watts operation at 95% modulation. SQUAREWAVE OVERSHOOT: Less than 3.5% at 400 Hz. SQUAREWAVE TILT: Less than 3% at 20 Hz, 90% modulation.

Less than 1.5% at 40 Hz, 90% modulation. NOISE (UNWEIGHTED): Better than 60 dB below 100% modulation, 1000 Hz at 2500 watts to 5000 watts. POSITIVE PEAK CAPABILITY: Greater than 130% positive peak program modulation capability at 5600 watts. INCIDENTAL QUADRATURE MODULA-

30 dB typical below 95% modulation of L+R channel at 1 kHz. TION (IQM):

AUDIO INPUT: Continuouslyadjustable from -10 to+10dBm,transformer-lessactive600 ohms input. ACVOLTAGE INPUT: 197-251 VAC, 50/60 Hz, three phase or international 341 to 434 VAC. Compatible

with WYE or closed delta power sources. AC voltage variation: +5, -10% for full

performance. Single phase version accepts 197 to 251 VAC 50/60 Hz. OVERALL EFFICIENCY: Better than 65% at 5000W. POWER CONSUMPTION: At 5000 watts carrier, 7692 watts or less at 0% modulation, 11538 watts or less at

100% sine wave modulation, 9615 watts during typical programming. MONITOR PROVISIONS: Adjustableto 5 volts nominal RMS modulated output sample at50ohms for six power

levels from 500 watts to 5600 watts. REMOTE CONTROL/MONITORING: Self-contained interface for most remote control systems TTL compatible. AMBIENT TEMPERATURERANGE: -10°Cto+50°C AMSL (derate upper limit 2°C per 1000 feet altitude). AMBIENT HUMIDITY RANGE: To 95%, non condensing. AIR FLOW: 500 CFM, (14.16 CMM). HEAT GENERATED: 13790 BTU per hour at 5000 watts, 100% tone modulation. ALTITUDE: Up to 13,000 feet (4000 meters). SIZE: 72"H X 28"W X 30"D (1830 mm X 712 mm X 762 mm). WEIGHT: (Unpacked) 500 lbs. (230 kg) - approximate. Domestic packed, 700 lbs. (320 kg) -

approximate. Export packed, 800 lbs. (370 kg) - approximate. CUBAGE: 68.7 cubic feet (2 cubic meters) packed. NOTE: ALL SPECIFICATIONS TAKEN WITH TRANSMITTER CONNECTED TO TEST LOAD. SPECIFICATIONS SUBJECT

TO CHANGE WITHOUT NOTICE.

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Page 17

SECTION II

INSTALLATION/OPERATION

2.1. Introduction

This section of the technical manual provides detailed installation procedures and setup instructions for the GATES Series™ AM transmitters.

Under normal conditions, the GATES Series™ T ransmitters are shipped completely assembled and ready for installation. However ,if adverseshipping conditions are anticipated, certain components may be removed for transport in which case these components will be properly identified with appropriate instructions for reinstalling the components and making wiring connections.

2.2. Unpacking

Carefully unpack the transmitter and perform a visual inspection to determine that no apparent damage was incurred during shipment.Retain theshippingmaterialsuntil ithas been determined that the unit isnot damaged. The contents of the shipment should be as indicatedonthePackingCheckListwhich accompanies each shipment. If the contents are incomplete or if the unit is damaged electricallyormechanically ,notifytheCARRIER and HARRIS CORPORATION.

2.3. Returns and Exchanges

Damaged or undamaged equipment should not be returned unless written approval and a ReturnAuthorizationisreceivedfrom HARRIS CORPORATION, Broadcast TransmissionDivision.Special shipping instructions and coding will be provided to assure proper handling. Complete details re garding circumstances and reasonsforreturnaretobeincludedinthe requestforreturn.Customequipmentorspecial order equipment is not returnable. In those instances where return or exchange of equipment isat the request of the customer ,or conv enience ofthe customer,arestockingfeewillbe charged. Allreturnswill be sent freightprepaidandproperly insured by the customer .When communicating with HARRIS CORPORATION, Broadcast Transmission Division, specify the Factory Order Number or InvoiceNumber.

2.4. General Installation Information

The GATES Series™ Transmitters have been designed for rapid installation. In addition to the 28 inch width by 30 inchdepth of the equipment, a minimum of 24 inches should be allowed for maintenance access from both the front and rear of the cabinet. Signal and power wires can be connected through several different entries or any desired c ombination thereof.

The holes for cable entrance are 2 inches in diameter, and are located at the front and rear bottom of each side panel. These entriesprovidea means to entertheequipment with wires that are then routed into the base of the equipment.

Input powerwiresshouldrun to the terminal board installed in the base of the transmitter. Access to this terminal board is gainedby removing the coverplate overthe face of the contactor chassis. The screws holding the chassis must then be removed and the chassis pulled forward.

The normal air flow through the transmitter is taken in through the back of the unit (at the bottom of the cabinet). Maximum temperature at the base of the transmitter should not be more than 50°C. The air moves from the base of the cabinet into the side panels and into themain enclosure. Air passes over the heat sink fins in the side panelsand exits through the holes inthetop ofthe cabinet. This providesefficientchimney action cooling of all the Power Amplifier and Modulator transistors.

The air that enters the main enclosure passes directly over the components dissipating heat and exhauststhroughtheoutput coils and out the top of the transmitter. The circuit cards and their heat sinks have been designed to provide a chimney action to the maximum extent practical.

NOTE

Note that the two blowers have separate

air intakes. One is filtered and the other

is not. The unfiltered side is dedicated to

the PA side wall. No filter is needed be-

cause most of the air passes through the

heat sink fins. A small amount of air is

channeled in the cabinet to flush the PA

Toroids. At approximately one year in-

tervals, the PA heat sink fins should be

inspected and cleaned. They may be re-

moved by removing the 10/32 mounting

screws.

2.4.1. Power Distribution for Optimum

Transmitter Performance

(This section is applicable to the three phase GATES FIVE only, as well as other three phase equipment.)

For many years HARRIS engineers have recommended that the three phase power distribution system should be either a closed delta or W YE configuration to provide better radio and television transmitter performanceby helping preventlineunbalance. Operation with substantial voltage unbalance from line toline results in higher

than normal signal-to-noise ratio in the transmitter output signal, increased three phase transformer heating, and hot three phase motors.

2.4.1.1. Overheating from Line Unbalance

Evenadeviceassimpleasathreephase motor should be operated from a power line in which the voltage is balanced within 1%. It takes only a 3.5% line unbalance to produce a 25% increase above normal temperature. A 5%unbalancewillcausedestructivetemperature rises of 50% greater than normal!

Similar characteristics can be expected in the windings of a three phase power transformer down inside the cabinet of your transmitter. Transformers and motors can be designedwithextrasafetyfeatureswherethermal rise is limited to acceptable levels; however ,in this case, other transmitter parameters cannot be made acceptable at a reasonable cost.

2.4.1.2. Transmitter Noise Performance

The most difficultparameter to meet with power line unbalance is transmitter noise performance. Most large transmitters use six-phase or twelve-phase high voltage power supplies. The energy storage capacitors are expensiveto install and largestored energiesmake destructive faults inevitable. A good design will have sufficient energy storage capacitors to meet thespecifiedsignal-to-noise but not much more. When the equipment is then operated from an unbalanced line, the power supply ripple frequency will be twice the line frequency instead of six to twelve times. It becomes obvious that it would take three times as much energy storage to achieve the original performance goal.

2.4.1.3. The Causes of Line Unbalance

How does a line unbalance occur? It is a rare case in w hich a large commercial powerproducer would generateunbalanced voltage, so we must look elsewhere in the system. When you have large single phase power u sers on a power line this can cause uneven distribution of the line currents in the system. Uneven currents through balanced impedances will result in line-to-line voltage unbalance.

Another likely source of this problem can come from unbalanced impedances in the power distribution system. Unbalanced impedance will always be seen when an “open” delta three phase distribution system is used. Transformer design textbooks

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Page 18

clearly show that the voltage regulation of an unbalanced system is poor.

2.4.1.4. Three Phase Delta Distribution

Transformers

Figure 2-1 shows open and closed delta systems. The closed delta impedance looking into each terminal (A, B & C) is exactly thesame;butthisisnotthecaseintheopen delta configuration. Depending on the impedances of the transformers in the open delta circuit, line voltage unbalance sufficient to impair satisfactory operation of the overall transmitter may result. For this reason, along with their inherent susceptibility to transients, Harris does not recommend the use of open delta systems.

over voltage spikes. These units are limited in the amount of energy that can be dissipated, but will handle, if designed properly, very large currents. You can’t take a direct lightning hit and still operate, but not many things will. It has been reported by engineers that installation of a thirdtransformer and trans ient protection devices, have eliminated the difficulty.

2.4.1.5. Three Phase Wye Distribution

Transformers

The WYE connected system is also considered a symmetrical form of three phase power distribution. All impedances are balanced as seen from each terminal (see Figure 2-2). It is important when using a WYE connected system that the fourth wire (neutral) is connected to the mid-point of the system as shown in the diagram. When this connectionismadeit providesa path for the zerosequencecurrentsaswellasanyharmonic currents which are generated due to the rectificationof the secondary voltages.

In summary, both symmetrical power distribution systems are satisfactory because of their balanced impedances. Use either a closed delta or a four wire WYE system for maximum transmitter performance. Never use an open delta system just to cut costs it could cost dearly in the long run.

2.5. General Installation

Requirements

The key to a rapid and successful setup is careful planning prior to delivery of the system. HARRIS offers, as an option, engineering services to reviewand comment on proposedinstallations. InadditionHARRIS offers,as anoption,design,fabrication,and installation services to any required level for total integration of the system into a facility.

Lifting Equipment (Fork Lift, etc)

Hand Tools For opening wooden

Shims (2" by 2") Aluminum,assorted

Hand Operated Hole Punch

900 lbs (408 kg) capacity

crates

thicknesses For adding 0.25"

hardware holes to

0.020" thick copper ground strap at transmitter ground connection.

Figure 2-1. Three Phase Delta

Distribution Transformers

The only advantage of the open delta is lower initial cost, and this is partiallyoffset by the fact that when only two transformers are used, they must be larger than the three transformers in a closed delta system.

Difficulties have often been experienced with open delta systems; but when a third transformerwasaddedtoclose thedelta,the problems disappeared.

Thereisanother problem which can occur with an open delta system, and that i s caused by lightning and switching transients. When lightning strikes or heavy loads are switched on a power distribution system, high voltage transients are propagated throughout the system. Unbalanced impedances will enhance these transients and can cause transmitter damage, particularly to solid state rectifiers.

Many transmitters are located at the end of a long transmission line which is highly susceptible to transient phenomena. Devices such as Metal Oxide Varistors are inexpensive and very effective in reducing

Figure 2-2. Three Phase WYE

Distribution Transformers

Today, many transformers are supplied with all of the primary terminals available sothateitheradeltaor WYEconnectioncan be made. Table2-1 shows the different lineto-line voltages that are available with this configuration.

Delta connected

transformer

WYE connected

transformer

210 364

220* 380*

230 400

240* 415*

250 433

* Typical voltages in some areas of the world.

Table 2-1. Typical Line Voltages

Delta or WYE

Table 2-2. Special Installation

Tools and Equipment

Tra ns forme r, Low

472 1678 000 (1)

Level,A20T01 Transformer,

Power,A19T01

Table 2-3. Equipment Supplied with

Transmitter and Listed on Packing

Check List Supplied with Transmitter

2.5.1. Equipment Placement

See packing list for part number

The transmitter should be located to permit adequate maintenance access and sufficient ventilation. Primary AC power cables can enter the transmitter at a variety of locations and the specific location of entry will need to be determined on site. The grounding strap between the transmitter and the station earth ground must be properly connected before AC power wiring is attached to transmitter.

2.5.2. Pre-Installation Inspection

Prior to performing the installation of the GATES Series™ transmitter, it should be thoroughly inspected for any connections which may have loosenedduring shipment.

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Page 19

This is important due to numerous high current connections in the transmitter.

Also check that all ribbon cablesare properly locked into their respective printed circuit board connectors.

The mechanical interconnecting integrity of the above mentioneditems is essential to the attaining of proper transmitter operation. Although appropriate packaging and shipping precautions are taken prior to the equipment leaving the factory, hardware may, in isolated cases, work loose in transit and result in a failure.

Check for debris or loose hardware, especiallyaroundthe high current power supply connections.

2.5.3. Equipment Positioning

Following removal of the shipping material, move the cabinet on its skid as near as possible to its permanent position. If shipping bolts have been used, they will be locatedateachcorneroftheskid.Remove the bolts from the underside of the skid.

NOTE

Positioning of the cabinet is to be per-

formed by experienced personnel to pre-

vent damage to the equipment or injury

to personnel.

With a suitable lifting device, raise one end of the transmitter cabinet sufficientlyto permit the placing of three lengthsof circular bar stock under the cabinet. In this manner the cabinet can be efficiently and carefully rolled off the skid.

2.5.4. Ground Strap Installation

The importance of a good groundingsystem and lightning protection can hardly be overemphasized for reasons of personnel safety, p rotection of the equipment, and equipment performance. The following is only a brief overview.

Lightning and transient energy via the powerline or towerconnectionscanimpose serious threats to your personal safety as well as damage the equipment. For these reasons you should have a good protective earthing system to divert these forms of energyto earth ground.Propergrounding of theequipmentalso guards against electrical shock hazards that would exist if the equipment failed in a way which put a hazardous voltage on the chassis.

A good grounding system should include substantial grounding at the tower base usingcopper ground rods and/or a buriedcopper ground screen, with copper strap used to connect the tower base to earth ground. A low impedance will help carry lightning current directly into the ground instead of into your building. Additionally, coax shield(s)should be electricallyconnectedto

and exit the tower as near to the bottom as practical to minimize the lightning voltage potential carried by the coax into your building.

For coaxes, a singlepoint of entry into the building is best, with all connected to a common grounding plate (or bulkhead panel) having a low impedance connection tothebuildingperimeter ground.Widecopper straps should be used for making the connection from the common grounding plate to earth ground.

Acommongroundingplate is alsothebest locationfor coaxialsurgeprotectorsforsensitive equipment such as an STL receiver. Ideally, this plate should also be the entry point for all signal lines, and serve as a single point ground for AC power surge protection.

A good ground system should include perimeter grounding of the transmitter building using copper ground rods and copper strap. There should also be a copper strap running from tower ground to the building perimeter ground.

Good grounding and shielding will help keep stray RF current to a minimum. RF interference usually shows up in one of several ways, intermittent problems with digital or remote control circuits, audio feedback or high pitched noise. Even a smallamountofnon-shieldedwiremakesa very efficient antenna for RF and transient energy. If RF is allowed into the audio equipment,itcanberectifiedand may show up as noise or feedback. Wire and cable shields should normally be connected at both ends to the equipment chassis.

Agroundstrapattachment point islocated on the bottom, right rear, of the cabinet behind the dust cover (uses a 10-32 brass screw with brass washer). Use this connectionwhenutilizingasinglepointgrounding system, attaching your ground strap to the common grounding plate. See 839-7920044 Gates series Outline drawing.

A groundingstud is also providednearthe AC input connections in the lower portion of the transmitter. Use this connection for the power line ground. It is located under the low voltage power supply board.

2.6. Electrical Installation

NOTE

All GATES Series™ transmitters are

shipped with A19T1 and A20T1 con-

nected for 251 VAC operation. It is ad-

vised that the end user determine the ap-

propriate tap settings during the initial

turn-on. In this procedure, the trans-

former tapping is determined by the re-

sulting DC supply voltage. This ensures

that the DC supplies are operated in the desired range.

2.6.1. Power Requirements

The GATES Series™ GATES FIVE (3 phase version) is designed to operate from a3phase,208/240 VAC,50to60 Hz source. Sixty ampere service is required. Use 6 gauge wire for this connection.

The single phase GATESFIVE requires a 100 amp 208/240 VAC, 50 to 60 Hz source. Use 4 gauge wire for this connection.

The GATES TWO requires a 60 amp 208/240 VAC, 50 to 60 Hz source. Use 6 gauge wire for this connection.

The GATES ONE requires a 30 amp 208/240 VAC, 50 to 60 Hz source. Use 8 gauge wire for this connection.

There is no requirement for 120 VAC in any case.

As an option, the low voltage circuits can be powered from a separate circuit breaker. Although not a requirement, thissetup sometimes is advantageous for maintenance and troubleshooting. If you choose to wire your transmitter this way,you will need to provide a separate 10 amp circuit breaker.

NOTE

If service voltage is less than 208 VAC,

a higher current service may be needed.

Refer to the Outline drawing for mechanical dimensions and wire feed locations.

WARNING

ENSURE THAT ALL AC POWER IS OFF PRIOR TO STARTING THE FOLLOWING INSTALLATION

2.6.1.1. Procedure.

For a three phase GATES FIVE, connect 3 phaseACinput powerfromafuseddisconnect box or circuit breaker to transmitter cabinet terminal board TB1 terminals 1, 2 and 3. The powersourcecan be either a closeddelta(usually 230 to 240 volts) or aWYE (usually 208).

For a four wire WYE system (341 to 434 volts), connect the neutral wire to terminal board TB1 terminal 4. Also for a WYE system ensure that the high voltage transformer has been tapped correctly for the configuration (see the Wiring Diagram for the three phase GATESFIVE transmitter).

For the GATES ONE, GATES TWO, or single phase GATESFIVE, connect ACinput power(197 to 251 VAC)from afused disconnect box orcircuit breaker to transmitter cabinet terminal board TB1 terminals 1 and 2.

NOTE

Terminal board TB1 is accessed by remov-

ing the four screws which hold the circuit

breaker panel to the front of the transmit-

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ter and then sliding the circuit breaker panel forward. Terminal board TB1 is located on the floor of the transmitter directly below the AC Power panel. Terminals are numbered left to right.

Ifyou choose towireyourtransmitterwith separatelow voltageandhigh voltagefeeds, you will need to remove the factory installedjumperwiresfrom TB1, and connect a10ampservicetoTB1terminals5and6.

For the 3 phase GATESFIVE, ensure that the Phase Monitor relay A19K3 is installed

Table 2-4. Interface Board Connections

CONTROL

INPUTS TERMINAL

Low TB2-1 Two TB2-2 Three TB2-3 Four TB2-4 Five TB2-5 High TB2-6 Off TB2-7 Raise TB2-8 Lower TB2-9 Ext Kill (RF mute) TB2-10 FAILSAFE TB1-1 and TB1-2

METERING

OUTPUTS TERMINAL

PA Voltage TB2-11 PS Current TB2-12 Power Output TB2-13 STATUS TERMINAL Low TB2-15 Two TB2-16 Three TB2-17 Four TB2-18 Five TB2-19 High TB2-20

OVERLOAD

STATUS TERMINAL

Overload Ind Reset TB2-14 Auto Cutback TB2-21 Supply Voltage TB2-22 Supply Current TB2-23 Underdrive TB2-24 VSWR TB2-25 Audio TB2-26 Audio TB2-27 Ground TB2-28

in the AC Power panel and is adjusted to MIN.SeeNotebelow.

NOTE

To adjust the Phase Monitor, remove all power from transmitter and rotate the voltage adjustment screw to your approximate AC line voltage. The actual setting will have to be determined by trial and error. Refer to paragraph 2.7.1.g for adjustment information.

2.6.2. RF Output Connection

Connect the output transmission line from theantennato theRFOUTPUTconnectorjack J1 located on top of the transmitter cabinet.

A GATES ONE requires a male type N connector. Specific type N connectors are availablefor various types of coax.

TheGATESTWOandGATESFIVErequire a 7/8 EIA flange. Specific connectors of this type are available for various kinds of coax.

2.6.3. Battery Installation

The purpose of the battery on the Controller board (on the swing out panel) is to maintain transmitter operational status during a power interruption. It is not important to install it until

you are nearly ready to put the transmitter into regular operation. The transmitter will operate properly without the battery, however , po wer interruptions lasting more than a few seconds will result in an OFF condition, and all overload lights lit.

A standard 9 volt battery will last about 2 weeks of continuous running with no AC powerapplied.Alkalinebatterieswillgivethe longest shelf life. It is a good idea to change the battery after a long outage or yearly.

2.6.4. Audio Input

Route the audio cable up from the base of the transmitter to the Interface board. The Interface board is located in the lower left portion of the transmitter in the front. Connecttheaudioinputwiresto terminals TB226 and TB2-27 on the Interface Board. TB2-28is ground for the audiocable.Refer to Table 2-4 and Figure 2-3.

2.6.5. Remote Control

Allremote controlconnectionsaremadeatthe Interfaceboard. Cabling forremotecontrolmay be routed up from the base of the transmitter.

To prepare wire, strip insulation back approximately 1/4" and twist strands back into

their natural position.

A small flat blade screwdriveris an appropriate tool to use to make the connection.

To make connection, align wire in side opening “B” and depress clamp down from opening “A”with tool. Insert wire or component in opening “B” andsecurebywithdrawing tool.

Figure 2-3. Making Connections to WAGO Block

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Note:Allremotecontrol inputs areactivated by applying a momentary ground connection to each desired input. This makes the transmitterdirectlycompatiblewithopencollector type remote control units as well as dry contact systems. With a dry contact (relay) system, you will simply need to momentarily switch each of the desired control inputs to ground in order to cause a function to occur.

The status outputs for power levels and overloads are open collector outputs. These are directly compatible with TTL type inputs,or may be usedto drivesmallrelays or other indicating devices as long as the current requirements are 100 ma or less.

To use a status output to drive a small relay, you will need to connect the relay from the status output toa DC power source with a positive voltage between 5 volts and 24volts.As with anyDCpoweredrelay,you should connect a diode across the coil, with the cathode toward the positive supply.

2.6.6. Airflow Sensor Status

In addition to the status outputs described above, transmitters manufactured December 1995 and later are equipped with an Airflow Sensor circuit which includes a status output. A relay contact closure is providedonTB1onthemainAirflowSensor circuit board, located in the air inlet for A20B1.

All metering samples are positive with respect to ground and are less than 5 volts into a 10k ohm input resistance.

2.6.7. Failsafe Connection

24VAC contactor coil current passes through the Failsafe Interlock t ermi nals. Therefore, high voltage power supply activationrequires the presence of a continuous closure across the Failsafe Interlock terminals. Opening of the contacts results in deenergizing the HV contactors.

A connection is required at the Failsafe terminals even if the transmitter will be locally controlled. Switching the transmitter to Local control does not bypass the Failsafe interlock.

Contacts and wiring connected to these terminalsshouldberatedfor atleast24 VAC @ 1 amp. Refer to the listing of Interface Board connections in the Table 2-4.

The shield connection forthe remote controlcablingshouldbe connected to a nearby ground stud or one of the Interface board mounting screws.

2.6.8. Modulation Monitor Sample

An adjustable, 1 to 5 Volt RMS signal source is provided on the Output Monitor board.The Output Monitor board is located behind an access door on the front. Route

the cable for the modulation monitor from the base of the transmitter up to thelocation of the Output Monitor board. The coax will slip into the gap between the transmitter wallandtheenclosurefortheOutputMonitor, RF Oscillator, and PDM Generator.

Connect modulation monitor to the BNC jackon theOutputMonitorboardA18.Besure topositionthecoaxsafelyawayfromany components which may generate enough heat to melt the insulation on the coaxial cable.

2.7. Initial Turn On Procedure

Before initial t urn on, ensure that the following items are checked:

a. Ground strap is properly connected be-

tween tran smitter and station earth ground.

b. Check for debris/hardware in base of

transmitter and in AC Panel.

c. Make sure all hardware connections are

tight. d. AC input wiring is properly connected. e. Transmitter output is properly termi-

nated into a suitable load capable of

handling rated output power (antenna or

dummy load). f. Audio input is properly connected. g. Monitoring equipment is properly con-

nected. h. The REMOTE/LOCAL switch on the

Controller board (on the swing out

panel) should be in the local mode. i. Be sure the front and rear covers are in

place.

2.7.1. Initial Turn On

Important

Temporarily remove F1 from the Interface board. This will disable the contactor circuit for the first part of the turn-on procedure. Fasten the bottom frontpanel in place with at least two screws.

WARNING

THE NORMAL PROCEDURE FOR TRANSMITTER TURN OFF SHOULD BE FOLLOWEDINORDERTOPROPERLY DISCHARGE THE HIGH VOLTAGE COMPONENTS. TURN OFF THE HIGH VOLTAGEBYDEPRESSING THEOFF BUTTON. IFYOUMUSTENTERTHETRANSMITTER, SET THE REMOTE/LOCAL SWITCH TO LOCAL AND ALLOW THE POWER SUPPLY TO DISCHARGE AS INDICATED BY THEFRONTPANEL METERS. LOWVOLTAGE MAY THEN BE REMOVED BY SETTING THE LOW VOLTAGE CIRCUIT BREAKER TO OFF. DISCONNECT ALL PRIMARY POWER SERVICE. REMOVE THE REAR LIFT OFF PANEL SLOWLY TO ALLOW THE RESISTOR DISCHARGE MECHANISMTOFUNCTION.AGROUNDING STICK IS PROVIDEDIN THE TRANS-

MITTER AND SHOULD BE USED TO ASSURE THAT ALL HIGH VOLTAGE HAS BEEN REMOVED UNDER FAULT CONDITIONS. BE CAREFUL NOT TO GROUND ANY CONNECTIONS WHICH ARE STILL ENERGIZED.THISWOULDINCLUDE ALL LOW VOLTAGE CIRCUITS IF THE LOW VOLTAGE CIRCUIT BREAKER HAS NOT BEEN SET TO OFF POSITION.

CAUTION

IF ANY ABNORMALITIES ARE ENCOUNTERED IN THE FOLLOWING STEPS, STOP THE PROCEDURE, REMOVE ALL POWER, AND PROCEED TO TROUBLESHOOTING SECTION OF MANUAL.

a. Using a small blade screwdriver or ad-

justing tool, rotate the LOWpowerlevel control pot (located below the LOW powerON switch)severalturns counterclockwise. The other pots may be left at

the factory settings for now. b. Apply AC power to transmitter. c. Set the LOW VOLTAGE circuit breaker

A20CB1 to ON position. d. Verify the +/- 12 volt supply LED’sillu-

minate on the control panel. e. If you havea3 phase GA TESFIVE,verify

red LED on Phase Monitor (inthe contac-

tordrawer) isilluminated.Ifthe LEDisnot

illuminated, either the Phase Monitor is

not adjusted for the correct line voltage or

thephasesequenceis backwards.Remove

all po wer and adjust the volta ge selector

on the Phase Monitor to the lowest setting

and re-apply power. f. If the LED is still not illuminated, re-

move all power and reverse any two

leads in the main disconnect box and

re-apply power and verify that the LED

is illuminated. Adjust the voltage selec-

tor so that the red LED on the Phase

Monitor relay illu minates when AC

power is applied. In this adjustment, al-

low for a reasonable sag in line voltage,

butdo not desensitize it so far that itwill

be ineffective.

Note: The Phase Monitor relay adjustment is affected only by the particular line voltage.Itisnot affectedbythe changing of transformer taps which may be done later.

g. Install screws holding AC Power panel

in place.

WARNING

ENSURE ALL VOLTAGE IS REMOVED FROM TRANSMITTER AND ALL POINTS WHERE VOLTAGE HAS BEEN APPLIED ARE GROUNDED BEFORE CHANGING ANY TAPSIN THE FOLLOWING STEP.

h. Use a suitable voltmeter to measure the

+/-20voltsupply. A convenientpointfor checking these voltages is on the PDM

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Page 22

Generator, A15 at the fuses. Measure each voltage with respect to ground. If the voltages are under 19 Vdc, disconnect AC power and re-tap A20T1 to the nextlowerprimary voltage(taps240,0).

It is desired thatthe low voltage supply be between 19 and 23 Vdc both plus and minus. Use a procedure of removing AC power, grounding transformer taps, moving the primary wiring to the next lower increment, then measuring +/-20 volt supplies, to achieve the desired supply voltages.

Note: The transformer tap connections are provided on TB3, terminals 15 through

19. Refer to Figure 2-3 for instructions on using the Wago block terminals. Move the AC connection as deemed appropriate to achieve the desired output voltage.

i. Verify that all overloadand fault indica-

tors can be extinguished by pressing the Reset button.

j. Check theRFDrivereadingontheMul-

timeter. It should be close to the values recorded on the factory test data sheet. If it is not, re-check the low voltage transformer tapping. If needed, check the actual RF Drive on the PA module(s) per the procedure in Section C.

k. Confirm that when any of the power ON

pushbuttonsaredepressed theyilluminate. The AC contactors in the pull out drawer should not be heard energizing at this time sinceF1isnotinthe Interfaceboard.Also, thePDMKILLandPDMFAULTLED’s will light in this condition.

l. Verifythat depressing the OFFpushbut-

ton clears all power ON pushbuttons.

m.Disconnect all primary power, and in-

stall F1 in place on the Interface board. n. Reapply primary power. o. Rotate the multimeter switchto theSup-

ply Voltage position. Depress the LOW

power pushbutton. The contactors

should close and apply main ACvoltage

tothehigh voltagesupply.Themultime-

ter should show a voltagein the rangeof

220 to 270 on the 300 scale.

WARNING

IF CONTACTORS DO NOT CLOSE IN THE PRECEDING STEP, REMOVE ALL POWER FROM TRANSMITTER AND ENSURE FAILSAFE INTERLOCK CONTACTS ARE JUMPERED OR EXTERNAL FAILSAFE HIGH VOLTAGE INTERLOCK CIRCUIT IS PROPERLY CONNECTED. ALSO BE SURE THE REAR PANEL IS SECURELY FASTENED.

p. Switch the multimeter to read Detector

Nullandverifythatthereadingiszero. q. Rotate the LowPowercontrol potclock-

wise and observe the PA Voltage, PA

Amps, and FWD Power meters, and raise the power until the power level is as stated on the factory Final Test Data Sheets for the Low Power setting.

r. If the Detector Null reading increases

from zero, adjust the TUNING and LOADING controls to minimize the reading. This will match the PA to the load impedance you are using.

Duringtheinitial tune-up, the null should be found to be well withinthe range of the TUNING and LOADING controls. If these controlsrequire considerable adjustment,theload impedance on the transmitter is probably not very close to 50 ohms. Ifconsiderable adjustment is required, the impedance presented to the transmitter output terminal should be measured and corrected as necessary.

Although the transmitter is designed to match up to a 1.5:1 VSWR, the optimum condition is to terminate it into 50 ohms.

s. Depress Power Level number 2. The

power level should increase to near the factory setting for this power level. It probably will not be exactly the same since the Fine Power adjustment has not been made.

t. AdjusttheTuningand Loading controls

as necessary to null the Detector Null readingtozero.

u. Compare the present readings against

thefactorydataforanymajordiscrepancies. If any exist, it should be investigated at this time.

v. Progressively step the power level up-

ward by selecting each higher level, check the readings against the Final Test Data Sheets. Adjust the TUNING and LOADINGcontrols to minimize the Detector Null reading to zero.

w.Compare all readings against the Test

Data. Since the High Voltage transformer is tapped at 240 +11 from the factory, it will probably be necessary to changethetransformertapsaccordingly. The need to do this or not is determined by the Supply Voltage reading on the Multimeter.Itshouldbe250to265 volts at full power.

A change from one transformer tap setting to the next will produce about a 5% change in DC Supply voltage. For example, moving from 240, +11 to a setting of 240, 0 would result in a DC Supply increase of about 5%.

NOTE

The smaller gauge wiring on the trans-

former primary is for the fans. These

smaller wires should always be left on

240, -11.

If you will be operating the transmitter well below its rated power, then you may leave the High Voltage transformer at it

highest primary setting. This will yield the best overall performance if it is to be operating at a reduced power level.

WARNING

ENSURE ALL VOLTAGE IS REMOVED FROM TRANSMITTER AND ALL POINTS WHERE VOLTAGE HAS BEEN APPLIED ARE GROUNDED BEFORE CHANGING ANYTAPS ONTHETRANSFORMER.

x. Look at the range of the Fine Power

adjustment using the Raise/Lower switches. It is desirable to seteach of the coarse power level pots (LOW through HIGH) with the Fine adjustment in the middle portion of its range.

The PDM Power Level reading on the Multimeter is essentially the power control settings. This reading may serveas a handy reference for each desired power level. These readings should be recorded when the transmitter is initially set up, and used later if you need to troubleshoot a power level change.

y. Check or set each powerlevelaccording

to your needs and compare all readings with the factory test data. Report any major discrepancies to the HARRIS Service Department.

The GATES Series™ incorporates a protectiveactionnamed Automatic Cutback in which the transmitter will step to each successivelylowerpowerinanefforttostayat thehighesttolerable powerlevelwhen there is an overload condition. This is similar to the automatic foldback feature in some transmitters, but is different in that the power level steps down rather than going through a gradual reduction.

Because of the Automatic Cutback feature,it isusefulto setall6 powerlevels.This way, the transmitter output will remain at a reasonable level should an Automatic Cutback occur. These power levels that you would not ordinarilyuse may be intermediate power levels, or lowerthan your normal operating powers.

2.7.2. Modulation Monitor Carrier Level

After each power level has been adjusted, you should set the RF sample level for your Modulation Monitor. If you are not using a modulation monitor at the transmitter, you should leave all of the monitor level controls setfullycounterclockwise(minimumoutput).

The output levels of the monitor circuit are independent of one another, so they may be set in any order. While operating at a particular powerlevel,rotateeach corresponding control clockwise to achieve adequate carrier level.

Switching the REMOTE/LOCAL switch (nearthe battery on the Controllerboard)to

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Page 23

the REMOTE position will enable the remote control circuits and should be in REMOTE position for normal operation. In addition to enabling the remote inputs, the transmitter will mute the RF Oscillator when in an OFF condition.

Note: The PA Voltmeter deflects upward when shut off in the Remote mode. This is a normal function of the RF drive being removed when PA voltage is present.

2.7.3. Application of Audio

Apply audio to the transmitter, and observe the resulting modulation level on the monitor. The audio input sensitivity is factory set for +10dBm, but is continuously

adjustabledown to -10dbm. Ifyou desire to increasethesensitivity, you may adjust R21 on the PDM Generator.

Audio polarity is important, especially if youoperateinstereo. Observetheresultson yourmonitor,and change the audio polarity if the need is indicated.

2.7.4. Remote Meter Calibration

The remote sample outputs of the transmitter are designed to be compatible with mostmodernday remote controlunits,with lessthan5voltsdc of output intoa10Kohm impedance. There are no internal adjustments for these voltages.

Set the remote control unit’s calibration adjustments to match the transmitter’sme- ter readings.

Note: The remote current reading is Supply Current, which is not the same as PACurrent. The remote Supply current reading should be calibrated against the Supply Current reading on the transmitter multimeter.

Supply Current actually reads lower than PA Current in normal operation due to the manner in which the PDM system operates.

Thisconcludes the initial turn onprocedure.

Referto sections A through K for individual board controls and indicators.

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WARNING: Disconnect primary power prior to servicing.

Page 24

CONTROL/INDICATOR FUNCTION Power TransformerA19T1 Main Power Supply transformer for 260 volt dc supply. PDM Pullup Resistors Shield shown covering 250 watt resistor(s) used by PDM Pull-up circuits. Low Voltage Transformer A20T1 Secondary for +20VDC, -20VDC, 24 VAC, and IPA Supply (60/75/90/105/120 Vdc).

2-8 888-2314-001 Rev. AC: 2/29/00

WARNING: Disconnect primary power prior to servicing.

Figure 2-4. Base of GATES Transmitter

Table 2-5. Base of GATES Transmitter

Page 25

CONTROL/

INDICATOR FUNCTION

Relay K1 Relay K1 is used to

applyACtothehigh voltage transformer through current limiting resistor(s) during the step start sequence.

Relay K2 Relay K2 is used to

apply ACmains directly to the high voltage transformer.

Terminal Board TB1

Step Start Resistors A19R3, A19R2, & A19R1

Provides connections for AC input power.

(Only one resistor is used in the single phase transmitter.) The step start resistors limit the power supply surge currenton initial turn on.

Phase Monitor Detects loss of phase on

primary AC input power and h as capability to detect low primary AC input voltage (3 phase GATES FIVE only).

FAN C ircuit Breakers A20CB2 &

Protect wiring to fans from over current condition.

A20CB3 Lamp A20DS1 DS1 will illuminate

whenpoweris applied to thelowvoltagecircuitry.

Circuit Breaker, CB1

10 Amp circuit breaker to protect the low volta g e power supply from an over current condition.

Lamp A19DS1 A19DS1 will illuminate

when power is applied from the Main Disconnect Switch (i.e. cabinet is receiving AC power).

Figure 2-5. AC Power Panel

Rev. AC: 2/29/00 888-2314-001 2-9

WARNING: Disconnect primary power prior to servicing.

Table 2-6. AC Power Panel

Controls and Indicators

Page 26

Table 2-7. GATES ONE

Typical Readings at 1340kHz

Power Output 1000W 800W 600W 400W 200W 100W PA Volts 92.5 84 74 62 46.5 35 PA Amps 12.5 11.3 10 8.4 6.4 4.9 PDM Level 6.4 5.8 5.1 4.3 3.2 2.4 Supply Voltage 242 244 246 248 252 254 Supply Current 4.8 4.1 3.3 2.5 1.6 1.1 RF Drive 7.4 7.4 7.4 7.4 7.4 7.4 VSWR Detector Null 0 0 0 0 0 0 VSWR Detector Null Set 5.3 5.3 5.3 5.3 5.3 5.3 Underdrive Set 6.4 5.8 5.1 4.3 3.2 2.4 Supply Current Set 8.3 8.3 8.3 8.3 8.3 8.3 Supply Voltage Set 297 297 297 297 297 297 Battery 9.8 9.8 9.8 9.8 9.8 9.8 The readings above are typical readings. Refer to the Factory Test Data Sheets supplied for readings actually obtained during factory

tests.

Table 2-8. GATES TWO

Typical Readings at 800kHz

Power Output 2500W 2000W 1500W 1000W 500W 200W PA Volts 98.5 90.0 79.0 66.0 50.0 35.0 PA Amps 28.7 26.1 23.0 19.0 14.0 10.0 PDM Level 6.8 6.2 5.5 4.6 3.4 2.4 Supply Voltage 249 250 252 257 260 265 Supply Current 12.0 10.0 8.0 5.0 3.0 2.0 RF Drive 8.9 8.8 8.8 9.0 9.0 9.0 VSWR Detector Null 0 0 0 0 0 0 VSWR Detector Null Set 6.6 6.6 6.6 6.6 6.6 6.6 Underdrive Set 6.7 6.2 5.5 4.5 3.4 2.4 Supply Current Set 23.5 23.5 23.5 23.5 23.5 23.5 Supply Voltage Set 299 299 299 299 299 299 Battery 9.8 9.8 9.8 9.8 9.8 9.8 The readings above are typical readings. Refer to the Factory Test Data Sheets supplied for readings actually obtained during factory

tests.

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Page 27

Table 2-9. GATES FIVE

Typical Readings at 920kHz

Power Output 5000W 4000W 3000W 2000W 1000W 500W PA Volts 96.0 87.0 76.0 62.0 48.5 37.0 PA Amps 57.5 52.5 46.0 38.5 29.5 22.5 PDM Level 6.7 6.0 5.3 4.5 3.4 2.5 Supply Voltage 247 250 252 255 259 262 Supply Current 24.1 20.0 15.8 12.0 6.8 4.2 RF Drive 8.7 8.7 8.6 8.5 8.4 8.3 VSWR Detector Null 0 0 0 0 0 0 VSWR Detector Null Set 5.1 5.1 5.1 5.1 5.1 5.1 Underdrive Set 6.7 6.0 5.3 4.4 3.3 2.5 Supply Current Set 44.8 44.8 44.8 44.8 44.8 44.8 Supply Voltage Set 297 297 297 297 297 297 Battery 9.8 9.8 9.8 9.8 9.8 9.8 The readings above are typical readings. Refer to the Factory Test Data Sheets supplied for readings actually obtained during factory

tests.

Rev. AC: 2/29/00 888-2314-001 2-11

WARNING: Disconnect primary power prior to servicing.

Page 28

2-12 888-2314-001 Rev. AC: 2/29/00

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Page 29

SECTION III

MAINTENANCE

3.1. Introduction

This section provides preventive maintenance information and corrective maintenance procedures. The information contained in this section is to provide guidance for establishing a comprehensive maintenance program to promote operational readiness and eliminate down time. Particularemphasis is placed on preventive maintenanceand record-keeping functions. For further information on maintenance of particularboard, refer to sections A through K.

3.2. Station Records

The importance of keeping station performance records cannot be overemphasized. Se parate logbooks should be maintained by operation and maintenance activities. These records can provide data for predicting potential problem areas and analyzing equipment malfunctions.

3.2.1. Maintenance Logbook

The maintenance logbook should contain a complete description of all maintenance activitiesrequired to keep the equipment in operationalstatus.A listing of maintenance information to be recorded and analyzed to provide a data base for a failure reporting system is as follows:

DISCREPANCY Describe the nature of the malfunction including all observable symptoms and performance characteristics. CORRECTIVE ACTION Describe the repair procedure used to correct the malfunction. DEFECTIVE PART(S) List all parts and components replaced or repaired and include the following details:

a. Time In Use B. Part Number C. Schematic Number D. Assembly Number E. Reference Designator

SYSTEM ELAPSED TIME Total time on equipment NAME OF REPAIRMAN Person who actually made the repair STATION ENGINEER Indicates Chief Engineer noted and approved the repair of the equipment

3.3. Preventive Maintenance

Preventive maintenance is a systematic series of operations performed periodically on equipment. Because these procedures cannotbe applied indiscriminately,specific instructions are necessary.Preventivemain-

tenance consists of six operations: inspecting,feeling,tightening,cleaning, adjusting, and painting.

INSPECT. Inspection is the most important preventive maintenance operation because it determines the necessity for the others.Become thoroughlyacquaintedwith normaloperatingconditionsin order to recognize and identify abnormal conditions readily. Inspect for the following:

Overheating, which is indicated by discoloration, bulging of parts, and peculiar odors. Oxidation. Dirt, corrosion, rust, mildew, and fungus growth.

FEEL. Use this operation to check parts for overheating. By this means the lack of proper ventilation or the existence of some defect can be detected and corrected before serious trouble occurs. Become familiar with operating temperatures in orderto recognize deviations from the normal range.

TIGHTEN. Tighten loose screws, bolts, and nuts. Do not tighten indiscriminatelyas fittings that are tightened beyond the pressure for which they are designed may be damaged or broken.

CLEAN. Clean parts only when inspection shows that cleaning is required and only use approved cleaning solvent.

ADJUST. Make adjustments only when inspection shows that they are necessary to maintain normal operation.

PAINT. Paint surfaces with the original type of paint(using prime coat if necessary) wheneverinspectionshowsrust, or worn or broken paint film.

3.3.1. Maintenance Of Components

The following paragraphs provide information necessary for the maintenance of components.

TRANSISTORS. Preventive maintenanceof transistorsis accomplishedby performing the following steps:

Inspect the transistors and surrounding area for dirt as accumulations of dirt or dust could form leakage paths.

Use compressed dry air to remove dust from the area.

WARNING

ALWAYS WEAR SAFETY GOGGLES WHEN USING COMPRESSED AIR.

Examine all transistors for loose connections or corrosion. Tighten the transistor mounting hardware to no more than 5 inch-

pounds. Over-tightening the transistor hardwarewillcausethesiliconinsulatorsto curl up on the ends and possibly short through. When replacing a MOSFET transistor, be sure to alternate frequently between the mounting posts to tighten the hardware down evenly. This will minimize the possibility of shorting through an insulator.

CAUTION

IF THE TRANSISTORS IN THE PA OR IPA REQUIRE CHANGING, ENSURE THAT ALL OF THE TRANSISTORS ARE OF THE SAME TYPE NUMBER AND ARE FROM THE SAME MANUFACTURER.

INTEGRATED CIRCUITS.Preventive

maintenance of integrated circuits is accomplished by performing the following steps:

CAUTION

USE CARE TO AVOID THE BUILDUP OF STATIC ELECTRICITY WHEN WORKING AROUND INTEGRATED CIRCUITS.

Inspect the integrated circuits and surrounding area for dirt as accumulations of dirt or dust could form leakage paths.

Use compressed dry air to remove dust from the area.

WARNING

ALWAYS WEAR SAFETY GOGGLES WHEN USING COMPRESSED AIR.

CAPACITORS. Preventive maintenance of capacitors is accomplished by performing the following steps:

Examine all capacitor terminals for loose connections or corrosion. Ensure that component mountings are tight. (Do not over tighten capacitor mounting straps as excessive pressure could cause internal shorting of the capacitors. Examine the body of each capacitor for swelling, discoloration, or other evidence of breakdown. Use standard practices to repair poor solder connections with a low-wattage soldering iron. Clean cases and bodies of all capacitors.

Inspectthe bleederresistorswhen inspecting the electrolytic capacitors.

FIXED RESISTORS. Preventive maintenance of fixed resistors is accomplished by performing the following steps:

When inspecting a chassis, printedcircuit board, or discrete component

Rev. AD 888-2314-001 3-1

WARNING: Disconnect primary power prior to servicing.

Page 30

assembly, examine resistors for dirt or signs of overheating. Discolored, cracked, or chipped components indicate a possible overload. When replacing a resistor, ensure that the replacement value corresponds to the component designated by the schematic diagram and parts list. Clean dirty resistors with a small brush.

VARIABLETUNINGAND LOADING

COILS.Lubricateat six month intervals,or

as required if binding is evident, the mating surfaces of the ribbon and wiper with HARRIS lubricant (part number 055 0115 007) using a cotton swab to apply the liquid. Follow directions provided with lubricant forproperapplicationtechniques. Use sparingly as too much may prove ineffective. This lubricant can also be obtained locally or from CAIG LABORATORIES, INC., Escondido, CA., 92025-0051 under the name of CRAMOLIN R.

FUSES. Preventive maintenance is ac-

complished by performing the following steps:

When a fuse blows, determine the cause

before installing a replacement.

CAUTION

IF ANY OF THE FUSES IN THE GATES SERIES™ TRANSMITTER REQUIRE REPLACING, ENSURE THAT ONLY AN EXACT REPLACEMENT FUSE IS USED. A DIFFERENT MANUFACTURER’SFUSEOFTHESAME SIZE AND/OR RATING DOES NOT FULFILL THE REQUIREMENT FOR EXACT REPLACEMENT.

Inspect fuse caps and mounts for charring

and corrosion.

Examine clips for dirt, and, if necessary,

clean with a small brush.

If necessary, tighten fuse clips and connectionsto the clips. The tensionofthefuse clips may be increased by pressing the clip sides closer together.

SWITCHES. Preventive maintenance of switchesisaccomplished by performingthe following steps:

Inspect switch for defective mechanical action or looseness of mounting and connections.

Examine cases for chips or cracks. Do not disassemble switches.

Inspect accessible contact switches for dirt, corrosion, or looseness of mountings or connections. Check contacts for pitting, corrosion, or wear. Operate the switches to determine if they move freely and are positive in action. Tighten all loose connections and mountings.

Be sure to include an inspection of the power supply discharge switches located at the bottom of the rear panel opening.

TOROIDS. Inspect the drive transformer

assemblies periodically for any signs of stress. These would be T11 and T12 on the IPA andT11,T12,T21, T22,T31,T32,T41, and T42 on the Power Amplifierboards A1 through A4. In particular, check the zener diodes on these transformer assemblies for signs of over dissipation. When over dissipated, these zeners will lose their normal glossy finish. If any of these zeners are found in this condition, check the RF drive system.

Thetoroidson the backsideof the IPAand PA should be inspected when the modules are removed for replacing transistors. A crack or break in any core may cause damage to the transistors of the same quad. The best way of inspecting the toroidal cores is by rotating the core. This will allow a complete visual inspection.

PRINTED-CIRCUIT BOARDS.Preventive maintena nce of printed circuit boards is accomplished by performing the following steps:

Inspect the printed circuit boards for cracks or breaks. Inspect the wiring for open circuits or raised foil. Check components for breakage or discoloration due to overheating. Clean off dust and dirt with a clean, dry lint-free cloth. Use standard practices to repair poor solder connections with a 40 watt soldering iron.

CAUTION

ENSURE THAT THERMAL COMPOUND IS APPLIED TO PLATES OF PA, IPA, AND PDM AMPLIFIERBOARDSBEFORETHEYAREINSTALLEDON HEAT SINKS AND THAT HARDWARE SECURING BOARD TO HEAT SINK IS PROPERLYTORQUED TO 6-INCH POUNDS. ALSO INSURE NO BURRS OR DIRT PARTICLES ARE ON THE MATING SURFACES.

3.3.2. Air System

The air filter should be cleaned routinely. The intervalsbetween cleaning will depend on the environment.

Replace filter if it is worn out.

3.3.3. GATES Series™ Top Removal

Procedure

The GATES Series™ top may have to be removed to change frequency determinant components if a frequency change is required, or any capacitors need replacing.

WARNING

ENSURE ALL POWERIS REMOVED AND NETWORK COMPONENTS ARE SHORTED WITH SHORTING STICK BEFORE PERFORMING THE FOLLOWING PROCEDURE.

a. Make sure all power is turned off and

Output Network components are shorted to ground with shorting stick.

b. Disconnect A21L1 in the Output Net-

work from PA module A1 (see Figure 3-2).

c. Remove the eight screws holding RF

shield below L2 and remove RF shield from transmitter.

d. Disconnect the tubing which connects

A21L7 to the TUNING control, L4 as showninFigure3-3.

e. Remove10-32 Phillips headscrewfrom

C3 connector strap that goes to L4 (see Figure 3-3).

f. Separate the two halves of A18P4. This

connector is in line with three coaxes which go from the bracket e nd of A21 L2 to the Output Monitor board (see Figure 3-2).

g. Disconnect gray wire #112 from the HV

shorting switch at the upper left of the rear opening.

h. Remove all of the 8-32 screws around

the perimeter oftop access panel and the eightr screws on the top rear (see Figure 3-1).

CAUTION

THE REMOVABLE TOP ASSEMBLY WEIGHS APPROXIMATELY 46 POUNDS.

i. From the rear of transmitter, pick up on

thetop and pull complete assembly back about one inch. It may be necessary to pull slightly on top back section to disengage edges from guide slots in corner posts.

j. At this point it maybe more desirable to

grasp bottom of L2 with one hand and topbacksection with the otherhand.Lift top rear about one inch and pull complete assembly straight back and then down to desired work area.

k. Reinstall the GATES Series™ top by

reversing the above procedure.

3.3.4. Low Voltage Supply Adjustment

The Low Voltage power supply outputs need to be in the desired voltage range in order for the transmitter to work properly. One Low Voltage Supply output is +/-20 volts for use by the Controller, PDM Generator, RF Oscillator, PDM Amplifiers, Output Monitor, and Interface board.

The other output from the Low Voltage Supply is for use by theIPA and is60to120

3-2 888-2314-001 Rev. AD

WARNING: Disconnect primary power prior to servicing.

Page 31

Figure 3-1. Cabinet Top

Rev. AD 888-2314-001 3-3

WARNING: Disconnect primary power prior to servicing.

Figure 3-2. Output Network Removed from Transmitter

Page 32

Figure 3-3. Cabinet Top with Output Network Removed

volts depending on the particular needs of the transmitter and frequency.

TheprimaryoftheLowVoltagetransformer should be tapped correctly in order toproducethe desired outputfromthe+/-20 volt section.

A convenient place to measure both voltages is at the fuses on the PDM Generator. Use a suitable voltmeter to measure the +/-20 volt supply. Measure each voltage with respect to ground. If the voltages are under 19 Vdc, disconnect AC power and re-tap A20T1 to the next lower primary voltage (taps 240, 0).

It is desired that the low voltage supply be between 19 and 23Vdc both plus and minus. Use a procedure of removingACpower,temporarily safety grounding transformer taps, moving the primary wiring to the next lower increment, then measuring +/-20 volt supplies, to achieve the desired supply voltages.

Note: The transformer tap connections are provided on TB3, terminals 15 through

19. Refer to Figure 2-3 for instructions on using the Wago block terminals. Move the AC connection as deemed appropriate to achieve the desired output voltage.

3.3.5. High Voltag e Supply Adjus tment

TheHighVoltageSupplyreadingonthe multimeter should be in the range of 250 to 265 volts for normal full power operation.

Significantly less than this will sacrifice positive peak modulation if operating at or near the transmitter’sratedpower.Significantly higher than 265 volts will result in Supply Voltage overloads.

WARNING

ENSURE ALL VOLTAGE IS REMOVED FROM TRANSMITTER AND ALL POINTS WHERE VOLTAGE HAS BEEN APPLIED ARE GROUNDED BEFORE CHANGING ANYTAPS ON THETRANSFORMER.

IftheHighVoltagereadingistoohigh,the transformerprimaryneeds to be changedto a higher setting.

If the High Voltage reading is too low,the transformerprimaryneeds to be changedto a lower setting.

The Supply Voltage can be changed in approximately 5% increments by changing to the next tap position.

3.3.6. RF Drive Measurement

WARNING

ENSURETHEHIGH VOLTAGEIS TURNED OFF BEFORE PROCEEDING WITH THE FOLLOWING STEPS.

Measure the actual RF drive level with a scope connected to a PA module. Place the

oscilloscope probe across R13 or the equivalentterminal of any module.

Attach the probe ground lead to the RF drive ground plane. Do not use the cabinet or chassis ground as this will give an incorrect waveform.Properdrivelevelshould be 26-32 volts peak to peak on all eight inputs ofeachPAmoduleA1,A2,A3,andA4,with high voltage OFF.

If the RF Drive exceeds 32 volts peak to peak, the tap settings on the low voltage transformer will have to be changed.

WARNING

ENSURE ALL VOLTAGE IS REMOVED FROM TRANSMITTER AND ALL POINTS WHERE VOLTAGE HAS BEEN APPLIED ARE GROUNDED BEFORE CHANGING ANY TAPSIN THE FOLLOWING STEP.

To checkif the primary is properlytapped, it is advisable to measure the +/-20 volt supply on the PDM Generator.Measuredat the fuses, it should be in the range of 19 to 23 volts. If too high, change the primary setting of A20T1 to a higher position (for example, from 240/0 to 240+11).

If the primary setting is proper, but the RF drive level produced by the IPA is too high, the secondary taps on A20T1 will have to be changed to a lower number to reduce the IPA

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Page 33

supply voltage. The transformer secondaries are designated 60/75/90/105/120 Vdc. Moving from the 105 tap to the 90 tap will reduce the IPA supply voltage and the drive level.

3.3.7. IPA Tuning

Adjust A26L2 with a slotted screwdriver for a peak in drive level as measured on the PA modules.

Coarse IPA Tuning coil A26L1 has multiple taps so that A26L2 can be kept within its adjustment range. If the drive does not peak within the range of L2, the tap setting ofA26L1willhaveto be changed by selecting another tap position.

WARNING

THE IPA CIRCUITRY UTILIZES FAIRLY HIGH VOLTAGES WHICH CAN CAUSE ELECTRICAL SHOCK AND RF BURNS. BE SURE TO DISC ONNECT THE PRIMARY POWER AND DISCHARGE ANY RESIDUALVOLTAGES BEFORE MAKING ANY TAP CHANGES ON A26L1. BE SURE THAT THE SAFETY C OVERS ARE IN PLACE ON THE IPA SECTION BEFORE REAPPLYING POWER.

Some of the components in the A26C1 position may not be used. Refer to the Factory Test Data Sheets forthe proper amount of capacitance.

If the RF Drivewhen peaked is lower than 25 volts peak to peak, make sure the IPA is fullyworking,and that it is not beingloaded down by PA failures. Refer to the troubleshooting procedures, as well as the checks of the PA modules.

WARNING

ENSURE ALL VOLTAGE IS REMOVED FROM TRANSMITTER AND ALL POINTS WHERE VOLTAGE HAS BEEN APPLIED ARE GROUNDED BEFORE CHANGING ANY TAPSIN THE FOLLOWINGSTEP.

If the drive is not low because of a component failure, then the IPA power supply secondary wil l have to be tapped for a highervoltage output.Forexample,moving a tap from the 105 volt connection to the 120 volt connection will increase the IPA supply voltage and the RF drive level.

3.3.8. PA Voltage Electrical Zero

Unplug P2 from the PDM Generator so that there will be no PA voltage when the high voltage is energized.

Energize the high voltage by depressing one of the powerlevel buttons. The contactors should energize, and Supply Voltage should appear on the Multimeter.

Adjust R31 on the Controller board to

make the PA Voltmeter read zero.

3.3.9. PA Volt Meter Calibration

The PA volt meter can be calibrated against an external meter of known accuracy, using the following procedure.

WARNING

TURN OFF TRANSMITTER AN D DISCHARGE HIGH VOLTAGE BEFORE PROCEEDING.

Routesomelongvoltmeterleads tothePA modules through one of the bottom side holes made for a cable entrance.

Connectthepositivelead of the voltmeter to the 260 volt line of a PA module (L11 or thefuse,for example).Connectthe negative lead to the cathode of CR13 on the PA board. This is the same electrical point as the small banana jacks.

Turn the transmitter on at high power. AdjustR76on the Controllerboardtomake the front panel PA voltmeter agree with the external voltmeter.

Turnoff high voltage. Allow discharge of power to zero. Remove voltmeter leads.

3.3.10. PA Current Calibration

The PA AMPS meter can be calibrated against an external meter using the following procedure. The external meter and its leads must be capable of accurately reading at least 12 amps for a GATESONE, at least 30 amps fora GATES TWO, and at least 60 amps for a GATES FIVE.

WARNING

ENSURE ALL POWER IS REMOVED FROM THE TRANSMITTER BEFORE ATTEMPTINGTOROUTETHELEADSINTHE FOLLOWING STEPS.

Locate the DC Ammeter where it can be seen from front of transmitter and route its leads through one of the bottom side access holes and up through one of the wiring grommets.

Interrupt the connection between the white, PA supply wires and PA metering shunt (A19R6) on the floor of the transmitter below the IPA.Insertleads from external DC ammeter in series with PA metering shuntandPA supplywiresobservingproper polarity (positive goes toward the PA shunt).

Besurethe external DC ammeter leads are positioned so they will not short to ground.

Ifa Clamp OnDCAmmeteris used,insure that it is not RFI or EMI sensitive.

Turn transmitter on at HIGH power and adjust the power level to set the reading on

the external ammeter on a convenient calibration level.

Adjust A19 R10(on the floorof the transmitter below the Interface board) to make the PA AMPS meter read the same as the external meter.

3.3.11. Power Supply Current Calibration

The Power Supply current can be calibrated against an external meter using the following procedure. The external meter and its leads must be capable of reading at least 6 amps for a GATES ONE, at l east 20 amps for a GATES TWO, and at least 30 amps for a GATES FIVE.

WARNING

ENSURE ALL POWER IS REMOVED FROM THE TRANSMITTER BEFORE ATTEMPTINGTOROUTETHELEADSINTHE FOLLOWING STEPS.

Locate the DC Ammeter where it can be seen from front of transmitter and route its leads through one of the bottom side access holes and up through one of the wiring grommets, to near the high voltage rectifiers.

Connect the DC Ammeter in series with the supply current shunt resistor A19R7. This is located ab ove the PDM Filter boards. Connect the positiveside of the DC

Ammeter to the shunt (leave the white wire in place on the shunt).

The negative side of the meter should connecttotheblackweldingcableremoved from the shunt.

Turnthe transmitter on at HIGHPOWER, and adjust the power level to some convenient calibration level.

Note the reading on the external meter, and adjust R25 on the Controller board to make the Supply Current reading on the Multimeter agree with the external meter reading.

3.3.12. Power Output Calibration

Connect the transmitter into a load with the capability of accurately measuring the power output. This is best done with a calorimetric dummy load, where the water temperature rise is measured against a known flow rate. A second choice is a dummy load and an RF ammeter of known accuracy.

Operate the transmitter at a convenient power level within the capabilities of the test setup.

Calibrate the Power Output meter to the same reading as measured externally using R85 on t he Controller board.

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3.3.13. Overload Adjustment Procedures

3.3.13.1. Power Supply Current Overload

Check the present Power Supply Current reading against the value on the factory test data sheet for the same operating conditions. If the present reading is significantly higher,it will be advisableto investigatethe cause before proceeding with the following overload adjustment.

The overload threshold can be set to the same value as recorded on the factory test data sheet, or by checkingthe trip threshold by modulating it with a tone according to the following procedure.

Forsettingtheoverloadunder modulating conditions, operate the transmitter at 110% of its rated power output (5500 watts for GATES FIVE, 2750 watts for a GATES TWO, and 1100 watts for a GATES ONE).

Modulate with 20 Hz to 100%. Increase the audio level 0.5dB (6%).

Adjust R11 on the Controllerboard counterclockwise until the transmitter faults, then 1/3 of a turn clockwise from this trip point.

3.3.13.2. Underdrive Fault

Note:TheUnderdriveFaultthresholdvaries directly with the PDM Level such that the minimum drive requirements are less stringent at low power levels, but require fullRFDriveatfullpower.

The indicated RF Drive level should alwaysbesomewhatabovethe threshold(UnderdriveSet) in a normal condition.

With the actual RF Drive having been verified on the PA module(s), the RF Drive reading is adjusted so that it reads sufficiently above the Underdrive Set reading at full power.

Verifying the correct RF drive amplitude (26-32 Vpp) requires checking the PA inputs with a scope. Measure across R13, R14, R23, R24, R33,R34, R43 and R44 for each PA mod ule. For the procedure on checking the drive on the PA module(s), refer to Section C.

After verifying the actual RF drive to be in the normalrange, modulate the transmitter to 100% with 400 Hz at 110% power output (5500 watts for GATESFIVE, 2750 watts for a GATES TWO, and 1100 watts for a GATES ONE).

Adjust R143 on the Controller board counterclockwiseuntilthetransmittersteps to the next lower power level and displays the Underdrive fault. Then rotate R143 clockwise from the trip point about 2 turns.

3.3.13.3. VSWR Detector

You may set the VSWR trip threshold using the value recorded on the factory test data sheets, or may use a more involved process which actually causes the overload circuit to operate.

With the transmitter on, and NO modulation applied, set the LOWpowercontrol all the way to zero power output.

Use a clip lead to short a cross R18 on the Output Monitor board. This will cause the

VSWR detector to not be nulled when you bringupRFpower.

Gradually increase the power output, and watch the VSWR Detector Null reading comeup from zero. Adjust R14 on theController board so that the transmitter trips off when the VSWR Detector Null reading reaches 7.5 on the Multimeter.

3.4. Replacing Boards and

Replacing Board Components

The following boards may be replaced or havecomponents replaced without the need for adjustments or measurements:

Interface Board

PDM Pull Up boards

PDM Filter board

IPA Power Splitter board

PA Toroidboards

The remainder of the boards have adjustments or frequency determined components. Refer to section on particular board that is being replaced for information on checkout procedures to follow.

NOTE

When board replacement is required,

caution must be exercised in tightening

both current carrying and non-current

carrying surfaces. Non-current carrying

tightness should be only a snug fit (i.e.

PA module heat sink); while current car-

rying tightness should be more secure

than snug but not over tightened. Re-

member that relatively fragile printed

circuit board surfaces are being tight-

ened and damage to boards can occur if

excessive torque is applied.

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Page 35

SECTION IV

TROUBLESHOOTING

4.1. Introduction

This section of the technical manual c ontainsoveralltroubleshootingproceduresfor the GATES Series™ AM Transmitter. As needed,referencesaremadetotheindividualized sections of the manual.

4.2. Definition of

Front Panel Indicators

UNDERDRIVE LED When lit is an in-

dication of low or no RF drive to the PA module(s).

VSWR LED Indicates a mismatch at the transmitteroutput or the TEE section of the Output Network.

SUPPLY VOLTAGE LED The DC output of the high voltagesupply has exceeded the maximum threshold of 290 volts.

SUPPLY CURRENT LED The current drawfrom thehighvoltagesupplyexceeded normal values.

AUTOMATIC CUTBACK LED Indicates the transmitter has reduced to a lower power level on its own because of a persisting overload condition.

PDM KILL LED Indicates that the transmitter is being muted by either an externalcommand,or by the transmitter’sstep start circuitry failing to complete its connections.

PLUSandMINUS12VOLTS When lit, indicates presence of Controller supply voltage.

REMOTE LED Indicates that the remote inputs are enabled. This does not inhibit any local control functions.

LOCAL LED Lights when the transmitter can only be controlled locally.

PDMFAULTSENSING The PDM fault sensing LED’s indicate a significant imbalance in the PDM operation, resulting in a PDM Amplifier doing more or less than its share of work.

PA FUSE INDICATORS When lit indicate one or more fuses are blown in the corresponding PA module.

AIRFLOWSENSOR In addition, transmitters manufactured in December 1995 and later are equipped with an Airflow Sensor which shuts the transmitter down, and producesan audible alarm in the eventa fan failure is detected. This audible alarm is a continuous 2.8 Khz tone, plus a visual indicatorprovidedononeoftheAirflowSensor boards. If the transmitter shuts down due to a fan failure, the transmitter can be turned back on. However, it will shut down in 1 to 2 minutes when the fan failure is again detected.

4.3. Symptom: Transmitter Will

NotTurnOn-Noneofthe Green LED’sonthePower Level Switches are Illuminated

4.3.1. Possible Causes

4.3.1.1. Loss of AC Power

Lookatthe+/-12V LED’son the Controller panel. If these are not illuminated, look at the amber indicators down by the Low Voltage circuit breaker at the bottom of the cabinet. If the circuit breaker is up and both indicators are illuminated, the AC power is getting to the transmitter.

4.3.1.2. Control Supply Failure

Loss of the +/-12V supplies, as indicated by the +/-12V LED’s being extinguished, points to a failure of one of the regulators (U32 or U33) on the Controller board, or a short circuit on the Controller.

Check fuses F2 and F3 on the Interface board.These are in line with the +/-20 volts to the Controller. A blown fuse most likely indicates excessive curren t draw by the Controller.

4.4. Symptom: Green Power Level

Status LED’s Illuminate, but the Primary Contactors Do Not Energize and No Overload LED’s Illuminate

The contactors normally produce anaudible clunk as theyclose,and result in Supply Voltage registering on the Multimeter.

4.4.1. Possible Causes

4.4.1.1.

Phase Monitor (3∅ FIVE only)

Check to see if the LED on the Phase Monitor relay in the contactor drawer is illuminated. If it is not, there may be a loss of phase, low line voltage, or improper adjustment of the Phase Monitor relay. Although less common, there may also have been a phase reversal by the power company.

4.4.1.2. Blown fuse

CheckfuseF1ontheInterfaceboard.Also make sure 24 VAC is present at F1 anytime AC power is applied to the transmitter.

4.4.1.3. Open Interlock

Makesure the rear panel is inpositionand fastened. Make sure the panel closure actually closes the interlock switch. A “click” should be audible as the panel is pushed shut.

WARNING

BEFORE PERFORMING THE FOLLOWING STEP, DISCONNECT ALL POWER FROM THE TRA NSMITTER AND USE GROUNDINGSTICK TODISCHARGE ALL POINTS BEFORE TOUCHINGTHEM.

4.4.1.4. Failsafe Interlock Open

A closure should be provided between TB1-1and TB1-2 of the Interface Board for normal operation. If a remote control system or other equipment is connected to these terminals, check for the closure at the Failsafe terminals. Turn the low voltage OFF and ground the terminals with a grounding stick before using an ohmmeter to check for a closure at TB1-1 and TB1-2.

4.4.1.5. Interface board Output

WithAC powerappliedandanyof theON pushbuttons depressed, 24 VAC should appear at TB1-2 on the Interfaceboard.It will not be necessary to installthe rear panel for this test.

4.4.1.6. Open Contactor Circuit

If the voltage checks okay at TB1-2 in the preceding step, then it is apparent that the K1 coil circuit is open. This would include the back panel interlock, Failsafe, the coil of K1, the Airflow Sensor, and the Phase

Monitor relay (3∅ FIVE only).

4.4.1.7. Contactor Control Signal

If 24 VAC does not appear at TB1-1 and TB1-2 when any of the ON pushbuttons are depressed, check for the presence of a control signal at R18 on the Interface board. About5voltsDCshouldappear ontheinput sideof R18 in an ONcondition.Ifnotthere, trace its origin at the Controller.

4.5. Symptom: One or Both Pri-

mary Contactors Energize, But There Is No Power Output

4.5.1. High Voltage Supply Failure

Checkthe SupplyVoltageon theMultimeter. This should be 250-265 volts with the transmitter in any of the ON modes. If the supply voltage is zero, a High Voltage Supply problem is indicated. Check the step start resistors in the contactor drawer. An open step start resistor would indicate a failure in the high voltage supply, most likely a shorted rectifier.

Also check the condition of the MOV devices on TB2 in the contactor drawer. A blown MOV would be an indication of a significant power line surge or transient.

Rev. T: Jan. 1996 888-2314-001 4-1

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Page 36

4.6. Symptom: High Voltage Is Pre-

sent, But There Is No Power Output

4.6.1. PDM Kill Condition

Check the PDM Power Level reading on the multimeter, and the status of the PDM Kill LED on the front panel. If there is no signal of a closure of the Run contactor (K2), there will be a PDM kill condition. Listen for the closure of K2. It should be heard closing after K1 has closed. Clean the auxiliary contacts of K2.

A PDM Kill can also come from an external device such as an RF contactor in a phasor.Check for an external kill signal and make sure that all RF contactors in the antenna system are fully seated.

4.6.2. PDM Level

CheckthePDMLevelreading on the Multimeter.If itiszeroforallpowerlevels, there may be a failure on the Controller board. Refer to the troubleshooting information in Section J on the Controller.

4.7. Possible Causes For Overloads

4.7.1. Supply Voltage Overload

4.7.1.1. Supply Voltage Too High

Check the Supply Voltage reading on the Multimeter. If the transmitter will stay on long enough, compare this reading with the valuerecorded on the factorytest data. Also checktheSupplyVoltageSetreadingonthe Multimeter. This is the threshold at which anoverloadshould occur.Thisisreadonthe same scale as the Supply Voltage, and is normally 290 volts. This value is determinedbytheratioofresistorsR10andR52 on the Controller board.

WARNING

ENSURE ALL AC VOLTAGE HAS BEEN REMOVED FROM THE TRANSMITTER AND THAT THE GROUNDING STICK IS USEDTOREMOVEANYRESIDUALVOLTAGE THAT MAY BE PRESENT BEFORE THETAPSONTHEHIGHVOLTAGE TRANSFORMER ARE CHANGED.

If the present Supply Voltage reading is significantly higher, remove all AC voltage being supplied to transmitter and re-tap the high voltage power supply transformer to a higher primary setting. For example, if the transformer is presently tapped to 240/0, change the tapping to 240/+11. This will reduce the supply voltage by about 5%.

If the transmitter has been operating with the proper supply voltage for some time, and only recently increased, check to see if the power line voltage has increased.

4.7.2. Power Supply Current Over-

loads- At Turn On

4.7.2.1. Supply Short

If the transmitter doesnot try to operate at a reduced power, there may be a High Voltage Supply short. There are two protection modes: The normal response of the protection circuitry is to perform a momentary PDMinterrupt.If the high currentcondition remains, an OFF command is given.

A short of the Supply may be caused by mechanical failure of the safety switch which is normally openedby installation of the rear panel.

Another cause could be a shorted High Voltage filter capacitor.

4.7.3. Power Supply Current Over-

loads, Continuous Cycling and Automatic Cutback

4.7.3.1. PDM System Problem

If the over current problem is affected by the PDM interrupt, but exists upon return of PDM, the transmitter will step to the next lower power. This Automatic Cutback action can continue until the transmitter cycles all the way OFF, or the current drops below a safe value.

Check the Supply Current Set reading on the Multimeter to be sure it is at a normal value as indicated on the factory test data sheet. This reading should not change unlessa change has been made to theoverload adjustment.

Check the actions of the PA AMPS and Power Output meters at turn on. If they deflectupwardsat turn on, it isevidentthere is current actually flowing in the PA.

Check the PDM Power Level reading on the Multimeter.If the Multimeter is pinned, there is a problem on the Controller. Refer to Section J concerning troubleshooting of the Controller. If the PDM Power Level reading is okay, the problem is in the PDM system.

4.7.3.2. PDM Generator Outputs High

Check the outputs of the PDM Generator at the right side of R45, R46, R62, and R63 with a scope or voltmeter. If any of the outputs are continuously high (12 to 14 volts) a PDM Generator problem is indicated. You may also isolate the problem by disconnecting the output (P2) from the PDM Generator. Refer to the troubleshooting procedures in Section F on the PDM Generatorif the resultsindicatetheproblem resides there.

4.7.3.3. PDM Amplifier Shorts

If the Outputs of the PDM Generator are okay, there may be some short(s) on the PDM Amplifiers. Observe the PDM Fault

sensing LEDS on the front panel, and refer to Section G, Troubleshooting the PDM Amplifiers.

4.7.3.4. Supply Current Calibration

If you havejust installed a newController board, the Supply Current calibration may have been overlooked. Check this, per the procedure outlined in Section J on the Controller.

Check the Supply Current Set reading on theMultimeter.Itwouldneedtobeadjusted only if you have just installed a new Controller board.

Also check the condition of the power supply current shunt resistor A19R7, located on the right side wall above the PDM Filter boards. Loose hardware or an open shunt wire would result in Supply Current overloads.

4.7.4. Random Supply Current Over-

loads With Modulation

4.7.4.1. Sub-audible Signals

Random Power Supply current overloads are most likely caused by significant levels of sub-audible signals on the transmitter audio input. The GATES Series™ of transmitters and some modern day audio equipment can pass sub-audible signals. Check your audio sources and the setup of your audio processing.

4.7.5. Underdrive Fault

4.7.5.1. Low/No Drive

Check the RF Drive reading on the Multimeter. If lowor zero, thereis a problem in the RF Drive system.

Oscillator Output. Having no RF drive could be caused by failed RF Oscillator.

Check the status of the green RF Output LED on the Oscillator board. If it is not lit, refer to Section A, Troubleshooting the RF Oscillator.

4.7.5.2. IPA and PA Transistors

Another cause for low/no drive may be failed IPA transistors, abnormally low IPA supply voltage, or several shorted PA transistors. Refer to Sections B and C covering the IPA and PA.

4.7.6. VSWR Overload- Continuous

VSWR Cycling

4.7.6.1. Bad Load Impedance

Continuous VSWR cycling resulting in the Automatic Cutback operation indicates a severe change in the impedance into which the PA is operating. The transmitter will probably stay on at a reduced power, but the VSWR Detector Null reading will be high, depending upon the extent of the problem.

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WARNING: Disconnect primary power prior to servicing.

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Isolate the problem further as outlined below. If a change in antenna impedance is indicated, it may bedueto a failed capacitor or other change in the antenna system. Whether to re-tune the transmitter should dependonthe extentandnatureoftheproblem.

If there is a change in antenna impedance due to a change in ground conductivity (resulting from rain), it would be permissible to re-tune the transmitter to match it to the new load impedance.

However, if the impedance change is due to a failing capacitor in the antenna system, it would be best to avoid readjusting the transmitter tuning. Re-tuning the transmitter to match the failing part would probably accelerate the failure.

4.7.6.2. Antenna Problem

Connect t he transmitter into a dummy load if one is available to determine if the faultiswiththeantennasystemorthetransmitter. If the antennasystem is a directional array, the VSWR problem may be found to be peculiar to one attenna pattern only.

4.7.6.3. Output Network

Afaultycapacitoror broken connectionin the Output Network may be the cause if the transmitter also does not operate properly into a dummy load. A thorough inspection ofthe Output Network may revealthe problem. Look for any loose or burned connections,and any physicalsignsof stressonany of the capacitors.

WARNING

REMOVE ALL AC POWER AND DISCHARGE ALL POINTS WHERE RESIDUAL VOLTAGE MAY REMAIN BEFORE PERFORMING AN INSPECTION OF THE OUTPUT NETWORK.

WARNING

THE VSWR PROTECTION CIRCUIT SHOULD NEVER BE DEFEATED AS A MEANSOFGETTINGTHETRANSMITTER BACK ON THE AIR.

4.7.7. VSWR Trips With High Levels

Of Modulation and High Power

4.7.7.1. Improper Tuning and Loading

If this problem is encountered in the first hours of operation, there may be a setup problem. Refer to the initial turn on procedure and maintenance section where PA Tuning and PA Loading are described.

Check the VSWR Detector Null reading on the Multimeter. This reading should be zero. An increase in the VSWR Detector Null reading would indicate that the load

impedancehas changedfromthe initialtune up or that the transmitter tuning or loading has changed (either through front panel adjustment or by a failure of an Output Network component).

4.7.7.2. Antenna

Ifadummy load is available,try operating the transmitter into it. There should be no significant Detector Null reading when operating into the dummy load, assuming the antenna impedance is close to the dummy load impedance. If the VSWR Detector Null reading reads upscale, there is probably a problem in the antenna system.

4.7.7.3. Output Network

If the VSWR problem still exists when operating into the dummy load, there may be a faulty capacitor or connection in the transmitter’s Output Network. Check the output spark gap on top of the Loading control to see ifit is shorted,and C3 and C4 in the Output Network. These are the components which would affect the impedance seen by the VSWR Detector.

WARNING

THE VSWR PROTECTION CIRCUIT SHOULD NEVER BE DEFEATED AS A MEANSOFGETTINGTHETRANSMITTER BACK ON THE AIR.

4.8. Symptom: Remote Control

Functions Do Not Work

4.8.1. Possible Causes

4.8.1.1. Remote/Local Switch

Check to see that the REMOTE/LOCAL switch on the Controller is in the REMOTE position.

4.8.1.2. Remote Control Improperly Wired

Review the installation instructions in Section II. Each remote control input of the transmitter is activated by a momentaryclosure to ground.

4.8.1.3. Remote Control Unit Not Func-

tioning

Check the remote unit to see that it is providing closures to the transmitter. You might use a clip lead to momentarily provide the contact closures at the remote control unit to see which piece of equipment is at fault.

4.8.1.4. Ribbon Connectors Loose

Ensure that the ribbon connectors on the Interface board and the Controller are fully seated.

There may be a failed optical isolator on theControllerboard.Refertothe Controller troubleshooting procedures in Section J.

4.9. Causes for a PA Volts/PA

Amps Ratio Change

This discussion covers causes which might not be apparent based on front panel indications and readings.

4.9.1. No +20 Volts to PDM Amplifier

Loss of the +20 volt supply to a PDM Amplifier should cause one or more PDM FaultLED’sto illuminate. Tobe certain this is not the problem, measure the voltage on the fuses on each PDM Amplifier to make sure+20Vdc ispresent. If not, trace +20Vdc back to its origin via the Interface board.

4.9.2. Impedance Change

The Output network can cause a change in the PAVolts toAMPSratio.The PAvolts to PAAMPS ratio is affectedby the impedance seen by the PA module. If the impedance seen by the PA module changes, whetherfroman antenna impedanceshiftor fromadjusting the frontpanelTUNING and LOADING controls, the PA VOLTS/PA AMPS ratio willbe affected. Small changes will only cause a ratio change. Large changes will cause VS WR overloads. Check the Detector Null reading on the multimeter. It should be zero.

If the Detector Null reading is zero, but you suspect an Output Network failure, it will be in the L1/C1 and L2/C2 sections. This circuitry is ahead of the VSWR sensing.

A failure of C1 will shift the PA Tuning. RotatethePA TuningcontroltopeakthePA current. The PA Amps should peak within threesmalldivisionsonthePA Ampsmeter. If the PA Tuning has to be changed by a considerableamount topeakthePAcurrent, it is indicated that there is a problem with L1/C1. Inspect the C1 capacitors for any physical signs of stress.

A failure of C2 will shift the PA load resistance. Youcan measure the impedance looking into the Output Network to determine if there is a problem withL2/C2. This is done by connecting anRFbridge in place of the A1 output connection. An RF resistance significantly different than the test datavaluefor “CombinerLoadImpedance” wouldbean indicationofanL2/C2 problem if the impedance at the back end of L2 is verified to be 50 ohms j0.

The parallel resonant frequency of L2/C2 may also be checked per the procedure in Section III (Maintenance).

4.9.3. PA Failure

Although a rare condition, an open PA transistor could cause a ratio change withoutblowingtheassociatedfuse.Onewayto isolate this problem wouldbe to disconnect PA transistor pairs by removing fuses to see

Rev. T: Jan. 1996 888-2314-001 4-3

WARNING: Disconnect primary power prior to servicing.

Page 38

if one particular pair is not drawing any current.

WARNING

TURN THE TRANSMITTER OFF DISCONNECT PRIMARY POWER AND DISCHARGE ALL HIGH VOLTAGE COMPONENTS B EFOR E REMOVING A FUSE FROM A PA BOARD.

Pulling one fuse at a time to observe its affect on the transmitter operation is one way to isolate a non-working amplifier. If no change is observed after removing a particular fuse, then it is apparent that you have isolated a bad amplifier.

Another approach is to removetransistors to test them out of circuit as described in the sectiononthePA modules.However, do not operate the transmitter with any transistors removed.

4.10. Troubleshooting AM Noise

When troubleshooting a noise problem, it is important to know the level and frequencyof the noise.Knowingthe frequency of the noise, it is possible to isolate the source. The frequency of the noise may be determined by connecting an oscilloscope to the output of most distortion analyzers. The scope display will be the total noise. Measure the period of the noise with the highest amplitude to determine the dominant noise component.

An alternate method of determining the noise frequency is by tuning a distortion analyzer to it. A fully automatic distortion analyzer cannot be used in this way. While measuring the noise, switch the analyzer to the THD mode. Then tune the frequency of the analyzer for a dip in the meter reading on the analyzer. Depending on the number of significant noise frequencies affecting the total noise figure, there may be more than one dip in the analyzer reading. Frequency of the noise may be read from the analyzerfrequencysettings.Anaudiospectrum analyzer may also be used for determining both noise frequency and amplitude.

A listening test could be misleading since the dominant noise component may actu-

ally be above or below the range of the receiver or human hearing. Following are some hints on solving various noise problems. These are categorized according to frequency.

4.10.1. 50/60 Hz

This is a power line frequency and is not usuallyasignificantnoise component in the GATES Series™ transmitter, due to the design of the power supplies. If investigating a 50/60 Hz noiseproblem,firstexaminethe audio input wiring and make a measurement with the audio cable going directly from the audio generator to the transmitter input terminals. This will eliminate any effectsofthepatchpanelwiring or noise from other audio equipment in the system.

4.10.2. Audio Lines are Normally Balanced

That is, the audio line current does not flow in ground. Grounding of either side of the audio connectors can sometimes result in noise. If it is determined that the 50/60 Hz noise is actually generated in the transmitter, a bad rectifier i s suspected. The dominant noise frequencyof a single phase fullwaverectifiedpowersupplyisnormally twice t he power line frequency.

WARNING

ENSURE ALL VOLTAGE HAS BEEN REMOVEDAND THE SHORTINGSTICK HAS BEENUSEDTOREMOVEANYRESIDUAL VOLTAGES BEFORE MEASURING THE RESISTANCE OF ANY RECTIFIERS.

Use an ohmmeter to check each of the rectifier diodes in the HV supply A19CR1, A19CR2,A19CR3,A19CR4(alsoA19CR5 and A19CR6 if 3 phase supplied). Also check the block type rectifier bridge (A20CR1) in the +/-20 volt supply.

Anopenrectifierwouldalsoresultina decrease in supply voltage. Also use an oscilloscope to look for any evidence of 50/60 Hz noise in the power supplies. +/-20 volts and a high voltage supply sample appear on the PDM Generator, A15. +/-20 voltsisatthefusesofthePDMGenerator and the high voltage supply sample is at J1-7.

4.10.3. 100/120Hz

This is the p rinciple noisefrequencyofall the low level supplies. If 100/120Hz noise isgeneratedinthe3-phaseversion,youwill also need to look for an imbalance having to do with the 3 phase power supply.

Check the balance of the 3-phase AC primary power by using an AC voltmeter.Use caution in this measurement and be sure to measure between all AC legs.

It may also be necessary to check the high voltagerectifiersand interconnecting wires for l oose or open connections.

4.10.4. 300/360Hz

In the standard GATES FIVE, which uses a 3-phase HV supply, the principle power supply noise component is 300/360Hz. High noise of this frequency may indicate openfiltercapacitorsoropenanconnection inthehighvoltagesupply.Anotherpossible cause is a failure in the noise cancellation circuit (U15) on the PDM Generator.

4.10.5. 60 kHz

This can only show up in a wideband audio noise measurement or as a spurious emission 60 kHz above or below the transmitter operating frequency. This could be caused by a significant imbalance in the operation of the Polyphase system. Check the PDM Fault indicators to see if any are lit.

If any are lit, it will be necessary to troubleshoot the PDM Generator (A15) or the PDM Am plifiers (A6 thru A9) for pulse width imbalance. A failure of a PDM Amplifier will also cause a substantial change in power output.

4.10.6. RFI Noise on Audio

Check the audio wiring to the transmitter for proper grounding of the shield at the Interfaceboard. Also makesurethatneither audio conductor is grounded. Grounding of either side of an audio line takes away common mode rejection, which is essential in preventing this type of noise.

The GATES Series™ transmitter is designed with extensive RFI filtering on the audio input circuitry and furthermore has a solid state instrumentation input circuit with high common mode rejection.

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SECTION V

TRANSMITTER OVERALL

5.1. Introduction

This section of the maintenance manual will present the principles of operation for the individual sections of the GATES Series™ AM Transmitter. Included will be information on AC Power Flow, RF Power Flow, and miscellaneous parts of transmitter not covered in sections A through K.

5.2. Personnel Protection

Extensive interlocking and safety switcheshavebeen provided on these transmitters because of the low impedance high currentcapabilitiesof these power supplies. The rear access panel to these transmitters areprovidedwith threesafetyswitches.The first safety switch is operated by asmall pin protruding through a hole. As you start to remove the rear panel, the interlock interrupts the control voltage to the primary contactors allowing them to de-energize.

Upon further removal of the rear panel, a HV discharge switch will discharge the energy storage capacitors through large resistors for current limiting. Upon opening the rear panel even further, a switch also operated by the rear panel shorts the power supply discharging the voltage remaining on the filter capacitors.

WARNING

THE NORMAL PROCEDURE IN TRANSMITTER TURN OFF SHOULD BE FOLLOWEDINDE-ENERGIZINGTHISTRANSMITTER. TURN OFF THE HIGH VOLTAGE BY DEPRESSING THE OFF BUTTON. IF YOU MUST ENTER THE TRANSMITTER, SET THE REMOTE/LOCAL SWITCH ON THE CONTROLLER BOARD TO LOCAL AND ALLOW THE POWER SUPPLY TO DISCHARGE AS INDICATED BY THE FRONT PANEL METERS. REMOVE THE REAR PANEL SLOWLY TO ALLOW THE INITIALRESISTORDISCHARGE MECHANISM TO FUNCTION. UPON OPENING THE REAR PANEL FURTHER THE POWER SUPPLY WILL BE SHORTED TO GROUND AND MADE SAFE. A GROUNDING STICK IS PROV IDED IN THE TRANSMITTERTOASSURE THATALL VOLTAGE HAS BEEN REMOVED UNDER FAULT CONDITIONS.

If the above warning is not heeded substantial damage may be done to circuit card foil,grounding switches, and the capacitors themselves. Always allow the voltage to be discharged prior to opening the rear panel. Ifimmediateaccessisanabsolutenecessity, it is recommended that the high voltage be

turned off, the rear panel be opened approximately 2 inches and be allowed to remain in this position for 2 seconds before being opened further.

5.3. Principles Of Operation

5.3.1. FET’SintheGATESSeries™

All of the FET’susedintheGATESSeries™ operate in a switching mode of operation. In a switching mode, the FET’sare either completely ON or completely OFF. The type of FET’susedintheGATESSeries™ transmitters are well suited for this application because they have a very low and consistent ON resistance, very high OFF resistance, and very fast switching times.The benefit of these characteristics is high efficiency and excellant modulation linearity.

5.3.2. PDM Theory In Brief

Pulse Duration Modulation (PDM) is a high efficiency type of modulator system whereinthemodulatoroperatesin a switching mode. Since the FET’shaveverylow ON resistance, very high OFF resistance, and very fast switching times, the modulator efficiency is relatively high.

The b asic makeup of the modulator system used in the GATES Series™ transmitters is with the PA, the PDM filter, and the PDM Amplifiers in series. The PDM Amplifierspurpose is to switch the PDM Filter inputs to ground at a 60 kHz rate. For the sakeofunderstanding,a relay could beused for this purpose if it could switch at a 60 kHz rate.

The PDM Filter, which is between the PDM Amplifiers and PA, removes the switching frequency so that the signal provided to the PA is high level DC and audio.

ThepercentageoftimethatthePDM Amplifiersare ON varies with changes in pulse width or duty cycle. This change in duty cycleis what causesa change in PAvoltage, and is howthe PAis modulated. The higher thePDMdutycycle, thehighertheresulting PA voltage.

The voltage for the PA is the difference betweenthe high voltage supply (about 260 volts)and the output of the PDM Filter. For anormalfull power,unmodulatedcondition the PDM Filter Outputs will be 100 to 105 volts less than the high voltage supply.

On 100 percent negative modulation peaks, the PDM Amplifiers cease to conductandthere will be no voltagedifferential across the PA (zero PA volts).

On the highest positive modulation peaks, the PAvoltagemay reach the 260 volt level if the PDM duty cycle reaches 100 percent.

5.3.3. Polyphase Theory

One inherent drawback to single phase PDM relates to the amount of filtering that is required to remove the PDM switching frequency. Considerable filtering is required to prevent spurious signals from being transmitted. With inadequate filtering, there would be spurious signals above and belowcarrier,spaced bythePDM switching frequency.

However, a large amount of filtering will also limit the transient response and modulation density of the transmitter. This is most noticeable when modulating with a square waveor with the a udio heavilyprocessed. False modulation peaks can occur due to effects of the filtering.

Polyphase PDM was created as a means of achieving the benefits of PDM without the m odulation overshoot problems associated with PDM filtering.

In Polyphase PDM, the frequency of the PDM is effectively multiplied by the numberofPDMphases.Thisisvery similar to power supplies with multiple phases of rectification. A basic half wave supply operatingon60Hzwillhavearipplefrequency of 60 Hz. A full wave supply operating on 60 Hz will have a ripple frequency of 120 Hz. A three phase full wave supplyoperatingon 60Hzwill have aripple frequency of 360 Hz.

As with multi-phase power supplies, Polyphase PDM requires less filtering to removetheripple.InthecaseoftheGATES Series™, there are four PDM phases of 6 0 kHz each. The effect of this is a PDM frequency of 240 kHz. Therefore, the PDM filtering is designed to attenuate 240 kHz instead of 60 kHz. This degree of filtering ensures excellent transient response.

5.3.4. Audio/PDM Signal Flow

Refer to the PDM Flow diagram.

The audio input signal is applied to the PDM Gen erator, which generates four phases of 60 kHz pulse width modulated signals. These signals are about 13 to 14 voltspeak to peak. For furtherdiscussionon the operation of the PDM Generator, refer to section F.

The outputs of the PDM Generator are routed to the PDM Amplifiers. The PDM Amplifiers produce switching of the low side of the PA modules through the PDM

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5-2 888-2314-001 Rev. T: Jan. 1996

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Figure 5-1. PDM Flow Diagram

Page 41

Filters. For further discussion on the operationof the PDM Amplifiers, referto section G.

The positivesupply inputs of the PA modules are connected directly to the 260 volt supply. The PA voltageis then increasedby pulling the low side of t he PA toward ground, and decreased by letting the low side increase up to the same potential as the high side (about 260 volts). The PDM amplifiers do this by varying their conduction duty cycle.

PDM Amplifiers A6 and A7 provide output for PA modules A1 and A4 (A4 is not included in a GATES ONE).

PDM Amplifiers A8 and A9 provide output for A2 and A3 (GATESFIVE only).

5.3.5. PDM Loop

Refer to the PDM Loop diagram. This shows the current paths for one specific PDM amplifier circuit and the relationship between the PDM, the PA, and the metering.

The drive signal from the PDM Generator drives the PDM Amplifier transistors (Q19 and Q20) into switching operation via a drivercircuit on the PDM Amplifier.

During the ON portion of the 60 kHz pulse, these transistors provide a low resistance path for the PDM Filter to ground. Current flows from ground, through Q19 and Q20, the fuses, the PDM Filter,and the PA.

During the 60 kHz OFF cycleof the PDM Amplifier transistors, current continues to flow in the PAbecause of the stored energy in the PDM filtering. On the input side of thePDMfilter,thevoltagerisesduetothe collapsingfield around thePDMFiltercoils (otherwise known as flyback). This flyback voltage then creates current flow in the damper diode circuit.

The purpose of the damper diode is to absorb the voltage overshoots by conducting them back into the high voltage supply. The PA voltage is varied by the modulator (PDM) section. This is done by varying the low side of the PA with respect to ground.

Each PA transistor pair produces a square waveinpeak to peak amplitude equal tothe PA voltage.

Each half of a PA Quad operates 180 degrees out of phase, and provides this differentialtotheprimaryof the toroidal transformers. The secondaries of the toroidal transformers are connected in series to the input of the Output Network.

ThePA Voltage is meteredfromthe output of the PDM Filter (or low side of the PA) to the 260 volt supply (high side of the PA). The PA Current is metered in line with the 260 volt line to the PA modules.

The Power Supply Current is metered in

the return side of the 260 volt supply.

Supply current is less than PAcurrent as a function of the PDM duty cycle. Supply current is metering of the current out of the 260 volt power supply, and PA current is metering of the current actually flowing in the PA.

5.3.6. RF Power Flow

The transmitter’s carrier frequency originates from the Oscillator (A16). The output signal drives the Intermediate Power Amplifier (IPA, A5) with 1 to 2 watts of carrier power. The output square waveofthe oscillator board is about 16V p-p typically.

The IPAamplifiesthe carrier signal to the 100-200 watt level and provides the Power Amplifiermodules(A1andA4) with its RF drive.The output of the IPA goes to the IPA Output Network A26, which is a series tuned LC filter.This filter is tuned to series resonance and attenuates the harmonics of the IPA drive signal so that a sinusoidal waveform of the carrier frequency appears at the input of the PA modules. The IPA Output Network is connected to the PA modulesby the Splitter boardwhichdistributes the RF drive through a separate multicoax cable to the PA modules.

The RF is then amplified and modulated on the PA modules. The PA Toroid boards (A1A1 and A1A4) combine the RF power from the individual amplifiers on the PA modulesand connecttotheOutput Network (A21).

For a discussion on the theory and setup of the output network, refer to S ection D.

5.3.7. Failsafe

The fail-safe interlock, the rear panel interlock switches, the Airflow Sensor, and the Phase Loss Monitor are in series with thestartcontactorcoil(K1).If therearpanel interlock is broken the main contactors will drop out thereby removing high voltage powerfrom the transmitter. The transmitter will not comeon if the rear panel interlocks are broken or if the external interlock is broken.No visible indication is provided to display an open interlock, except that the PDM Kill LED will be lit along with the selected power level LED.

5.3.8. AC Power Flow

Primary power for the high voltage circuits enters thetransmitter at TB1 terminals 1,2, and 3. Itisthenfed inparallelto A19K1 and A19K2. Step start action is obtained by first energizing relay A19K1. This action suppliestheprimarypowerthrough the step start resistors A19R1, A19R2, and A19R3 to transformer A19T1. When relay A19K2

is energized,it shorts out step-start resistors and supplies full AC power to transformer A19T1. This action result in two clunks producedbythecontactorsduring transmitter turn on.

Singlephase ACpowerforthelow voltage circuits enters the transmitter at TB1 terminals5and6.Itisthenfedtocircuitbreaker A20CB1. When A20CB1 is set to ON, the load side of A20CB1 supplies AC power to A20T1 which is thelow voltage powersupply transformer.

5.3.9. High Voltage Power Supply

5.3.9.1. Introduction

The GATES Series™ AM transmitters contain power supplies with very low impedance and high current capabilities with large amounts of stored energy.

WARNING

DUE TO THE LARGE CURRENT CAPABILITIES OF THESE POWER SUPPLIES UNDER SHORT CIRCUIT CONDITIONS EXTREME CAUTION SHOULD EXHIBITED WHEN TROUBLESHOOTING AND WORKING AROUND THIS TRANSMITTER.ALWAYS DISCONNECT POWER BEFORE OPENING COV ER, REAR PANEL, ENCLOSURES, PANELS OR SHIELDS. ALWAYS USE G ROUNDING STICKS AND SHORTOUT HIGH VOLTAGE POINTS BEFORE SERVICING. ENSURE DUST, DIRT AND CHIPS ARE REMOVEDFROMCABINET BEFORE POWER SUPPLY OPERATION IS STARTED. NEVER MAKE INTERNAL ADJUSTMENTS, PERFORM MAINTENANCE, OR SERVICE WHEN ALONE ORWHENTIRED.

The purpose of the High Voltage Power Supply is to supply the high voltage for operationofthe poweramplifierandmodulator circuitry.

The main high voltage transformer is installed in the bottom of the cabinet with the associated rectifiers on the wall directly beside the transformer.

5.3.9.2. Description

The GATES Series™ transmitter use full wave bridge rectification. The rectified voltage is capacitive filtered and no series inductive choke is used. Resistors are connected directly across the terminals of each capacitor to provide slow discharge of a capacitor in case the capacitor should not get discharged by normal means.

Some transient protection is provided by MOV’s (Metal Oxide Varistor) located at the AC input and across the secondary terminals of the transformers. The purpose of these devices is to clamp the secondary voltageat some voltageinexcess of normal

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Figure 5-2. PDM Loop

Page 43

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Figure 5-3. RF Flow

Page 44

operating voltage in case of a high voltage transient coming in the AC power line.

It is recommended that spare MOV’sof the appropriate size becarried as spare parts for each transmitter.If severe transient conditionsexiston thepowerline and the MOV fails frequently other transient suppression means should be utilized to eliminate this problem.

The three phase input to the transmitter in the standard GATESFIVEis monitored for correct phase and amplitude. This helps to protect the three phase transformer from damage due to a severe phase imbalance (or loss). This detector monitors all three lines of ACand provides a contact closure when theACiscorrectforoperation.Thiscontact closure is wired in series with the cabinet interlock.

The negative side of the high voltage power supply is returned to cabinet ground through a shunt resistor A19R7 which is used to measure power supply current.

The positive voltage is applied to the PA modules via connections at the PA Current shunt A19R6.

The supply voltage is set by the primary taps of A19T1 to allow line voltage adjustment from 197 volts to 251 volts with 11 volt steps.

During the turn on sequence resistors are connected in series with the primary of the highvoltagetransformertolimitthecapacitor charging current to a safe value. When the primary voltage builds up to a near normal level, the Run contactor,K2, closes and allows full voltage to be applied to the primary of the transformer.

5.3.10. Low Voltage Power Supply and

IPA Power Supply

5.3.10.1. Introduction

The purpose of the low voltage power supply is to providea +/-20 volts supply for all control and driver functions in the transmitter.The Low Voltage Supply is not regulated, however individual boards that require regulation will do on-board regulation for 15 and 12 volt applications. The Low Voltage Supply provides 60 to 120 VDC to the IPA module.

5.3.10.2. Description

The IPA and +/-20 volt power supply transformeris A20T1.Ithas 208/240 inputs plus taps for +/-11 volt variations to compensate for AC line variations. The low voltagesecondary of the transformer is center tapped with two MOV’s(MetalOxide Varistor) across the secondary terminals for transient protection the same as on the high voltage power supply.

The center tap of the low voltage secondary is grounded and full wave rectifier diodes rectify each half of the secondary voltage to produce +20 volts at 2 amps maximum and -20 volts at 2 amps maximum.

TheIPA portion of A20T1 secondary consists of a common tap plus 5 taps to provide a range of voltages to control the proper RF drive level to the PA modules.

The low voltage power supply is not step/started and is on whenever AC power is applied to the transmitter. If the circuit breaker in the base of the cabinet is ON the pilot light on the front panel in the base of the cabinet will be illuminated.

Since this is a low voltage power supply, there are no interlocks on the rear panel controlling this power supply.

5.3.11. Airflow Sensor

5.3.11.1. Introduction

An air flow sensor circuit, located in the air inlet for both fans, provides protection against a fan failure by sensing wind chill. If a fan fails, the lack of wind chill is detected, and the transmitter shuts down. An audible alarm sounds to signify a fan failure.

5.3.11.2. Description

The function of the Air Flow sensor is based on a comparison of voltage outputs from individual temperature sensing devices.One sensing device (U3) is unheated, such that it samples the ambient temperature. There are two other sensors (U2 and U4); one for each fan, and they are heated by resistors R2 and R1, respectively.

If a fan stops running, the corresponding heated sensor increases in temperature, whereas the ambient sensor is unaffected. As the heated sensor increases in temperature, the voltage difference climbs. When the pre-determin ed threshold is crossed, comparator U1 triggers, and closes the onboard relay, K1. Contacts of this relay interrupt the contactor coil circuit (K1 in the AC drawer). At the same time, the relay providesvoltage to the audible warning device and the red led, DS1. Also, the status of the remote contacts change position.

As soon as relay K1 closes, power for the heated sensors is removed. This allows them to cool down so that you may restart the transmitter.

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Page 45

Section VI

Parts List

Introduction

This section of the technical manual contains a list of the replaceable parts for the GATES Series™ AM TRANSMITTER.

Replaceable Parts List Index

Table 6-1. GATES ONE ..........................9949202002 6-2

Table6-2. BASICGATESONE.....................9949202001 6-3

Table6-3. GATESONEFINALPARTS.................9928149001 6-3

Table6-4. GATESONECONVPARTS ................9928158001 6-4

Table 6-5. GATES TWO ..........................9949203002 6-5

Table6-6. BASICGATESTWO.....................9949203001 6-6

Table6-7. GATESTWOFINALPARTS ................9928149002 6-6

Table6-8. GATESTWOCONVPARTS ................9928159001 6-7

Table 6-9. GATES FIVE, 1PH .......................9949204002 6-8

Table6-10. BASICGATESFIVE1PH..................9949204001 6-9

Table6-11. GATESFIVE1PHCONVPARTS..............9928160001 6-10

Table6-12. GATESFIVE1PHUNIQUEPTS ..............9928291001 6-11

Table 6-13. GATES FIVE, 3PH .......................9949205002 6-11

Table6-14. BASICGATESFIVE3PH..................9949205001 6-12

Table6-15. GATESFIVE3PHCONVPARTS..............9928161001 6-12

Table 6-16. BASIC GATES SERIES XMTR ................9928143001 6-14

Table6-17. AIRFLOWSENSOR.....................9929146001 6-17

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Table 6-1. GATES ONE - 994 9202 002

Harris PN Description QTY UM Reference Designators (N)

494 0378 000. . . .. . CHOKE 0.33UH10% 780MA. . . . . . . . . . . . 0.0 EA A01L14 A01L15 A01L24A01L25 A01L34A01L35 A01L44A01L45 FREQ

DET

4940399000...... CHOKERF12.0UH................... 0.0EA A18A1L3FREQDET

4940401000...... CHOKERF18.0UH................... 0.0EA A18A1L2A18A1L3FREQDET

500 0755 000. . . . . . CAP, MICA, 270PF 500V5%. . . . . . . . . . . . 0.0 EA A18A1C10 FREQ DET

500 0835 000. . . . . . CAP, MICA, 470PF 500V5%. . . . . . . . . . . . 0.0 EA A18A1C10 FREQ DET

5000841000...... CAP,750PF300V5% ................. 0.0EA A18A1C10FREQDET

500 0844 000. . . . . . CAP, MICA,1000PF 100V 5%. . . . . . . . .. . 0.0 EA A18A1C10FREQDET

500 0883 000. . . . . . CAP, MICA, 4700PF 500V5%. . . . . . . . . . . 0.0 EA A01C10A01C15 A01C20 A01C25A01C30 A01C35 A01C40 A01C45

FREQ DET

504 0239 000. . . . . . CAP 2200PF6KV 5% (291).. . . . . . .. . . . . 0.0 EA A21C03

504 0240 000. . . . . . CAP 2700PF6KV 5% (291).. . . . . . .. . . . . 0.0 EA A21C03

504 0243 000. . . . . . CAP 4700PF6KV 5% (291).. . . . . . .. . . . . 0.0 EA A21C02

504 0244 000. . . . . . CAP 5100PF4KV 5% (291).. . . . . . .. . . . . 0.0 EA A21C02

504 0256 000. . . . . . CAP 1000PF6KV 5% (291).. . . . . . .. . . . . 0.0 EA A21C03

504 0267 000. . . . . . CAP 2000PF5KV 5% (272).. . . . . . .. . . . . 0.0 EA A21C04

504 0270 000. . . . . . CAP 7500PF4KV 5% (291).. . . . . . .. . . . . 0.0 EA A21C02

504 0354 000. . . . . . CAP 5100PF10KV 5% (293). . . . . . . . . .. . 0.0 EA A21C01 FREQ DET

504 0368 000. . . . . . CAP 3000PF3 KV 5% (272) . . . . . . . . . .. . 0.0 EA A21C04

504 0372 000. . . . . . CAP 5600PF4KV 5% (291).. . . . . . .. . . . . 0.0 EA A21C02

504 0379 000. . . . . . CAP 4300PF12KV (293) .. . . . . . . . .. . . . . 0.0 EA A21C01

504 0382 000. . . . . . CAP 2400PF12KV 5% (293). . . . . . . . . .. . 0.0 EA A21C01 FREQ DET

504 0384 000. . . . . . CAP 3900PF3KV 5% (272).. . . . . . .. . . . . 0.0 EA A21C04

504 0396 000. . . . . . CAP 6200PF4KV 5% (291).. . . . . . .. . . . . 0.0 EA A21C02

504 0410 000. . . . . . CAP 1200PF6KV 5% (291).. . . . . . .. . . . . 0.0 EA A21C03A21C04

504 0411 000. . . . . . CAP 1600PF6KV 5% (291).. . . . . . .. . . . . 0.0 EA A21C03

504 0418 000. . . . . . CAP 2700PF 12KV 5% (293) .. . . . . . . . . . 0.0 EA A21C01FREQ DET

504 0419 000. . . . . . CAP 3300PF 12KV 5% (293) .. . . . . . . . . . 0.0 EA A21C01FREQ DET

504 0420 000. . . . . . CAP 3900PF 12KV 5% (293) .. . . . . . . . . . 0.0 EA A21C01FREQ DET

504 0424 000. . . . . . CAP 2000PF6KV 5% (291).. . . . . . .. . . . . 0.0 EA A21C03

504 0430 000. . . . . . CAP 8200PF4KV 5% (291).. . . . . . .. . . . . 0.0 EA A21C02

504 0431 000. . . . . . CAP 9100PF4KV 5% (291).. . . . . . .. . . . . 0.0 EA A21C02

504 0432 000. . . . . . CAP 11,000PF4KV 5%(291) . . . . . . . . . . . 0.0 EA A21C02

504 0433 000. . . . . . CAP 3600PF12KV 5% (293). . . . . . . . . .. . 0.0 EA A21C01 FREQ DET

504 0435 000. . . . . . CAP 5600PF10KV 5% (293). . . . . . . . . .. . 0.0 EA A21C01 FREQ DET

5040437000...... CAP7500PF10KV5% ................ 0.0EA A21C01

504 0442 000. . . . . . CAP 13,000PF3KV 5%(291) . . . . . . . . . . . 0.0 EA A21C02

504 0443 000. . . . . . CAP 18,000PF2KV 5%. . . . . . . . . . . . . . . . 0.0 EA A21C02

504 0444 000. . . . . . CAP 12,000PF3KV 5%(291) . . . . . . . . . . . 0.0 EA A21C02

504 0445 000. . . . . . CAP 16,000PF3KV 5%(291) . . . . . . . . . . . 0.0 EA A21C02

504 0453 000. . . . . . CAP 2400PF6KV 5% (291).. . . . . . .. . . . . 0.0 EA A21C03

504 0463 000. . . . . . CAP 2200PF12KV 5% (293).. . . . . . . . .. . 0.0 EA A21C01

504 0464 000. . . . . . CAP 1300PF5KV 5% (272).. . . . . . .. . . . . 0.0 EA A21C04

504 0465 000. . . . . . CAP 1500PF5KV 5% (272).. . . . . . .. . . . . 0.0 EA A21C04

504 0466 000. . . . . . CAP 1600PF5KV 5% (272).. . . . . . .. . . . . 0.0 EA A21C04

504 0467 000. . . . . . CAP 1800PF5KV 5% (272).. . . . . . .. . . . . 0.0 EA A21C04

504 0468 000. . . . . . CAP 2200PF5KV 5% (272).. . . . . . .. . . . . 0.0 EA A21C04

504 0469 000. . . . . . CAP 2400PF5KV 5% (272).. . . . . . .. . . . . 0.0 EA A21C04

504 0470 000. . . . . . CAP 2700PF3KV 5% (272).. . . . . . .. . . . . 0.0 EA A21C04

504 0471 000. . . . . . CAP 3300PF3KV 5% (272).. . . . . . .. . . . . 0.0 EA A21C04

504 0472 000. . . . . . CAP 3600PF3KV 5% (272).. . . . . . .. . . . . 0.0 EA A21C04

504 0473 000. . . . . . CAP 910PF6KV 5%(291). . . . . . . . . . . . . . 0.0 EA A21C03

504 0474 000. . . . . . CAP 1100PF6KV 5% (291).. . . . . . .. . . . . 0.0 EA A21C03

6-2 888-2314-001 Rev.AD1: 1/15/02

WARNING: Disconnect primary power prior to servicing.

Page 47

504 0475 000 .. . . . CAP1300PF6KV 5% (291) . . . . . . . . . . . . 0.0EA A21C03

504 0476 000 .. . . . CAP1500PF6KV 5% (291) . . . . . . . . . . . . 0.0EA A21C03

504 0477 000 .. . . . CAP1800PF6KV 5% (291) . . . . . . . . . . . . 0.0EA A21C03

504 0496 000 .. . . . CAP4700PF10KV 5% (293) . . . . . . . . . . . 0.0 EA A21C01

504 0497 000 .. . . . CAP6200PF10KV 5% (293) . . . . . . . . . . . 0.0 EA A21C01

504 0498 000 .. . . . CAP6800PF10KV 5% (293) . . . . . . . . . . . 0.0 EA A21C01

516 0204 000 .. . . . CAP,RF, 100PF 5KV 10% N750 . . . . . . . . 0.0 EA A26C01FREQ DET

516 0205 000 .. . . . *CAP,RF, 500PF 5KV 20% X5T. . . . . . . . . 0.0EA A26C01 FREQDET

516 0819 000 .. . . . CAP,RF, 200PF 5KV 10% N3300 .. . . . . . 0.0 EA A26C01 FREQ DET

8170914253..... STRAP,.020X1.0X6.4IN............. 0.0EA

8170914254..... STRAP,A21L8TOL4................. 0.0EA

817 2131 014 .. . . . FREQ DET CHART, GATES ONE .. . . . . . 0.0EA SEE THIS CHART FOR XMTR FREQ DET PARTS

8397920013..... FAMILYTREE,GATESSERIES......... 0.0EA

9172131034..... KIT,CEMODIFICATION,GATES1...... 0.0EA

9298305546..... XFMRASSY,20TURN................ 0.0EA A26T01

9298305642..... XFMRASSY,17TURN................ 0.0EA A26T01

9298305643..... XFMRASSY,10TURN................ 0.0EA A26T01

9298305750..... XFMRASSY,10TURN................ 0.0EA

939 5695 332 .. . . . COIL, FIXED 20FC2243 . . . . .. . . . . . .. . . 0.0EA A21L08 FREQ DET

9882314002..... DPGATESONE..................... 1.0EA

9890086001..... PKGLISTGATESONEVERT.......... 0.0EA

9890086002..... PKGLISTGATESONEHORZ.......... 0.0EA

9901099001..... R-SK-GATESONE................... 0.0EA

992 6414 001 .. . . . CRYSTAL SELECTION LIST .. . . .. . . . . . 0.0EA A16Y1 OSCIL 1 REQD A17Y1 OSCIL OPTION 1 REQD

9928146002..... OSCILLATORPKG................... 0.0EA A017OPTION

9949202001..... BASICGATESONE.................. 1.0EA

9949238001..... R-BK-GATESSERIES ................ 0.0EA

9949239001..... R-PK-GATESONE................... 0.0EA

Table 6-2. BASIC GATES ONE - 994 9202 001

Harris PN Description QTY UM Reference Designators (C)

9928143001..... BASICGATESSERIESXMTR.......... 1.0EA

9928149001..... GATESONEFINALPARTS............ 1.0EA

9928158001..... GATESONECONVPARTS............ 1.0EA

9992620001..... HARDWARELIST,BASIC,GATES...... 1.0EA

Table 6-3. GATES ONE FINAL PARTS - 992 8149 001

Harris PN Description QTY UM Reference Designators (K)

3001629000 ..... SCR,1/4-28X5/16................... 8.0EA

3570092000..... NUT,HEX1/4-20TEFLON............. 1.0EA A21L01

357 0093 000 .. . . . SCREW,1/4-20 X 7/8 FHMS . . . . .. . . . . . 1.0 EA A21L01

3980015000..... FUSE,FASTCART.500A250V ......... 2.0EA

3980016000..... FUSE,FASTCART.750A250V ......... 2.0EA

3980019000..... FUSE,FASTCART2A250V ........... 5.0EA

398 0081 000 .. . . . FUSE,SLOCART2A 250V. . . . . .. . . . . . . 1.0 EA

3980402000..... FUSE,RECTIFIER2A250V............ 4.0EA

3980403000..... FUSE,RECTIFIER3A250V........... 10.0EA

646 1353 000 .. . . . NAMEPLATE, XMTR EQUIPMENT . . . . . . 1.0 EA

817 0914 195 .. . . . STANDOFF,INSULATED1.5LG . . . . . . . . 8.0EA #A21C01 #A21C03

8170914204..... STRAP,CAPTAPPING ............... 4.0EA #A26C01

8298305616..... STRAP,A26L2TOA26C1 ............. 1.0EA

8298305690..... STRAP,A21C1TOL2................. 1.0EA #A21L02

Rev.AD1: 1/15/02 888-2314-001 6-3

WARNING: Disconnect primary power prior to servicing.

Page 48

8298305719...... ANGLE,A21C1MTG.................. 1.0EA

8395695402...... STRAP,A21L1TOA21C1.............. 1.0EA

8397920048...... STRAP............................. 1.0EA

9298305650...... STRAP,A21C4TOL7................. 1.0EA

9298305687...... BRACKET,CAPMTG ................. 2.0EA #A21C03

9395695403...... ANGLE,A21C1MTG.................. 1.0EA

9433777014...... COIL,FIXED13TURN................. 1.0EA A21L1

943 5450 475. . . . . . CBL, PA DRIVE COAX 44" LG . . . . . . . . . . 1.0 EA

9947784002...... COILCLIP3/8RIBBON................ 1.0EA #A21L07

9947784003...... COILCLIP1/2RIBBON................ 1.0EA

Table 6-4. GATES ONE CONV PARTS - 992 8158 001

Harris PN Description QTY UM Reference Designators (Z)

3350227000...... WASHER,INSULATING............... 8.0EA #A19CR1#A19CR2#A19CR3#A19CR4

3350252000...... WASHER,TEFLON................... 4.0EA #A19CR1#A19CR2#A19CR3#A19CR4

3580004000...... BRACKETRESISTORMTG............ 2.0EA #A19R21

3582511000...... STANDOFF,10-32X3/4............... 1.0EA

3582635000...... CABLETIE,PUSHMOUNTSNAPIN..... 2.0EA

3582739000...... PLASTICCAP5/8-24.................. 1.0EA #J001

3583123000...... STUD,BRS10-32X1-1/2.............. 2.0EA

384 0705 000. . . . . . RECT 85A 1000V PIV ESD. . .. . . . . . . . . . 4.0 EA A19CR1A19CR2 A19CR3 A19CR4

4721315000...... XMFR,PWR,817-2114-001............. 1.0EA A19T1

516 0200 000. . . . . . CAP, HV25PF 7500V10% .. . . . . .. . . . . . 1.0 EA A18C1

5240178000...... CAP860UF450V .................... 2.0EA A19C1A19C3

6140720000...... *TERMBD6TERM................... 1.0EA TB001

632 1153 000. . . . . . AMMETER, 0-20ADC, 4.5",[W] . . . . . . . . . . 1.0 EA M003

632 1158 000. . . .. . WATTMETER, 0-1500W,4.5",[W] . . .. . . . . 1.0 EA M004

8135002048...... STDOFF10-32X7/81/2HEX............ 1.0EA

8135007026...... STDOFF6-32X1/21/4DIA.............. 1.0EA

8170914097...... STRAP,RECTIFIERS ................. 2.0EA

8170914261...... SPACER,.75ODX.256IDX1.7........... 2.0EA

8220981011...... COVERPLATE ...................... 3.0EA

8220981012...... COVERPLATE ...................... 1.0EA

8220981013...... COVERPLATE ...................... 1.0EA

8298305026...... ANGLE,DIODE...................... 1.0EA

8298305647...... BRACKETH.V.RECT................. 1.0EA #A19CR1

8298305648...... PLATEH.V.RECT.................... 1.0EA #A19CR1

8298305713...... ADAPTOR,OUTPUTCONN............ 1.0EA #J001

9170914167...... RECEPTACLE,OUTPUTTYPEN........ 1.0EA J001

9170914207...... RES,METERINGSHUNT.............. 1.0EA A19R6

9170914221...... XFMR,PHASEANGLE28T............. 1.0EA A18T1

9172131006...... PHASEANGLEXFMR................. 1.0EA A18T2

9172244001...... SPACER,1.0LG.75DIA............... 3.0EA

9220981079...... SHUNT............................. 1.0EA A19R7

9298305301...... CLAMP,MODIFICATION............... 4.0EA

9397920002...... METERTRIM........................ 1.0EA

9398187001...... INSULATOR,PAMODULE............. 1.0EA #A001

943 5479 024. . . . . . PANEL, REAR ACCESS, GATES ONE. . . . 1.0 EA

9925872006...... *PDMPULLUPBOARD*.............. 2.0EA A6A1A7A1

9925874011...... PWA,PDMFILTER ESDSAFE........ 1.0EA A010

9928227001...... CBLPKGGATESONE................ 1.0EA

6-4 888-2314-001 Rev.AD1: 1/15/02

WARNING: Disconnect primary power prior to servicing.

Page 49

Table 6-5. GATES TWO - 994 9203 002

Harris PN Description QTY UM Reference Designators (N)

494 0378 000 .. . . . CHOKE0.33UH 10% 780MA . . . . . .. . . . . 0.0EA A01L14 A01L15 A01L24 A01L25 A01L34 A01L35A01L44 A01L45

A04L14 A04L15 A04L24 A04L25 A04L34A04L35 A04L44A04L45 FREQ DET

4940399000..... CHOKERF12.0UH................... 0.0EA A18A1L1FREQDET

494 0401 000 .. . . . CHOKERF18.0UH. . . . . . . . . . . . . .. . . . . 0.0EA A18A1L2 A18A1L3FREQ DET

500 0755 000 .. . . . CAP,MICA, 270PF 500V 5% . .. . . . . . . . . 0.0 EA A18A1C10FREQ DET

500 0835 000 .. . . . CAP,MICA, 470PF 500V 5% . .. . . . . . . . . 0.0 EA A18A1C10FREQ DET

5000841000..... CAP,750PF300V5%................. 0.0EA A18A1C10FREQDET

500 0844 000 .. . . . CAP,MICA, 1000PF 100V 5% . . . . . . . . . . 0.0 EA A18A1C10 FREQ DET

500 0883 000 .. . . . CAP,MICA, 4700PF 500V 5% . . . .. . . . . . 0.0 EA A01C10 A01C15A01C20 A01C25A01C30 A01C35 A01C40 A01C45

A04C10A04C15 A04C20 A04C25

504 0258 000 .. . . . CAP1000PF20KV 5% (293) . . . . . . . . . . . 0.0 EA A21C03 FREQ DET

504 0274 000 .. . . . CAP1500PF 10KV 5% (292) . . . . .. . . . . . 0.0 EA A21C03 A21C04FREQ DET

504 0353 000 .. . . . CAP3000PF 12KV 5% (293) . . . . .. . . . . . 0.0 EA A21C01 A21C02FREQ DET

504 0354 000 .. . . . CAP5100PF10KV 5% (293) . . . . . . . . . . . 0.0 EA A21C02 FREQ DET

504 0355 000 .. . . . CAP2000PF20KV 5% (294) . . . . . . . . . . . 0.0 EA A21C01 FREQ DET

504 0373 000 .. . . . CAP1200PF10KV 5% (292) . . . . . . . . . . . 0.0 EA A21C04 FREQ DET

504 0378 000 .. . . . CAP1200PF15KV 5% (293) . . . . . . . . . . . 0.0 EA A21C03 FREQ DET

504 0379 000 .. . . . CAP4300PF12KV (293) . . . . . . . . . . . . . . 0.0EA A21C01 FREQDET

504 0382 000 .. . . . CAP2400PF12KV 5% (293) . . . . . . . . . . . 0.0 EA A21C01 FREQ DET

504 0383 000 .. . . . CAP1500PF25KV 5% (294) . . . . . . . . . . . 0.0 EA A21C01 FREQ DET

504 0388 000 .. . . . CAP3000PF8KV 5% (292) . . . . . . . . . . . . 0.0EA A21C04 FREQ DET

504 0417 000 .. . . . CAP910PF 20KV 5% (293) . . .. . . . . . . . . 0.0 EA A21C03FREQ DET

504 0418 000 .. . . . CAP2700 PF 12KV 5% (293). .. . . . . . . . . 0.0 EA A21C01 FREQ DET

504 0419 000 .. . . . CAP3300 PF 12KV 5% (293). .. . . . . . . . . 0.0 EA A21C10 FREQ DET

504 0420 000 .. . . . CAP3900 PF 12KV 5% (293). .. . . . . . . . . 0.0 EA A21C02 FREQ DET

504 0433 000 .. . . . CAP3600PF 12KV 5% (293) . . . . .. . . . . . 0.0 EA A21C01 A21C02FREQ DET

504 0434 000 .. . . . CAP4000PF12KV 5% (293) . . . . . . . . . . . 0.0 EA A21C01 FREQ DET

504 0435 000 .. . . . CAP5600PF10KV 5% (293) . . . . . . . . . . . 0.0 EA A21C02 FREQ DET

504 0439 000 .. . . . CAP9100PF8KV 5% (293) . . . . . . . . . . . . 0.0EA A21C02 FREQ DET

504 0440 000 .. . . . CAP10,000PF8KV 5% (293) . . . . . . .. . . . 0.0 EA A21C02 FREQ DET

504 0441 000 .. . . . CAP11,000PF8KV 5% (293) . . . . . . .. . . . 0.0 EA A21C02 FREQ DET

504 0446 000 .. . . . CAP12,000PF5KV 5% (293) . . . . . . .. . . . 0.0 EA A21C02 FREQ DET

504 0447 000 .. . . . CAP13,000PF5KV 5% (293) . . . . . . .. . . . 0.0 EA A21C02 FREQ DET

504 0448 000 .. . . . CAP16,000PF5KV 5% (293) . . . . . . .. . . . 0.0 EA A21C02 FREQ DET

504 0449 000 .. . . . CAP18,000PF5KV 5% (293) . . . . . . .. . . . 0.0 EA A21C02 FREQ DET

504 0460 000 .. . . . CAP1100PF20KV 5% (293) . . . . . . . . . . . 0.0 EA A21C03 FREQ DET

504 0461 000 .. . . . CAP1300PF 15KV 5% (293) . . . . .. . . . . . 0.0 EA A21C03 A21C04FREQ DET

504 0463 000 .. . . . CAP2200PF12KV 5% (293) . . . . . . . . . . . 0.0 EA A21C01 FREQ DET

504 0478 000 .. . . . CAP1300PF10KV 5% (292) . . . . . . . . . . . 0.0 EA A21C04 FREQ DET

504 0479 000 .. . . . CAP1600PF 10KV 5% (292) . . . . .. . . . . . 0.0 EA A21C03 A21C04FREQ DET

504 0480 000 .. . . . CAP1800PF 10KV 5% (292) . . . . .. . . . . . 0.0 EA A21C03 A21C04FREQ DET

504 0481 000 .. . . . CAP2000PF 10KV 5% (292) . . . . .. . . . . . 0.0 EA A21C03 A21C04FREQ DET

504 0482 000 .. . . . CAP2200PF 8KV 5% (292) . . . . . . . . . . . . 0.0 EA A21C03A21C04 FREQDET

504 0483 000 .. . . . CAP2400PF 8KV 5% (292) . . . . . . . . . . . . 0.0 EA A21C03A21C04 FREQDET

504 0484 000 .. . . . CAP2700PF 8KV 5% (292) . . . . . . . . . . . . 0.0 EA A21C03A21C04 FREQDET

504 0485 000 .. . . . CAP3300PF8KV 5% (292) . . . . . . . . . . . . 0.0EA A21C04 FREQ DET

504 0486 000 .. . . . CAP3600PF8KV 5% (292) . . . . . . . . . . . . 0.0EA A21C04 FREQ DET

504 0487 000 .. . . . CAP3900PF8KV 5% (292) . . . . . . . . . . . . 0.0EA A21C04 FREQ DET

504 0492 000 .. . . . CAP1300PF25KV 5% (294) . . . . . . . . . . . 0.0 EA A21C01 FREQ DET

504 0494 000 .. . . . CAP1600PF25KV 5% (294) . . . . . . . . . . . 0.0 EA A21C01 FREQ DET

504 0495 000 .. . . . CAP1800PF25KV 5% (294) . . . . . . . . . . . 0.0 EA A21C01 FREQ DET

516 0204 000 .. . . . CAP,RF, 100PF 5KV 10% N750 . . . . . . . . 0.0 EA A26C01FREQ DET

Rev.AD1: 1/15/02 888-2314-001 6-5

WARNING: Disconnect primary power prior to servicing.

Page 50

516 0205 000. . . . . . *CAP, RF, 500PF 5KV20% X5T .. . . . . .. . 0.0 EA A26C01 FREQ DET

516 0819 000. . . . . . CAP, RF,200PF 5KV 10% N3300. . . . . . . . 0.0 EA A26C01 FREQ DET

8170914253...... STRAP,.020X1.0X6.4IN ............. 0.0EA

8170914254...... STRAP,A21L8TOL4................. 0.0EA

817 2131 015. . . . . . FREQ DET CHART, GATES TWO . . . . . . . 0.0 EA SEE THIS CHART FOR XMTR FREQ DET PARTS

8397920013...... FAMILYTREE,GATESSERIES......... 0.0EA

917 2131 035. . . .. . KIT, CE MODIFICATION, GATES2. . . . . . . 0.0 EA

9298305546...... XFMRASSY,20TURN................ 0.0EA A26T01

9298305642...... XFMRASSY,17TURN................ 0.0EA A26T01

9298305643...... XFMRASSY,10TURN................ 0.0EA A26T01

9298305750...... XFMRASSY,10TURN................ 0.0EA

9395695332...... COIL,FIXED20FC2243................ 0.0EA A21L08FREQDET

9397920102...... MOUNTINGADAPTER................ 0.0EA BOTTOMOUTPUTADAPTOR

9882314003...... DPGATESTWO ..................... 1.0EA

9890087001...... PKGLISTGATESTWOVERT .......... 0.0EA

9890087002...... PKGLISTGATESTWOHORZ.......... 0.0EA

9901100001...... R-SK-GATESTWO................... 0.0EA

9926414001...... CRYSTALSELECTIONLIST............ 0.0EA A16Y1OSCIL1REQDA17Y1OSCILOPTION1REQD

9928146002...... OSCILLATORPKG................... 0.0EA A017OPTION

9949203001...... BASICGATESTWO .................. 1.0EA

9949238001...... R-BK-GATESSERIES................. 0.0EA

9949240001...... R-PK-GATESTWO................... 0.0EA

Table 6-6. BASIC GATES TWO - 994 9203 001

Harris PN Description QTY UM Reference Designators (B)

9928143001...... BASICGATESSERIESXMTR.......... 1.0EA

9928149002...... GATESTWOFINALPARTS............ 1.0EA

9928159001...... GATESTWOCONVPARTS............ 1.0EA

Table 6-7. GATES TWO FINAL PARTS - 992 8149 002

Harris PN Description QTY UM Reference Designators (M)

3001629000...... SCR,1/4-28X5/16 ................... 8.0EA

3001981000...... SCR,3/8-24X1...................... 1.0EA

3570092000...... NUT,HEX1/4-20TEFLON ............. 1.0EA A21L01

3570093000...... SCREW,1/4-20X7/8FHMS............ 1.0EA A21L01

3980015000...... FUSE,FASTCART.500A250V.......... 2.0EA

3980016000...... FUSE,FASTCART.750A250V.......... 2.0EA

3980019000...... FUSE,FASTCART2A250V............ 5.0EA

3980081000...... FUSE,SLOCART2A250V ............. 1.0EA

3980403000...... FUSE,RECTIFIER3A250V ........... 10.0EA

3980435000...... FUSE,RECTIFIER5A250V ............ 8.0EA

646 1353 000. . . . . . NAMEPLATE, XMTR EQUIPMENT. . . . . . . 1.0 EA

8170914092...... SPACER............................ 1.0EA #A21C02

817 0914 195. . . . . . STANDOFF, INSULATED 1.5LG.. . . . . . . . 8.0 EA #A21C01#A21C03

8170914204...... STRAP,CAPTAPPING................ 4.0EA #A26C01

8298305616...... STRAP,A26L2TOA26C1.............. 1.0EA

8298305653...... STRAP,A21C4TERMINATION.......... 1.0EA

8298305690...... STRAP,A21C1TOL2................. 1.0EA #A21L02

8298305719...... ANGLE,A21C1MTG.................. 1.0EA

8395695402...... STRAP,A21L1TOA21C1.............. 1.0EA

8397920048...... STRAP............................. 1.0EA

9298305650...... STRAP,A21C4TOL7................. 1.0EA

6-6 888-2314-001 Rev.AD1: 1/15/02

WARNING: Disconnect primary power prior to servicing.

Page 51

9298305687..... BRACKET,CAPMTG................. 2.0EA #A21C03

9298305694..... STRAP,A2A1,TOA3A1............... 1.0EA #A02A01#A03A01

9395695403..... ANGLE,A21C1MTG.................. 1.0EA

9433777014..... COIL,FIXED13TURN................ 1.0EA A21L1

943 5450 475 .. . . . CBL,PA DRIVE COAX44" LG . . . . . . . . . . 2.0 EA

9947784002..... COILCLIP3/8RIBBON................ 1.0EA #A21L07

9947784003..... COILCLIP1/2RIBBON................ 1.0EA

Table 6-8. GATES TWO CONV PARTS - 992 8159 001

Harris PN Description QTY UM Reference Designators (AN)

335 0256 000 . . . . . WASHER, SHOULDER .765 ID . . . . . . . . . 4.0 EA #A19CR1 #A19CR2 #A19CR3 #A19CR4

335 0257 000 . . . . . WASHER, KAPTON .687/1.625 . . . . . . . . . 4.0 EA #A19CR1 #A19CR2 #A19CR3 #A19CR4

3570092000..... NUT,HEX1/4-20TEFLON............. 1.0EA

3580004000..... BRACKETRESISTORMTG............ 2.0EA #A19R21

358 2635 000 . . . . . CABLE TIE, PUSH MOUNT SNAP IN. . . . . 2.0 EA

3583123000..... STUD,BRS10-32X1-1/2.............. 1.0EA

384 0839 000 .. . . . RECT1000PIV 275A 1N4056 ESD . . . . . . 4.0 EA A19CR1 A19CR2A19CR3 A19CR4

4721280000..... XFMR,PWR,829-8305-087............ 1.0EA A19T1

516 0413 000 .. . . . CAP, RF, 10PF 7.5KV 10% NPO . . . . . . . . 1.0 EA A18C1

524 0341 000 .. . . . CAP5100 UF 350WVDC.. . . . . . . . . . . . . . 2.0 EA A19C1 A19C3

6140158000..... TERMSTRIP2TERM................. 1.0EA TS002

6140720000..... *TERMBD6TERM................... 1.0EA TB001

6200831000..... TADAPTERBNCUG-274A/U .......... 1.0EA J002

6201906000..... ENDTERM,7/8EIAFLANGE........... 1.0EA J001

632 1152 000 .. . . . AMMETER, 0-40ADC, 4.5",[W] . . . . . . . . . . 1.0 EA M003

632 1156 000 .. . . . WATTMETER, 0-5KW, 4.5",[W] .. .. . . . . . 1.0 EA M004

8135001071..... STDOFF10-32X1.753.8HEX ......... 1.0EA

8135007026..... STDOFF6-32X1/21/4DIA............. 1.0EA

8170914101..... STANDOFF,HVRECT................ 2.0EA #A19CR1#A19CR2

817 0914 195 . . . . . STANDOFF, INSULATED 1.5LG . . . . . . . . 4.0 EA

8170914261..... SPACER,.75ODX.256IDX1.7........... 2.0EA

8170914350..... STANDOFF,PAGROUND............. 1.0EA

8220981009..... MULTIMETERSWPLT................ 1.0EA

8220981011..... COVERPLATE...................... 2.0EA

8220981012..... COVERPLATE...................... 1.0EA

8220981013..... COVERPLATE...................... 1.0EA

8298305389..... BRACKET,RECTIFIER................ 1.0EA #A19CR1

8298305623..... RETAINER,CABLE................... 1.0EA

8397920103..... ASSYINSTR,MODCOIL.............. 0.0EA

9170914222..... XFMR,PHASEANGLE44T............ 1.0EA A18T1

9170914250..... RES,METERINGSHUNT.............. 1.0EA A19R6

9172131007..... PHASEANGLEXFMR ................ 1.0EA A18T2

9220981080..... SHUNT ............................ 1.0EA A19R7

9298305301..... CLAMP,MODIFICATION .............. 6.0EA

9298305395..... BRKT,HVRECT .................... 1.0EA #A19CR2

9298305732..... XFMR,IPANEUTRALIZER............. 1.0EA A26T2

9397920017..... METERTRIM ....................... 1.0EA

9398187001..... INSULATOR,PAMODULE............. 2.0EA

9433655196..... HEATSINK,PA ...................... 1.0EA

943 5479 025 . . . . . PANEL, REAR ACCESS, GATES TWO . . . 1.0 EA

9925868008..... PWA,PATOROID ESDSAFE........ 1.0EA A4A1

9925872007..... *PDMPULLUPBOARD* ............. 2.0EA A6A1A7A1

992 5874 009 . . . . . PWA,PDM FILTER ESD SAFE . . . . . . . 1.0 EA A010

9928228001..... CBLPKGGATESTWO ............... 1.0EA

Rev.AD1: 1/15/02 888-2314-001 6-7

WARNING: Disconnect primary power prior to servicing.

Page 52

9929714001...... PWA,PAMODULE ................... 1.0EA

999 2621 001. . . .. . HARDWARE LIST, GATES TWO CONV. .. 1.0 EA

Table 6-9. GATES FIVE, 1PH - 994 9204 002

Harris PN Description QTY UM Reference Designators (M)

494 0378 000. . . .. . CHOKE 0.33UH10% 780MA. . . . . .. . . . . . 0.0 EA A01L14A01L15 A01L24A01L25 A01L34A01L35 A01L44A01L45

A02L14 A02L15 A02L24 A02L25 A02L34A02L35 A02L44A02L45 A03L14 A03L15 A03L24 A03L25 A03L34A03L35 A03L44A03L45 A04L14 A04L15 A04L24 A04L25 A04L34A04L35 A04L44A04L45 FREQ DET

4940399000...... CHOKERF12.0UH................... 0.0EA A18A1L3FREQDET

4940401000...... CHOKERF18.0UH................... 0.0EA A18A1L2A18A1L3FREQDET

500 0755 000. . . . . . CAP, MICA, 270PF 500V5%. . . . . . . . . . . . 0.0 EA A18A1C10 FREQ DET

500 0835 000. . . . . . CAP, MICA, 470PF 500V5%. . . . . . . . . . . . 0.0 EA A18A1C10 FREQ DET

5000841000...... CAP,750PF300V5% ................. 0.0EA A18A1C10FREQDET

500 0844 000. . . . . . CAP, MICA,1000PF 100V 5%. . . . . . . . .. . 0.0 EA A18A1C10 FREQ DET

500 0883 000. . . . . . CAP, MICA, 4700PF 500V5%. . . . . . . . . . . 0.0 EA A01C10 A01C15 A01C20 A01C25A01C30 A01C35 A01C40 A01C45

A02C10A02C15 A02C20 A02C25 A02C30 A02C35A02C40 A02C45 A03C10A03C15 A03C20 A03C25 A03C30 A03C35A03C40 A03C45 A04C10A04C15 A04C20 A04C25 A04C30 A04C35A04C40 A04C45

FREQ DET

504 0258 000. . . . . . CAP 1000PF20KV 5%(293).. . . . . . .. . . . 0.0 EA A21C03 A21C04 FREQ DET

504 0353 000. . . . . . CAP 3000PF12KV 5%(293).. . . . . . .. . . . 0.0 EA A21C02 A21C04 FREQ DET

504 0354 000. . . . . . CAP 5100PF10KV 5%(293).. . . . . . .. . . . 0.0 EA A21C02 A21C03 FREQ DET

504 0374 000. . . . . . CAP 2000PF15KV 5%(293).. . . . . . .. . . . 0.0 EA A21C03 A21C04 FREQ DET

504 0377 000. . . . . . CAP 1500PF15KV 5%(293).. . . . . . .. . . . 0.0 EA A21C03 A21C04 FREQ DET

504 0378 000. . . . . . CAP 1200PF15KV 5%(293).. . . . . . .. . . . 0.0 EA A21C03 A21C04 FREQ DET

504 0382 000. . . . . . CAP 2400PF12KV 5%(293).. . . . . . .. . . . 0.0 EA A21C03 A21C04 FREQ DET

504 0417 000. . . . . . CAP 910PF20KV 5% (293). . . . . . . . . . . . . 0.0 EA A21C03 FREQ DET

504 0418 000. . . .. . CAP 2700 PF 12KV 5% (293) .. . . . . . . . . . 0.0 EA A21C03 A21C04 FREQ DET

504 0419 000. . . . . . CAP 3300PF 12KV 5% (293) .. . . . . . . . . . 0.0 EA A21C04FREQ DET

504 0420 000. . . .. . CAP 3900 PF 12KV 5% (293) .. . . . . . . . . . 0.0 EA A21C02 A21C04 FREQ DET

504 0433 000. . . . . . CAP 3600PF12KV 5%(293).. . . . . . .. . . . 0.0 EA A21C02 A21C04 FREQ DET

504 0435 000. . . . . . CAP 5600PF10KV 5% (293). . . . . . . . . .. . 0.0 EA A21C02 FREQ DET

504 0439 000. . . . . . CAP 9100PF8KV 5% (293). . . . . . . . . .. . . 0.0 EA A21C02FREQ DET

504 0440 000. . . . . . CAP 10,000PF8KV 5%(293) . . . . . .. . . . . 0.0 EA A21C02 A21C05 FREQ DET

504 0441 000. . . . . . CAP 11,000PF8KV 5% (293) .. . . . . . . . .. 0.0 EA A21C02FREQ DET

504 0446 000. . . . . . CAP 12,000PF5KV 5% (293) .. . . . . . . . .. 0.0 EA A21C02FREQ DET

504 0447 000. . . . . . CAP 13,000PF5KV 5% (293) .. . . . . . . . .. 0.0 EA A21C02FREQ DET

504 0448 000. . . . . . CAP 16,000PF5KV 5% (293) .. . . . . . . . .. 0.0 EA A21C02FREQ DET

504 0449 000. . . . . . CAP 18,000PF5KV 5% (293) .. . . . . . . . .. 0.0 EA A21C02FREQ DET

504 0454 000. . . . . . CAP 1600PF15KV 5%(293).. . . . . . .. . . . 0.0 EA A21C03 A21C04 FREQ DET

504 0460 000. . . . . . CAP 1100PF20KV 5% (293). . . . . . . . . .. . 0.0 EA A21C03 FREQ DET

504 0461 000. . . . . . CAP 1300PF15KV 5%(293).. . . . . . .. . . . 0.0 EA A21C03 A21C04 FREQ DET

504 0462 000. . . . . . CAP 1800PF15KV 5%(293).. . . . . . .. . . . 0.0 EA A21C03 A21C04 FREQ DET

504 0463 000. . . . . . CAP 2200PF12KV 5%(293).. . . . . . .. . . . 0.0 EA A21C03 A21C04 FREQ DET

516 0204 000. . . . . . CAP, RF,100PF 5KV 10% N750. . . . . . . . . 0.0 EA A26C01 FREQ DET

516 0205 000. . . . . . *CAP, RF, 500PF 5KV20% X5T .. . . . . .. . 0.0 EA A26C01 FREQ DET

516 0207 000. . . . . . CAP, RF,25PF 15KV 10% NPO . . . . . . .. . 0.0 EA A21C01 FREQ DET

516 0208 000. . . . . . CAP, RF,50PF 15KV 10% NPO . . . . . . .. . 0.0 EA A21C01 FREQ DET

516 0209 000. . . . . . CAP, RF,100PF 15KV10% N750. . . . . . . . 0.0 EA A21C01FREQ DET

516 0819 000. . . . . . CAP, RF,200PF 5KV 10% N3300. . . . . . . . 0.0 EA A26C01 FREQ DET

8170914253...... STRAP,.020X1.0X6.4IN ............. 0.0EA

8170914254...... STRAP,A21L8TOL4................. 0.0EA

6-8 888-2314-001 Rev.AD1: 1/15/02

WARNING: Disconnect primary power prior to servicing.

Page 53

817 2131 016 .. . . . FREQ DET CHART,GATES FIVE. . . . . . . . 0.0 EA SEE THIS CHART FOR XMTR FREQ DET PARTS

8397920013..... FAMILYTREE,GATESSERIES......... 0.0EA

9172131036..... KIT,CEMOD,GATES5,1PH .......... 0.0EA

9298305546..... XFMRASSY,20TURN................ 0.0EA A26T01

9298305642..... XFMRASSY,17TURN................ 0.0EA A26T01

9298305643..... XFMRASSY,10TURN................ 0.0EA A26T01

9298305750..... XFMRASSY,10TURN................ 0.0EA

939 5695 332 .. . . . COIL, FIXED 20FC2243 . . . . .. . . . . . .. . . 0.0EA A21L08 FREQ DET

9397920102..... MOUNTINGADAPTER................ 0.0EA BOTTOMOUTPUTADAPTOR

9433777005..... COIL,FIXED45FC2046............... 0.0EA A21L1

9433777014..... COIL,FIXED13TURN................ 0.0EA A21L1

9882314004..... DPGATESFIVE1PH................. 1.0EA

9890092001..... PKGLISTG51PHVERT .............. 0.0EA

9890092002..... PKGLISTG51PHHORZ.............. 0.0EA

9901102001..... R-SK-GATESFIVE1PH............... 0.0EA

992 6414 001 .. . . . CRYSTAL SELECTION LIST .. . . .. . . . . . 0.0EA A16Y1 OSCIL 1 REQD A17Y1 OSCIL OPTION 1 REQD

9928146002..... OSCILLATORPKG................... 0.0EA A017OPTION

9949204001..... BASICGATESFIVE1PH.............. 1.0EA

9949238001..... R-BK-GATESSERIES ................ 0.0EA

9949241001..... R-PK-GATESFIVE................... 0.0EA

Table 6-10. BASIC GATES FIVE 1PH - 994 9204 001

Harris PN Description QTY UM Reference Designators (C)

9928143001..... BASICGATESSERIESXMTR.......... 1.0EA

9928149003..... GATESFIVEFINALPARTS............ 1.0EA

9928160001..... GATESFIVE1PHCONVPARTS........ 1.0EA

9992619001..... HARDWARELIST,BASIC,GATES...... 1.0EA

@T = GATES FIVE FINAL PARTS - 992 8149 003

Harris PN Description QTY UM Reference Designators (P)

3001981000..... SCR,3/8-24X1...................... 1.0EA

3570092000..... NUT,HEX1/4-20TEFLON............. 1.0EA A21L01

357 0093 000 .. . . . SCREW,1/4-20 X 7/8 FHMS . . . . .. . . . . . 1.0 EA A21L01

3980015000..... FUSE,FASTCART.500A250V ......... 2.0EA

3980016000..... FUSE,FASTCART.750A250V ......... 2.0EA

3980019000..... FUSE,FASTCART2A250V ........... 5.0EA

398 0081 000 .. . . . FUSE,SLOCART2A 250V. . . . . .. . . . . . . 1.0 EA

3980403000..... FUSE,RECTIFIER3A250V........... 10.0EA

3980435000..... FUSE,RECTIFIER5A250V............ 8.0EA

646 1353 000 .. . . . NAMEPLATE, XMTR EQUIPMENT . . . . . . 1.0 EA

8170914092..... SPACER........................... 1.0EA #A21C02

817 0914 195 .. . . . STANDOFF,INSULATED1.5LG . . . . . . . . 8.0EA #A21C01 #A21C03

8170914204..... STRAP,CAPTAPPING ............... 4.0EA #A26C01

8298305616..... STRAP,A26L2TOA26C1 ............. 1.0EA

8298305653..... STRAP,A21C4TERMINATION ......... 1.0EA

8298305690..... STRAP,A21C1TOL2................. 1.0EA #A21L02

8397920048..... STRAP............................. 1.0EA

9221256001..... PLATE............................. 1.0EA #A21C01

9221256003..... STRAP,L1TOC1.................... 1.0EA

9221294001..... PLATE,A21C1CONTACT............. 1.0EA #A21C01

9298305650..... STRAP,A21C4TOL7................. 1.0EA

9298305687..... BRACKET,CAPMTG................. 2.0EA #A21C03

9298305694..... STRAP,A2A1,TOA3A1............... 1.0EA #A02A01#A03A01

943 5450 475 .. . . . CBL,PA DRIVE COAX44" LG . . . . . . . . . . 4.0 EA

9947784002..... COILCLIP3/8RIBBON................ 1.0EA #A21L07

Rev.AD1: 1/15/02 888-2314-001 6-9

WARNING: Disconnect primary power prior to servicing.

Page 54

9947784003...... COILCLIP1/2RIBBON................ 1.0EA #A21L01

Table 6-11. GATES FIVE 1PH CONV PARTS - 992 8160 001

Harris PN Description QTY UM Reference Designators (AZ)

3570092000...... NUT,HEX1/4-20TEFLON ............. 1.0EA

3580003000...... BRACKETRESISTORMTG............ 4.0EA #A19R2

3580004000...... BRACKETRESISTORMTG............ 4.0EA #A19R22

3582492000...... PLUG,SNAP-IN2-1/2DHOL........... 1.0EA

3582511000...... STANDOFF,10-32X3/4............... 1.0EA

3582555000...... BUSHING,FLANGED.375ID........... 2.0EA

3582588000...... FLATCABLEMOUNT................. 2.0EA

3582635000...... CABLETIE,PUSHMOUNTSNAPIN..... 4.0EA

516 0413 000. . . .. . CAP, RF,10PF 7.5KV 10% NPO. . . .. . . . . 1.0 EA A18C1

524 0341 000. . . . . . CAP 5100UF 350WVDC.. . . . . . . . .. . . . . 5.0 EA A19C2 A19C4 A19C6

542 0103 000. . . . . . RES 20KOHM 5%12W. . . . . . . . . . . . . . . . 3.0 EA A19R12 A19R14 A19R16

5420358000...... RES500OHM5%225W............... 1.0EA A19R22

5421586000...... RES2.0OHM180W10% .............. 1.0EA A19R2

6140158000...... TERMSTRIP2TERM................. 1.0EA TS002

6200831000...... TADAPTERBNCUG-274A/U........... 1.0EA J002

6201906000...... ENDTERM,7/8EIAFLANGE........... 1.0EA J001

632 1151 000. . . . . . AMMETER, 0-80ADC, 4.5",[W] . . . . . . . . . . 1.0 EA M003

632 1157 000. . . .. . WATTMETER, 0-10KW,4.5",[W].. . . . . . . . 1.0 EA M004

8135001068...... STDOFF10-32X13/8HEX............. 2.0EA

8135007026...... STDOFF6-32X1/21/4DIA.............. 1.0EA

8170914260...... INSULATOR,1/4-20X1.7L ............ 2.0EA

8170914350...... STANDOFF,PAGROUND ............. 1.0EA

8220981009...... MULTIMETERSWPLT................ 1.0EA

8298305623...... RETAINER,CABLE................... 1.0EA

8397920103...... ASSYINSTR,MODCOIL .............. 0.0EA

9170914223...... XFMR,PHASEANGLE63T............. 1.0EA A18T1

9170914250...... RES,METERINGSHUNT.............. 1.0EA A19R6

9172131008...... PHASEANGLEXFMR................. 1.0EA A18T2

9172244001...... SPACER,1.0LG.75DIA............... 1.0EA

9172256074...... ASSY,TERMBLK,GATES5,1PH....... 1.0EA

9220981080...... SHUNT............................. 1.0EA A19R7

9220981081...... SHUNT............................. 1.0EA A19R7

9298305089...... CLAMPADJ......................... 6.0EA

9298305285...... STANDOFF10-32X0.75............... 2.0EA

9298305293...... BRACKET,SX-2.5CAP................ 2.0EA

9298305732...... XFMR,IPANEUTRALIZER............. 1.0EA A26T2

9397920018...... METERTRIM........................ 1.0EA

9398187001...... INSULATOR,PAMODULE............. 4.0EA

9433655079...... HEATSINK,PDMAMP................ 1.0EA

9433655196...... HEATSINK,PA....................... 3.0EA

943 5479 026. . . .. . PANEL, REAR ACCESS, GATES FIVE. . . . 1.0 EA

9925868008...... PWA,PATOROID ESDSAFE......... 3.0EA A2A1A3A1A4A1

9925872005...... *PDMAMPBOARD*................. 2.0EA A008A009

9925872007...... *PDMPULLUPBOARD*.............. 4.0EA A6A1A7A1A8A1A9A1

9925874009...... PWA,PDMFILTER ESDSAFE....... 2.0EA A010A011

9928291001...... GATESFIVE1PHUNIQUEPTS......... 1.0EA

9929714001...... PWA,PAMODULE ................... 3.0EA

6-10 888-2314-001 Rev.AD1: 1/15/02

WARNING: Disconnect primary power prior to servicing.

Page 55

Table 6-12. GATES FIVE 1PH UNIQUE PTS - 992 8291 001

Harris PN Description QTY UM Reference Designators (E)

335 0256 000 .. . . . WASHER, SHOULDER .765 ID . . . . . . . . . 4.0 EA

3350257000..... WASHER,KAPTON.687/1.625......... 4.0EA

384 0839 000 .. . . . RECT 1000PIV 275A 1N4056 ESD . . . . . . 4.0 EA

4721649000..... XFMR,PWR,829-8305-735............ 1.0EA

8170914101..... STANDOFF,HVRECT................ 2.0EA

817 0914 195 . . . . . STANDOFF, INSULATED 1.5LG . . . . . . . . 3.0 EA

8298305389..... BRACKET,RECTIFIER................ 1.0EA

9298305395..... BRKT,HVRECT .................... 1.0EA

9928229001..... CBLPKGGATESFIVE1PH............ 1.0EA

Table 6-13. GATES FIVE, 3PH - 994 9205 002

Harris PN Description QTY UM Reference Designators (M)

494 0378 000 .. . . . CHOKE0.33UH 10% 780MA . . . . . .. . . . . 0.0EA A01L14 A01L15 A01L24 A01L25 A01L34 A01L35A01L44 A01L45

A02L14 A02L15 A02L24 A02L25 A02L34A02L35 A02L44A02L45 A03L14 A03L15 A03L24 A03L25 A03L34A03L35 A03L44A03L45 A04L14 A04L15 A04L24 A04L25 A04L34A04L35 A04L44A04L45 FREQ DET

4940399000..... CHOKERF12.0UH................... 0.0EA A18A1L3FREQDET

494 0401 000 .. . . . CHOKERF18.0UH. . . . . . . . . . . . . .. . . . . 0.0EA A18A1L2 A18A1L3FREQ DET

500 0755 000 .. . . . CAP,MICA, 270PF 500V 5% . .. . . . . . . . . 0.0 EA A18A1C10FREQ DET

500 0835 000 .. . . . CAP,MICA, 470PF 500V 5% . .. . . . . . . . . 0.0 EA A18A1C10FREQ DET

5000841000..... CAP,750PF300V5%................. 0.0EA A18A1C10FREQDET

500 0844 000 .. . . . CAP,MICA, 1000PF 100V 5% . . . . . . . . . . 0.0 EA A18A1C10 FREQ DET

500 0883 000 .. . . . CAP,MICA, 4700PF 500V 5% . . . .. . . . . . 0.0 EA A01C10 A01C15A01C20 A01C25A01C30 A01C35 A01C40 A01C45

A02C10A02C15 A02C20 A02C25 A02C30 A02C35A02C40 A02C45 A03C10A03C15 A03C20 A03C25 A03C30 A03C35A03C40 A03C45 A04C10A04C15 A04C20 A04C25 A04C30 A04C35A04C40 A04C45

FREQ DET

504 0258 000 .. . . . CAP1000PF20KV 5% (293) . . . . . . . . . . . 0.0 EA A21C03 FREQ DET

504 0353 000 .. . . . CAP3000PF 12KV 5% (293) . . . . .. . . . . . 0.0 EA A21C02 A21C03A21C04 FREQ DET

504 0354 000 .. . . . CAP5100PF10KV 5% (293) . . . . . . . . . . . 0.0 EA A21C02 FREQ DET

504 0374 000 .. . . . CAP2000PF 15KV 5% (293) . . . . .. . . . . . 0.0 EA A21C03 A21C04FREQ DET

504 0377 000 .. . . . CAP1500PF 15KV 5% (293) . . . . .. . . . . . 0.0 EA A21C03 A21C04FREQ DET

504 0378 000 .. . . . CAP1200PF 15KV 5% (293) . . . . .. . . . . . 0.0 EA A21C03 A21C04FREQ DET

504 0382 000 .. . . . CAP2400PF 12KV 5% (293) . . . . .. . . . . . 0.0 EA A21C03 A21C04FREQ DET

504 0417 000 .. . . . CAP910PF 20KV 5% (293) . . .. . . . . . . . . 0.0 EA A21C03FREQ DET

504 0418 000 .. . . . CAP 2700 PF 12KV 5% (293) . . . . . . . .. . . 0.0EA A21C03 A21C04 FREQ DET

504 0419 000 .. . . . CAP3300 PF 12KV 5% (293). .. . . . . . . . . 0.0 EA A21C04 FREQ DET

504 0420 000 .. . . . CAP 3900 PF 12KV 5% (293) . . . . . . . .. . . 0.0EA A21C02 A21C04 FREQ DET

504 0433 000 .. . . . CAP3600PF 12KV 5% (293) . . . . .. . . . . . 0.0 EA A21C02 A21C04FREQ DET

504 0435 000 .. . . . CAP5600PF10KV 5% (293) . . . . . . . . . . . 0.0 EA A21C02 FREQ DET

504 0439 000 .. . . . CAP9100PF8KV 5% (293) . . . . . . . . . . . . 0.0EA A21C02 FREQ DET

504 0440 000 .. . . . CAP10,000PF 8KV 5% (293) . . . . .. . . . . . 0.0 EA A21C02 A21C05FREQ DET

504 0441 000 .. . . . CAP11,000PF8KV 5% (293) . . . . . . .. . . . 0.0 EA A21C02 FREQ DET

504 0446 000 .. . . . CAP12,000PF5KV 5% (293) . . . . . . .. . . . 0.0 EA A21C02 FREQ DET

504 0447 000 .. . . . CAP13,000PF5KV 5% (293) . . . . . . .. . . . 0.0 EA A21C02 FREQ DET

504 0448 000 .. . . . CAP16,000PF5KV 5% (293) . . . . . . .. . . . 0.0 EA A21C02 FREQ DET

504 0449 000 .. . . . CAP18,000PF5KV 5% (293) . . . . . . .. . . . 0.0 EA A21C02 FREQ DET

504 0454 000 .. . . . CAP1600PF 15KV 5% (293) . . . . .. . . . . . 0.0 EA A21C03 A21C04FREQ DET

504 0460 000 .. . . . CAP1100PF20KV 5% (293) . . . . . . . . . . . 0.0 EA A21C03 FREQ DET

504 0461 000 .. . . . CAP1300PF 15KV 5% (293) . . . . .. . . . . . 0.0 EA A21C03 A21C04FREQ DET

Rev.AD1: 1/15/02 888-2314-001 6-11

WARNING: Disconnect primary power prior to servicing.

Page 56