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Users Manual Model HL-1.5KFX

1. oa T AC POWER 675 SCALER Sage ete PRI MARY TERM NAL IO PO ER TRANSFORVER FAN SPEED NTA 37 LPF 1681 POLESZ POWER X FORMER PRIMARV TERMINAL TA PA 1662 MAIN POWER X FORMER DC DC CONVERTER FOR 24V FAN 501830 SUB POWER SUPPLY MAIN CONTROL 51699 FILTER CAPACITOR 68 000 u METER FAN AC IN MAIN POWER SUB DC 18110 X FORMER POWER SUPPLV 27 2006 51699 38 MAIN CONTROL FRONT VIEW PCS1699 VR6 A D VREF JUP VR3 vri VR5 TXLEVELADJ PRSCALEADJ PFSCALEADJ ID SCALE ADJ KEN C Lo MAIN CONTROL PCS1699 TOP VIEW VEN FUSE F1 F2 2A x2 A SOMFiz PFADJ DN JUP MAIN CONTROL PCS1699 BOTTOM VIEW POTENTION METERS ON BOTTOM SIDE PCS 1699
2. ALC mie 0 65175 PESI so STBY 1 5 4 3 2 1 5 5 ICOM SELECT 5512 05 0 JACK 2 1 J9 1 1007 24 3 1 50 1007 24 5 KENWOOD 81675 7 PreScaler JA ANT B Hi M J al 1007 24 15 CNT LED D SUB 9 0 1007 24 15 BAND OUT 38 CIRDIN 8 R PCS1669 YAESU 1007 24 5 MTR SEL sw4 DS 850S F2 00 K ANT A 1007 24 4 SWUpDn Fron OPR 20 oi M J 6 1007 24 6 pec Panel KO gt 503 rreo our 1507 L 51 1007 24 5 OHD3 70M 1007 24 6 5 51699 OPSW PC1667 Control INPUT RF SW DEL MA J2 Detector OHD3 40M 1007 24 2 1007 24 4 TR ALC BAND OUT 411 15702 Ur 10072477 ALC VR BAND OUT TUNER 1 50 QEV 1007424 3 VI IN
3. 4 RB7 KBI3 PGD 22 gt 1 1 5 2 RC5 SDO RPE104 LS RC4 SDIISDA CSA RC3ISCKISCL 75 1 RO2 CCP1 gt RJAJBAQ 5 4 RJG LB PIC18F8722 avn SELECT our LIBIHNI gt gt gt gt FUSELL gt RN1201 1 70 ON AIR 5V 70 JIT 70 70 70 70 70 370 PR 70 ANTE FN B15B EH D PCS1699 Main Control Document Number lt Doc gt Monday November 26 2007 4504 TMP J01X V6 BNC 1W 1501 470uH 20 0501 1 2076 6502 C503 1S2076A 120p 150p 7 C C501 RPE103 C519 SHORT FB501 ZJSR5101 222 01 502 ZJSR5101 222 01 4506 f ZJSR5101 222 0 6 1 ZJSR5101 222 01 Ki 6 8 505 515 21585101 222 01 B9B EH 100 L ZJSR5101 222 01 0504 57 91502 0506 28507 WZ 233 2 DK1aib 152076 ZJSR5101 222 01 4 0504 1 2 7 516 517 518 129 24 LED 2 GND 02 Y
4. Transceiver 00 13 9 Band Data Cable Connection Connection methods with ICOM Yaesu and Kenwood transceivers are described here in detail respectively This connection enables the automatic band setting of the amplifier with the band set command from the transceiver Four types of cable connections are explained 9 1 ICOM DC Voltage Band Data For your safety please turn off the power AC to both the transceiver and amplifier Connect the cable for ICOM DC Voltage Band Data Connection as shown in the following illustration Slide the BAND DECODE slide switch on the rear panel toward ICOM Other side is for Cl V Set the BAND SELECT rotary switch on the front panel to ICOM Now turn on the AC to the transceiver and then turn the POWER switch to the amplifier on Observe that the band indicator LED of the amplifier matches that of the transceiver DIN PLUG 7P RCA PLUG ICOM DC Voltage Band Data Cable lt TRANSCEIVER 16 146 756 7800 etc SWR POWER METER WY 20715 ANT 580 2 REMOTE DIN ICOM DC VOLTAGE BAND DATA CABLE DIN HL 1 5KFX REAR VIEW ANT A ALC INPUT A BAND DECODE SW SELECT This connection is for IC
5. gt gt R227 0204 RAX 502933 1210 LN R226 10k 207 9211 7 1805W 212 212 Cip 1201 225 9203 DS1E M DC12V 502933 R224 10k 7 204 100 10W V7 R223 125w J201 F201 R210 2204 2205 TMP JO1X V6 R205 100 10W LM 101A 30 10W TMP JOIX V6 TMP 01 5 5 Ce 2 KI R206 10010 R207 R208 301 10W 301 10W WY R203 AWZ 7 50 10W WW R202 50 10W 202 R201 50 10W C201 3 34 25 R217 R234 C226 120 1W 104 VOUT 8 cata 2205W 0 1u 0 1ux2 5 8 H B8B EH 7 5202 3206 70 0 01 4 5201 40 C EX 0 01 202 7 5 5 5 2 5 2 F203 20 lt 22 0 1ux2 231 ff 47 TLP521 1 C237 0 01u 2 235 Chip 202 BNC T203 D12A 1 3 SZ SZ A it C230 Bottom Sid lt 01 1662 Document Number lt Doc gt Date Friday July 13 2007 Bheet 1 of 1 L302 1390pF 2560 1220 3 2 7130 2 1 2PEW 191 Ti 9 2 106 2 1 2PEW 181 5 E 884 Ez Ti LE 14444 4 3 UCSS 102 1k A3 5 UC55 82pF 1K 1305 01 40007 0102 2 8108 0103 103 04 43
6. D Overdrive 0 Decrease the drive Check ALC setting 2 RF leakage from coax cable grounding wire AC power cord etc 2 Insert common mode filters on antenna cable or AC line Add clamp on ferrite cores TDK Amidon Palomar on various cables 24 APPENDIX Auto Band Set Compatibility Tokyo Hy Power HL 1 5KFX For Major Brand Radios 1 ICOM ICOM CI V According to any radio model manufactured 1987 or thereafter is equipped with Cl V Consequently most of ICOM s owned by the user now work Auto Band Set through Cl V ICOM DC VOLTAGE BAND DATA Following models are equipped with DIN sockets to supply HL 1 5KFX with DC voltage band data as well as Cl V 736 746 756 756Pro 756Proll 756Prolll 7400 7750 Il 780 7700 7800 IC 706MK series and 7000 need modification for DC VOLTAGE BAND DATA CABLE connector See ICOM manual 2 YAESU Binary Coded Voltage FT 920 1000D 1000MP 1000MP 2000 DX9000 FT 857D and 897D need modified special Yaesu Band Data Cable and or Cable Adaptor Contact HRO or Tokyo Hy Power Head Office Japan For FT 450 and 950 users special band cable YBC 1 5K 950 is available from HRO 3 KENWOOD RS 232C Serial Data To our regret there are only three models available that has RS 232C port Kenwood says old popular models such as TS 950 940 are not equipped with these features TS 870S TS 480 TS 2000 Some Kenwood owners may
7. TO BE MADE FROM FRONT SUB PANEL 39 PA PC1662V FUSE F201 BIAS REF FET BIAS ADJ 4 VR201 204 LPF PC1681 TOP VIEW _ AED um U We CT 2 A aw 4 40 POWER DETECTOR 1667 503 TX ADJ PRESCALER PC1675 RF SIGNAL IN 116 FREQ OUT FAN SPEED CONTROL UNIT 501830 41 1 5KFX REAR PANEL CONNECT 54321 9876 BAND BAND BAND BAND TUNER Not used H2V Qutput AD Not used 12V Qutput EVENT Not used TX2 Not used RX2 FREQ Rear vi ew 42 51699 12 EEEE PCS1699 19 YAESU YAESU YAESU 51699 28 H2V OO WU 4 15 Parts Layout 15 1 Top View Detailed AC POWER CONTROL 1662 2 POWER POWER TRANSFORMER 21 501830 FAN SPEED CONTROL 68000uF FILTER CAPAC I TOR Aux FUSE For EXTERNAL FAN FRON TPANEL 37 POWER DET
8. Top Bottom 39 LPF amp Bottom 22 40 RF Power Detector Pre scaler Fan Speed Control Unit Surge Absorber Unit 41 Rear Panel Connector Connections 42 34 36 42 1 Introduction Thank you for purchasing the HL 1 5KFX This compact and lightweight desktop HF 50MHz linear power amplifier has a maximum input power of 1 75kW Our solid state broadband power amp technology makes it the smallest and lightest in the industry Typical output power is 1KW PEP SSB HF and 650W on band with the drive power of 85 90W The built in band decoder will let you forget about the band setting when the amplifier is connected to your modern radio through such band data cables as ICOM Cl V DC voltage ICOM Yaesu RS 232C Kenwood See the Appendix page 26 for the list of the recommended radios All the data cables are included in your amplifier for your convenience 2 Cautions 2 1 Unpacking the amplifier check the fan guard net at the rear panel to see if there is any damage caused by the physical shock during the transportation The amplifier is cooled by forced airflow Several inches of clearance on the top and the rear wall are necessary to allow for smooth air intake into the fan Do not block the air vents on the top cover 2 2 Keep the amplifier out of direct sunlight in a cool dry environment 2 3 Internal high voltages AC DC and RF are present at all times ON AIR or OFF Internal
9. Two Antenna System Example RANSCE I VER 50MHz ANTENNA SWR SWR POWER METER HF ANTENNA gt TO AC200V 100V PLUG 10 7 1 Connect cord and coax cables as illustrated above Connect cable from to the remote terminals of transceiver where it is marked SEND or TX GND These terminal pins are shorted to ground when the transceiver is in TX ON AIR mode If these connections are not made the amplifier will not go into TX amplification mode For a temporary check to the amp ground the STBY center pin by inserting an RCA plug whose center pin has been soldered to the outer case of the plug with a small piece of wire As a side note this STBY terminal is pulled up to a DC 5V level that is connected to a internal microprocessor pin When grounded DC sink current of 1 mA only will flow The transceiver s control circuit is under a very light load 7 2 At first turn the ALC knob full clockwise to avoid ALC voltage to the transceiver Application of ALC will be covered in the following section 8 7 3 Keeping the POWER AC mains switch off check the SWR of your antenna by keying the transceiver to TX mode CW or RTTY mode Monitor the SWR with an external SWR Power meter If SWR is 1 8 or higher at band center the antenna has to be adjusted for lower SWR As an alternativ
10. circuit of the transceiver for the amplifier to be keyed The DC current flowing into your radio to key the amplifier to transmit is as low as 5V 1mA RCA Jack for ALC Voltage Output Negative DC voltage appears at the center pin which is fed back to the ALC terminal of the transceiver ALC is used to keep the amplifier output power at certain limits Also it is useful when the transceiver output power is higher than 100W See page 13 8 ALC Connection Also consult your HF transceiver s user manual Potentiometer to adjust ALC voltage level Minus 10V is available at maximum when turned full counter clockwise Factory setting is 0 volts with the pot turned full clockwise A pair of fuses for AC Mains 15 glass fuse Change to 25 fuses if 115V line voltage is selected Cl V Jack for the DC voltage derived band data cable from the ICOM transceiver Reference page 14 Band Data Cable Connection with ICOM Earphone jack for band data cable for ICOM transceivers so equipped See page 15 BAND DECODE D TUNER YAESU 05 KENWOOD Slide switch to select band data communication method with ICOM transceivers This selects either DC voltage band data or CI V band data DIN Socket for External Auto Antenna Tuner DIN Socket for band data cable from the Yaesu transceiver See page 16 D Sub 9 pin socket for band data cable for Kenwood transceivers RS 232C See page 17 EX
11. into the neighborhood The ALC is effective in preventing the output signal from being distorted or to limit the carrier level to within rated output levels As long as you do not overdrive you can disregard the ALC connection See Section 8 ALC CONNECTION for details 7 7 Protection circuits may work during operation depending on the conditions If the protection circuit 11 has shut down amplifier check the antenna SWR Vd line voltage try to reduce the drive level To reset turn off the POWER switch once then back on again The power transformer has an overheat protection in the coil layer If this temperature switch activates the amplifier will put you in receive mode with the cooling fan operating until the transformer has cooled off It may take ten to fifteen minutes to cool depending upon room temperature For more details on this protection circuit see Section 10 12 8 ALC Connection ALC voltage is available at the terminal marked ALC RCA phono jack on the right upper corner of the rear panel Negative maximum DC voltage of ten volts 10V is produced at this terminal when the amplifier is fully driven This voltage is adjustable with the ALC ADJ knob located above the ALC jack If the ALC voltage is properly fed back to the transceiver we advised you to keep the maximum output power constant or hold the power at a certain level Also ALC is useful in avoiding your SSB signal from being distorted when ove
12. of fan and which LED get lit are all performed by the MPU on this board METER SW METER WARNING FORWARD 6 11 0 DIRVE 0 HEAT 7 0 VOLT REFLECT H FUSE 2 3 MPU 1 18 8722 VD o ONAIR 47 FAN a 10 FAN High Low PA CONT ANT LT 1 1 AN ANT RY STBY ALC AMP i ALC ALC ADJ 22 11 5 Band Decoder Frequency Counter The band decoder will decode the various operating band information as issued by the major brands of the radios ICOM Yaesu Kenwood Using the decoded signal the amplifier will automatically determine the frequency band of the radio From these three manufacturers there are four kinds of band data used in their latest radio models DC voltage 4 bit TTL RS 232C and serial data The HL 1 5KFX is designed to be able to use any of these methods when the matched cable is connected The MPU also performs a frequency counting function The RF drive signal from the transceiver is sampled and divided by 16 PC1675 this signal is then sent to the input of the MPU In the manual band select mode if the frequency of the RF drive and band setting of the amplifier do not match each other the MPU will send a band miss set signal which will force an amplification halt command shut down Additionally any RF measured between 26 0 28 0 MHz will immediately shut down amplifier operation ICOM YAESU BAND SELECT KENWOOD MANUAL ICOM BAND DEC
13. push pull Forced Air Cooling PIC 18F8722 Output Power Pf 1kW Reflected Power Pr 100W Drain Voltage Vd 60V Drain Current Id 50A UHF SO 239 with low loss Teflon insulator AC 230V 200 220 240V 10A max AC 115V 100 110 120V 20A max 1 max when 272 x 142 x 363 mm WxHxD 10 7 x 5 6 x 14 3 inches Approx 20kgs 45 5lbs AC Power Cord x1 RCA Plug x2 Band Decoder Cable x5 Spare Fuse 15 for AC 230 line x2 Spare Fuse 25A for AC 115V line x2 Spare Fuse 2 Miniature Fuse x 2 For PCS1669 main control board x 2 Spare Fuse 2A Miniature Fuse 2 For PCSO1830 Fan Speed Control Unit x 1 PC1662V power amp board 1 Users Manual x 1 Auto Antenna Tuner HC 1 5KAT External Cooling Fan HXT 1 5KF for high duty cycle RTTY 5 5 1 Although the amplifier is designed to work with both 115V 100 120 and 230V 200 240V for stability we recommend operation from AC 230V 5 2 The correct AC plug not included in the package must be obtained locally due to the AC plug variations worldwide 5 3 The AC voltage has been factory preset for 230V use or as requested by the customer at the time of order If you wish to change to AC 115V change the voltage setting by sliding the switch knob located on the chassis bottom as illustrated below See the other illustration for AC voltages other than 230 115V For your safety before making these adjustments be sure to p
14. temperature reaches 70 deg C the LED lights to indicate the protection circuit has worked It is necessary for the cooling fan to operate for several minutes to cool the PA module LED lights when the 20A glass fuse has blown from excessive Id Two 20A fuses are on the PC1622V PA board LED lights when reflected power from antenna exceeds 80W to indicate protection circuit has worked Turning the main POWER switch to off and then on again can reset the Protection Circuits One of the green LED lights will indicate which band is selected for operation Pf Forward output power Pr Reflected power from antenna Vd FET drain voltage and Id FET drain current are shown on the scale as selected by 3 METER select switch 6 B Rear Panel Description D ANT 2 3 INPUT 4 5 STBV ALC ALC ADJ FUSE ah RF Output Connector Connect the coax cable to the antenna RF Output Connector Connect the coax cable to a second antenna or a dummy load 50 1kW for example RF Input Connector Connect the coax jumper cable from the transceiver AC Mains Socket Socket for the AC power cord Socket is EMI filtered Ground Terminal RCA Jack Connect the control cable from the ACC terminal or SEND TX GND etc of the transceiver The center pin is to be shorted to ground through the relay
15. 04 0105 6105 Css _ 4 5 3 5 1520 168 21Mi g 14 2 8 0 Header 10p 150 ES 3279P 150 Ti 83 5 11 E B Se 77 DRE LE 150 100 62 24 L312 4411 1 6AT Bt 811 1 6AT 7t 24 28 7 E a StrayCapacit Sira ue sig b 19pF 33pF d 11 1 6 71 4 11 1 6 61 G2R 1 12V0C 21 35pF A G2R 1 12VDC 3 somis SO Hz i 2 5 53 8 48 5416 5478 75 ae eae mem 4 C172 ucss 55 22 9 a KA CH1 LCD RW 82 lt TLep RS 19 RHO A16 RETWRADS 2 5 10 8 11 a RE4 AD12 9 SWB PGD RG1 TX2 CK2 RES5 AD13 lt _ 4 SWA PGC RG2 RX2 DT2 RE6 AD14 ROGPSPOADO 4 1 MCLRIVE 10 VDD vss VDO__ RDUPSPI AD1 RPE104 7 55 2 02 5 2 RD3 PSP3 AD3 RFZ ANTICIQUT RD7 PSP7 AD7 7 15 RJOALE RHO AN14 RIVOE RJ2WRE RJAWRH RSMINTI 2 2 2 RB4 KBIO ISWANT TRIN RB6 KBI2 PGC 5 VSS OSC2 CLKO RAS OSCH CLKI RAS ANA LVDIN
16. 10074249 AN1 CNT 1547 CIRDIN_7 R PC1662V ICSP DEC c 3D2V POWER Temp SW U3 7 0808 51681 SWUpDn YAESU AMP CONTROL PW OP ATT SW 3D2V 1 5D QEV METER 1007 24 2 304 LPF 9 4 METER 1 5D QEV MTR SEL 15 1 50 QEV GND 1007 24 10 3 7 sw1 a F 70 10A 20A V 21 3CR6 1015 14w to g 1007 2473 ON prong 02 kK gt ACIIN POWER 1007 24 2 2 4 GND F 70 10 20 IDV AC15V 1007424543 1015 14w 100742444 ANA 10158148 1007 24 2 A SHORT 100742447 B 1015 16w 15 1007 24 5 51750 1015 22 Ph 150 d 5 1 lt 23 oto IS lt DE a 100742453 9 9 VR1 5 led 8 RV16YN15SB BWS12SX U ALC ADJ SUB 1015 22 VDD 1015 16r 2 sw3 04 POWER DS 850S F2 00 K POWER GND 1015 16bk 2 VDD 100742442 200 as VDD GND 50183 1007 501830 2 FAN 2007 FAN SPEED 4 1007 850 60 CONTROL SW2 1007 4 5 876 1015 16br VDD 115 220V 5 8 07 3 5 1015 16 C1 63V68000u 1007 10158160 R1 15 60 ov 1 Title 1015 16y 1015411 2 HL 1 5KFX BLOCK DIAGRAM L1125 PT B Ley Size Document Number ev IDV A3 5D2801SS TOKYO HY POWER LABS INC 13 ate Thursday December 17 2009 of 1 15 Parts Layout 15 1 Top View Detailed NG
17. ECTOR 1681 f PRIMARY TERMINAL 1682 MAIN POWER X FORMER DC DC CONVERTER FOR 24V FAN 501830 SUB DC POWER SUPPLY METER MAIN CONTROL 81699 FILTER CAPACITOR 68 000 u F METER FAN 4 nd 7 __ gt MAINPOWER 30806 161106 X FORMER POWER SUPPLY 2081089 RF POWER _ 4 1667 38 MAIN CONTROL FRONT VIEW PCS1699 __VR3 VR2 LU TX LEVELADJ PR SCALE ADJ PF SCALE ADJ ID SCALE ADJ JIEN C Lo Hi C Lo Hi C Lo Hi Lo CONTROL 5 1688 VIEW ners FUSE F1 F2 2A x 2 s _ Re _ PURE DM JUP JUF CONTROL PCS1698 BOTTOM VIEW WR POTEN TION METERS ON BOTTOM SIDE B E 1899 MADE ACCESS FROM FRONT SUB PANEL 39 4202 1662 2201 VR205 FUSE F201 BIAS REF 4 TOL Le 204 2 FET BIAS ADJ 4 VR201 204 LPF 1681 VIEW OUTPUT X 40 1667 PEAR 501 TX ADJ PRESCALER PC1675 9 1 16 FREQ OUT SIGNAL SPEED CONTROL UNIT PCSO1830 41 HL 1 5KFX REAR PANEL C
18. Fan Speed Control Curcuit DRAWING_No 1 00 HL 1 5KFX TOKYO HY POWER PCSO1830 SHEET DATE DESIGN 26 Nov 2009 Shigetaro Suzuki 1201 96 G3VM 351A 15522 104 U1__NJM78L05 SM C2 1Qu 25V 2 VOUT 5 51750 Document Number A4 lt Doc gt Date ONAIR ONAIR ANT SEL PC1665 DETECTOR INPUT INPUT DET 2 1520764 Persie PRESCALER 78051 1 LIMITER ANT A 12V PC1662V POWER AMP ji 1 9MHz LPF LPF Sia 7 10MHz LPF 14MHz LPF mile 70 9 40 H SD CNDC24B7V PER SN SUB POWER BWS12SX U MAIN DIODE LINE FIL SSR X FORMER BRIDGE PC1611DC S50VB60 AC POWER TOKYO HY POWER MODEL AL 5K 501830 FAN SPEED CONT DCDC 53V BLOCK DIAGRAM 15 60mV ALC ADJ af 1 4 June 14 711 1669 FRONT PANEL PCS1699 MAIN CONTROL 152076 TL431 8 21 4 28 000000008 c 5 UE U BAND CT SW c DRIVE VOLT FUSE 00000 im 008 gt gt m c 000
19. ODE BAND AMP Gl V ICOM 2 RX RX KENWOOD 9 MAX1406 TX TX 18 21MHz LP 24 28MHz LP MPU PIC18F8722 BAND DATA lt m 0000 f IMH 1 16 f 16 MH TX POWER Law Ter ae 12 Trouble Shooting Failure Possible Cause Solution mains not AC fuses blown 0 Replace with new ones operating 2 cord not plugged in Plug in securely 8 Interlock switch lifting 8 Screw bolts tightly on the top cover 0 Wrong tap used 4 Correct primary wiring power transformer primary Can t enter D Remote control cable Check the cable and connect properly Transmit mode not connected Protection circuits on 2 Check drive power antenna SWR antenna selector A B Reset with AC POWER switch O Drive lights RF overdrive 1 Decrease drive 3 Band miss set 2 Match the BAND correctly Manual mode PR lights 0 Reflected power high Check adjust antenna Or decrease drive Antenna SWR high Poor connection to 2 Check the coax cable connectors coax cables FUSE lights 2 Fuse blown Replace F202 and F203 20A on the PA board PC1662V 2 Antenna SWR high 2 Adjust the antenna 9 Short circuit 8 Contact the distributor or service center O Heat lights Internal Temperature 0 Cool off until LED turns off Check for air intake above 70deg blockages Also check air vent on top cover TVI FMI
20. OM models of 746 756 7800 etc 706 7000 need special connection to the ACC socket using the ICOM supplied accessory cable assembly See the 706 7000 manual IC 7700 is to be connected to CI V terminal 14 9 2 The following initial settings are needed on the ICOM transceiver CI V BAUDT RATE 9600 CI V ADDRESS 5 TRANSCEIVER with 731 OFF For details refer to your radio manual Turn off the power to both the transceiver and amplifier Connect the following band data cable as shown in the illustration Slide the BAND DECODE switch knob to side BAND SELECT rotary switch on the front panel should be set to the ICOM position Make sure the transceiver is in receive mode Turn on the POWER switches to the transceiver and the amplifier Observe that the band indicator LED of the amplifier matches that of the transceiver CI V Band Data Cable 93 5 PLUG 5 0 TRANSCEIVER WY SWR POWER METER 2071 ANT ACC 2 REMOTE ICOM CI V BAND DATA CABLE HL 1 5KFX REAR VIEW 9 4 9 ALC l V INPUT N N DECODE SW SELECT 15 9 3 Yaesu Band Data Using the Yaesu band data connection cabl
21. ONNECTOR CONNECTIONS KENWOOD 94321 00000 9876 Rear view Rear view KENWOOD O1 YAESU 4 BAND DATA BAND DATA B BAND DATA BAND DATA D GND TUNER SNOOP Not used TX2 Not used RX2 FREQ Not used 12V Output GND Not used 12V Output EVENT 42 PCS1699 J12 RX TX CTS RTS GND gt ND PCS1699 J19 YAESU YAESU YAESU YAESU GND O1 gt PCS1699 J28 12V GND 12V EVENT RX2 PWM 00
22. SB modes Optional Fan Kit recommended 2 14 To prevent damage to the precision electronic components avoid extreme physical shock to the amplifier If factory service is required the amplifier MUST be shipped using the original box and packaging materials 3 Features 3 1 Our solid state broadband design engineers worked to make the HL 1 5KFX the lightest and most compact 1kW HF amplifier in the industry This world class compact 1kW HF 6m amplifier is the easiest to handle and operate 3 2 The amplifier is equipped with a newly developed band decoder The amplifiers decoder changes bands automatically as the data signal is received from the associated HF transceiver s frequency bands 3 3 The amplifiers main PA section includes 4 high power MOS FET 02933 THP2933 resulting in 1kW PEP SSB max on HF and 650W on 6m The amplifier s broadband characteristics require no further tuning once the operating band is selected 3 4 The amplifier allows operation in full break in CW mode due to the use of the amplifier s high speed antenna relays made by Panasonic Matsushita 3 5 With the unique duct structure design and the powerful blower fan the aluminum heat sink block for RF PA module and other components are effectively cooled The fan s quiet operation allows for even the weakest DX signals to be heard 3 6 The amp utilizes an advanced 16 bit MPU microprocessor to run the various high speed protection circuits s
23. TERNAL FAN POWER Plastic Female Connector for DC power supply cable to feed the optional external cooling fan kit HXT 1 5KF 6 C Chassis Bottom Description 115 220V Slide switch to select AC line voltage Set to 220V for 200 220 230 240V 2 FUSE Set at 115V for 100 110 115 120V lines Fuse socket for the External Cooling Fan Unit HXT 1 5KF When the optional fan is installed on top of the cover a 1A glass fuse is recommended 7 Connection 4 Operation This section explains system or two antenna system with basic connections to transceiver where no band data cable is connected In this case band setting is made with MANUAL mode pushing UP DOWN keys Advanced operation using the band data cable is described in Section 9 CAUTION Under the Manual Band Set operation always be sure to check if BAND Switch position matches that of your radio before keying PTT or the CW paddle Also when you have changed the BAND do not make the full power CW carrier drive but reduced level power to see if the BAND is set correctly and the amplified RF power comes out properly Full power CW drive under the BAND Miss Set leads to the failure of the valuable final power FET devices One Antenna System Example TRANSCEIVER Antenna SWR POWER METER TO AC200V or 100V PLUG
24. Users Manual Solid State 50 Band 1kW Linear Power Amplifier Model HL 1 5KFx Tokyo Hy Power Labs Inc 10 11 16 9 1 9 2 9 4 5 Introduction 1 Cautions 2 22 42 4466 1 F ES TR 3 Specifications 2 22 4 AC Line Voltage kk 5 Front Panel Description 6 Rear Panel Description 8 Chassis Bottom Description 9 Connection amp Operation 10 ALC Connection 22222 13 Band Data Cable Connection _______ 14 DC Voltage Band Data 14 CI V 15 Yaesu Band Data 16 Kenwood RS 232C Data 2 2 17 Protection Circuits ss 18 Explanations of Major Circuits 19 Main DC Power Supply 2 19 PowerAmp L P F sss 20 RF Power Detector TX RX Switch 21 Main Control 22 Band Decoder Frequency Counter _ 23 Trouble Shooting ss 24 Appendix 2 2222 2 42 4 25 Schematic Diagrams 26 PC1662V 22 26 1681 L P F Low Pass Filter 27 PCS1699 Control 28 1667 Power Detector 29 PC1669 Front Panel Board 30 PC1675 31 1611 AC Power 32 PCSO1830 Fan Speed Control Unit 33 PCS1750 Surge Absorber Unit 34 Block Diagrams 35 Simplified Diagram 35 Overall Diagram 36 Led 1 tan 37 Top View Detailed 37 Top View Side View Left Right 38 Main Control Front View PCS1699
25. access should be limited to avoid injury 2 4 Turn off the AC main power immediately upon any unusual sounds sights or odors Check the multimeter readings of Vd and Id the fuses and all cable connections around the amplifier Please notify the dealer or the factory of any problems 2 5 For your safety do not operate the amplifier without adequate grounding A proper ground connection will result in peak performance and stability in addition to reduced RF strays or noises 2 6 To eliminate the RF interference to such home appliances as TV FM radio telephone sets and etc it is recommended that clamp on ferrite cores be inserted at both ends of the remote control cable ALC cable coaxial jumper cable and antenna cables as needed Also a common mode AC line filter near the AC outlet and in line low pass filters on the antenna coaxial cable as necessary are recommended 2 7 The amplifier has fast acting sophisticated protection circuits controlled by the latest microprocessor technology Please note however any such actions that cause the same fault to occur repeatedly will lead to failure of the valuable final power FET transistors Also note that the full power CW or carrier drive under the erroneous MANUAL BAND SET leads to the failure of the final power FET s See Section 6 at page 11 In this sense it is highly recommended that the amplifier is connected to the radio with supplied Band Data Cable 2 8 Befo
26. e an antenna tuner may be inserted 7 4 Turn the POWER switch on Turn the BAND switch to MANUAL position Then push UP DOWN keys to select desired band Turn the STAND BY switch to OPER operate position and the amplifier is ready to go If you key the transceiver with the carrier level set relatively low Such as 20 30W you will achieve an amplified output signal of a few hundreds watts Monitor this output with the multimeter in the Pf position or with an external power meter Increase drive level to roughly 50W and see if the antenna SWR stays constant As higher RF currents flow some antennas may show a changed SWR value due to heated connector junctions and trap coils 7 5 You can now increase the drive level to nearly 80 90W to achieve maximum carrier output power of 900W CW RTTY from the amplifier If you change to SSB mode peak voice power will reach approximately 1kW For high duty cycle transmissions like RTTY SSTV or FM modes it is recommended you reduce the drive power by 20 30 compared with SSB CW In AM mode the drive power should be strictly reduced to one third of SSB or 30W at most otherwise modulated amplitude peaks will be distorted 7 6 With a high power transceiver in SSB mode you can overdrive the amplifier resulting in a distorted output signal This can also occur if you speak too loud or if you set the microphone gain too high Speak into the microphone properly to reduce the possibilities of splattering
27. e shown below connect the transceiver example FT 1000MP MK V to the HL 1 5KFX Turn off the AC POWER to the transceiver and the amplifier Connect the 8 pin DIN plug to the BAND DATA 8 pin socket of the Yaesu transceiver Connect the other end the 5 pin DIN plug to the 44 YAESU of 5 pin DIN socket on the rear panel of the amplifier Check and make sure that the transceiver is in receive mode Power up the transceiver and then turn on the AC POWER to the amplifier Observe that the band indicator LED of the amplifier matches that of the transceiver DIN PLUG 8P DIN PLUG 5P YAESU Yaesu Band Data Cable YAESU TRANSCEIVER SWR POWER METER ANTENNA BAND DATA ANT TX GND EXT ALC ANT YAESU BAND DATA CABLE YAESU DIN 5P HL 1 5KFX REAR VIEW 16 9 4 Kenwood RS 232C Band Data Using the Kenwood band data connection cable shown below connect the transceiver example TS 950 TS 870 to the HL 1 5KFX as illustrated below Initial settings for the transceiver are as follows Communication Speed 9600 bps Stop Bit bit Refer to the Kenwood radio manual for more details Turn off the AC POWER to the transceiver and the amplifier Connect the D SUB 9 pin plug to the COM D SUB 9 pin socket on the rear panel of the Kenwood transceiver Connect the other D sub 9 pin plug to the KENWOOD D SUB 9 pin sock
28. ellow B6B EH OPER Green gt poner 51 SRAM3AS S20P J1 5V 03 Green 1 gt 10w 25V JUMPER RPE104 C2 RPE104 SWin SW FM GND OUT TD7101F RPE104 54MHz 16 3 375MHz U2 C6 NJM78L05A 25 VOUT 5 VIN 0425 Q1 25 1815 2 PC1675 PreScaler Size Document Number R A lt Doc gt 21 2005 42 2 L aj B3B EH Sheet 1 of 1 28401 066 RF401 022050 7 STBYAC1 STBYAC2 9 SSR401 9 G3NE 220T THM401 THM402 1002 1400 1002 1400 2 ACT OUT ACI IN ACT OUT B 2 OUT AC2IN 2 OUT PCI611DC Document Number lt Doc gt 93 Twisted Red Black Wire J2 Twisted Green Black Wire _ LM317T 395 D1 1N4002 Out FighiLow_ 5 C6 RPE 103 HeatSink HeatSink 17PB23 30PC30 J1 F1 2A R1 RNP 20S 759 No 2 1 OUT GND _ 8 gt gt sit 98 4 2 95 85 DT e R4 RN10k Low Speed ADJ G3VM 353A J1 Twisted Orange Black Wire amp 2 1830 O TITLE
29. et on the rear panel of the amplifier Check that the transceiver is receive mode on the AC POWER to the transceiver and the amplifier Observe that the band indicator LED of the amplifier matches that of the transceiver D SUB 9P FEMALE Kenwood RS232C Band Data Cable KENWOOD TRANSCEIVER ANTENNA WY SWR POWER METER TX 2 21 KENWOOD RS232C BAND DATA CABLE DSUB 9P FEMALE KENWOOD HL 1 5KFX REAR VIEW DSUB 9P MALE of Jo QC o STBY ome O INPUT L 17 10 Protection Circuits There are five major protection functions in this amplifier If the amplifier has shut down for some reason before re setting correct the possible cause of the shut down Turn off the POWER once and back on to reset 10 1 O DRIVE Over Drive Band Miss set When the drive power exceeds the 100W level the amplifier will shut down to STAND BV mode or receive in order to protect the input side of the power FET s This protection might also activate if the band is set wrong This usuallv occurs in MANUAL BAND mode when the amplifier band setting is lower than that of the transceiver complv with rules RF between 26 0 28 2 will cause Amplifier to shut down and not operate 10 2 O HEAT Over Heat When the temperature of the aluminum heat sink in the power am
30. itch is pushed The selected antenna is stored in the memory for the respective bands Note the antenna switch always defaults to A when the POWER switch is turned off FAN ID ON AIR 7 1 ON AIR Green LED lights when the amplifier is in transmit TX mode 2 FAN This LED lights when the cooling fan runs at high speed When the PA heat sink temperature reaches 40 degrees C the fan will run at high speed for enhanced cooling If the FAN LED is lit it is recommended that the power switch not be 7 3 ID turned off immediately after finishing operation Allow the cooling fan to run for extended period of time Excessive Id Indicator gt 35A Depending the band and antenna situation high drain current may flow into FET s If 35A is exceeded this LED flickers and or lights to indicate that high Id is being drawn This light does not necessarily mean a failure of the amplifier However if it lights too often or too long it is possible the drive power should be reduced and the antenna should be checked for SWR to avoid stress to the FET s O DRIVE O HEAT O VOLT FUSE PR 8 1 O DRIVE 2 9 3 O HEAT 8 4 FUSE 8 5 PR BAND MULTIMETER When overdrive or band miss set is detected LED lights to indicate the protection circuit has worked When the DC drain voltage of the FET s Vd is too high the LED lights to indicate the protection circuit has worked When the PA module
31. ntrol board which monitors the operating condition of the entire amplifier The TX RX switch Send Receive switching will switch the flow of drive power output power and the incoming signal from the antenna with two high speed relays mounted at the input and output sides of the PA A two channel antenna switch A B is also installed on this main board The limiter on this board together with the pre scaler on PC1675 help the MPU on the Main Control to count the frequency of the RF drive signal ONAIR ONAIR SEL PC1667 DETECTOR ANT A INPUT INPUT DET A OUTPUT DET ANT B 152076 152076 ww 1S2076A 1675 PRESCALER 78105 7101 12V Main Control MPU POWER DRIVE 21 11 4 51699 This is the heart of the control signal processing for HL 1 5KFX judges the operating condition of the amplifier as well as issuing the commands to the peripheral circuits Various analog signals are sent to the MPU such as RF drive from the transceiver RF power signals at various points DC power supply information etc These are converted to digital signals using a A D converter The MPU will then numerically compute the data to determine the amplifier status and issue commands for protections as needed Transmit Receive switching high low control
32. plifier reaches 70 degrees C the amplifier defaults to RECEIVE mode to protect the power FET s Likewise if the temperature of the inside laver of the power transformer reaches 130 deg C the amplifier will default to RECEIVE mode for your safety O HEAT protection cannot be reset until the heat sink or transformer has sufficiently cooled off 10 3 O VOLT Over Voltage If there is a sudden AC line voltage spike or if the transformer primary develops a fault the FET drain voltage may rise above acceptable levels If O VOLT protection trips check the AC line voltage with a circuit tester or an AC voltmeter 10 4 FUSE Fuse Blown If either of the glass fuses 20A on PC1662V fails O VOLT protection activates Under normal usage of the amplifier this failure should rarely if ever occur If it occurs there is a possibility that the power FET s have failed together If the amplifier cannot be reset consult with the dealer or the service center 10 5 PR Reflected Power Protection If reflected power because of the antenna reaches approximately 80W the PR protection may trip If it does one solution is to reduce the drive power from the transceiver Or you may need to check that your antenna match SWR is still ok If the match cannot be corrected and the antenna system isn t faulty use an antenna tuner As noted above the amplifier is equipped with several kinds of fast acting protection circuits using the latest in microproces
33. pull type of class AB amplifier The gate bias supply circuit is regulated for the best stability and is thermally compensated The has attenuator on the input for gain reduction and to enhance the stability of the wide band power PA The heat sink has two different thermal sensors to detect temperatures of 40 deg C and 70 deg C respectively At 40 deg C the cooling fan shifts into high speed mode At 70 deg C the amplifier will lock the amplifier into RECEIVE mode to protect the power FET s In the L P F output low pass filter circuit there are eight different band filters that are selected either by the auto band decoder or by the manual band switch Each L P F is used to reject harmonics so that the amplifier meets international telecommunication equipment standards ANT A INPUT ANT B AMP DRIVE AMP OUT PC1662V POWER AMP PC1681 LPF mma mma Cr mm 70 40 9 9 WARNING FAN ONAIR VD 53V High Low 20 11 3 RF Power Detector TX RX Switch 1667 As illustrated below there are two RF power detectors on this board One detects the drive signal level from the radio and the other monitors the outgoing power and the reflected power from the load antenna These detected signals are sent to the MPU PCS1699 Main Co
34. rdriven You may not always need to connect ALC to the transceiver if you set the mic gain properly and do not overdrive the amplifier Depending upon the manufacturer of the transceiver the suitable ALC voltage differs may need 0 4 and Yaesu may need 0 5V range Kenwood may need 6 8V maximum Check your transceiver manual 8 1 Prepare an ALC control cable using the RCA plug supplied in the package Solder a single wire or more preferably a shielded single wire to the center pin of RCA plug and solder the shield braid to the outer side of the plug Connect the control cable to the ALC or EXTERNAL ALC jack of the transceiver External ALC input is sometimes available at one of the pins of the ACC socket of the transceiver as well 8 2 At first turn ALC ADJ full clockwise Drive the amplifier in CW RTTY mode to full output power Then turn the ALC ADJ counter clockwise Observe the SWR Power meter at the output or Pf of the multimeter Stop turning the ALC ADJ at the point the power starts to decrease Or if you wish to further reduce the power keep turning ALC ADJ until the desired level is achieved If you further try to increase the drive power you will now see the output power become rather saturated from these adjustments Maximum ALC voltage produced is 10V when the amplifier output is over 200W REAR VIEW Upper Right Corner ALC VOLUME ALC OUT max ALC OUT min ale
35. re checking inside the amplifier be sure to wait a few minutes for the high DC voltage to discharge monitor Vd meter reading The potentiometers for RF power detector protection circuits FET bias voltage circuit etc are precisely adjusted at the factory and should not be altered Doing so would require readjustment with precision measuring instruments 2 9 The primary power transformer is factory pre wired for AC 230V operation Sliding the select switch located on the bottom of the chassis will switch the voltage from 230V to 115V See AC Power section Be sure to verify switch selection before you plug the AC power cord into the outlet 2 10 Before powering on the amplifier be sure to connect a dummy load 50 ohms 1kW min or a well adjusted antenna to the output terminal Operating without any load will cause extreme stress to the RF power 5 although protection circuits should work under critical conditions 2 11 Required drive power is slightly less than 100W to obtain the full 1kW output Do not attempt to operate with excessive drive from a high power transceiver Transmitting high drive RF over 100W into the amplifier will void the warranty 2 12 Keep the aluminum heat sink and air openings free from dust and blockages Periodic cleaning will prevent degraded cooling efficiency 2 13 For long continuous operation in RTTY modes it is recommended you reduce the RF drive levels by 20 to 30 lower output than CW S
36. sor technology However if the amplifier is operated in such a manner that multiple protections work repeatedly over a long period of time the amplifier can be seriously damaged 18 11 Explanation of Major Circuits Five major circuit blocks are explained in there basic form and using signal flows 11 1 Main DC Power Supplv 11 2 Power Amp L P F 11 3 RF Power Detector TX RX Switching 11 4 Main Controller 11 5 Band Decoder Frequency Counting 11 1 Main DC Power Supply The main DC power supply feeds the 50V DC power to the final PA stage It is a non regulated power supply and consists of the compact power transformer using an oriented core a bridge diode rectifier a high capacity electrolytic capacitor of 68 000uF for the filter soft start circuit suppresses the AC rush current using a thyristor A part of 50V line is converted to 24V using a DC DC converter and is supplied to the cooling fan POWER SW POWER AMP 02933 AG IN MAIN 1 9 DIODE LINE FIL X FORMER BRIDGE 68000uF S50VB60 15 PC1611DC AC POWER Main Control MPU FAN PCS01830 sgy D FAN SPEED High L 22 CONT DCDC CNDC24B7V 19 11 2 Power Amp 1662 L P F 1681 The is the heart of this amplifier and is composed of four 02933 2933 MOS FET s The amplifier is a parallel push
37. uch as overdrive high antenna SWR DC overvoltage band miss set etc 3 7 This amplifier is compatible with both AC 230V 200 220 240V included and AC 115V 100 110 120V included See the illustration in the AC Power Section for changing primary wiring of the power transformer 3 8 For the safety of the operator an Interlock system is employed The AC power is shut down if the top cover is removed and the automated safety interlock is activated 3 9 An analog multimeter allows the operator to monitor Pf Forward output power Pr Reflected power Vd Drain voltage of power FET Id Drain current etc 3 10 For future expansion the amplifier rear panel is equipped with a control cable connection socket this is for the upcoming model HC 1 5KAT auto antenna tuner by Tokyo Hy Power Labs 4 Specifications Frequency Mode RF Drive Output Power 1 8 28MHz all amateur bands including WARC bands and 50MHz SSB CW RTTY 85W typ 100W max HF 1kW PEP max 900W CW typ 5OMHz 650W PEP Matching Transceivers for Auto Band Decoder Most ICOM Yaesu Kenwood Drain Voltage Drain Current Input Impedance Output Impedance Final Transistor Circuit Cooling Method MPU Multi Meter Input Output Connectors AC Power AC Consumption Dimension Weight Accessories Optional Items 53V when no RF drive 40A max 500 unbalanced 500 unbalanced 02933 THP2933 x 4 Class AB parallel
38. ull the AC plug from the AC outlet to avoid injury 200V 230Vetc 100V 115Vetc and or AC200V AC110V and or AC220V 819 00 6 4 09 9 VO 90090990 T 12 01 18 98 AC115V and or AC230V 120 and or AC240V 0 0 0 0 OOOO 09 04 6 Front Panel Description TA 0 2 22 fel PS 1 4 71 4 CI POWER Main power switch to turn AC power off LED green lights when turned on OPER OPERATE STAND BY switch At OPERATE the amplifier is ready to go into ON AIR TX mode and at STBY it is on STAND BY mode 3 METER To change the multimeter scales Meter reads Pf Pr Vd and Id BAND SELECT To select band switching methods AUTO or MANUAL When using AUTO the manufacturer for the transceiver in use should be selected When the band data cable is not used MANUAL should be selected See page 14 9 Band Data cable Connection 5 UP DOWN Push switch for band change in manual mode While the transceiver is on Receive RX mode push the button to select the desired frequency band to operate The switches will not work when the transceiver and the amplifier are in Transmit TX mode ANT Select switch for antenna A or B Aand B are selected alternatively as the sw
39. wish to use RS232C port for PC controlled logging purposes In this case the user will need a Y shaped special 232C cable that has two D Sub plugs in parallel on one end one for radio and one for linear and one D Sub plug for PC where the TX line is rather OPEN and not closed to avoid the double hand shakings For this purpose special cable KIC II is available Contact HRO 4 ELECRAFT We have prepared a cable EBC 1 5K K3 to be used especially with K3 Connect 5 pin DIN plug to the YAESU socket of HL 1 5KFX 5 OTHERS TEN TEC Using the signal data converter one may connect ORION to Yaesu socket of HL 1 5KFX The converter IC such as 74C147 will convert the nine band data of ORION DC level into binary codes Then being polarity inverted through four 74C14 inverter IC data is sent to 5 PIN DIN sockets of VAESU For more details please contact For further questions please contact the respective manufacturers USA service center and or THP Japan THP believes above information is accurate and correct However THP assumes no responsibility for any damage resulting from the connections of the equipments by the users Prepared by TokyoHy Power Labs Inc Website www tokyohypower com www thp co jp Email thosupport airmail net for USA info thp co jp for other countries Rev Mar 23rd 2011 25 R238 1k LED201 GREEN 7 R228 215 2205W 213

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