Array Solutions Array Solutions X8NAA1500 Amateur Radio Linear Amplifier User Manual Exhibit 6 User 146 s Manual

Array Solutions dba Array Solutions Amateur Radio Linear Amplifier Exhibit 6 User 146 s Manual

Exhibit 6: User’s Manual

1 Exhibit 6: User’s Manual External Radio Frequency Power Amplifier ACOM 1500 Model 1500 Array Solutions 2611 North Beltline Rd Suite 109 Sunnyvale, Texas 75182 USA Tel: 214 954 7140 fax: 214 954 7142 E-mail: info@arraysolutions.com
2 Table of Contents 1. GENERAL INFORMATION .................................................................... …3 1-1. Introduction and Description ................................................................ 3 1-2. Owner Assistance ................................................................................. 3 1-3. Equipment Supplied ............................................................................. 3 1-4. Features ............................................................................................... 3 1-5.Safety Considerations, Explicit Definitions ............................................. 4 2. INSTALLATION ...................................................................................... 6 2-1.Unpacking and Initial Inspection ............................................................ 6 2-2. Line Voltage Selection .......................................................................... 6 2-3. Amplifier Location Selection ................................................................. 6 2-4. Connections ......................................................................................... 7 2-5. Installation of External Fan ................................................................... 8 3. POWER ON, CONTROLS AND INDICATORS ......................................................... 9 4. OPERATION ......................................................................................... 11 4-1. Turning ON and OFF ........................................................................... 11 4-2. Changing Operate and Standby Modes ................................................ 11 4-3. Antenna charge .................................................................................. 12 4-4. Tuning ............................................................................................... 12 4-5. ON LINE Information Screens and Control Functions............................ 14 4-6. Auto-Protection System ...................................................................... 15 5. OFF LINE OPERATION ........................................................................... 16 5-1. Display brightness control ................................................................... 16 5-2. Auto-Operate enabling and disabling ................................................. 16 5-3. Antenna outputs assignment...............…………………………………………………..16 5-4. Reading Auto-protection Signatures …………………………………………………..16
3 6. MAINTENANCE .................................................................................................... 17 6-1. Cleaning………………………………………………………………………………….17 6-2. Fuses Replacement………………………………………………………………………17 6-3. Tube Replacement……………………………………………………………………….17 6-4. The ACOM1500 Simplified Schematic Diagram…………………………………………17 6-5. Troubleshooting……………………………………………………………………..…..18 7. SPECIFICATIONS……………………………………………………………………..20 7-1. Parameters………………………………………………………………………………..20 7-2. Functions………………………………………………………………………………….20 7-3.Storage and Shipment……………………………………………………………………..21 NOTE This unit has been set for 240VAC at the factory. Means is provided, however, to reconnect it for 200/240VAC, as well as for 100/120VAC, in 10-Volt steps. Please contact your dealer or look at the enclosed schematic diagram whenever a change is needed.
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5 1. GENERAL INFORMATION 1-1. Introduction and Description This manual explains the installation, operation, and maintenance of the ACOM1500 HF+6 meters linear amplifier. The ACOM1500 is a complete and self-contained linear amplifier that covers all amateur bands from 1.8 through 54MHz and provides over 1500W PEP (1200W continuous carrier) output power with less than 85W exciter drive. Antenna VSWR up to 3:1 is acceptable at full power. Tuning is substantially simplified by a plate-load True Resistance Indicator (TRI) and by an automatically controlled input attenuator. Operating parameters are displayed by a multi-functional high brightness vacuum fluorescent display (VFD). Full break-in transmit/receive switching (QSK) is standard. 1-2. Owner Assistance If assistance is needed, you should contact your local dealer first. If you still have an issue you need to discuss with one of ACOM's specialists, the contact information is as follows: fax + 359 2 920 96 56, tel. + 359 2 920 96 55, e-mail acom@mail.orbitel.bg or by mail: bul. Nikola Mushanov Nr.151, 1330 Sofia, Bulgaria. 1-3. Equipment Supplied The ACOM1500 amplifier and this manual are shipped in a cardboard carton. 1-4. Features • Easy to operate. The TRI is a powerful tuning aid which, together with the automatically controlled input attenuator, helps the operator to quickly and precisely match antennas (5-10 seconds typically). The auto-operate function (when enabled) maintains the amplifier in OPERATE mode for you, thus saving manual operations and time. • No heavy outboard antenna tuners required for antenna VSWR up to 3:1 (and higher on some bands). Your amplifier will perform the functions of an antenna tuner, thus enabling you to change antennas faster and use them over a wider frequency range (saving tuning time). • An amplifier that is both user-friendly, and that looks after itself. It is designed to safely withstand up to 300W reflected power, up to 100 milliseconds duration of drive spikes, drive RF "tails" after a PTT or KEY release, operator's inadvertent tuning errors etc. It would also not cease to function with a "soft" AC line and would deliver more than half power at only 85% of nominal mains voltage. It would withstand up to 10 milliseconds (down to zero) voltage drops, and up to +15% line voltage spikes, which is important particularly when used at field days, DXpeditions, and other portable events. • VFD comment display. All amplifier status indications are explained via detailed text displayed on the dot matrix high brightness vacuum fluorescent display (VFD). The upper-line's strip on the VFD always reads peak forward power. LED indicators are provided for: OPERATE mode, attenuation-on (ATT), transmit request (TX), the selected antenna output (1, 2, or 3), and ON/OFF conditions. • Antenna selection. Three antenna outputs are selectable using a button on the front panel. • Easy maintenance. Signatures of the amplifier internal status are stored in a nonvolatile memory for 7 most recent auto protection trips. This information can be forwarded to your dealer for diagnostics.
6 Using an EXCEL APPLICATION (available from ACOM or your dealer free of charge) and a PC you can decode the signatures by yourself, too. • Less noise in the shack: the input bypassing and the vacuum antenna relays are virtually silent even in QSK CW mode due to their special mounting. • Less QRM and improved Electro Magnetic Compatibility during tuning. Antenna matching can be achieved in less than 10 seconds at a quarter of nominal output power. • Operates without special signals from the transceiver - "ground on TX" and 85W RF drive power are sufficient. • Broadband input matching circuit resulting in very good load to the transceiver over the entire spectrum from 1.8MHz up to 54MHz. • Uses a single 4CX1000A/8168 ceramic and metal radial beam tetrode with plate dissipation of 1000W (forced air cooled, grid-driven) which is specifically designed for class AB1 RF linear amplifiers. • Permanent monitoring and protection of plate and grid voltages and currents, as well as of the exhaust air temperature. The Bias Optimizer decreases the heat dissipated from the tube, and there is automatic protection against overheating in accordance with the specifications of the tube producer. • An output RF Arc protection is employed. It safeguards the amplifier, antenna, antenna selector, and tuner against severe damage in case of possible break down. • High voltage power supply inrush current protection, which eliminates the danger of affecting sensitive devices, connected to the same mains circuit (important when used portable). The amplifier can be configured for 8 nominal line voltages: 100, 110, 120, 200, 210, 220, 230, and 240VAC, 50 or 60Hz. • Continuous monitoring and/or selectable measurement of 12 most important parameters of the amplifier, exciter, and the selected antenna via VFD. • The amplifier can be shipped with 10 and 12 meters capability disabled as required by the FCC for US users. Contact your dealer about enabling those bands. 1-5. Safety Considerations, Explicit Definitions The ACOMI500 HF + 6 meters Linear Amplifier is a Safety Class I unit. The third grounding lead of its mains cord (which is colored yellow with two green stripes) and the ground stud on the rear panel of the amplifier (marked GND) must be connected to the station's grounding system for safe operation. The amplifier is designed to meet international safety standards and complies with CE safety and electromagnetic compatibility requirements, as well as FCC regulations. This operating manual contains information, precautions, indications for cautions and warnings which must be followed by the user to ensure safe operation and to keep the ACOMI500 in safe operating condition. PRECAUTIONS: The EXPLICIT DEFINITIONS described below apply to this operating manual:
7 W A R N I N G notes call attention to a procedure which, if not correctly performed, could result in personal injury, fire hazard or electric shock. C A U T I O N notes call attention to a procedure which, if not correctly performed, could result in equipment damage, not only in the amplifier. N O T E notes call attention to a procedure which, if not correctly performed, could result in inconvenience. W A R N I N G HIGH VOLTAGE! The amplifier works with high voltages up to 3000V, which are LETHAL! Also, for your safety, pull the amplifier power plug out of the mains wall outlet and WAIT AT LEAST 30 minutes EACH TIME BEFORE you remove the cover of the amplifier. Do not touch any part inside while the amplifier is open because some residual voltages may still be present. W A R N I N G HIGH VOLTAGE! NEVER ALLOW ANYONE, ESPECIALLY CHILDREN, to push anything into holes in the case - this will cause electric shock. NEVER TOUCH AN ANTENNA during transmission - this may result in an electric shock or burn. NEVER EXPOSE the amplifier to rain, snow or any liquids. AVOID placing the amplifier in excessively dusty environments or in direct sunlight. DO NOT OBSTRUCT AIR INTAKE (rear panel) and EXHAUST (top cover) areas of the amplifier. Keep a minimum distance of 10cm (4 inches) to the intake and 50cm (20 inches) to the exhaust openings. W A R N I N G Do not undertake on your own repairs or changes in hardware or software of the amplifier. Otherwise you may endanger your or other's health and life or damage the amplifier and the equipment connected with it, not covered by warranty. The manufacturer is not liable for another's actions and responsibility shall be assumed by the doer. C A U T I O N To avoid damage (not covered under warranty) read the Installation - Section 2 of this operating manual carefully. If you have any doubts about the installation, operation or safeties of the amplifier please consult your dealer.
8 2. INSTALLATION 2-1. Unpacking and Initial Inspection N O T E Before you start to install the amplifier, thoroughly read this manual. First, carefully inspect the cardboard carton and its contents for physical damage. If damage is noticed, notify your dealer immediately. Delay may infringe carrier's warranty conditions. Keep all packing for possible future transportation! 2-2. Line Voltage Selection C A U T I O N To avoid damage (not covered under warranty), check carefully if the voltage for which the amplifier is set corresponds to your mains nominal voltage. Normally the amplifier is supplied set for a nominal line voltage of 240V. If your line voltage is not 240 V, you must contact your dealer for instructions on how to change the voltage selector inside the amplifier. The only exception to this is if the unit has been custom ordered, in which case the voltage selection will be noted in the Table of Individual Data (Table 2-1, below). Voltage Selector Tube s/n VAC AMP s/n Table 2-1. ACOM 1500 Individual Data C A U T I O N The current consumed by the amplifier from the line (mains) supply should not exceed 16A from 200/240VAC and 20A from 100/120VAC. Therefore you will have to reduce the output power to about 1000W PEP in case of operation at 120V or lower line (mains) supply voltage. 2-3. Amplifier Location Selection C A U T I O N The weight of the unit is about 26.5 kg, which should preferably be handled by two persons. Position the amplifier near the place where it will be used. You'll need an easy access to the command knobs and indicator's area, as well as to the rear panel cabling.
9 No magnetic-field sensitive devices should be located next to the right side of the amplifier as its power transformer is located there. It's best to position it to the right of your transceiver. No temperature sensitive devices should be located above the exhaust hot air area, so don't push it under a shelf. You may prefer to use the bottom scales of both variable capacitor knobs (TUNE and LOAD) if you install it on a shelf. DO NOT OBSTRUCT AIR INTAKE (rear panel) and EXHAUST (top cover) areas of the amplifier. Keep a minimum distance of 10cm (4 inches) to the intake and 50cm (20 inches) to the exhaust openings. 2-4. Connections Connection to your station must be accomplished in the order described below, before you apply mains voltage to the amplifier. W A R N I N G Note that the grounding system may have to withstand currents over 20A with insignificant voltage drop on it. Therefore, it may be necessary to improve it considerably, i.e. to become less resistive, with heavier leads and lower-resistive ground path. The grounding leads should be at least 8mm2(AWG 8 or SWG 10). Fig.2-1 Connections a) First, connect the ground stud of the amplifier (on the rear panel, marked GND) to the station's grounding system (Fig.2-1). b) Connect a coaxial cable with a PL-259 plug from the transceiver output to the amplifier rear panel RF INPUT socket. C A U TI O N If this is the first time you will use a power amplifier in your station, pay attention to the coaxial cable type from the amplifier's three outputs. The cable must handle the increased power safely, particularly on the 10 and 6 m bands. We recommend that you use RG213 or better. Check the same for the antenna selector and tuner as well as the antenna itself (especially multi-band trap antennas).
10 c) Connect a suitable coaxial cable from your antennas to the appropriate amplifier output on the rear panel, marked ANTENNA 1, ANTENNA 2, and ANTENNA 3, using PL-259 plugs with PTFE insulation. d) Run a cable terminated in a Phono (RCA) connector from the transceiver socket providing "ground on transmit" control signal to the amplifier rear panel KEY-IN socket. N O T E Your amplifier will not work if KEY-IN is not connected properly. Transceiver producers give different names to this output and they are for instance TX-GND, SEND, T/R-LINE, etc. Some transceivers require that "ground on transmit" is implemented via a software command, or by changing the setting of a switch on the rear panel, or interior of the transceiver. Check your transceiver's manual. e) The KEY-OUT socket on the rear panel provides an extra control signal from the amplifier to the transceiver. It could be used to improve the transmit/receive switching safety. If your transceiver has a suitable input that disables transmission, we recommend that you connect it with a cable terminated in a Phono (RCA) connector to the KEY-OUT socket of the amplifier. Transceiver producers give different names to this input and they are for instance TX-INHIBIT, MUTE, LINEAR, etc. Check your transceiver's manual or consult your dealer. If your transceiver does not have such an input, don't worry - the amplifier will function normally as well, and then the KEY-OUT may remain unused. f) Preparation of wall outlet for the amplifier. W A R N I N G If your amplifier is only fitted with one line (mains) fuse, it is suitable for the European Union ONLY. Your dealer will check that your amplifier is correctly fused before it is shipped to you, based upon your indicated location. Customers should check with a qualified electrician if the amplifier is to be used outside the country in which it was purchased. Due to the different standards in different countries, the mains plug is supplied and mounted by the dealer. He connects to the mains cord a standard mains supply plug which meets the Safety Class I units standard in your country. The ground lead of the amplifier's power cord is colored yellow with two green stripes and the blue and brown leads are active. When the amplifier is to be used with only one mains fuse, it is connected in series with the brown lead, which must be the active. If you have any doubts about the correct way of connecting the wires, consult your dealer. W A R N I N G Before connecting the amplifier to your mains supply, be sure that the supply is correctly wired, and is adequate for the current drawn by the amplifier - up to 16A from 200/240V and 20A from 100/120V. Make certain that the grounding lead is connected properly in the wall outlet for the amplifier. It is preferable that you use the wall outlet closest to the source. The installation leads should be at least 2.5mm2 (AWG 13 or SWG 15). Check if the respective fuses can handle current up to 16A as well, and whether the voltage corresponds to the voltage for which the amplifier is set (S.2-2). If you connect the amplifier to a different mains outlet, be sure that you check it, too.
11 Make sure the main Power Switch on the rear panel is in OFF position and insert amplifier's mains plug into the wall outlet prepared for it. The amplifier remains switched off. 2-5. Installation of External Fan This fan (Fig. 2-1) is not necessary in SSB and CW modes, nor in continuous carrier modes (RTTY, SSTV etc.) with carrier down times of maximum 15 minutes and a subsequent pause of 3 minutes. For higher duties or increased ambient temperatures the fan is recommended. The auxiliary fan (92x92x25mm or 92x92x38mm) must be brushless type, 2...5W/24VDC. It may be installed by your dealer or by the manufacturer on request. 3. POWER ON, CONTROLS AND INDICATORS C A U T I O N Do not turn the amplifier on for at least 2 hours after unpacking it in the room where it will be used. Pay particular attention when you move it from a very cold into a warm place - condensation is likely and this could result in damage to the high voltage circuits. In such a case, wait at least 4 hours. A similar effect can occur after a rapid warming of the operating room (for instance after switching on a powerful heater in a cold shack). C A U T I O N To avoid damage (not covered under warranty) carefully check that the voltage for which the amplifier is set corresponds to your mains nominal voltage (see S.2- 2 and table 2-1). After following all instructions in S.2, you can turn ON the main power switch marked "LINE" on the rear panel (Fig.2-1). The LED indicator above the red ON/OFF button located on the front panel must light red and a black inscription "ACOMI500" will appear on the display (Fig.3-1):
12 Fig.3-1 ACOM1500 Display and Control You'll note that the upper line of the LCD always reads the peak forward power, even in STBY mode. The 1500W scale resolution is 15W per bar. Note that levels below 20W may be not detected. N O T E If the characters on the fluorescent dispaly are dim, please follow the method of Display brightness control described in S.5-1. In this position (called OFF LINE hereafter) only the micro-controller is operational, while the amplifier itself is still turned off (the tube is not powered at all). The control of the amplifier is accessible during OFF LINE and ON LINE states, each having several information screens and control functions (see Fig. 3-2): Fig.3-2 Information Screens and Control Functions Structure The OPER button changes operate and standby modes alternatively (S.4-2) while ON LINE. Please note that Auto-Operate might be enabled. The same button activates signature list while OFF LINE. The PREV and NEXT buttons change information screens or select control functions (S.4-5) for both OFF LINE and ON LINE modes. The ON/OFF button switches OFF LINE and ON LINE states of the amplifier alternatively. You can proceed in one of two directions:
13 a) You can use the OFF LINE information screens and control functions. They refer to the auto-protection signatures list, Display brightness control, as well as the Auto-Operate feature. This is described in S5. b) You can turn on the amplifier and start the warm-up sequence. After 3 minutes you may tune and begin operating the amplifier and you can use the ON LINE information screens or control functions (see below). 4. OPERATION Operation of the amplifier is simplified due to the TRI tuning aid, Auto-Operate function, and automatic protection system, so you'll be able to begin using the amplifier immediately after the installation. However, to make full use of amplifier's potential and to fully configure it to your local conditions, we recommend that you thoroughly read the following information. There are I4 ON LINE information screens, which can be selected by pressing repeatedly the NEXT or PREV buttons (see fig.3-2). Their purpose and method of use are described in the next five sections 4-1 through 4-6. 4-1. Turning ON and OFF In order to turn on the amplifier, while the Main Power Switch (located on the rear panel) is on, press the red ON/OFF button (located under the red LED on the front panel right-bottom corner) and hold it on for about one second. The VFD will light at full brightness and the ON/OFF LED indicator above the button will change the color from red to green. You'll hear the blower and the optional external fan starting at high speed for a second, then slow down. After successfully passing the initial amplifier self-tests, the ON/OFF LED begins flashing green while the following inscription on the LCD remains lit: WARMING UP: nnn s (nnn above is the number of seconds remaining to readiness for operation) A tube warm-up period of 180 seconds (3 minutes) follows. During this time the amplifier remains in standby mode, so you can continue operating with the transceiver.
14 Pressing either the PREV or NEXT buttons during this period will result in changing the screen to one of the I4 available information screens described in S.4-5 below. This action will not influence the warming-up process, so you may pass through all information screens, for instance to monitor the High Voltage value or the Exhaust Air temperature. You can also return to the old one to see how many seconds are still needed for the tube's heater. N O T E When you intend to have a short operating break, it is better to leave the amplifier in standby mode instead of turning it off. Tubes life is shortened by repeatedly turning on and off the heater. However, if you unintentionally power-off the amplifier, it is best to switch it on again immediately. When the pause is short (up to one minute) and the cathode is still warm, the warm-up period is shortened significantly, which reduces the waiting time and prolongs the tube's expected life. After the indicated period expires, the ON/OFF button stops flashing and lights green constantly. If the auto-operate function has been selected to ON (see S.5-2), the green OPER LED will light automatically. The last used (one out of I4) information screen appears on the display, for instance: "WARMING UP: Ready". The bargraph on the upper line always indicates the peak forward power (as well as during OFF LINE). In order to turn the amplifier off press shortly the red ON/OFF button. If you intend to have a break for a long time, it is best to turn it off using the Main Power Switch (on the rear panel) as well. 4-2. Changing Operate and Standby Modes With the Auto-Operate function disabled (see S.5-2), the OPER button changes two modes alternatively. When Auto-Operate is enabled, the amplifier will be maintained to operate mode by default, unless you use the OPER button manually to go to standby (then Auto-Operate is suppressed temporarily). Pressing OPER again would restore the Auto-Operate feature. This function can be enabled or disabled on the operator’s choice. When Auto Operate function is disabled, the amplifier will shift and stay in STBY mode after each protection trip. To restore the operation, the operator must press the OPER button manually. When the Auto Operate function is enabled (see S 5-2), the amplifier will also shift to the STBY mode on a protection trip, however it will return to the OPER mode after about four seconds automatically. The operator does not need pressing any button to return to OPER mode in this case. 4-3. Antenna change By pressing the ANT button, the amplifier output can be switched between three antenna outputs. The lights above the button indicate the current antenna selection. Selection possibility for any one of the antenna outputs can be disabled if it is not used - see S. 5-3 - Antenna outputs assignment. Thereafter you will not be able to select free outputs inadvertently, thus preventing no-load transmissions and possible damage. C A U T I O N To avoid damage (not covered under warranty) do not change antennas during a transmission. Do not transmit into an antenna output (1, 2, or 3) if it is not connected to an antenna or a dummy load.
15 4-4. Tuning Tuning is possible only in operate mode, so you may need to press the OPER button in order to illuminate the LED above it (unless Auto-Operate is active). a) Preliminary information. Tuning the amplifier is a procedure of matching the impedance of the currently used antenna to the optimum tube load resistance. This will ensure maximum plate efficiency and RF gain at nominal output power, with minimum IMD at that. Please note, that the REFLECTED POWER readings and the measured VSWR depend on the antenna impedance only, and not on the amplifier tuning. If the antenna impedance is different from 50-Ohm pure resistive (nominal), the REFLECTED POWER reading will always indicate reflected power presence (even at a perfect tuning). Proper tuning will allow operation at greater power without distortion or danger to the amplifier. Note also that the real OUTPUT POWER in the load is equal to the difference between the FORWARD- and REFLECTED- readings. For instance, at a reading of FORWARD I500W and REFLECTED 250W, the real OUTPUT POWER will be equal to their difference - I250W (into a 2.4:1 VSWR load). At very high VSWR (no antenna or badly mismatched antenna), the FORWARD and REFLECTED readings will be almost equal, while the real OUTPUT POWER (the difference between them) will be practically zero. The amplifier can operate safely if the following rule is obeyed: "REFLECTED POWER < 300W". Matching is assured for loads with VSWR up to 3:1. Nevertheless, for some loads and bands matching is possible at even higher VSWR. The maximum usable forward power at VSWR 3:1 is 1200W with 300W reflected. For higher than 300W reflected power you'll get the ** REFLECTED POWER ** soft-fault protection trip. For instance, this can happen at full-scale I500W forward and 375W reflected power, into an antenna having a VSWR of 3:1 or worse. C A U T I O N Using a feeder of coaxial cable at VSWR > 3:1 on HF, and particularly on the and 6 meters bands, is not recommended. At such high values of VSWR, the high voltages, high currents, and heat associated with line losses, risk to permanently damage your coaxial cable or antenna switch. Update amplifier tuning when you change the band or between CW and SSB segments within the same band. Update it each time when you change the antenna, even in the same band, as well as periodically, even though you may have not changed band or antenna. Be on the alert in particular when a significant change in the environment occurs (snow, ice, newly appeared or removed massive objects, alien wires nearby etc.) that would cause significant changes in the antenna impedance and eventually an increased VSWR. N O T E If you use more than one antenna per band, it is necessary that you select the proper antenna BEFORE the next step. Retune after selecting a different antenna for the same band, since the impedances may differ substantially (unless their VSWR is excellent, i.e. below I.2:I for both). C A U T I O N Do not switch the BAND switch knob while transmitting with the amplifier! Hot switching (while transmitting) will eventually destroy the band switch, not covered by the warranty! C A U T I O N When tuning, do not apply continuous drive longer than 3 minutes and after that pause I-2 minutes for tube cooling.
16 We recommend that you tune-up at the center frequencies of the preferred frequency band. First select the band switch and the correct antenna number (never with RF applied!). Then use table 4-I in order to achieve an approximate preset for both TUNE capacitor and LOAD capacitor knobs: Band, MHz Tune Knob Dial Load Knob Dial1.8 - 2 62 - 30 65 - 383.5 - 4 59 - 40 72 - 537 - 7.3 57 - 55 65 - 6010.1 - 10.2 15 - 14 27 - 2614 - 14.35 60 - 50 32 - 3018 - 18.2 70 - 68 67 - 6521 - 21.45 19 - 15 47 - 4424.9 - 25 67 - 66 60 - 5928 - 29.7 26 - 12 46 - 3950 - 54 32 - 13 24 - 20 Table 4-I. Approximate tuning presets b) Selecting the plate-load True Resistance Indicator (TRI) tuning aid. You may select TRI scale in three different ways: - By pressing simultaneously the PREV+NEXT buttons shortly. This will insert a 6dB attenuator between the driver and the amplifier's input (the ATT LED will light), so you'll not need to reduce the drive power during tuning. Press PREV+NEXT buttons momentarily again to switch the attenuator off the input and to return to the old screen. If you use any of PREV or NEXT buttons only, the attenuator would be switched off too, but the information screen would change to respectively previous or next. - By pressing repeatedly either PREV or NEXT button (whichever is nearest), until you reach the TRI scale. This will not insert the attenuator, so you'll have to use less than 20W drive (unless the amplifier is near correct tuning), otherwise the next step would be executed automatically: - By simply applying a normal working (60-85W) drive power, while the amplifier is not yet tuned. This will automatically invoke the TRI tuning aid and will insert the input attenuator (the ATT LED will light) after one second. The attenuator will be switched off, and the old screen will be returned automatically, after you release the PTT shortly. If you have achieved meanwhile a nearly good tuning, the attenuator would not be inserted again. If the old screen was the same (TRI, selected manually earlier), you'll then be able to precisely tune the amplifier also at nominal power, without changing drive at all. Use this hint to shorten the tuning process duration. c) Tuning Procedure. While a continuous (CW) signal at the desired frequency is still applied: - Look at the upper scale (forward power); obtain maximum power using the upper (TUNE) knob; - Look at the lower (Load Cap) scale and turn the lower (LOAD) knob in order to center the triangle marker at the "!" mark. - Release the PTT shortly in order to disable the attenuator, then repeat both steps at nominal power. - Always finish by peaking with the TUNE knob.
17 N O T E Appearance of an arrow on either left or right TRI scale edges means that the LOAD knob is too far from the proper position. To correct this, turn the LOAD knob to the prompted direction until the triangle marker appears inside the scale field. I _____!_____ IIII > ____!_____ IIIIIIIIIII _____!____< IIIIIII _____!__v___ IIIIIIIIIIIIIIII _____v_____no marker:use TUNE knob formax. P to get anymarker.marker is a far left:turn LOAD knobpointer to right untilmarker inside.marker is a far right:turn LOAD knobpointer to left untilmarker inside.marker inside:turn LOAD knobslightly left tocenter it.LOAD is tuned:turn TUNE knob topeak ForwardPower & finish. Fig. 4-I. Using TRI tuning aid Please note also, that the TRI mark will not appear until at least 5W drive is applied, and at least 20W forward power is achieved. If, for some reason, matching cannot be accomplished successfully, check the BAND switch position and proper antenna selection. Then check the antenna VSWR at the same drive frequency. d) Tuning hints. While turning the knobs, you'll note that both tunings would be virtually independent. This is a benefit of the TRI. The plate-load resistance increases to the right and decreases to the left of the TRI center. The scale center corresponds to the proper LOAD capacitor tuning, which presents an optimum load resistance to the tube. If you tune to the right, you'll obtain more gain, but less undistorted output power will be attainable. You may prefer to use this hint when your drive power is insufficient or when you need less output but better efficiency, for instance at heavy duty modes (RTTY, SSTV etc) where less heat is wanted (not only in the amplifier but also in the transceiver). Tuning to the left of the center would lead to the opposite: less gain and more power attainable. Of course, this requires more drive power, more plate current, and more plate heat, which shortens tube's- expected life, as its cathode would be faster exhausted. You might use the off-center tuning hint also to compensate for mains voltage variations in order to maintain tube efficiency: tune to the right when mains is higher, or tune to the left if it's lower than the nominal voltage. Please see S.2-2 (Line Voltage Selection) for more than 5% difference from the nominal. 4-5. ON LINE Information Screens and Control Functions. a) Besides the Warming Up and TRI (described above in S.4-1, S.4-3 and S.4-4), you have 12 more Information screens available. They are as follows: Forward Power, Reflected Power, Output Power (difference between forward and reflected), Antenna VSWR, Drive RF Power, RF Power Gain, Plate Current, High Voltage, Plate RF Peak, Screen Current, DC Power Input (product of plate current and high voltage), and Exhaust Air Temperature (Celsius and Fahrenheit scales). You can use them to monitor the technical state of the amplifier and the associated parameters in a digital form. Selection is made by the PREV and NEXT buttons. You may change them in a closed loop, while the amplifier is used and controlled in operate and standby modes, changes transmit and receive, without any influence by the measurement process.
18 b) You can control the display brightness, Auto-Operate feature, and antenna outputs assignment also while ON LINE. In order to enter the control menu press the PREV+NEXT buttons simultaneously and hold them for two seconds. Further proceed as described for OFF LINE mode below - see S.5-1, S.5-2, and S.5-3 for details. 4-6. Auto-Protection System When any abnormal condition is detected, the amplifier will evaluate the risk and may use three different degrees of protection, depending on the nature of the problem. Each event is accompanied by a text telling you the reason. The VFD brightness is flashed meanwhile in order to attract the operator's attention. a) The first degree of protection is issuing a warning message only, without any influence on the transmitting process. This might be for instance "Reduce Drive", "Plate Current", etc. You could continue to transmit under such conditions but you are close to a trip threshold. b) The second degree of protection is a trip in standby mode (Soft Fault). You'll get an appropriate message, for instance ** GRID CURRENT **. All Soft-Fault messages are marked with two asterisks on both screen edges. The message remains on the display until you press any button (or auto-operate function returns to operate mode automatically). The Soft Faults are of such kind where you can correct exploitation conditions operatively (using less drive, improving antenna VSWR, etc). c) The third degree of protection is a trip to OFF LINE mode (Auto-Protection). You'll get the corresponding signature (see S.6-5 - Troubleshooting). If you cannot guess what the reason is, you may try to turn the amplifier on again in order to check whether it's not an accidental condition. If the problem persists, you'll need to contact your dealer - see S.I-2. N O T E The 6dB input attenuator is automatically inserted about one second after a bad tuning is detected at drive levels above 20W. It is switched off at every PTT release (unless inserted manually).
19 5. OFF LINE MODE There are two control functions and I4 information screens available in this state of the amplifier. You can control the VFD brightness, enable/disable the Auto-Operate feature, and assign the antenna outputs. You can also list the auto - protection signatures. The tube is not powered at all (only the micro-controller is active) during these operations. 5-1. Display brightness control Press the PREV+NEXT buttons simultaneously and the “Brightness=…" screen will appear on the bottom line. Use the NEXT button to control the display brightness in steps from 1 to 4. Press shortly the PREV+NEXT buttons in order to reach the auto-operate function (see next S.5-2), or leave the buttons unused for 20 seconds if you want to accept these selections only (in order not to change Auto-Operate inadvertently). 5-2. Auto-Operate enabling and disabling When enabled, this function will maintain the amplifier in OPER MODE automatically - see also S.4-2. The OPER button will be still functional anyway, so you'll be able to change to STANDBY and return back to OPERATE mode manually when you want at any time. The auto-operate function will be disabled temporarily when you enter STANDBY mode but it will be restored after you return to OPERATE by the OPER button. After having selected the display brightness, (see the previous S.5-I) you may keep on pressing the PREV+NEXT buttons in order to enable or disable the Auto-Operate feature. The "Auto Operate = ..." screen will appear on the bottom line. Use the PREV button to select OFF or the button NEXT to select ON. Press shortly the PREV+NEXT buttons again in order to reach the last control function – the antenna outputs assignment (see the next S. 5-3). Alternatively, you may leave the buttons unused for 20 seconds if you want to exit this menu without exciting it. In any case, the selections made so far will be memorized. 5-3. Antenna outputs assignment If there is no antenna connected to an antenna output it could be disabled. This will make the switching between two available antennas easier and, which is more important, will prevent inadvertent no load transmissions. In order to enable or disable an antenna output, press shortly PREV+NEXT buttons successively until the “ Ant:(1-…) 2-…3-…” screen appears. Using the button ANT, move the brackets to enclose the antenna output you want to disable or enable. Press the PREV button to disable or NEXT to enable it. Press PREV+NEXT shortly again to confirm the antenna outputs assignment and leave the menu. N O T E All selections you make are stored in the amplifier nonvolatile memory to be used also thereafter. If no button is pressed within 20 seconds, the selections made so far are accepted and the control function is left automatically. 5-4. Reading Auto-protection Signatures On every Hard Fault protection trip of the amplifier, signature information is stored in its nonvolatile memory. The 7 most recent auto-protection trip signatures related to the amplifier internal status are stored there, which you can copy and forward to your dealer for diagnostics.
20 In order to read them press the OPER button while OFF LINE. The display will light at full brightness and you'll see the beginning of the signatures list. Use NEXT and PREV buttons to navigate through 7 pairs of screens. For each auto-protection trip there is a pair of information screens, beginning with nA... and nB... where: - "n" is the successive number of the event (nr.I is the latest, nr.7 is the oldest one); - A and B mark the first and the second part of an information screen pair. Two lines, three groups by six symbols (36 symbols in total) are to be copied concerning every one of the 7 memorized events, from IA-IB through 7A-7B. To decode the signatures please see S.6-5 (Troubleshooting). N O T E After every signature listing the tube warm-up time is reset to I80 seconds regardless of the time being in OFF LINE state. 6. MAINTENANCE N O T E If the characters on the VFD are dim, please follow the method of Display brightness control described in S.5-1. 6-1. Cleaning W A R N IN G Do not use solvents for cleaning - they may be dangerous both for you and for the amplifier paint or plastics. Do not open the amplifier. Cleaning of the amplifier outer surface can be done with a piece of soft cotton cloth lightly moistened with clean water. 6-2. Fuses Replacement If it is necessary to replace the mains fuses, use only standard ones. The two Primary Mains Fuses of the amplifier are located on the rear panel (Fig. 2-I). They are of the fast (quick blow) type, 1-1/4 x 1/4 inch Cartridge Fuses, Size "0". Use 20 A for 100-120 VAC operation. Use 16 A for 200-240 VAC operation (15 A standard is also admissible). Besides the primary fuses, on the MAINS PCB (inside the amplifier) there are three more, small glass fuses (5x20 mm European size): - one piece of I00 mA 250VAC normal blow, and - two pieces of 2 A 250VAC slow-blow type. These fuses should not be replaced by the user. Should one of these fuses be blown, it may be indicative of other failures. This is a complex and potentially dangerous operation. For this reason, we recommend this work be carried out by a trained service technician. 6-3. Tube Replacement A single 4CX1000A/8168 ceramic and metal tetrode is employed in the amplifier. Replacement is a complex and potentially dangerous operation. For this reason, we recommend this work be carried out by a trained service technician.
21 6-4. The ACOM1500 Simplified Schematic Diagram • See Fig.6-I ACOM1500 Simplified Schematic Diagram. * The 4CX1000A/8168 ceramic and metal radial beam tetrode (V1) with plate dissipation of 1000W is grid-driven. It can dissipate up to 1000W when forced air cooled and is specifically designed for class AB1 RF linear amplifiers. The input signal from the RF INPUT jack is passed through a broadband input matching circuit, which comprises some components in the INPUT PCB and Rsw. This circuit tunes out the tube input capacitance. The swamping resistor Rsw is a termination load for this circuit and can dissipate up to I00W of RF drive power. Cathode resistors Rc create DC and RF negative feedback, thus stabilizing the gain and equalizing the frequency response. The varistor VSsg in the screen grid circuit protects the tube and the screen grid voltage regulator in the events of an internal tube flashover. The combination LpI-RpI in the plate circuit is a VHF/UHF parasitic suppressor. DC plate voltage is fed through chokes RFCI-RFC2 and the capacitor Cb3 blocks it from the output. The output circuit comprises LPI, LP2, LL, CPI-CP3, and CLI-CL3 which form a classic Pi-L network and suppress the harmonic frequency emissions. This tank is switched and tuned over the bands by SIA-SIC and the air variable capacitors CPI, 2 and CLI, 2. The output signal is fed through an additional VHF low-pass filter for frequencies above 55MHz (LfI, Lf2 and Cf). Then it is passed through the vacuum antenna relay KI, wattmeter current transformer TAI, and a high-pass filter RFCasw-Casw for frequencies below I00kHz, to the antenna switch and the three outputs. The chokes RFC3 and RFCasw keep track of the antenna relay contact conditions and together with Casw prevent the plate supply from reaching the antenna. RFCasw shunts the high voltage to ground should the DC blocking capacitor Cb3 fail. The resistor Rasw protects the amplifier from charging Electro-static energy fed by the antenna. The PLATE CAPACITIVE DIVIDER and RF WATTMETER are the main sources of information for the control circuit of the amplifier during the antenna impedance matching process. The control circuit is based on the 80C552 micro-controller from Philips. All suupply voltages are delivered from the MAINS&LOW VOLTAGE and HIGH VOLTAGE SUPPLY PCBs. The control grid, screen grid, and plate currents, plate cooling airflow temperature, reflected power etc. are permanently monitored. Many software-derived protections are based on this information. * Detailed electrical schematic diagrams are available from ACOM or from your dealer on request. 6-5. Troubleshooting See S.5-4 for the method of reading the auto-protection signatures. You can decode them using the information below. * The signatures are structured in two lines, three groups by six symbols for every one event of auto- protection. The last event is numbered as IA-IB pair of lines, and the oldest one is 7A-7B. The meaning of the first group is as follows: a) nA - the number of the trip; b) Next three symbols mean the following: PN0 - tests made during Power-On procedure, before HV is ON; PN2 - tests made during Power-On procedure, after HV is ON and one second after step-start is closed;
22 SB0 - tests made in Stand-By, during the warm-up period or while entering Stand By (from Operate); SB2 - tests made during Stand-By, after the warm-up period; PR0 - tests made while entering Operate; PR2 - tests made during Operate; TR0 - antenna relay tests made while changing from Tx to Rx (during Operate) TR2 - antenna relay tests made while changing from Rx to Tx (during Operate) TR4 - antenna relay tests made during Tx (Operate mode) TR6 - antenna relay tests made during Rx (Operate mode) c) The last symbol of the first group designates the kind of the input parameter, which caused the protection to trip. The abbreviations in brackets below are the signal names/designations according to the CONTROL PCB electrical schematic diagram and signal type: 1 - peak forward power (pfwd, analogue) 2 - reflected power (rfl, analogue) 3 - input (drive) power (inp, analogue) 4 - peak anode alternate voltage (paav, analogue) 5 - screen grid current (g2c, analogue) 6 - plate current (ipm, analogue) 7 - high voltage (hvm, analogue) 8 - exhaust air temperature (temp, analogue) 9 - drive power exists (*GRIDRF, logic) A - antenna power exists (*PANT, logic) B - output relay closed (ORC, logic) C - arc fault (ARCF, logic) D - control grid current too high (GIC, logic) E - +24VDC power supply error (PSE, logic) F - low airflow (LAIR, logic) For instance, "IATR4B" in the first group would mean that the last auto-protection (IA) tripped by the antenna relay tests made during Tx - Operate mode (TR4), and the "output relay closed - ORC" signal was failing (B). The next five groups of symbols carry information about the analogue and logic values as measured by the micro-controller at the moment of auto-protection trip.
23 * Additional information is available from ACOM or from your dealer on how to interpret these values. Using an EXCEL APPLICATION (available from ACOM or your dealer free of charge) and a PC, you can decode these signatures by yourself. In case it is necessary to ship the amplifier please see S.7-3. 7. SPECIFICATIONS 7-1. Parameters a) Frequency Coverage: All amateur bands I.8-54MHz, extensions and/or changes on request. b) Power Output: I500W PEP or 1200W continuous carrier, no mode limit. In continuous carrier modes (RTTY etc.) for transmissions longer than I5 minutes (up to several hours depending on ambient temperature), the external auxiliary fan must be installed. c) Intermodulation Distortion: Better than 35dB below PEP rated output. d) Hum and noise: Better than 40dB below rated output. e) Harmonic Output Suppression: I.8-29.7MHz - better than 50dB below rated output, 50-54MHz - better than 66dB below rated output. f) Input and Output Impedances: - Nominal value: 50 Ohm unbalanced, UHF (SO239) type connectors; - Input circuit: broadband, VSWR less than I.3:I, I.8-54MHz continuously (no tunings, no switching); - Bypass path VSWR less than I.I:I, I.8-54MHz continuously; - Output (antenna) impedance matching capability: VSWR up to 3:I or higher. g) RF Gain: 12.5dB typically, frequency response less than I dB (60-85W drive power for rated output).
24 h) Primary Power: I00-264V (I00, II0,I20, 200, 2I0, 220, 230 & 240V nominal taps, +I0% -I5% tol.), 50-60Hz, single phase, 3500VA consumption at rated output. i) Complies with CE safety and electromagnetic compatibility requirements as well as FCC-regulations (I0 & I2m bands lock provided). l) Size & Weight (operating): W422mm x D355mm x HI95mm, 26.5kg. (I6.6 x I4 x 7.7 inches, 58.4 Lbs) m) Operating environments: - Temperature range: 0...+50 degs. Celsius; - Humidity: up to 95% @ +35 degs. Celsius. - Height: up to 3000m (I0 000 ft.) above sea level without output deterioration. 7-2. Functions a) Antenna Impedance Matching Process: plate-load True Resistance Indicator (TRI) aided. b) Three antenna outputs selectable by a button on the front panel. c) T/R System: QSK operation with built-in, vacuum RF antenna relay (special quiet installation). d) Protections: - Cover interlock for operator's safety; - Inrush power-on current control; - High voltage, control grid, screen grid, and plate currents; - Exhaust air temperature; - T/R sequencing; - Antenna relay contacts, including RF power induced in antenna from another nearby transmitter; - Antenna matching quality; - Reflected power; - RF arcs, including in antenna system; - Overdrive. e) Signatures of the amplifier internal status are stored in a nonvolatile memory for the 7 most recent auto protection trips. f) High brightness 5x7 dot character vacuum fluorescent display (VFD) with bargraph for forward peak power and text messages to the operator. g) Measurement and constant monitoring of I2 most important amplifier parameters via VFD. h) Menu-selectable display Brightness.
25 i) Tube: a single 4CX1000A/8168 ceramic and metal radial beam tetrode with plate dissipation of 1000W (forced air cooled, grid-driven), specifically designed for class AB1 RF linear amplifiers. 7-3. Storage and Shipment C A U T I O N Should you need to transport the amplifier, use the original packing as described below. First, switch off the amplifier. Pull the mains plug out of the wall outlet. Disconnect all cables from the rear panel of the amplifier (remove the ground connection the last). Finally, pack the amplifier in its original carton. a) Storage environments: the amplifier can be kept packed in dry and ventilated unheated premises without chemically active substances (acids, alkalis etc.) in the following climatic environment: - Temperature range: -40 to +70 degs. Celsius; - Humidity: up to 75% @ +35 degs. Celsius. b) Shipping Size and Weight: W560mm x D560mm x H300mm, 29.5kg. (22 x 22 x II.8I inches, 65 Lbs) c) Shipping environments: all types of transportation, including aircraft baggage section up to 12 000 meters (40 000 ft.) above sea level. E N D

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