Tokyo Hy Power Labs HL-15KFX LINEAR AMP User Manual USERS MANUAL
Tokyo Hy-Power Labs, Inc. LINEAR AMP USERS MANUAL
USERS MANUAL
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| Document Description | USERS MANUAL |
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| Date Submitted | 2006-06-19 00:00:00 |
| Date Available | 2006-06-19 00:00:00 |
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| Document Title | USERS MANUAL |
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M1111
Solid-State HF/SOMHZ Band
IkW Linear Power Amplifier
Model HL-l 5fo
H18.02.13. Contents Inst. Man, HL‘lfiKFX
pmscflquv-fisflsor
w»
10.
11.
12.
13.
9-2 :
9-3 :
11-1 :
11-2 :
11-3 :
11-4 :
11-5 :
13-1 :
13-2 :
13-3 :
13-4:
13-5 :
13-6 :
13-7 :
Contents
Introduction ....................................
Caution
Featurm
Specifications .
AC Line Voltage .........
Front Panel Description
Rear Panel Description ....................... 9
Connection & Operation .
ALC Connection ........
Band Data Cable Connection
ICOM DC Voltage Band Data
ICOM CI-V
Yaesu Band Data ..........
Kenwood RS-232C Data .
Protection Circuits .................
Explanations of Major Circuits
Main DC Power Supply ..........
PowerAmp, LRF.
RF Power Amp, TX-RX Switch .
Main Control .................................. 22
Band Decoder, Frequency Counter 23
Trouble Shooting .....
Schematic Diagram .,
PC1662 PA( Power Amp) .
PC1664 Band Decoder ..............
PC1681 L.P.F. ( Low Pass Filter ) .
PC1665 Main Control ...............
PC1667 RF Power Detector
PC1669 Front Panel Board .
PC1675 Pre-scaler ..............
14.
15.
13-8 :
14-1 :
14-2 :
14-3 :
14-4 :
14-5 :
14-6 :
15-1 :
15-2 :
PCl611FN/PC1611 DC-DC Conv. 32
33
Top View (Detailed ) ....... 33
Top View & Side View ( Left ) t. .. 34
Side View ( Right ) & PC1664, PC1665.. 35
PA , LPF (Top & Bottom) ................... 36
Power Detector, Pro-sealer,
DC-DC Convener .................. 37
Main Control ( Front View ) .. 38
Block Diagram .................................. 39
Simplified Diagram ...... .. 39
Overall Diagram ..........
1. Introduction ,
HL~1.5KFX is a most compact and light weight desk-top HF/SOMl-lz band linear power amplifier
with the maximum input power of 1.75kW. it boasts of being smallest and lightest in the industry
using our solid state broad band power amp technology.
Typical output power is 900W PEP/SSE ( 1kW max. ) on HF and 500W on 6m 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 hooked to your modern radio through such band data cables as lCOM Cl-V, DC voltage
( lCOM, Yaesu ), and RS-232C ( Kenwood ).
One of these data cables is included in the package as requested by the user at the time of order
placement with the dealer or the factory.
2. Cautions
2-1 This amplifier is cooled through the forced air flow. Leave at least several inches of space off
the room wall or from other substances for the smooth air intake to the fan. Do not block the
ventilation window on the top of the cover.
2-2 Do not place the amplifier where there is a direct sun rays, high humidity and or high
temperature environment.
2-3 There are high AC, DC, and RF voltages mnning inside of the cabinet especially when the
amplifier is keyed for ON AIR. Do not try to make an access to the internal parts carelessly.
24 if you happen to hear the bang sound or smell something unusual, turn off the AC main power
immediately. Check the multi meter readings oi Vd and Id . Also check the fuses and cable
connections around the amplifier. if you find any kind of the failure, please contact the dealer or the
factory.
2-5 Be sure to ground the amplifier for the best result of performance stability and your safety. It
helps reduce RF strays and noises.
2—6 To eliminate the RF interferences to such home appliances as TV, FM radio, telephone sets etc.,
it is recommended that proper number oi clamp—on ierrite cores are inserted to the both ends of
remote control cable, ALC cable, coaxial jumper cable, and antenna cable. Also it is recommended
that common mode AC line filter and low pass filter are inserted on AC cable ( near the AC consent)
and antenna coaxial cable.
2-7 This amplifier has fast acting sophisticated protection circuits controlled by the latest micro
processor, Please note, however, that such operations as to hit same protection circuits repeatedly
will lead to the failure of the valuable final power transistors.
2-8 When checking the inside of the amplifier, be sure to wait for a few minutes until the high DC
voltage is discharged ( monitor Vd meter reading ). Also do not try to turn the potentio-meters for RF
power detector, protection circuits, FET bias voltage circuit and so on, as they are precisely aligned
at the factory. Adjustment of these parts need an aid of precise measurement instmments.
2-9 Power transformer primary is wired for AC 230V operation ( or as specified by the user at the
time of order placement) at time of shipment from the factory. The voltage change from BOV to
115V can be made by sliding the select switch located at bottom of the chassis. (See AC Power
section. ) Be sure to check this switch before you plug the AC power cord to the AC line.
2-10 Tb run the amplifier1 be sure to connect either the dummy load ( 50 ohms, lkW min. ) or the
well adjusted antenna to the output terminal. Operation with no load vn‘ll give big stress to RF power
FET’s, although protection circuits may work at critical conditions.
2-11 Required drive power is slightly less than 100W to obtain full lkW output. Do not attempt to
over-drive with a high power transceiver.
2-12 When the aluminum heat sink and ventilation hole have become dirty with dust, clean them
periodically, as the cooling efficiency will be degraded.
2-13 For the long continuous operation under RTI'Y/FM modes, it is recommended that RF drive is
reduced to achieve 20% to 30% lower output compared with CW/SSB.
2-14 Do not apply hard physical shock to the amplifier as there are many precision electronic
components used inside the cabinet‘ Also the original carton box is the best packing material for the
amplifier transportation in the future when sending the amplifier back and forth to the service
facilities.
to
3. Features
3-1 HL-LSKFX is the most compact lkw HF amplifier that is easy to handle and to operate due to
the solid state broad band design. This amplifier is lightest and most compact in the industry. Our
solid state design engineering successfully developed the world class compact IkW HF/Gm
amplifier.
3-2 The amplifier is equipped with the newly developed band decoder which works with the band
data signal supplied from the associated HF transceiver so that the band change of the amplifier is
made automatically as the transceiver moves up and down the frequency bands.
3-3 Four units of powerful MOS FET SD2933’s by ST Micro ( French ltalian firm ) are used for the
main PA section. 900W PEP ( SSB type ) is obtained on HF and 500W on 6m.. Due to the broad band
amplifier characteristics, no tuning procedure is needed once the operating band is set‘
3-4 The amplifier operates in full break-in CW mode due to the use of the high speed antenna relays
made by Panasonic/Matsushita.
3-5 With the duct structure design, the heat sink aluminum block for RF PA module as well as other
components are effectively cooled with the powerful blower fan . Fan runs quietly so that it may not
annoy the operator for hearing the weak DX signal during the receive .
3-6 Advanced 16 bit MPU ( micro processor ) is employed to run the various high speed protection
circuits such as over drive, high antenna SWR, DC over voltage, 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 of AC Power Section for changing primary wiring of
the power transformer.
3-8 Interlock system is employed for the safety of the operator AC power is shut down as the top
cover is lifted.
3-9 Analog multi-meter will allow the operator to monitor Pf ( Forward output power ), Pr
( Reflected power ), Vd ( Drain voltage of power FET ), Id ( Drain current) etc.
3-10 For the future expansion of the amplifier system, there is eqm'pped a socket at the rear panel
for the control cable to connect to model HC—1.5KAT, auto antenna tuner by Tokyo I-Iy-Power Labsl
to be announced in 2006.
4. Specifications
Frequency : 1.8 ~ ZSMHz all amateur bands including WARC bands and 50MHz
( US model to cover 1.8 ~ 21MI-Iz only due to FCC regulation )
Mode : SSB, CW. R’ITY
RF Drive : 85W typ.( 100W maxi )
Output Power : I-IF : 900W(+/-10%) PEP typ., 850W (+/-10%)CW typ.
50MHz : 500W PEP/CW
Matching Transceivers for Auto Band Decoder : ICOM, Yaesu, Kenwood
Drain Voltage : 53V ( when no RF drive )
Drain Current : 40A max.
Input Impedance : 50 Q ( unbalanced )
Output Impedance : 50 Q ( unbalanced )
Final Transistor : SD2933 x 4 ( MOS FET by ST micro )
Circuit : Class AB parallel push-pull
Cooling Method : Forced Air Cooling
MPU : PIC 18F452 x 2
Multi-Meter : Output Power Pf lkW
Reflected Power Pr 100W
Drain Voltage Vd 60V
Drain Current Id 50A
Input/Output Connectors : Type M-J (UHF S0-239 )
AC Power : AC 230V ( 200/220/240V ) 10A max.
AC 115V ( 100/110/120V) 20Amax.
AC Consumption : 1.9kVA max. when TX
Dimension : 272 x 142 x 363 mm ( WxHxD )
10.7 x 5.6 x 14.3 inches
Weight : Approx. 20kgs. or 45.5lbs.
Accessories : AC Power Cord x 1
RCA Plug x 2
Band Decoder Cable x 1 ( Either one for ICOM, Yaesu, or
Kenwood )
Spare Fuse 15A( for AC 230V line ) x 2
Spare Fuse 25A( for AC 115V line ) x 2
Spare Fuse 1A( Miniature Fuse ) x 3
(For PC1664 , main control board x 1,
For PC1662 , power amp board x 1 )
Spare Fuse 2A( Miniature Fuse ) x 1
(For PC1611 FN DC-DC board It 1 )
User Manual x 1
Optional Items : Auto Antenna finer ( HC-1.5KAT)
External Cooling Fan ( HXT-LSKF for high duty cycle R’ITY )
5. AC Line Voltage
5-1 Although the amplifier is designed to work with both AC 115V ( lOO-IZUV ) and AC 230V
( 200— 240V ), we recommend the user to operate with AC 230V line for the stability reasonr
5-2 Since AC plug style differs from country to country. The plug is not included in the package
Please source locally the suitable one for your application.
5-3 AC voltage has been set for 230V use ( or as requested by the customer at time of order
placement) at the time of shipment. If you wish to change to AC 115V, change the voltage setting by
sliding the switch knob that is located at the chassis bottom as illustrated below. Also the other
illustration explains about how to cope with other AC voltages than 230/115V. Before starting this
work, be sure to pull the AC plug out of the AC line for the safety.
AGIOOV Ind/or A0200V , ACHOV Ind/of M2220V
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6-A. Front Panel Description
(1) POWER v Main power switch to turn on and off AC power.
LED (green) lights when turned on.
® OPER. OPERATE /STAND-BY switch. At OPERATE , the amplifier is ready to go
into ON AIR (TX) state and at STBY, it is on STAND-BY state.
® METER To change the multi-meter scales. Meter reads Pf, Pr, Vd, and Id.
@ BAND SELECT
To select the band changing methods ofAUTO and MANUAL. When AUTO,
the manufacturer of the transceiver in use should be selected. When the band
data cable is not used, MANUAL should be selected. ( See page 14, 9. Bans
Data cable Connection )
@ UP, DOWN Push switch for the band change on manual mode. While the transceiver is
on Receive (RX) state, push the button to select the desired frequency band
to operate. The switches do not work when the transceiver and the amplifier
are on Transmit (TX) state.
© ANT Select switch for antenna A and B. As the switch is pushed , A and B are
selected reciprocally. Selected antenna is stored in the memory for the
respective bands. Note that antenna is always held at A when the POWER
switch is turned off.
CD FAN, ID, ON AIR
®~1 ON AIR : Green ‘LED lights when the amplifier is on transmit state (TX).
®-2 FAN : LED lights when cooling fan runs at high speed. If the PA heat sink
temperature reaches 40 degrees C, fan will run at high speed to enhance the
®-3 ID :
cooling effect. It is recommended that the power switch is not turned off
immediately after finishing the operation if FAN is lit. Leave the cooling
fan running for the time being.
Excessive Id Indicator ( > 35A). Depending on the band and antenna used,
a high drain current may flow into FET’s. lf 35A is exceeded, LED flickers
and or lights to indicate the high 113 is being drawn. (This lighting does not
necessarily mean the failure of the amplifier. However if it lights too often,
and too long, it is suggested that the drive power is somewhat reduced and
that antenna is checked for SWR, as the stress may be given to FET’s‘ )
® 0. DRIVE,0. HEAT, 0. VOLT, FUSE, PR
®-1 ODRIVE : When over drive or band mis-set is detected, LED lights to indicate the
®-2 0.VOLT:
®-3 0.HEAT:
®-4 FUSE
®-5 PR
®BAND
protection circuit has worked.
When the DC drain voltage of PET ( Vd ) is too high, LED lights to indicate
protection circuit has worked.
When the PA module temperature reaches 70 deg. C, LED lights to indicate
the protection has worked. ( Usually it is needed for the cooling fan to keep
running to cool off the PA module for several minutes at least. )
LED lights when the 15A'glass fuse is blown with a high ld, ( No 20A
fuses are on PCl662 PA board. )
LED lights when the reflected power from antenna exceeds Bow to indicate
the protection circuit has worked.
( Protection can be reset by turning the main POWER switch
off, and then turn on again.)
One of the green LED’s lights to indicate that the band is selected for an
operation.
® MULTI METER 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 © METER select switch.
6-B. Rear Panel Description
® ANT A RF Output Connector. Connect the coax cable to the antenna.
® ANT B RF Output Connector. Connect the coax cable to another antenna or the dummy
load ( 500 IkW for example ).
(3) INPUT RF Input Connector. Connect the coax jumper cable from the transceiver
© AC POWER AC Mains Socket. Plug the AC power cord. ( Socket is EMI filtered.)
(9 GND Ground Terminal.
© SEND 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 the ground by
way of the relay circuit of the transceiver. DC current to flow this pin is 5V,
lmA only.
® ALC RCA Jack for ALC Voltage Output. Negative DC voltage appears at the center
pin, which is to be fed back to the ALC terminal of the transceiver. ALC is
effective to keep the amplifier output power at certain limit‘ Also it is useful
when the transceiver output power is higher than 100W. ( See page 13. 8. ALC
Connection. )
® ALC ADJ. Potentio-meter to adjust ALC voltage level. If turned fully counter-clockwise,
minus 10V is available at maximum. Factory setting is 0 volts, the pot being
turned fully clockwise.
@ FUSE A pair of fuses for AC Mains. 15A glass fuse. ( Change to 25A fuses if 115V
line is selected. )
® ICOM RCA Jack for the DC voltage derived band data cable from the ICOM
transceiver. ( See page 14, BAND DATA CABLE CONNECTION WITH
lCOM.)
® CI-V See Eye Five. Ear phone jack for CI-V hand data cable from the [COM
transceiver. ( See page 15. )
® BAND DECODE
Slide switch to select band data communication methods with ICOM
transceiver. To select either “DC voltage band data” or “Cl-V band data".
® TUNER DIN Socket for External Auto Antenna Tuner ( Onr HC-1.5KAT is expected to
avail in 2006. )
@ YAESU DIN Socket for band data cable from the Yaesu transceiver. (See page 16. )
@ KENWOOD D-th (9 pin) socket for band data cable from the Kenwood transceiver
(RS-232C} ( See page 17‘ )
® EXTERNAL FAN POWER
Plastic Female Connector for the DC power supply cable to feed to optional
external cooling fan kit ( l-DlT-l.5KF )
7. Chassis Bottom Description
® AC 115/220V Slide switch to select AC line voltage Set to 220V side for
10
200/220I230I2AOV. Set at 115V for 100/110/115/120V lines,
(9 FUSE Holder of Fuse fur the External Cooling Fan Unit, HXT-LSKF. Use 2A glass
fuse, when the optional fan is installed on top of the cover.
7. Connection & Operation
This section explain: about one antenna system and two antenna systems with basic connections
with the transceiver; where no band data cable is connected. In this case, band setting is made with
MANUAL mode, pushing UP/DOW keys. Advanced operation using the band data cable will be
described later in Section 9.
One tenna S stern m le
Transceiver
moAntenn S semE m le
Transceiver
L'Jll
7-1 Connect AC cord and coax cables as illustrated above. Connect the cable from “SEND” to ACC
11
or the remote terminals of transceiver, where it is marked “SEND” or "TX GND”. These terminal
pins are ones that is shorted to the ground when the transceiver is at TX/ON AIR state. if this wiring
is not made, the amplifier will not go into TX ( amplification ) state. For the temporary check of the
amplifier, ground the SEND center pin by inserting an RCA plug whose center pin is soldered to the
outer case of the plug with a small piece of wire. For your information, this SEND terminal is
pulled up at DC 5V level being connected to the internal micro processor pin. When grounded, DC
sink current of 1 mA (only) will flow. It is a very light load to the transceiver control circuit,
7-2 At first, turn fully clockwise ALC knob not to apply ALC voltage to the transceiver. Application
ofALC will be covered in the following section 8.
7-3 Keeping the POWER (forAC mains ) switch off, check the SWR of your antenna by keying the
transceiver to TX state ( CW or RTTY mode ). Monitor the SWR with an external SWR/Power
meter. if SWR is as high as 1,8 or more at band center, antenna has to be adjusted for better value,
As an alternative, antenna tuner may be inserted and have the tuner match the antenna impedance.
7—4 Turn the POWER switch out Turn the BAND switch to MANUAL position. Then push UP/
DOWN keys to select desired operation band, Turn on the STAND-BY switch to OPER ( operate )
position and the amplifier is ready to work. I! you key the transceiver with carrier level set at
relatively low level such as 20-30W, amplified out put signal of a few hundreds watts will come out
of the amplifier. Monitor this output with multi-meter (Pf position ) or with external power meter.
Increase drive level to roughly 50W and see if antenna SWR stays constant. ( Some antenna may
show changed SWR value due to heated connectors junctions and trap coils as higher RF currents flows.)
7-5 Now you can increase drive level to nearly 80-90W to achieve maximum carrier output power
of 900W (CW, Km) from the amplifier. if you change to $35 mode, peak voice power will reach
approximately 1kWr For high duty cycle transmission in RTI'Y, SSTV,FM modes, it is recommended
to reduce the drive power by 20-30% compared with SSE/CW. In AM mode, the drive power
should be strictly reduced to one third of $33, or 30W at most, otherwise modulated amplitude peak
will be distorted.
7-6 With high power transceiver in SSB mode, it may happen that you will over drive the amplifier
to have output signal distorted ifyou speak too loud or it you set microphone gain too high. Speak
to the microphone properly not to splatter the spurious to the neighborhood.ALC is effective to
prevent the output signal from being distorted or to limit the carrier level within rated output level.
As long as you do not over drive, you may disregard ADC connection. For the details, see Section 8,
ALC CONNECTION.
12
7-7 Protection circuits may work during operation depending on the conditions. If the protection
circuit has shut down the amplifier, check the antenna SWR, Vd ,AC line voltage, or try to reduce
the drive level. To reset, turn off the POWER switch once and turn on again. Also the power
transformer has the over heat protection in the coil layer, If this temperature switch once works, the
amplifier is set to the receive mode for a while with cooling fan kept running until the transformer
cools off. It may take ten to fifteen minutes for this cooling depending on the room temperature. For
the more details of protection circuit, see Section 10.
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 often volts ( - 10V) is produced at this terminal when the
amplifier is fially driven. This voltage is adjustable with ALCADJ. knob located above ALC jack. IIALC
voltage is properly fed back to the transceiver, it is most usefirl to keep the maximum output power
constant or hold the power at certain leveL Also ALC is effective to avoid SJB signal from being distorted
when overdriven. If you , however, set the mic gain properly and do not overdrive the amplifier, you may
not always need to connect ALC to the transceiver Depending on the manufacturer of the transceiver,
suitable ALC voltage differs. [COM may need 0» -4l{ and Yaesu may need 0-- -5Vrange.. Kenwood may
need -6 ~ -8Vmaximum, Check your trnmseeiver manual.
8-1 Prepare an ALC control cable using the RCA plug supplied in the package. Solder a single wire or
more profitably a shielded single wire to center pin of RCA plug and the shield braid being soldered to
outer slde of the plug. Connect the control cable to the “ALC ( or EXTERNAL ALC )” jack of the
transceiver. External ALC input is sometlmes available at one of the pins of "ACC" socket of the
transceiver also.
8-2 At first turn Au: ADJ. fully counterclockwise. Drive the amplifier on CW/RTI'Y mode
up to full output power. Then turn the ALCADJ counter clockwise. Observe the SWR/Power meter
at the output ( or Pfof multi-meter ). When the power started to drop a bit, stop turning ALC ADJ.
and leave the ALC ADJ. there. Or if you wish to further reduce the power, keep turning ALC ADJ
until the desired level is achieved. With these adjusunents, you will now see that output power is
rather saturated, if you further try to increase the drive power.
(-10Vis produced as maximum ALC voltage when the amphfier output Ls over 200W )
AL J REM. HEW
o {0} Upper Right: Cornet
N. OUT max, ALC our m
°® °®
° 0 ALC ] “Transceiver
m (N -
13
9. Band Data Cable Connection
Connection methods with ICOM, Yaesu and Kenwood transceivers are described in detail here
respectively. This connection enables the automatic band setting of the amplifier with the hand
set command from the transceiver: Four types of cable connections are explained.
9-1 ICOM DC Voltage Band Data
Turn off the AC mains of transceiver and amplifier for safety.
Connect the cable ( for ICOM DC Voltage Band Data Connection ) as shown in the following
illustration.
Slide the “ BAND DBCODE” slide switch on the real panel toward “ ICOM “. ( Other side is for
CI-V. )
Set the “ BAND SELECT “ rotary switch on the front panel to “ ICOM “t ‘l\|rn on the AC mains of
transceiver, and then turn the POWER switch of the amplifier on.
Observe the band indicator ( LED ) of the amplifier matches that of the transceiver.
lllil’,’ 7? ”1,57
, ICOM DC Vottaae sun Data Cable EM
mu Transcelver
(tout-750.410“) 7>~$~r
”IT ALB Ma) HEWTE
' fi 0
lCOM DC VMhll Bull Dal- (Isiahv (mg 7! my
ll-l. EKFX ll!
Note : This connection is at least good for [COM models of 746, 756, 7800 and so on. ( 706MK I! 6
needs a special connection to the ACC socket using the 706 accessoly cable assembly. See 706
manual.)
14
9-2 ICOM CI-V ( See Eye-Five )
Following initial setting is needed to the ICOM transceiver ;
CI-VBAUDTRATE : 4800
CI-V ADDRESS : Sch
CI-V TRANSCEIVE : ON
CI-V with IC-731 : OFF
( For the details, refer to the ICOM radio manuals. )
Turn off the AC mains of the transceiver and amplifier. Connect the following CI-V band data cable
as shown in the illustration.
Slide the BAND DECODB switch knob to the CI-V side. BAND SELECT rotary switch on the front
panel should be set to ICOM position.
Check if the transceiver is in the receive state. ”him on the POWER switches of the transceiver and
the amplifier. Observe the band indicator (LED) of the amplifier matches that of the transceiver.
3. 57, 7 A
ICOM CI-V aw Data Cable ’ a 5597
Ion! Transceiver 7>~7~r
sit/m"
"IT 330 ALO Mani!)
15
9-3 Yaesu Band Data
Using the Yaesu band data connection cable ( shown below ), connect the transceiver ( example,
F111 DOOM? MK-V) to the HL-LSKFX.
Thm off the AC POWER switches of the transceiver and the amplifier. Connect the plug of DIN 8
pin connector to the BAND DATA ( 8 pin ) socket of Yaesn transceiver, Connect the other plug of
DIN ( 5 pin ) connector to the‘ ® YAESU of DIN (5 pin) socket on the rear panel of the amplifieri
Check if the transceiver is in the receive state and tum on the AC POWER of the amplifier. Observe
the band indicator ( LED ) of the amplifier matches that of the transceiver.
Mil??? U DIH797 5’
VHS“ am am cm. mm
VAESJ Transceiver
'V|uu land Dut- Carl-
16
9-4 Kenwood RS-ZSZC Band Data
Using the Kenwood band data connection cable ( shown below ), connect the transceiver
( example 125-950, 73-870 ) to the HL-IfiKFXas illustrated below.
Initial setting to the transceiver is as follows ;
Communication Speed : 4800 (bps)
Stop Bit : 1 hit
( For the details, refer to the Kenwoad radio manual. )
Turn off the AC POWER switches of 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
mother D-sub 9 pin plug to the KENWOOD ( D-SUB 9 pin socket ) on the rear panel of the
amplifier.
Turn on the AC POWER switch of the transceiver and check if transceiver is in the receive state.
Turn on the AC POWER of the amplifier. Observe the band indicator (LED) of the amplifier
matches that of the transceiver.
Kelwlood R5233C Band Data Cable
mm Transceiver
17
10. Protection Circuits
There are five major protection functions in this amplifier: When the set was shut down for some
reason, correct the possible cause of the shut down. Turn of the POWER once and then turn on
to reset.
10-1 O.DRIVE (Over Drivel Band Mia-set)
When the drive power exceeds 100W level, the amplifier is shut down to become STAND-BY mode
( or receive ) in order to protect the input side of power FET’s. Also if the band setting is wrong,
protection may work. This especially occurs, on MANUAL BAND mode, when amplifier band
setting is lower than that of the transceiver
10-2 0,HEAT ( Over Heat )
When the temperature of the power amplifier aluminum heat sink reaches 70 degrees C, the
amplifier becomes RECEIVE state for the safety of the power FET devices. Also if the temperature
of the inside layer of the power transformer reaches 130 deg. C, the amplifier will become
RECEIVE state for safety. 0.HEAT protection can not be reset before the heat sink or transformer is
sufficiently cooled off;
10-3 O.VOLT ( Over Voltage)
Due to the sudden AC line voltage rise, and or the erroneous transformer primary wiring, the FET
drain voltage may rise above acceptable level. If O.VOLT protection works, check the AC line
voltage with the circuit tester or the AC voltage meter.
10-4 FUSE ( Fuse Blown )
If either of glass fuses (20A) on PC1662 fails, O.VOLT protection works. This failure will rarely
happen under normal usage of the amplifier. When it occurs, there is a possibility that power FET’s
have failed together. If the amplifier can not he recovered, consult with the dealer or the service
center.
10-5 PR (Reflected Power Protection )
If the reflected power from the antenna reaches approximately 80W, PR protection may work. In this
case, one solution is to reduce the drive power form the transceiver. Or you may have to check
antenna matching ( SWR ) status. If the matching can not be corrected properly, use the antenna
tuner,
As seen above, the amplifier is equipped with several kinds of fast acting protection circuits using
the latest micro processor. If the amplifier is, however, operated in such a manner that multiple
protections work repeatedly over the long time period, the amplifier may be seriously damaged.
18
11. Explanation of Major Circuits
Five major circuit blocks are explained on its basics and signal flows.
11-1 Main DC Power Supply
11-2 Power Amp, LtPtFt
11-3 RF Power Detector, TX/RX Switching
114 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 the
oriented core, bridge diode rectifier, and high capacity electrolytic capacitor of
68,000uF for the filter. Soft start circuit suppresses the AC rush current using the
thyristor. A part of 50V line is convened to 24V through DC-DC converter and is
supplied to the cooling fan.
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19
11-2 PowerAmp (PA PC1662 ) / L.P.F. (PC1681 )
RF PA is the heart of this amplifier and is composed of four pieces of SD2933 FET
made by ST Micro, a French-Italian joint venture firm. The amplifier type is a parallel
push-pull of class AB . Gate bias supply circuit is regulated for the best stability and is
thermally compensated as well.
The PA has a 6dB attenuator at the input side for the gain reduction and enhanced
stability of wide band power PA characteristics. On the heat sink are two kinds of
thermal sensors to detect temperatures of 40 deg C, and 70 deg C respectively. At 40
deg C, the cooling fan is shifted to high speed mode. At 70 deg C, the amplifier is
locked to RECEIVE state for the safety of PET devices.
In L.P.F. ( output low pass filter ) circuit, there are eight kinds of band filter that is
selected either by auto band decoder or by manual band switch. Each L.P.F. has a
harmonics rejection capability to meet the international telecommunication equipment
standards.
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20
11-3 RF Power Detector/ TX-RX SWitCII ( PC1667 )
As illustrated below, there are two RF power detectors on this board. The one detects
the drive signal level from the radio and the other monitors the out going power as well
as reflected power from the load ( antenna ). These detected signals are sent to the MPU
of PC1665, Main Control board, that monitors the operating condition of the whole
amplifier.
The Tx-RX switch ( Send-Receive switching ) will switch the flows of drive power/
output power and incoming signal from antenna with two high speed relays mounted at
input and output sides of the PA TWO channel antenna switch (N3) is also installed on
this board.
The limiter on this board together with prescaler on PC1675 help MPU in Main Control
count the frequency of the RF drive signal.
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11-4 Main Control ( PC1665 )
This is the heart of the control signal processing of HL1.5KFX. It judges the operating
condition of the amplifier and issues the commands to the peripheral circuits as well.
Various analog signals are put into MPU such as RF drive from the transceiver, RF
power signals at various points, DC power supply information and so on.
These are converted to the digital signals through A/D converter , MPU will then
numerically compute the data, to judge the amplifier status, and issue commands for
protections.
Transmit-Receive switching, high/low Control of fan, and LED lightings are all
commanded by the MPU on this board.
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11-5 Band Decoder/ Frequency Counter
The band decoder decodes the various operating band data issued by the major brands
of the radios ( ICOM, Yaesu, Kenwood ). With the decoded signal, the amplifier will
automatically follow the frequency band of the radio.
With these three manufacturers, there are four kinds of band data used in their latest
radio models, i.e. DC voltage, 4 bit TIL RS-232C, and serial data. HL~1.5KFX is
designed to meet any of these methods, if matched cable is connected respectively.
The MPU has the frequency counting function also. RF drive signal from the
transceiver is sampled and divided by 16 (PC1675 ), and then reaches the input of the
MPUA
Under the manual band select mode, if the frequency of RF drive and band setting of the
amplifier do not match each other, MPU will judge band mls-set to issue the
amplification “halt” command ( shut down ),
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12. Trouble Shooting
Failure Possible Cause Solution
AC mains not (D AC fuses blown ® Replace with new ones.
Come on ® AC cord not plugged in (2 Plug in securely.
® Inter-lock switch lifting ® Screw bolu tightly for top cover.
@ Wrong tapping on power @ Correct primary wiring.
transformer primary
Not enter into ® Remote control cable (D Check the cable and connect correctly‘
Transmit state not connected ® Check drive power, antenna SWR, antenna
@ Protection circuits onl selection A/B etc. Reset with AC POWER switch.
0.Drlve lights (D RF over-drive ® Decrease drive.
® Band mis-set (2 Match the BAND correctly ( Manual mode)
PR lights ® Reflected power high, i>® Check, adjust antenna. (Or decrease drive.)
Antenna SWR high @ Check the coax cable connectors.
@ Poor connection of
coax cables
FUSE lights ® Fuse blown (D Replace F202 and F203 ( 20A ) on the PA board
(2 Antenna SWR high ( PC1662 ).
@ Short circuit @ Adjust the antenna.
l—— ® Contact the distributor, or service center.
O.fleat lights G) Inside over heated Cool off until sign goes ofl. Check if air in-take area
above 70deg. C blocked with substances. Also check ventilation
window on top cover.
TVI, FM! 6) Over drive. ® Decrease the drive. CheckALC setting.
(2 RF leakage from coax ® Insert common mode filters on antenna cable or
cable. grounding Wire,
AC power cord etc.
AC line‘ Add clamp—on cores ( by TDK,
Amidon, Palomar ) on various cables.
24
13. Schematic Diagrams
13-1
13-2
13-3
13-4
13—5
13-6
13-7
13—8
PC1662 PA ( Power Amplifier )
PC1664 Band Deooder
PC1681 L.P.F. ( Low Pass Filter)
PC1665 Main Control
PC1667 RF Power Detector
PC1669 Front Panel Board
PC1675 Pre Sealer
PC1611FN/PC1611DC DC-DC Convener for Fan
14. Parts Layout
14-1
14-2
14-3
14-4
14~5
14-6
Top View ( Detailed )
Top View & Side View ( Left )
Side View ( Right ) & PC1664, PCl665
PA( PC1662 ), LPF ( PC1663 ) Top & Bottom
Power Detector ( P01667 ), Prescaler ( PCl675 ), DC-DC Convener
( PC1611FN )
Main Control ( PC1665 ) Front View
15. Block Diagram
15-1 Simplified Diagram
15-2 Overall Diagram
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