ACOM 1500 Manual
Contents
1. automatic protection system so you may begin using the amplifier immediately following installation However to make full use of the amplifiers potential and to fully configure it to your local conditions we recommend that you thoroughly read the following information There are 14 ON LINE information screens which can be selected by pressing repeatedly the NEXT or PREV buttons see fig 3 2 Their purposes and methods of use are described in the next 7 sections 4 1 through 4 7 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 will hear the blower and the optional external fan starting at high speed for a second and then slowing down After successfully passing the initial amplifier self tests the ON OFF LED begins flashing green while the following inscription on the VFD 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 Pressing either the PREV or NEXT buttons during this period will result i2. a PC you can decode these signatures In case it is necessary to ship the amplifier please see S 7 3 19 7 SPECIFICATIONS 7 1 Parameters a Frequency Coverage All amateur bands 1 8 54MHz extensions and or changes on request b Power Output 1500W PEP or 1200W continuous carrier no mode limit In continuous carrier modes RTTY etc for transmissions longer than 15 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 1 8 21 5MHz better than 50dB below rated output 24 54MHz better than 66dB below rated output f Input and Output Impedances Nominal value 50 Ohm unbalanced UHF SO239A type connectors Input circuit broadband VSWR less than 1 3 1 1 8 54MHz continuously no tunings no switching Bypass path VSWR less than 1 1 1 1 8 54MHz continuously Output antenna impedance range capability VSWR up to 3 1 or higher g RF Gain 13dB typically frequency response less than 1dB 60 85W drive power for rated output h Primary Power 100 264V 100 110 120 200 210 220 230 amp 240V nominal taps 10 15 tol 50 60Hz single phase 3500VA consumption at rated output i Complies with CE safety and electromagnetic compatibility requirements as well as FCC regulations j Size
3. amp Weight operating W422mm x D355mm x H195mm 26 5kg 16 6x14x7 7 inches 58 4Lbs k Operating environments Temperature range 0 50 degs Celsius Humidity up to 95 35 degs Celsius Height up to 3000m 10 000ft 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 quiet built in vacuum RF antenna relay d Protections Cover interlock for operator s safety Inrush power on current is limited 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 20 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 12 most important amplifier parameters via VFD h Menu selectable display Brightness i Tube a single 4CX1000A 8168 ceramic and metal radial beam tetrode with plate dissipation of 1000W forced air
4. cooled grid driven specifically designed for class AB1 RF linear amplifiers 7 3 Storage and Shipment CAUTION 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 11 8 inches 65Lbs c Shipping environments all types of transportation including aircraft baggage section up to 12 000 meters 40 OOOft above sea level END 21
5. not interrupt transmission Examples include Reduce Drive Plate Current etc You may continue to transmit under such conditions but you are close to a trip threshold b The second degree of protection is a trip to standby mode Soft Fault An example is GRID CURRENT All Soft Fault messages are marked with two asterisks on both screen edges The message remains on the display until any button is pressed or until the auto operate function returns to operate mode automatically The Soft Faults permit correction by the user such as by using less drive improving antenna VSWR etc c The third degree of protection is a trip to OFF LINE mode Auto Protection See S 6 5 Troubleshooting If it is not evident why the trip has occurred you may try to turn the amplifier on again If the problem persists you will need to contact your dealer see S 1 2 NOTE The 6dB input attenuator is automatically inserted about one second after faulty tuning is detected at drive levels above 20W Itis also switched off at every PTT release unless inserted manually 15 5 OFF LINE MODE There are three control functions and 14 information screens available in the Off Line Mode of the amplifier For example you may control the VFD brightness enable disable the Auto Operate feature and assign the antenna outputs You may also list the auto protection signatures The tube is not powered at all only the micro controller is active during t
6. to withstand currents over 20A with minimal voltage drop Therefore it may be necessary to improve grounding system conductivity with heavier conductors and a lower resistance ground path The grounding conductor should be at least 8mm AWG 8 or SWG 10 S 3 S 4 1 S 2 4 f 6 2 2 4 d S 2 4 e S 2 4 c LINE EY IN KEY OUT OFF E 100 120VAC 20A 240VAC 16A CEO ANTENNA 3 ANTENNA 2 ANTENNA 1 ON MODEL ACOM 1506CC ID DANGERSIGH VOLTAGE INSIDE SERIAL NO FOLLOW INSTRUCTIONS precrserv y ei facom MADE IN BULGARIA BEFORE REMOVING COVER A GND CG RF INPUT A d zal 2 5 2 4 5 2 4 a SC 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 CAUTION If this is the first time you are using a power amplifier in your station pay close attention to the coaxial cable type from the amplifier s three outputs The cable must be capable of handling the increased power levels particularly on the 10m and 6m bands We recommend that you use RG213 or better coaxial cables Consult your local cable supplier for the appropriate cable selection This caution applies equally to the antenna selector tuner and antennas system as well c Connect a suitable coaxi
7. which if not correctly performed could result in equipment damage not only in the amplifier NOTE notes call attention to a procedure which if not correctly performed could result in inconvenience WARNING 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 WARNING 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 WARNING Do not undertake your own repairs or changes in hardware or software of the amplifier Doing so will endanger your or others health or life or damage the amplifier and the equipment connected to it Such repairs or changes are not covered by warranty and may void the warranty The manufacturer is not liable for any suc
8. 00 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 with 1200W forward 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 ACOM OOD Blvd Nikola Mushanov 151 1330 Sofia Bulgaria 1 3 Equipment Supplied The ACOM1500 amplifier and this manual are shipped in a cardboard carton 1 4 Features e Easy to operate The TRI is a powerful tuning aid that together with the automatically controlled input attenuator helps the operator to quickly and precisely match the antenna impedance to the optimum tube load impedance 5 10 seconds typically The auto operate function when enabled maintains the amplifier in the OPERATE mode for you thus avoiding unnecessary manual operations e No heavy outboard antenna tuners req
9. D switch knob while tuning or transmitting with the amplifier Such hot switching will eventually destroy the band switch and this is not covered by the warranty CAUTION When tuning do not apply continuous drive longer than 3 minutes and after that pause 1 2 minutes for tube cooling 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 1 in order to achieve an approximate preset for both TUNE capacitor and LOAD capacitor knobs Band MHz Tune Knob Dial Load Knob Dial 1 8 2 3 5 4 7 7 3 10 1 10 2 14 14 35 18 18 2 21 21 45 24 9 25 28 29 7 50 54 Table 4 1 Approximate tuning presets b Selecting the plate load True Resistance Indicator TRI tuning aid You may select the TRI scale in three different ways By briefly pressing simultaneously the PREV NEXT buttons This will insert a 6dB attenuator between the driver and the amplifier s input the ATT LED will light removing the need to reduce the drive power during tuning Press PREV NEXT buttons momentarily again to switch the attenuator out of the input circuit and to return to the earlier screen If you use any of PREV or NEXT buttons the attenuator will be switched off too but the information screen will change By pressing repeatedly either the PREV or NEXT button until you reach the TRI scale This will not inser
10. Table of Contents 1 GENERAL INFORMATION lt iciecc2scoece2t ees ee eee cs ee sac orc ren sconces bet cane eet ec eden 3 1 1 Introduction and Description 3 1 27 Owner Assistance eooni ee e e Ee lee A Gav EEEE E E ELE EEE NE eL TEES 3 1 3 Equipment Supplied eee ee ee ee ee AA aa 3 1eASECALULCS cts etewt tant ee ere 3 1 5 Safety Considerations Explicit Definitions ccceececceeeeeeeeeeeeeeeeeeeeeeeeeeeesneees 4 2a INSTALLA TION gege 6 2 1 Unpacking and Initial Inspection 0 0 2 ceeeeeeeeeceeeeeeeeeeeeeeeeceeeeeeenaeeeeseeieeeesennes 6 2 2 Mains Voltage Selection ccccccccceceececceeeeeeeeeeeeneeeeeseeaeeeeeeeneeeeesscaeeeesesueeeeesnnaees 6 2 3 Amplifier Location Gelechon 6 2 4 CONNEC ONS ieia oere oeeie Esei E EC E ELECE ECEE E DEEE EE EEE EEEE ECEDEELA EEEE EEE E EEEn EE 7 2 5 Installation ot Extermal Pani t4a sei tee es E r EEEE N 8 3 POWER ON CONTROLS AND INDICATORS ceecseeeeeeteeeeeneeeeeeeeeeeeneeeeeeeeeseees 9 4 OPERATION ees 11 4 1 Turnirig ON and OR E 11 4 2 Changing Operate and Standby Modes 11 4 3 Antenna Change cccccccccccceeeeceeeeeeeeeeeeeeeecaeeeeeecaeeeeesenaneeecseaneeeeeseeeeeesseneeeeesaas 12 AA PURING DEE 12 den COntINUOUS attert MOUS vis eeeeedeieegeegr sec egdi geg ege eege 14 4 6 ON LINE Information Screens and Control Functions cece eeeeeeeeeeeeeeees 15 4 7 Auto Protection Gvstem terenn eren 15 5 OFF LINE MODE isis hae aetna 16 5 1 Display
11. The current consumed by the amplifier from the mains supply should not exceed 16A from 200 240VAC and 20A from 100 120VAC You will have to reduce the output power to about 1000W PEP if the amplifier is operated at 120V or lower mains supply voltage 2 3 Amplifier Location Selection CAUTION The weight of the unit is about 26 5kg 58 4Lbs which should be handled by two persons Position the amplifier near where it will be used You will need an easy access to the command knobs and indicator s area as well as to the rear panel cabling No magnetic field sensitive devices such as microphones should be located next to the right side of the amplifier because its power transformer is located there It is advisable to position the amplifier to the right of your transceiver No temperature sensitive devices should be located above the exhaust hot air area Do not locate the amplifier under a shelf for example 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 UNDER ANY CIRCUMSTANCES OBSTRUCT the AIR INTAKE rear panel or EXHAUST top cover areas of the amplifier Keep a minimum clearance distance of 10cm 4 inches from the intake and 50cm 20 inches from 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 WARNING Note that the grounding system may have
12. al 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 with a phono RCA connector from the transceiver socket providing a ground on transmit PTT control signal to the amplifier rear panel KEY IN socket NOTE Your amplifier will not work if KEY IN is not connected properly Transceiver producers give different names to this output such as TX GND SEND T R LINE PTT etc Some transceivers require that ground on transmit be implemented via a software command or by changing the setting of a switch on the rear panel or in the interior of the transceiver Check your transceiver manual Consult with your dealer if you are having difficulty The switching voltage presented from amplifier KEY IN socket to the transceiver ground on transmit output does not exceed 13V positive to the ground The closed circuit current is below 5mA e The KEY OUT socket on the rear panel provides an extra control signal from the amplifier to the transceiver It can be used to improve the transmit receive switching safety The rating on this output is very low current so be certain that the load will not exceed 50VDC when it is open circuit and 20mA when it is closed If your transceiver has a suitable input that disables transmission we recommend that you connect it with a cable terminated in a phono RCA conn
13. ard power TRI Auto Prot Reflected power Signatures Output Power Auto Operate OFF PREV Drive RF Power Auto Operate ON RF Power Gain VAEA Plate Current PREV NEXT High Voltage 2seconds PREV NEXT 5 3 Plate RF Peak Screen Current DC Power Input Antenna output ANT Exh Air Temp assignment Antenna Enable PREV Antenna Disable NEXT 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 S 5 2 The same button activates signature list while OFF LINE S 5 4 The PREV and NEXT buttons change information screens or select control functions S 4 6 for both OFF LINE and ON LINE modes The ON OFF button switches OFF LINE and ON LINE OPERATION states of the amplifier alternatively You can proceed in one of two ways a You may 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 and Antenna assignment This is described in S5 b You may 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 OPERATION information screens or control functions see below 10 4 OPERATION Operation of the amplifier is simplified through use of the TRI tuning aid Auto Operate function and
14. brightness Controliw ceatveatieaiea vie ieee 16 5 2 Auto Operate enabling and disabling sssssnnesssneseserreeetrnterirrrsrrtrtrernreeerereee 16 5 3 Antenna output asslgnment cece cece e cece cece e eee eae e este este eeeeeesaseeeaeees 16 5 4 Reading Auto protection Gignatures cece ccc ee ee eee eee eae aasseeeeeeeeeeeenes 16 6 MAINTENANCE desse d e eege deed SEENEN eege Seet 17 6 4 GIS ANING ss terete it aad ah de te rca sas PR vel ed eae ee hed au Ro sepne dle 17 6 2 Fuse Replacement ee eee ee eee eee ece teen seen e esse eeenneeeeeeneeeeeas 17 6 3 Tube Replacement ee ee cece cece e eect eee ee eee e eee ea eases EEEE EEES 17 6 4 The ACOM1500 Simplified Schematic Diagoram ee 17 6 5 Troubleshooting eee ee eeeee ease eee eeeeeeeeeeeeeeeeeeeeeeeee eas 18 TOP ECIFICA TIONS eebe ee de 20 Ze Parameterswa vei ea ae a e Ee ea aA ee eed 20 T 2 FUNCIONS tegen Seege Valdes bog tad adele ey a eh ef 20 7 3 Storage and Shipment eee c cece ee ee eee ee ee eee eeeeeeeeeaeeeeteeees 21 NOTE This unit has been set for 240VAC at the factory Means are 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 1 GENERAL INFORMATION 1 1 Introduction and Description This manual explains the installation operation and maintenance of the ACOM1500 HF 6 meter linear amplifier The ACOM15
15. e 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 may 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 an inscription ACOM1500 will appear on the display Fig 3 1 300 600 900 1200 1500 Fig 3 1 ACOM1500 Display and Control Note that the upper line of the VFD always reads the peak forward power even in STBY mode The 1500W scale resolution is 15W per bar Note too that levels below 20W may be not detected NOTE If the characters on the fluorescent display 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 and the tube is not powered at all Control of the amplifier is accessible during OFF LINE and ON LINE OPERATION states each having several information screens and control functions see Fig 3 2 POWER ON 3 D ON OFF z A OFF LINE S 5 q S 4 1 D OPERATION S ON LINE 0 NEXT or PREV PREV NEXT ANT S 4 3 d d Antenna change 1 2 3 PREV NEXT 5 4 IOPERIS SA INFORMATIONS 46 Tuning S 4 4 Brightness Control NEXT List of Forw
16. e 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 11 When Auto Operate is enabled the amplifier will be maintained in operate mode by default unless you use the OPER button manually to go to standby in which case the Auto Operate is suppressed temporarily Pressing OPER again will restore the Auto Operate feature When the Auto Operate function is disabled the amplifier will shift and stay in STBY mode after each protection trip To restore operation the OPER button must be depressed When the Auto Operate function is enabled see S 5 2 the amplifier will shift to the STBY mode on a protection trip It will return to the OPER mode after about four seconds automatically 4 3 Antenna change By pressing the ANT button the amplifier output can be switched between three antenna outputs The three lights above the button indicate the current antenna selection Selection of any of the antenna outputs can be disabled if not used see S 5 3 Antenna output assignment This prevents inadvertent selection of antenna outputs preventing no load transmission and possible amplifier damage CAUTION To avoid damage not covered under warranty do not change antennas while transmitting Do not transmit into an antenna output 1 2 or 3 if itis not connected to an antenna or a dummy load 4 4 Tun
17. ection until the triangle marker appears inside the scale field Ill II III III e E JL x Jv _ vV no marker marker is a far left marker is a far right marker inside LOAD is tuned use TUNE knob for turn LOAD knob turn LOAD knob turn LOAD knob turn TUNE knob to max P to get any pointer to right until pointer to left until slightly left to peak Forward marker marker inside marker inside center it Power amp finish Fig 4 1 Using TRI tuning aid Please note 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 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 more gain will be obtained but less undistorted output power will be attainable You may prefer to use this tuning approach 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 bu
18. ector 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 manual Your amplifier will function normally if the KEY OUT remains unused f Preparation of wall outlet for the amplifier WARNING If your amplifier is only fitted with one 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 for which it was purchased Your dealer will fit the correct mains plug for your country and will check that the amplifier is correctly set for the mains network applying there If the amplifier is to be connected to the mains network in another country check with your dealer or a qualified local electrician before use there WARNING Before connecting the amplifier to your mains supply be sure that the supply is correctly wired and that it 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 used for the amplifier It is preferable that you use a wall outlet close to the power source The power cord leads and associated wiring should be at least 2 5mm AWG 13 or SWG 15 Check if t
19. ent If there is no antenna connected to an antenna output then the output should be disabled This will make the switching between two available antennas easier and more important it will prevent potentially damaging no load transmissions In order to enable or disable an antenna output briefly press PREV NEXT buttons successively until the Ant 1 2 3 screen appears Using the ANT button 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 briefly again to confirm the antenna output assignments and then leave the menu NOTE All selections you make are stored in the amplifier nonvolatile memory If no button is pressed for 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 are stored there which may be forwarded to your dealer for diagnostics In order to read the trip signatures press the OPER button while OFF LINE The display will illuminate at full brightness and the beginning of the signatures list will appear Use NEXT and PREV buttons to navigate through the 7 pairs of screens For each auto protection trip there is a pair of information screens beginning with nA and
20. g in the screen grid circuit protects the tube and the screen grid voltage regulator in the event of an internal tube flashover The combination noted as Lp1 Rp1 in the plate circuit is a VHF UHF parasitic suppressor DC plate voltage is fed through chokes RFC1 RFC2 and the capacitor Cb3 blocks it from the output The output circuit consists of LP1 LP2 LL CP1 CP3 and CL1 CL3 which form a classic Pi L network to suppress any harmonic frequency emissions This tank is switched and tuned by S1A S1C and the air variable capacitors CP1 2 and CL1 2 The output signal is fed through an additional VHF low pass filter for frequencies above 55MHz Lf1 Lf2 and Cf Then it is passed through the vacuum antenna relay K1 wattmeter current transformer TA1 and a high pass filter RFCasw Casw for frequencies below 100kHz to the antenna switch and the three outputs The chokes RFC3 and RFCasw keep track of the antenna relay contacts and together with Casw prevent the plate supply voltage from reaching the antenna The RF choke RFCasw shunts the high voltage to ground should the DC blocking capacitor Cb3 fail The resistor Rasw protects Casw from electro static voltage build up from 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 supply voltages are de
21. h repairs or changes Any such repairs or changes are strictly the responsibility of the person or persons engaging therein CAUTION To avoid damage not covered under warranty read the Installation Section 2 of this operating manual carefully If you have any doubts or questions regarding the installation operation or safety of the amplifier please consult your dealer immediately 2 INSTALLATION 2 1 Unpacking and Initial Inspection NOTE Before you install your amplifier thoroughly read this manual First carefully inspect the cardboard carton and its contents for physical damage If damage is evident notify your dealer immediately Delay may void the carrier s warranty Keep all packing materials for possible future amplifier shipment 2 2 Mains Voltage Selection CAUTION To avoid damage which will not be covered under your warranty check carefully to be certain that the voltage for which the amplifier is set corresponds to your mains nominal voltage Normally the amplifier is supplied set for a nominal mains voltage of 240V If your mains voltage is not 240V 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 AMP s n Tube s n Voltage Selector VAC Table 2 1 ACOM 1500 Individual Data CAUTION
22. h voltage power supply inrush current limitation This feature reduces the risk to sensitive devices connected to the same mains circuit important when used portable when the amplifier is turned on The amplifier can be configured for 8 nominal mains voltages 100 110 120 200 210 220 230 and 240VAC 50 or 60Hz e Continuous monitoring and or selectable measurement of the 12 most important parameters of the amplifier exciter and the selected antenna via the VFD 1 5 Safety Considerations Explicit Definitions The ACOM1500 HF 6 meters Linear Amplifier is a Safety Class unit The third grounding lead of its mains cord colored yellow with two green stripes and the ground stud on the rear panel of the amplifier marked GND should be connected to the station s grounding system for safe operation The amplifier is designed to meet international safety standards and complies with UL and CE safety and electromagnetic compatibility requirements as well as FCC regulations This operating manual contains information precautions indications for cautions and warnings that must be followed by the user to assure safe operation and to keep the ACOM1500 operating properly PRECAUTIONS The EXPLICIT DEFINITIONS described below apply to this operating manual WARNING notes call attention to a procedure which if not correctly performed could result in personal injury fire hazard or electric shock CAUTION notes call attention to a procedure
23. he respective fuses can handle current up to 16A 20A for 120VAC 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 as well Make sure the main Power Switch on the rear panel is in the OFF position and insert the amplifier s mains plug into the wall outlet prepared for it The amplifier remains switched off at this time 2 5 Installation of External Fan This fan Fig 2 1 is not necessary in SSB and CW modes or in continuous carrier modes RTTY SSTV etc with a maximum carrier down time of 15 minutes and a subsequent pause of 3 minutes For higher duty cycles such as continuous broadcast or increased ambient temperatures the fan is recommended The auxiliary fan 92x92x25mm or 92x92x38mm must be a brushless type 2 5W 24VDC It may be installed by your dealer or by the manufacturer on request 3 POWER ON CONTROLS AND INDICATORS CAUTION 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 CAUTION To avoid damag
24. heless for some loads and bands matching is possible at even higher VSWR figures The maximum usable forward power at a VSWR of 3 1 is 1200W with 300W reflected For higher than 300W reflected power a REFLECTED POWER soft fault protection trip will occur This can happen at full scale 1500W forward and 375W reflected power into an antenna having a VSWR of 3 1 or worse CAUTION Using a coaxial cable with VSWR gt 3 1 on HF and particularly on the 10 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 permanently damage to your coaxial cable or antenna switch 12 Adjust amplifier tuning when you change the band or between CW and SSB segments within the same band Readjust 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 A significant change in the environment such as snow ice new or removed large metallic objects alien wires nearby etc can cause significant changes in the antenna impedance and an increased VSWR NOTE 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 VSWRs are excellent i e below 1 2 1 for both CAUTION Do not switch the antenna or BAN
25. hese 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 Briefly press 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 5 2 Auto Operate enabling and disabling When enabled this function will maintain the amplifier in OPER MODE automatically see S 4 2 The OPER button will be still functional so you can change to STANDBY and return to OPERATE manually at any time The auto operate function will be disabled temporarily when you enter the STANDBY mode but it will be restored after you return to OPERATE by depressing the OPER button After having selected the display brightness see the previous S 5 1 you may continue depressing 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 NEXT button to select ON Briefly press 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 In any case the selections made so far will be retained in the amplifier s memory 5 3 Antenna output assignm
26. ing 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 optimum plate efficiency and RF gain at nominal output power with minimum resulting IMD 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 some reflected power even with optimal tuning Proper tuning will assure operation at maximum 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 1500W and REFLECTED 250W the real OUTPUT POWER will be equal to their difference 1250W into a 2 4 1 VSWR load At avery 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 lt 300W Matching is assured for loads with VSWR up to 3 1 Nevert
27. livered from the MAINS amp LOW VOLTAGE and HIGH VOLTAGE SUPPLY PCBs The control grid screen grid and plate currents plate cooling airflow temperature reflected power etc are continuously 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 1A 1B 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 PNO 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 relay is closed SBO 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 PRO tests made while entering Operate PR2 tests made during Operate TRO 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 du
28. mation can be forwarded to your dealer for diagnostics Using an Excel application available from ACOM or your dealer free of charge and a PC you can decode the status data by yourself e Less noise in the shack The input bypassing and vacuum antenna relays are virtually silent even in the CW QSK mode thanks to specially designed mounting hardware e Less QRM and improved Electro Magnetic Compatibility during tuning Amplifier tuning can be achieved in less than 10 seconds at a quarter of nominal output power e Operates without special signals from the transceiver Ground on TX PTT and 85W RF drive power are sufficient e Broadband input matching circuit design provides excellent transceiver loading over the entire spectrum from 1 8MHz up to 54MHz e 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 amplifier operation e Permanent monitoring includes protection of plate and grid voltages and currents as well as exhaust air temperature The Bias Optimizer decreases the heat dissipated from the tube and there is automatic protection against overheating in accordance with specifications of the tube manufacturer e Output RF arc protection is employed This important feature safeguards the amplifier antenna antenna selector and tuner against severe damage in case of possible breakdown e Hig
29. n changing the screen to one of the 14 available information screens described in S 4 6 below This will not influence the warming up process so you may pass through all information screens to monitor the High Voltage value or the Exhaust Air temperature for example You may also return to the earlier screen to see how many seconds are still needed until the tube cathode reaches its operating temperature NOTE When you intend to have a short operating break it is better to leave the amplifier in standby mode instead of turning it off Tube life is shortened by repeatedly turning on and off the heater filament 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 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 illuminate automatically The last used one out of 14 information screen appears on the display e g WARMING UP Ready The bar graph on the upper line always indicates the peak forward power as well as during OFF LINE In order to turn the amplifier off press the red ON OFF button If you intend to have a break for a long time it is best to turn it off using th
30. nB where 16 n is the successive number of the event nr 1 is the latest nr 7 is the oldest one Aand B mark the first and second parts 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 1A 1B through 7A 7B To decode the signatures please see S 6 5 Troubleshooting NOTE After every signature listing the tube warm up time is reset to 180 seconds regardless of time in the OFF LINE state 6 MAINTENANCE NOTE If the characters on the VFD are dim please follow the method of Display brightness control described in S 5 1 6 1 Cleaning WARNING 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 Fuse 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 1 They are of the fast quick blow type 1 1 4 x 1 4 inch Cartridge Fuses Size 0 Use 20A for 100 120VAC operation Use 16A for 200 240VAC operation 15A standard is also acceptable Besides the primary fuses on the MAINS PCB inside the amplifier there are three small glass fuses 5x20mm European size one 100mA 250VAC normal bl
31. ng Up and TRI described above in S 4 1 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 associated parameters in a digital form Selection is made by the PREV and NEXT buttons You may change them while the amplifier is used and controlled in operate and standby modes changes transmit and receive without any influence by the measurement process b You can control the display brightness Auto Operate feature and antenna output assignments 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 7 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 descriptive text The VFD brightness is flashed to attract the operator s attention a The first degree of protection consists of a warning message only and does
32. ow and two 2A 250VAC slow blow These fuses should not be replaced by the user Should one of these fuses be blown it may be indicative of a serious fault A fault of this type will not occur under normal operating circumstances Replacing these fuses involves special skills and is inherently dangerous For these reasons 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 procedure For this reason we recommend this work be carried out by a trained service technician Check with your dealer before attempting to replace your tube 6 4 The ACOM1500 Simplified Schematic Diagram See Fig 6 1 ACOM1500 Simplified Schematic Diagram The 4CX1000A 8168 ceramic and metal radial beam tetrode V1 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 consists of 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 100W of RF drive power 17 Cathode resistors labeled Rc create DC and RF negative feedback thus stabilizing the gain and equalizing the frequency response The varistor VSs
33. ring Rx Operate mode 18 c The last symbol of the first group designates the kind of the input parameter that caused the protection circuit 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 RF arc fault ARCF logic D control grid current too high G1C logic E 24VDC power supply error PSE logic F low airflow LAIR logic For instance 1ATR4B in the first group would mean that the last auto protection 1A tripped by the antenna relay tests made during the 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 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
34. t 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 the tubes expected life as its cathode would be exhausted more quickly You might use the above 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 is lower than the nominal voltage Please see S 2 2 Mains Voltage Selection for more than 5 deviation 4 5 Continuous carrier modes The maximum output power in continuous carrier modes such as RTTY etc is 1200W You may exceed this limit up to about 1300W for short periods one minute or less while adjusting the drive power for instance Please have in mind however that the mean output power should not exceed 1200W for longer periods 14 For prolonged transmissions the amplifier gain can drop between 5 and 10 during the first minute which is normal while temperature balance of the tube is achieved You can easily compensate this by increasing the drive power slightly Once the drive power has been set the output power remains stable with the time for hours CAUTION For transmissions longer than 15 minutes the external auxiliary fan must be installed see S 2 5 4 6 ON LINE Information Screens and Control Functions a Besides the Warmi
35. t the attenuator so you must be careful to use less than 20W drive unless the amplifier is near correct tuning otherwise the next step will be executed automatically By simply applying a normal 60 85W drive level 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 PTT is released If near optimal tuning is achieved the attenuator will not be inserted again If the old screen was unchanged TRI selected manually earlier it will be possible to precisely tune the 13 amplifier at nominal power without changing drive at all Use this approach to shorten the tuning process duration c Tuning Procedure While a continuous carrier CW key down RTTY or FM 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 briefly in order to disable the attenuator then repeat both steps at nominal power Always finish by peaking with the TUNE knob NOTE Appearance of an arrow on either left or right TRI scale edges means that the LOAD knob position is far off To correct this turn the LOAD knob to the prompted dir
36. uired for antenna VSWRs up to about 3 1 Your amplifier will enable you to change antennas virtually instantaneously and allow you to use your antennas over wider frequency ranges e 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 The amplifier also will not cease to function with a soft AC mains and will deliver more than half power at only 85 of nominal mains voltage It can withstand voltage drops down to zero Volts for up to 10 milliseconds and can tolerate 15 mains voltage spikes which is especially important on Field Day during DXpeditions and at portable operating events where emergency power is relied upon e VFD information display All amplifier status indications are explained via detailed text displayed on the dot matrix high brightness vacuum fluorescent display VFD The upper line on the VFD always reads peak forward power LED indicators are provided for OPERATE mode attenuation on ATT transmit TX selected antenna output 1 2 or 3 and ON OFF conditions e Antenna selection Three antenna outputs are selectable using a push button on the front panel e Easy maintenance Data regarding amplifier internal status is stored in a nonvolatile memory for 7 of the most recent auto protection trips This infor
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