HL1.1Kfx Users Manual
Contents
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4. FUSE IN PUT TX db ds AC Mains Socket Socket for the AC power cord Socket is EMI filtered RCA ack Connect the control cable from the ACC terminal or SEND TX GND etc of the transceiver The center pin is to be shorted to ground though the relay circuit of the transceiver The DC current necessary is 5V 1mA only RCA for ALC Voltage Output Negative DC voltage appears at the center pin which is fed back to the ALC terminal of the transceiver ALC is used to keep the amplifier output power at certain limits Also it is useful when the transceiver output power is higher than 100W See page 12 8 ALC Connection Also consult your HF transceiver 5 user manual Ground Terminal Potentiometer to adjust ALC voltage level Minus 10V is available at maximum when turned full counter clockwise Factory setting is 0 volts with the pot turned full clockwise pair of fuses for AC mains 15A glass pre installed fuse Change to 8A fuses if 230V lineis used RF Input Connector Connect the coax jumper cable from the transceiver ANT OUTPUT RF Output Connector Connect the coax cable to the antenna nner Layout of H 1 1KFX Upper M ew RF Power Detector and Send Receive Switching Relay 2 Inter lock Switch 3
5. Sub Power Source Unit LPF Board amp Main Power Source Unit Sub Fan for Main Power Source Unit Control Board Power Amp Unit 9 F requency Detector Board Cooling Fan AC Fuse 7 Connection and Operation This section explains a one antenna system connected to the transceiver and an external SWR POWER meter 7 1 7 2 7 3 ANTENNA TRANSCEI VER SWR POWER METER AC HL 1 IKFX REAR SI DE Connect AC cord and coax cables as illustrated above Connect the cable from SEND to ACC or the remote terminals of transceiver where it is marked SEND or TX GND These terminal pins are shorted to the ground when the transceiver is in TX ON AIR mode If these connections are not made the amplifier will not go into TX amplification mode For a temporary check to the amp ground the SEND center pin by inserting and RCA plug whose center pin has been soldered to the outer case of the plug with a small piece of wire At first turn the ALC knob full clockwise to avoid AL C voltage to the transceiver Application of ALC will be covered in the following Section 8 ALC CONNECTION Keeping the POWER AC mains switch off check the SWR of your antenna by keying the transceiver to TX mode CW or RTTY mode Monitor the SWR with an external SWR Power meter If SWR is 1 5 or higher at band center the antenna has to be adjusted for lower SWR As an alternative an antenna tuner may be inserted 10 7 6 7 7 T
6. Users Manual Solid State HF Band 600W Linear Power Amplifier Model HL 1 1KFX TOKYO HY POWER 1 ntroduction Thank you for purchasing the HL 1 1KFX This compact and lightweight desktop HF linear power amplifier has a maximum input power of 1 35kW Our solid state broadband power amp technology makes it the smallest and lightest in the industry in its class Typical output power is 600W PEP SSB CW with the drive power of 65 90W It is best suited for the DX pedition use due to its light and compact design 2 2 1 2 2 2 3 2 4 2 6 Cautions The amplifier is cooled by forced airflow Several inches of clearance on the top and the rear wall are necessary to allow for smooth air intakeintothe fan Do not block the air vents on the top cover the amplifier out of direct sunlight in a cool dry environment This unit is not corresponded to protection against dust water condensation nor vibration Internal high voltages AC DC and RF are present at all times ON AIR or OFF nternal access should be limited to avoid injury Turn off the AC main power immediately upon any unusual sounds sights or odors Check the multimeter readings of Vd and Id the fuses and all cable connections around the amplifier Please notify the dealer or the factory of any problems For your safety do not operate the amplifier without adequate grounding A proper ground connection will result in peak perform
7. age Vd 60V Drain Current Id 50A 200 260V 50 60Hz 7 5 max 100 130V 50 60Hz 15A max 1 4kVA max when TX 232 x 145 x 392 mm 9 1 x 5 7 x 15 4 inches WxH xD Approx 9 5kgs or 22 5lbs AC Power Cord x 1 Coax J umper Cable with PL259 s x 1 RCA Plug x 2 Spare Fuse 8A x 2 for AC200V line Spare Fuse 15A x 2 for AC100V line Spare Fuse 15A x 2 for F 202 F 203 of PC1662V power amp board Spare Fuse 1A x 1 for PC1662V power amp board miniature fuse Spare Fuse 2A x 1 for PC1785V control board miniature fuse Users Manual 5 Line Voltage 5 1 Although the amplifier is designed to work with both 115V 100 130V and AC 230 200 260V for stability we recommend operation from AC 230V 5 2 The correct AC plug not included in the package must be obtained locally due to the plug variations worldwide 5 3 The AC line fuse has been factory preset for 115V use or as requested by the customer at the time of order If you wish to change to AC 230V change the fuse to 8A For your safety before making this change be sure to pull the AC plug from the AC outlet to avoid injury NOTICE Please note the followings when you are using AC100V line AC100V 120V NEVER EXCEED OUTPUT POWER OF 500W WHEN RUNNING THE AMP FROM AC100 120V LINE Otherwise over current protection completely shuts down the drain voltage power supply for five minutes before it gets resettable When this protectio
8. ance and stability in addition to reduced RF strays or noises To eliminate the RF interference to such home appliances as TV FM radio telephone sets and etc it is recommended that damp on ferrite cores be inserted at both ends of the remote control cable ALC cable coaxial jumper cable and antenna cables as needed Also a common mode AC line filter near the AC outlet and in line low pass filters on the antenna coaxial cable as necessary are recommended 2 8 2 10 2 11 2 12 2 13 2 14 The amplifier has fast acting sophisticated protection circuits Please note however any such actions that cause the same fault to occur repeatedly will lead to failure of the valuable final power FET transistors Before checking inside the amplifier be sure to wait a few minutes for the high DC voltage to discharge monitor Vd meter reading The potentiometers for RF power detector protection circuits FET bias voltage circuit etc are precisely adjusted at the factory and should not be altered Doing so would require readjustment with precision measuring instruments The DC power supply section consists of most efficient and sophisticated switching mode circuit It accepts the wide AC line voltages ranging from AC 100V up to 260V Since the line voltage is detected and selected automatically you do not have to worry about the tap change of internal power transformer whichever country you will travel Be sure to verify capaci
9. bove the amplifier is equipped with several kinds of fast acting protection circuits using the latest n analog technology However if the amplifier 15 operated in such a manner that multiple protections work repeatedly over a long period of time the amplifier can be seriously damaged 13 10 Explanation of Major Circuits Five major circuit blocks are explained in their basic form and using signal flows 10 1 10 2 10 3 10 4 10 1 10 2 10 3 Main DC Power Supply Power Amp L P F RF Power Detector TX RX Switching Control Board Main DC Power Supply The main DC power supply feeds the 50V DC power to the final PA stage It is a state of art switching power supply with high efficiency A part of 50V line is converted to 24V using a DC DC converter and is supplied to the cooling fan Power Amp PA PC1662V L P F PC1399B The RF PA is the heart of this amplifier and is composed of four 502933 MOS FET s made by ST Micro a French Italian joint venture firm The amplifier is a parallel push pull type of dass AB amplifier The gate bias supply circuit is regulated for the best stability and is thermally compensated The PA has a 6dB attenuator on the input for gain reduction and to enhance the stability of the wide band power PA The heat sink has two different thermal sensors to detect temperatures of 40 deg C and 80 deg C respectively At 40 deg C the cooling fan shifts into high speed mode At 80 deg C the amp
10. commended to make AL C connection especially when 200W out high power radio is used to drive 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 then back on again The power transformer has an overheat protection in the coil layer If this temperature switch activates the amplifier will put you in receive mode with the cooling fan operating until the transformer has cooled off It may taketen to fifteen minutes to cool depending upon room temperature F or more details on this protection circuit see Section 9 PROTECTION CIRCUITS 11 8 ALC Connection ALC voltage is available at the terminal marked ALC RCA phono jack on the right upper corner of the rear panel Negative maximum DC voltage of ten volts 10V is produced at this terminal when the amplifier is fully driven This voltage is adjustable with the ALC knob located above the AL C jack If the ALC voltage is properly fed back to the transceiver we advise you to keep the maximum output power constant or hold the power at a certain level Also ALC is useful in avoiding your SSB signal from being distorted when overdriven You may not always need to connect ALC to the transceiver if you set the mic gain properly and do not overdrive the amplifier Depending upon the manufacturer of
11. lifier will lock the amplifier into RECEIVE mode to protect the power FE T 5 In the L P F output low pass filter circuit there are eight different band filters that are selected either by the auto band decoder or by the manual band switch Each L P F is used to reject harmonics so that the amplifier meets international tel ecommunication equipment standards RF Power Detector TX RX Switch PC1398B As illustrated in the block diagram there are two RF power detectors on this board One detects the drive signal level from the radio and the other monitors the outgoing power and the reflected power from the load antenna The TX RX switch Send Receive switching will switch the flow of drive power output power and the incoming signal from the antenna with two high speed relays mounted at the input and output sides of the PA 14 10 4 Control Board 1698 This is the heart of the control signal processing for the HL 1 1KF X It judges the operating condition of the amplifier as well as issuing the commands to the peripheral circuits Various analog signals are processed such as RF drive from the transceiver RF power signals at various points DC power supply information etc There are ope amps various three terminal voltage regulators GAL logic device etc Warning signals are processed by the logic C for Over Heat Over Voltage Pr Band Miss set etc Ope amps produce the necessary DC signals to drive the Pf Pr meters Alsothe
12. n works O DRIVE lamp lights and HL 1 1KFX will enter the through state the reset of the amp being disabled for five minutes To restart the amp turn the POWER switch OFF and wait for 5 five minutes Then turn the power ON If the protection works too often please take one or all of the following measures Lower the drive power of the transceiver Connect the ALC line Adjust the ALC Output Adjustment Knob on the rear panel so that the drain current ID will never exceed 26 0A on any frequency Change to AC200 240V line 6 A Front Panel Description 44 BOU wowed anamudu O FAN 9 49 METER BAND r PROTECI PO R PER CN AR QERIVE PR FUSE OHAT CI 9 STBY 5 1 POWER Main power switch to turn AC power on and off POWER LED Green LED lights when power is turned on G OPER OPERATE STAND BY switch At OPERATE the amplifier is ready to go into ON AIR TX mode and at STBY it is on STAND BY mode WON AIR LED Green LED lights when the amplifier is in transmit TX mode amp O DRIVE LED When overdrive or band miss set is detected LED lights to indicate the protection circuit has worked PR LED LED lights when reflected power from antenna exceeds 70W to indicate protection circuit has worked VO VOLT LED When the DC drain voltage of the FET Vd is too high the LED lights to indicate the protection circuit has
13. re is a control circuit that issues the drive shut down command in case of the over drive band miss set and high antenna SWR conditions 15 11 Trouble Shooting AC mains not 0 AC fuses blown Replace with new ones operating cord not pluggedin Plugin securely Interlock switch lifting Wrong tap used on Screw bolts tightly on the top cover power transformer primary Correct primary wiring Can t enter Remote control cable Check the cable and connect properly Transmit not connected mode Protection circuits on Check the drive power antenna SWR antenna selector A B Reset with AC POWER switch O Drive lights RF overdrive Decrease drive Band miss set Match the BAND correctly PR lights Reflected power high Check adjust antenna Antenna SWR high Or decrease drive Poor connection to coax cables Check the coax cable connectors Volt lights Drain voltage of power Check AC line stability p FUSE lights Fuse blown Replace F 202 and F 203 20A on the PA board PC1662V Antenna SWR high Adjust the antenna Short circuit Contact the distributor or service center lights Internal Temperature Cool off until LED turns off Check for air above 80 deg C intake blockages Also check air vent on top cover TVI FMI Overdrive Decreasethe drive Check AL C setting RF leakage from coax Insert common mode filters on cable grounding
14. the transceiver the suitable ALC voltage differs ICOM may need 0 4V ad Yaesu may need 0 5V range Kenwood may need 6 8V maximum Check your transceiver manual 8 1 Prepare an ALC control cable using RCA plug supplied in the package Solder a single wire or more preferably a shielded single wire to the center pin of RCA plug and solder the shield braid to the outer side of the plug Connect the control cable to the ALC or ETERNAL ALC jack of the transceiver External ALC input is sometimes available at one of the pins of the ACC socket of the transceiver as well 8 2 At first turn ALC ADJ full dockwise Drive the amplifier in CW RTTY mode to full output power Then turn the ALC ADJ counter clockwise Observe the SWR Power meter at the output or Pf of the multimeter Stop turning the ALC at the point the power starts to decrease Or if you wish to further reduce the power keep turning ALC ADJ until the desired level is achieved If you further try to increase the drive power you will now see the output power become rather saturated fro these adjustments Maximum AL C voltage produced is 10V when the amplifier output power IS over 200W AC ALC AD N REAR PANEL ALC POT AC Transce ver 12 9 Protection Circuits There are five major protection functions 0 this amplifier If the amplifier has shut down for some reason before re setting correct the possible cause of the shut down T
15. tics require no further tuning once the operating band is sel ected The amplifier allows operation in full break in CW mode due to the use of the amplifier s high speed antenna relays made by Panasonic With the unique duc structure design and the powerful blower fan the aluminum heat sink block for RF PA module and other components are effectively cooled The fan s quiet operation allows for even the weakest DX signals to be heard The amp utilizes a sophisticated circuit to run the various high speed protection Circuits such as overdrive high antenna SWR DC overvoltage band miss set etc This amplifier is compatible with wide AC line voltage ranging from AC 100V to 260V Although AC line voltage is automatically selected be sureto install proper fuse into AC line fuse holder For the safety of the operator an Interlock system is employed The AC power is shut down if the top cover is removed and the automated safety interlock is acti vated An analog multimeter allows the operator to monitor Pf Forward output power Pr Reflected power Vd Drain voltage of power F ET Id Drain current etc 4 Specifications Frequency M ode RF Drive Output Power Drain Voltage Drain Current Input I mpedance Output Impedance Final Transistor Circuit Cooling M ethod M ulti meter Input Output Connectors AC Power AC Consumption Dimension Weight Accessories Output Power Pf IkW Reflected Power Pr 100W Drain Volt
16. ty of AC line fuse before you plug the AC power cord into the outlet Before starting the amplifier be sure to connect a dummy load 50 ohms 600W min or a well adjusted antenna to the output terminal Operating without any load will cause extreme stress to the RF power FET s although protection circuits should work under critical conditions Required drive power is slightly less than 100W to obtain the full 600W output Do not attempt to operate with excessive drive from a high power transceiver Keep the aluminum heat sink and air openings free from dust and blockages Periodic cleaning will prevent degraded cooling efficiency For long continuous operation in RTTY FM modes it is recommended that you reduce the RF drive levels by 20 to 30 lower output than CW SSB modes To prevent damage to the precision electronic components avoid extreme physical shock to the amplifier If factory serviceis required the amplifier should be shipped using the original box and packing materials 3 1 3 3 3 5 Features Our solid state broadband design engineers worked to make the HL 1 1KF X the lightest and most compact 600W out portable HF amplifier in the industry This world class compact 600W HF amplifier is the easiest to handle and operate anywhere in the world The amplifier s main PA section includes 4 high power MOS FET SD2933 THP2933 resulting in 600W SSB CW on HF The amplifier s broadband characteris
17. urn off the POWER once and back on to reset 9 1 9 4 O DRIVE Over Drive Band Miss set When the drive power exceeds the 100W level the amplifier will shut down to STAND BY mode or receive in order to protect the input side of the power FET s This protection might also activate if the band is set wrong This usually occurs when the amplifier band setting is lower than that of the transceiver O HEAT Over Heat When the temperature of the aluminum heat sink in the power amplifier reaches 80 degrees C the amplifier defaults to RECEIVE mode to protect the power FE T 5 O VOLT Over Voltage If there is a sudden AC line voltage spike the FET drain voltage may rise above acceptable levels and O VOLT protection may trip FUSE Fuse Blown If either of the glass fuses 15A on PC1662V fails O VOLT protection activates Under normal usage of the amplifier this failure should rarely if ever occur If it occurs there is a possibility that the power FET s have failed together If the amplifier cannot be reset consult with the dealer or the service center PR Reflected Power Protection If reflected power because of the antenna reaches approximately 80W the PR protection may trip If it does one solution is to reduce the drive power from the transceiver Or you may need to check that your antenna match SWR is still OK If the match cannot be corrected and the antenna system isn t faulty use an antenna tuner As noted a
18. urn the POWER switch on Turn the BAND switch to a desired operating frequency band Turn the STAND BY switch to OPER operate position and the amplifier is ready to go If you key the transceiver with the carrier level set relatively low such as 20 30W you will achieve an amplified output signal of few hundred watts Monitor this output with the multimeter in the Pf position or with an external power meter Increase drive level to roughly 50W and see if the antenna SWR stays constant As higher RF currents flow some antennas may show a changed SWR value due to heated connector junctions and trap Coils You can now increase the drive level to nearly 80 90W to achieve maximum carrier output power of 600W CW from the amplifier If you change to SSB mode average voice power of a few hundred watts will be observed on the panel meter Pf scale while peak voice power reaching a little over 600W For high duty cydetransmissions like RTTY mode it is recommended that you reducethe drive power by some 3096 With a high power transceiver in SSB mode you can overdrive the amplifier resulting in a distorted output signal This can occur if you speak too loud or if you set the microphone gain too high Speak into the microphone properly to reduce the possibilities of splattering into the neighborhood The ALC is effective in preventing the output signal from being distorted or to limit the carrier level to within rated output levels It is strongly re
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20. wire antenna cable or AC line Add AC power cord etc clamp on ferrite cores TDK Amidon Palomar on various cables 16 12 Parts L ayout 12 1 12 2 12 3 12 4 12 5 12 6 12 7 12 8 12 9 Top View Detailed Top View amp Side View PA PC1662V Power Detector PC1398B Control Board PC1785 Front View Control Board PC1785 Copper Side L P F PC1399B Frequency Detector Unit PCS1733 Sub DC Unit PC1784 13 Schematic Diagrams 13 1 13 2 13 3 13 4 13 5 13 6 PC1662V PA Power Amplifier PC1398B RF Power Detector PC1399B L P F Low Pass Filter PCS1733 Frequency Detector Unit PC1785 Control Board Overall Block Diagram 17 SUB SWPO R SUPPLY ALF1015 0000 UU 000 FUSE FY 1 17 LPF UN T PCL398B 10000 100 0000000138881 0000 DUI 0000 1000200000000 FT asss ss DE M e E NE m B xa PCloo2V VR205 PC1398B LET UNT 1504 RF IN 5 s m l T ra TOO TX A TC503 PR AU 8 FLI CONTRO BORO FRON V BV 785 VRIOL PF SCALE AD VRIO2 PR SCALE _ 8108 ID SCALE T LO 11 FUSE F101 F102 2A C108 D 04 o 1 F 4 M 1 5 UE T z de ferri p LER 4 Li E E NM mx pit 1 4 L d 4 Lis t AYA a w
21. worked FUSE LED LED lights when the 15A glass fuse has blown from excessive Id Two fuses are on the PC1622V PA board 9 O HEAT LED When the PA module temperature reaches 80 deg C the LED lights to indicate the protection circuit has worked It is necessary for the cooling fan to operate for several minutes to cool the PA module Turn the main POWER switch to off and then on again to reset the Protection Circuits BAND Select the desired operating frequency band METER To change the multi meter scales Meter reads Pf Pr Vd and Id ID LED FAN LED MULTIMETER LED lights when the input drain current is over 20A This does not mean that any damage occurred to the amplifier but is useful for the user to notice any stress influencing the final FET caused by high drain current load impedance trouble etc We recommend that you note the usual condition of the lighting When any unusual symptoms are noticed the user may lower the drive power from the transceiver check the antenna SWR etc LED lights when fan is running at high speed When the heatsink reaches 50 C the cooling fan will switch to high speed mode to cool the heatsink 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 AC POWER STBY ALC GND ALC ADJ
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