Users Manual Model HL-550FX
Contents
1. Inner Layout of HL 550FX Upper View RF Power Detector and Send Receive Switching Relay 2 Inter lock Switch LPF Board Main Power Source Unit Switching Mode Power Supply Sub Power Source Unit 6 Control Board D Power Amp Unit PA board heatsink Freguency Detector Board 9 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 ANTENNA TRANSGEIVER SWR POWER METER AGG ALG emm ep ANT STBY ALC Q Q HL 550FX REAR 7 1 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 STBY center pin by inserting an RCA plug whose center pin has been soldered to the outer case of the plug with a small piece of wire 4 2 At first turn the ALC knob full clockwise to avoid ALC voltage being fed to the transceiver Application of ALC will be covered in the following Section 8 ALC CONNECTION 773 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 exter band center the ant2. 22 LPF UNIT PC1817 amp SUB AC UNIT PC1819 PC1817 LPF PCB PC1817 LPF PCB COPPER SIDE J301 J302 L l LE i m w 3 2 A LA skr G 8 j yew RE te PC1817 7 a be zw SH D KX te oa i due r s eA 47 JG J303 PC1819 SUB AC PCB PC1819 SUB AC PCB COPPER SIDE F301 J302 L801 KWD15 1212 23 FREQUENCY DETECTOR UNIT PCS1733 amp RF POWER DETECTOR UNIT PC1821 LED PC PC1821 DET UNIT PCS1733 F DET UNIT PC1821 DET UNIT COPPER SIDE LED PC COPPER SIDE EN H JA ERA Ce Ki ef i ka LJ PEA ga PCS1733 F DET UNIT COPPER SIDE 24 CONTROL UNIT PC1818 PC1818 CONT UNIT IC103 C102 IC101 IC108 PC1818 CONT UNIT COPPER SIDE SW102 EET ALMA k r sg Ki AE wie SW i ST e 25 SW101 GJ TOKYO HY POWER DECLARATION OF CONFORMITY 1 1 Hatanaka 3 chome Niiza Saitama 352 0012 Japan We Tokyo Hy Power Labs Inc C declare on our sole responsibility that the product 15th September 2012 Date of issue Equipment HF SOMHz 600W Linear Amplifier Model HL 550FX fulfills the requirements of the standard and regulations of the Directives 1 DIN EN 55022 2010 VDE 0878 22 2011 12 Nobuki Wa 2 DIN EN 55024 2010 VDE 0878 24 2011 09 President 3 DIN EN 60950 1 VDE 0805 1 2011 01 Tokyo Hy Power Labs Inc G TOKYO HY POWER 26
3. drive power antenna SWR Reset with AC POWER switch O Drive lights RF overdrive Decrease drive Q Band miss set Select the BAND correctly 3 O Current works High Same as l Wait for more than 5 Id when using AC100V minutes and turn power ON PR lights VD Reflected power high Check adjust antenna Antenna SWR high Or decrease drive 2 Poor connection to coax cables Check the coax cable connectors O Volt lights Drain voltage of power Check AC line stability red a a FR FUSE lights Fuse blown Replace F202 and F203 15A on the PA board PC1662V Antenna SWR high 2 Adjust the antenna 3 Short circuit 3 Contact the distributor or service center O Heat lights Internal Temperature Cool off until LED turns off Check for above 80 deg C air intake blockages Also check air vent on top cover Vd appears VW 1A fuse of PA unit is Replace 1A mini fuse F203 Confirm blown input power normal but no power Vd is OV l O Current protection O Turn off power and wait for 5 minutes circuit of power supply before turning it on again unit has worked 17 TVI FMI I Overdrive D Decrease the drive Check ALC setting Q RF leakage from coax 2 Insert common mode filters on cable grounding wire antenna cable or AC line Add AC power cord etc clamp on ferrite cores TDK Amidon Palomar on various cables 18 12 Parts Layout 12 1 12 2 12 3
4. eliminate the RF interference to such home appliances as TV FM radio telephone sets and etc it is recommended that clamp on ferrite cores be inserted at both ends of the remote control cable ALC cable coaxial jumper cable and antenna cables as needed Also a common mode AC line filter near the AC outlet and in line low pass filters on the antenna coaxial cable as necessary are recommended 2 7 2 8 2 9 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 capacity of AC line fuse before you plug the AC power cord into the outlet Before start
5. 12 4 12 5 12 6 Top View Detailed Top View amp Side View PA Unit PC1662V LPF Unit PO1817 Sub AC Unit PC1819 Frequency Detector Unit PCS1733 RF Power Detector Unit PC1821 Control Unit PC1818 13 Schematic Diagrams 13 1 13 2 13 3 13 4 13 5 13 6 PC1662V PA Power Amplifier Unit PC1821 RF Power Detector Unit PC1817 LPF Low Pass Filter Unit PCS1733 Frequency Detector Unit PC1818 Control Unit Overall Block Diagram 19 MAIN SW POWER SUPPLY ADA1000F48 TOP VIEW DETAILED DET UNIT PC1821 FAN FUSE F1 F2 LPF UNIT PC1817 DET UNIT PCS1733 F ta l A A A A ATA A ta ATA A Av ita ta l fii 000365 000550 dl Jen s Jen Nan Ye NE Pe 4 mean ee pg mmm saans amaan ajama i san eses naaa gt lt PA UNIT PC1662V aas mamma nanaaa samma TEEF Ta Ve naaaaa WO ee O M 00000008 w rvarTaPaPaA aa ETER A NETT Fae Ze AO SIE AN Vala ITS pee A A bd ed ed hd 029249 474 hd Vaera s GOs SUB SW POWER SUPPLY KWD15 1212 20 CONT UNIT PC1818 TOP VIEW amp SIDE VIEW lt TOP VIEW gt lt RIGHT SIDE VIEW gt lt LEFT SIDE VIEW gt 21 PA UNIT PC1662V F203 Fuse 15A F202 Fuse 15A J202 RF OUT J203 J201 RF IN om Ch Li Ae i A mad 2 1 a ml ser ami kal l N eo w L li vii i A as 4 FN VR204 VR203 VR202 VR201 F201 MINI FUSE 1A VR201 VR204
6. Users Manual Solid State HF 5OMHz Band 550W Linear Power Amplifier Model HL 550Fx HL 550FX TOKYO HY POWER 1 Introduction Thank you for purchasing the HL 550FX This compact and lightweight desktop HF linear power amplifier has a maximum input power of 1 2kW Our solid state broadband power amp technology makes it the smallest and lightest in the industry in its class Typical output power is 550W 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 5 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 intake into the fan Do not block the air vents on the top cover Keep the amplifier out of direct sunlight in a cool dry environment Internal high voltages AC DC and RF are present at all times ON AIR or OFF Internal 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 performance and stability in addition to reduced RF strays or noises To
7. Vd 60V Drain Current Id 50A AC Power AC 200 260V 50 60Hz 7 5A max AC 100 130V 50 60Hz 15A max AC Consumption 1 3kVA max when TX Dimension 232 x 145 x 392 mm 9 1 x 5 7 x 15 4 inches WxHxD Weight Approx 9 2kgs or 20 9lbs AC Power Cord x 1 Coax Jumper Cable with PL259 at both ends x I 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 F202 F203 of PC1662V power amp board Accessories Spare Fuse 1A x 1 for PC1662V power amp board miniature fuse Spare Fuse 3 2A x 1 for PC1819 sub AC control board miniature fuse Users Manual 5 AC Line Voltage 5 1 Although the amplifier is designed to work with both AC 115V 100 130V and AC 230V 200 260V for stability we recommend operation from AC 230V 52 The correct AC plug not included in the package must be obtained locally due to the AC plug variations worldwide 5 3 The AC line fuse has been factory preset for 115V use or as reguested by the customer at the time of order If you wish to change to AC 230V change the fuse to BA 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
8. ch 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 The drive signal level of forward power and reflected power is sent to the control circult Frequency Detector Unit This unit detects the frequency of the drive power from the transceiver When frequency beyond the 26 28MHz amateur bands is detected the amp will stop operating Power Amp PC1662V The RF P is the heart of this amplifier and is composed of four VRF150 MOS FET s made by Microsemi of USA gaining 550W max output The amplifier is a parallel push pull class AB amplifier The gate bias supply circuit is regulated for the best stability and is thermally compensated The P 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 50 deg C and 80 deg C respectively At 50 deg C the cooling fan shifts into high speed mode At 80 deg C the amplifier will lock the amplifier into RECEIVE mode to protect the power FET s 15 10 4 10 5 10 6 LPF Unit PO1817 In the L P F output low pass filter circuit there are seven band filters that are selected by the manual band switch Each L P F is used to reject harmonics so that the amplifier meets international telecommunication equipment standards in
9. cluding FCC rule Control Unit PC1818 This is the heart of the control signal processing for the HL 550FX 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 IC for Over Heat Over Voltage Pr Band Miss set etc Ope amps produce the necessary DC signals to drive the Pf Pr meters Also there 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 Power Supplv The main DC power supply feeds the 44V DC power to the final PA stage It is a state of art switching power supply with high efficiency Sub AC power supply feeding 15V is also installed to consist a high quality power circuit along with the LPF circuit 16 11 Trouble Shooting AC mains not AC fuses blown OD Replace with new ones operating 2 AC cord not pluggedin Plug in securely 3 Interlock switch lifting 4 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 2 Protection circuits ON Check the
10. ective in preventing the output signal from being distorted or to limit the carrier level to within rated output levels It is stronglv recommended to make ALC connection especiallv when 200W out high power radio is used to drive Protection circuits mav 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 laver If this temperature switch activates the amplifier will put vou in receive mode with the cooling fan operating until the transformer has cooled off It may take ten to fifteen minutes to cool depending upon room temperature For more details on this protection circuit see Section 9 PROTECTION CIRCUITS 11 8 ALC Connection ALC voltage is available at the terminal marked ALC RCA phono jack on the right lower corner of the rear panel Negative maximum DC voltage of ten volts 10V is produced at this terminal when the amplifier is fully driven This voltage is adjustable with the ALC ADJ knob located above the ALC jack Setting ALC voltage properly fed back to the transceiver we recommend 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 Depending upo
11. eiver Or you may need to check that your antenna match SWR is still OK If the match cannot be corrected and the antenna system isn t faulty use an antenna tuner As noted above the amplitier is equipped with several kinds of fast acting protection circuits using the latest analog technology However if the amplifier is operated in such a manner that multiple protections work repeatedly over a long period of time the amplifier can be seriously damaged 13 O Current protection of Power Supply Note that you need to reset in a different way from the above 5 protections when O Current protection works on the power supply See NOTICE on page 5 When this protection works the meter display of Vd will be OV Turn the POWER switch OFF and wait for more than 5 minute before turning it ON again to reset 14 10 Explanation of Major Circuits Six major circuit blocks are explained in their basic form and using signal flows Refer to the Block Diagram on the final page 10 1 10 2 10 3 10 4 10 5 10 6 10 1 10 2 10 3 RF Power Detector TX RX Switch PC1821 Freguency Detector Unit PA Unit LPF Unit Control Unit Power Supply RF Power Detector TX RX Switch PC1821 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 swit
12. enna has to be adjusted for lower SWR As an alternative an antenna tuner may be inserted 10 1 4 775 776 l Turn the POWER switch on Turn the BAND switch to a desired operating frequency band Turn the STAND BX switch to OPER operate position and the amplifier is readv to go If vou kev the transceiver with the carrier level set relativelv low such as 20 30W vou will achieve an amplified output signal of a few hundred watts Monitor this output with the multimeter at the Pf position or with an external power meter Increase drive level to roughly 50W and see if the antenna SWR stavs 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 550W CW from the amplifier If vou 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 550W For high duty cycle transmissions like RTTY mode it is recommended that you reduce the drive power by some 30 With a high power transceiver in SSB mode vou can overdrive the amplifier resulting in a distorted output signal This can occur if vou 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 eff
13. for five minutes before it gets resettable When this protection works O DRIVE lamp lights and HL 550FX 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 2 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 3 Change to AC200 240V line 6 A Front Panel Description 12 8 11 Q PROTECT POWER OPER ON AIR O DRIVE PR O VOLT FUSE om CJ E ER GE GE MODEL LODOFX OFF STBY O O DPOWER Main power switch to turn AC power on and off POWER LED Green LED lights when power is turned on OPER OPERATE STAND BY switch At OPERATE the amplifier is ready to go into ON AIR TX mode and at STBY it is on STAND BY mode ON AIR LED Green LED lights when the amplifier is in transmit TX mode 0 DRIVE LED When overdrive or band miss set is detected LED lights to indicate the protection circuit has worked When this lamp is on the amp is in a through state When over current protection of switching power supply has worked this LED also lights for approx 5 minutes To reset protection turn POWER off and turn on again PR LED LED lights when reflec
14. ing the amplifier be sure to connect a dummy load 50 ohms 550W 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 550W 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 service is required the amplifier should be shipped using the original box and packing materials 3 3 1 372 373 JA SN 376 3 7 378 Features Our solid state broadband design engineers worked to make the HL 550FX the lightest and most compact 550W out portable HF 50MHz amplifier in the industry This world class compact 550W 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 VRF150 resulting in 550W SSB CW max on HF and 500W on 50MHz bands The amplifier s broadband characteristics require no further tuning o
15. n the manufacturer of the transceiver the suitable ALC voltage differs ICOM may need 0 4V and Yaesu may need 0 5V range Kenwood may need 6 8V maximum Check your transceiver manual 8 1 8 2 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 EXTERNAL ALC jack of the transceiver External ALC input is sometimes available at one of the pins of the ACC socket of the transceiver as well At first turn ALC ADJ full clockwise Drive the amplifier in CW RTTY mode to full output power Then turn the ALC ADJ counter clockwise Observe the SWR Power meter at the output or Pf of the multimeter Stop turning the ALC ADJ at the point the power starts to decrease Or if you wish to further reduce the power keep turning ALC ADJ until the desired level is achieved If you further try to increase the drive power you will now see the output power become rather saturated from these adjustments Maximum ALC voltage produced is 10V when the amplifier output power is over 200W AC ALC ADJ MAA IN REAR PANEL ALC POT E STBY ALG lo Iransceiver 12 J Protection Circuits There are five major protection functions in this amplifier If the amplifier has shut down for some reason before re setting co
16. nce the operating band is selected 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 duct structure design and the powerful blower fan the aluminum heat sink block for RF PA module and other components are effectively cooled The fan s quiet operation allows for even the weakest DX signals to be heard 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 sure to 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 activated An analog multimeter allows the operator to monitor Pf Forward output power Pr Reflected power Vd Drain voltage of power FET Id Drain current etc 4 Specifications Frequency Band 1 8 50 MHz all amateur bands including WARC bands Mode SSB CW RTTY RF Drive 65 90W typ 100W max HF 550W typ 50MHz 500W RTTY SSTV FM 250W max Output Power When set to AC100V 120V 500W on both HF and 50MHz Multi meter ES Output Power Pf 1kW Reflected Power Pr 100W Drain Voltage
17. power from the transceiver check the antenna SWR etc 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 bv DMETER select switch WAC POWER STBY ALC GND ALC ADJ FUSE IN PUT TX 6 B Rear Panel Description see 1 i AC Mains Socket Socket for the AC power cord Socket is EMI filtered RCA Jack Connect the control cable from the ACC terminal or SEND TX GND etc of the transceiver The center pin is to be shorted to ground through the relay circuit of the transceiver RCA Jack for ALC Voltage Output Negative DC voltage appears at the center pin which is fed back to the ALC terminal of the transceiver ALC is used to keep the amplifier output power at certain limits Also it is useful when the transceiver output power is higher than 100W See page 12 8 ALC Connection Also consult your HF 50MHz transceiver s user manual Ground Terminal Potentiometer to adjust ALC voltage level Negative DC10V is available at maximum when turned full counter clockwise Factory setting is 0 volts with the pot turned full clockwise A pair of fuses for AC mains 15A glass pre installed fuse Change to 8A fuses if 200V 230V line is used RF Input Connector Connect the coax jumper cable from the transceiver ANT OUTPUT RF Output Connector Connect the coax cable to the antenna
18. rrect the possible cause of the shut down Turn off the POWER once and back on to reset 9 1 9 2 9 3 9 4 9 5 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 Note that O DRIVE LED will also light when Over Current protection of switching power supply works when operating AC100V line 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 FET s 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 FUSE lamp lights 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 from the antenna reaches approximately 80W the PR protection may trip If it does one solution is to reduce the drive power from the transc
19. ted power from antenna exceeds 70W to indicate protection circuit has worked O VOLT LED When the DC drain voltage of the FET Vd is too high the LED lights to indicate the protection circuit has worked FUSE LED O HEAT LED To reset protection turn POWER off and turn on again LED lights when the 15A glass fuse F202 203 has blown from excessive Id Two fuses are on the PC1622V PA board When the PA module temperature reaches 80 deg C the LED lights to indicate the protection circuit has worked and the amp will enter the through state 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 METER FAN LED GID LED WMULTIMETER Select the desired operating frequencv band To change the multi meter scales Meter reads Pf Pr Vd and Id LED lights brighter 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 LED lights when the input drain current is over 20A This does not mean that anv damage occurred to the amplifier but is useful for the user to notice anv stress influencing the final FET caused bv high drain current load impedance trouble etc We recommend that vou note the usual condition of the lighting When anv unusual svmptoms are noticed the user mav lower the drive
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