Sunair CU-9150 Service guide

TM – 8120000501

3131 SW 42nd Street, Fort Lauderdale, Florida 33312 U.S.A.

http://www.sunairelectronics.com

1 KW DIGITAL

ANTENNA COUPLER

CU-9150

Operation and Maintenance Manual (Rev. C)

CU-9150

Proprietary/Confidentiality Notice

The information disclosed in this document, including all designs and related materials, is the

property of RIIMIC LLC dba (doing business as) Sunair Electronics (hereinafter “Sunair”)

and/or its licensors. Sunair and/or its licensors reserve all patent, copyright, and other proprietary
rights to this document, including all design, manufacturing, reproduction, use, and sales rights
thereto, except to the extent said rights are expressly granted to others. Reproduction of this
document or portions thereof without prior written approval of Sunair is prohibited.

Return Material Authorization (RMA) Procedures

In case of difficulty, please contact the Sunair Product Service Department between the hours of
8:30 a.m. and 5:30 p.m. EST.

Telephone: [phone]
Fax: [phone]
Email: [e-mail]

To return an item for repair or replacement, a Return Material Authorization (RMA) is required
from the Product Service Department. When you receive the RMA number, carefully pack the
item(s) and ship the package(s) to the address provided by your Product Service Representative.

Write the RMA number in a visual location on the outside of the shipping container.
Retain a copy of all information sheets included with the packaging.

ii Use or disclosure of information from this document is subject to the restrictions

indicated on the proprietary/confidentiality page of this document.

CU-9150

Warranty Policy

Ground and Marine Products

Sunair Electronics warrants each piece of equipment manufactured by it to be free from defects
in material and workmanship, under normal use for the lesser of one (1) year from the date of
installation or 15 months from the date of shipment from Sunair.

Sunair will repair or replace, at its option, any defective equipment or component of the
equipment returned to it at its factory, transportation prepaid, within such warranty period. No
reimbursement will be made for non-factory repair charges.

This warranty is void if equipment is modified or repaired without authorization, subject to
misuse, abuse, accident, water damage or other neglect, or has its serial number defaced or
removed.

THIS WARRANTY IS ESPECIALLY IN LIEU OF ANY AND ALL OTHER WARRANTIES
EXPRESSED OR IMPLIED, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. The obligation and
responsibility of Sunair shall be limited to that expressly provided herein and Sunair shall not be
liable for consequential or other damage or expense whatsoever therefore or by any reason
thereof.

Sunair reserves the right to make changes in the design or additions to or improvements in its
equipment without obligation to install such additions or improvements in equipment theretofore
manufactured.

Training

Sunair offers training programs of varying lengths covering operation, service and maintenance
of all Sunair manufactured equipment. For details please contact the Product Service
Department.

Use or disclosure of information from this document is subject to the restrictions iii
indicated on the proprietary/confidentiality page of this document.

CU-9150

Revision

Page(s)

Manual

Revision

Date

Unit Serial No.

Effectivity

Addendum

Covered

B

Page changes 1:

05/27/98

Page changes 2:

07/15/98

Page changes 3:

08/24/99

Page changes 4:

06/25/03

C

3/22/2011

 Reformatted to current

standards. This includes new
numbers for Figures and
Tables.

All
 Added temperatures in

Fahrenheit.

1-2

 Updated the contact

information with the new
address and phone numbers.

i, ii, 2-1, 2-2

 Re-created some of the hand-

drawn diagrams using
illustrating software.

2-6, 2-8,
2-10,

Revision Record

Copyright © 1998, 1999, 2003, 2011 by Sunair Electronics Inc.
All rights reserved.

No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any
means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of Sunair
Electronics, Inc.

iv Use or disclosure of information in this document is subject to the restrictions

indicated on the proprietary/confidentiality page of this document.

CU-9150

Table of Contents

1.0 General Information ............................................................................................................................ 1-1

1.1 Scope of Manual ........................................................................................................................ 1-1

1.2 General Description ................................................................................................................... 1-1

1.2.1 Assemblies .................................................................................................................... 1-1

1.3 Technical Specifications ............................................................................................................ 1-2

1.3.1 General ......................................................................................................................... 1-2

1.3.2 Environmental .............................................................................................................. 1-2

1.4 Equipment Supplied .................................................................................................................. 1-3

1.5 Equipment Required, Not Supplied ........................................................................................... 1-3

1.6 Optional Equipment ................................................................................................................... 1-4

2.0 Installation ........................................................................................................................................... 2-1

2.1 General....................................................................................................................................... 2-1

2.2 Unpacking and Inspection ......................................................................................................... 2-1

2.3 Return of Equipment to Factory ................................................................................................ 2-1

2.4 Power Requirements .................................................................................................................. 2-2

2.5 Installation Considerations and Mounting Information ............................................................. 2-2

2.5.1 General Installation Procedures and Requirements ...................................................... 2-2

2.5.2 Mounting Considerations ............................................................................................. 2-3

2.5.3 Installation of Remote Control and RF Cables ............................................................. 2-3

2.6 Antennas and Ground Systems .................................................................................................. 2-3

2.6.1 General ......................................................................................................................... 2-3

2.6.2 Random Length Non-Resonant Antennas .................................................................... 2-4

2.7 Long-Wire Adapter Kit (1A1A5) 8120909003 ......................................................................... 2-4

2.8 TX Only Function ...................................................................................................................... 2-5

2.9 Software Revision ...................................................................................................................... 2-5

2.10 Checks after Installation ............................................................................................................ 2-5

2.11 Integration with Third Party Radio Systems.............................................................................. 2-5

3.0 Operation ............................................................................................................................................. 3-1

3.1 General....................................................................................................................................... 3-1

3.2 Operating the CU-9150 ............................................................................................................. 3-1

3.2.1 Operation with 9000 Series Exciters/Transceivers and LPA-9600 .............................. 3-1

3.2.2 1000 Watt Operational Checkout ................................................................................. 3-1

4.0 Theory of Operation ............................................................................................................................ 4-1

4.1 General....................................................................................................................................... 4-1

4.2 Antenna Impedance Matching Network .................................................................................... 4-1

4.3 Chassis Assembly 1A1 .............................................................................................................. 4-2

4.3.1 General ......................................................................................................................... 4-2

4.4 Input Connector Assembly 1A1A2 ........................................................................................... 4-2

Use or disclosure of information from this document is subject to the restrictions v
indicated on the proprietary/confidentiality page of this document.

CU-9150

Table of Contents

4.4.1 General ......................................................................................................................... 4-2

4.4.2 Configuration and Operation ........................................................................................ 4-2

4.5 CPU Assembly 1A1A3 .............................................................................................................. 4-2

4.5.1 General ......................................................................................................................... 4-2

4.5.2 Microprocessor ............................................................................................................. 4-2

4.5.3 Serial Communication .................................................................................................. 4-3

4.5.4 A/D Converter .............................................................................................................. 4-3

4.5.5 Relay Drivers ................................................................................................................ 4-3

4.5.6 Channel Change and Tune Command Detectors .......................................................... 4-3

4.6 RF Detector Assembly 1A1A4A1 ............................................................................................. 4-4

4.6.1 General ......................................................................................................................... 4-4

4.6.2 Magnitude Discriminator .............................................................................................. 4-4

4.6.3 Phase Discriminator...................................................................................................... 4-4

4.6.4 Attenuator Pad, -3 dB ................................................................................................... 4-5

4.6.5 50 Ohm Calibration Termination ................................................................................. 4-5

4.6.6 TX Only Function......................................................................................................... 4-5

4.7 Input Capacitor Assembly 1A1A4A2 ........................................................................................ 4-6

4.7.1 General ......................................................................................................................... 4-6

4.7.2 Configuration and Operation ........................................................................................ 4-6

4.8 Mother Board Assembly 1A1A1 ............................................................................................... 4-6

4.8.1 General ......................................................................................................................... 4-6

4.8.2 DC Power ..................................................................................................................... 4-6

4.8.3 Series L and Shunt C Relays ........................................................................................ 4-6

4.8.4 L-OUT Relays .............................................................................................................. 4-6

4.9 Interface Requirements for Third Party Equipment .................................................................. 4-7

4.9.1 Signal Descriptions ....................................................................................................... 4-7

5.0 General ................................................................................................................................................ 5-1

5.1 Preventive Maintenance............................................................................................................. 5-1

5.1.1 Gasket Replacement ..................................................................................................... 5-1

5.2 Disassembly ............................................................................................................................... 5-2

5.2.1 Cover Removal ............................................................................................................. 5-2

5.2.2 CPU Removal ............................................................................................................... 5-2

5.2.3 RF Detector/Input Capacitor Removal ......................................................................... 5-4

5.2.4 Chassis Removal .......................................................................................................... 5-4

5.3 Indicators ................................................................................................................................... 5-5

5.4 Test Equipment Required or Equivalent .................................................................................... 5-6

5.5 Alignment and Checks ............................................................................................................... 5-6

5.6 Troubleshooting ......................................................................................................................... 5-8

vi Use or disclosure of information from this document is subject to the restrictions

indicated on the proprietary/confidentiality page of this document.

CU-9150

Table of Contents

5.6.1 Coupler Will Not Tune - No Relay Action - No Tuning Fault ..................................... 5-8

5.6.2 Coupler Will Not Tune - No Relay Action - Tuning Fault Indicated ........................... 5-9

5.6.3 Relays Operate But Tuning Fault Indicated ................................................................. 5-9

5.6.4 Coupler Tunes but Memory Does Not Work ............................................................... 5-9

5.7 DIP Switch Settings ................................................................................................................... 5-9

6.0 Options ................................................................................................................................................ 6-1

6.1 Diagnostic Test Set .................................................................................................................... 6-1

6.1.1 General Information ..................................................................................................... 6-1

6.1.2 Test Set Operation ........................................................................................................ 6-2

6.2 CU-9150H Serial Control Upgrade ......................................................................................... 6-31

6.2.1 General Information ................................................................................................... 6-31

6.2.2 Installation .................................................................................................................. 6-31

6.2.3 Operation .................................................................................................................... 6-32

6.2.4 Theory ........................................................................................................................ 6-35

6.2.5 Troubleshooting .......................................................................................................... 6-36

Use or disclosure of information from this document is subject to the restrictions vii
indicated on the proprietary/confidentiality page of this document.

CU-9150

Listing of Figures

Figure 2.11-1. CU-9150 Control Cable P/N 8092500096 ........................................................................ 2-6

Figure 2.11-2. Coupler Outline Dimensions ............................................................................................. 2-7

Figure 2.11-3. LPA-9600 with CU-9150, 35-Foot Antenna (Roof Top Installation) ............................... 2-9

Figure 2.11-4. LPA-9600 with CU-9150, Non-Resonant Antenna ........................................................ 2-10

Figure 2.11-5. Longwire Antenna Kit ..................................................................................................... 2-11

Figure 2.11-6. Long-Wire Adapter Kit (1A1A5) 81200909003 Installation Configured for Long-Wire

Operation ........................................................................................................................................... 2-12

Figure 2.11-7. Long-Wire Adapter Kit (1A1A5) 81200909003 Installation Configured for Whip Wire

Operation ........................................................................................................................................... 2-12

Figure 2.11-8. Assembly/Disassembly of Antenna Output Lead (Long-Wire Adapter Kit Not Installed)2-13

Figure 4.9-1. Coupler Interface Timing .................................................................................................... 4-9

Figure 4.9-2. CU-9150 Assembly Tree ................................................................................................... 4-10

Figure 4.9-3. CU-9150 Block Diagram .............................................................................................. 4-11

Figure 5.2-1. Gasket Installation and Torque Sequence ........................................................................... 5-3

Figure 5.2-2 Chassis Removal .................................................................................................................. 5-5

Figure 5.5-1. 1A1A4A1 RF Detector Alignment Adjustment Locations ................................................. 5-7

Figure 5.7-1 CU-9150 Assembly Locations ........................................................................................... 5-11

Figure 5.7-2 1A1 Chassis Component Locations ................................................................................... 5-12

Figure 5.7-3. Non-Chassis Component Locations .................................................................................. 5-13

Figure 5.7-4. Final Assembly Tested CU-9150, Chassis Assembly 1A1 and Long Wire Adapter Kit

1A1A5 ............................................................................................................................................... 5-15

Figure 5.7-5. PC Assembly, CU-9150 Motherboard, 1A1A1 ................................................................. 5-17

Figure 5.7-6. PC Assembly, Input Connector, 1A1A2 ........................................................................... 5-21

Figure 5.7-7. PC Assembly, CPU, 1A1A3 ............................................................................................. 5-23

Figure 5.7-8. PC Assembly, RF Detector, 1A1A4A1 ............................................................................. 5-33

Figure 5.7-9. PC Assembly, PC Assembly, Input Capacitor, 1A1A4A2 ................................................ 5-35

Figure 6.1-1. PC Assembly, Test Fixture, CU-9150 CPU ........................................................................ 6-9

Figure 6.1-2. PC Assembly, Serial Breakout Board ............................................................................... 6-19

Figure 6.1-3. PC Assembly, Display Board ............................................................................................ 6-21

viii Use or disclosure of information from this document is subject to the restrictions

indicated on the proprietary/confidentiality page of this document.

CU-9150

Listing of Tables

Table 1.4-1 List of Equipment Supplied ................................................................................................... 1-3

Table 1.5-1 List of Equipment Required, Not Supplied ........................................................................... 1-3

Table 1.6-1. Optional Equipment .............................................................................................................. 1-4

Table 3.2-1. Acceptable Reflected Power Chart for VSWR 1.5:1. for LPA-9600 ................................... 3-2

Table 3.2-2. Acceptable Reflected Power Chart for VSWR 1.5:1. for LPA-9500 ................................... 3-2

Table 4.9-1. Signal List and Descriptions ................................................................................................. 4-7

Table 5.3-1. CU-9150 Indicators and Meanings ....................................................................................... 5-5

Table 5.7-1 S201 DIP Switch Settings.................................................................................................... 5-10

Table 5.7-2 CU-9150 Detailed Assemblies List ..................................................................................... 5-14

Table 6.1-1 Equipment Supplied .............................................................................................................. 6-1

Table 6.1-2 Coupler Operation Terms ...................................................................................................... 6-2

Table 6.1-3. Board Level Test Components Required .............................................................................. 6-2

Table 6.1-4 Serial Breakout Equipment Required .................................................................................... 6-6

Table 6.1-5. TuneView Parameters ........................................................................................................... 6-7

Table 6.2-1. CU-9150H Conversion Kit ................................................................................................. 6-31

Table 6.2-2. CU-9150H Control Cable Signals ...................................................................................... 6-32

Use or disclosure of information from this document is subject to the restrictions ix
indicated on the proprietary/confidentiality page of this document.

CU-9150

*(asterisk) Selected function
ACC Automatic Carrier Control
ADDR Address
AFSK Audio Frequency-Shift Keying
AGC Automatic Gain Control
ALC Automatic Level Control
ALE Address Latch Enable
Automatic Link Establishment
AM Amplitude Modulation
AME Amplitude Modulation

Equivalent

AMP/AMPL Amplifier
ARQ Automatic Request
ATC Air Traffic Control
AUD Audio
AUTO Automatic
AUX Auxiliary
BAUD Variable unit of data

transmission speed (bits per
second)

BELL U.S. Telephone standards
BFO Beat Frequency Oscillator
BITE Built In Test Equipment
BRD Board
CH/CHAN/
CHL/CHN Channel
CLR Clear
CMOS Complementary Metal Oxide

Semiconductor

CPLR Coupler
CPU Central Processing Unit

(Computer)

CTCSS Continuous Tone Coded Squelch

System

CW Continuous Wave
dB Decibel
dBm Decibels referred to 1 milliwatt
DCS Digital Coded Squelch
DSBSC Double Sideband Suppressed

Carrier

DSP Display
Digital Signal Processor
DTMF Dual Tone Multi-Frequency

DUART Dual Asynchronous Receive/

Transmit

EEPROM Electrically Erasable and

Programmable Read Only Memory
EIA Electronics Industry Alliance
EL Electroluminescent
EMI Electromagnetic Immunity
EMP Electromagnetic Pulse
ENTR Enter
EPROM Eraseable Programmable Read Only

Memory
ESD Electrostatic Discharge
ETSI European Telecommunications

Standards Institute
FAX Facsimile
FEC Forward Error Correction
FM Frequency Modulation
FREQ Frequency
FSK Frequency Shift Keying
FWD Forward
GRP Group
HF High Frequency
HPAC High Power Amplifier Controller
Hz Hertz
IC Integrated Circuit
IF Intermediate Frequency
IMD Intermodulation Distortion
I/O Input/Output
IONCAP Ionospheric Communications

Analysis and Prediction (Program)
ISB Independent Sideband
kHz Kilohertz
kW Kilowatt
LCD Liquid Crystal Display
LCL Local
LED Light Emitting Diode
LK Link
LO Local Oscillator
LRU Lowest Repairable Unit
LSB Lower Sideband
LT Light
LVL Level
MIC Microphone

Abbreviations/Acronyms

x Use or disclosure of information from this document is subject to the restrictions

indicated on the proprietary/confidentiality page of this document.

CU-9150

MAN Manual
M CH Manual Channel
MED Medium
MHz Megahertz
MED Medium
MHz Megahertz
MIC Microphone
MIL-STD Military Standard
MNL Manual
ms Millisecond
MTBF Mean Time Between Failures
MTR Meter
MTTR Mean Time To Repair
NAR Narrow
NB Narrow Band
PA Power Amplifier
P.C. Printed Circuit
PEP Peak Envelope Power
PLL Phase-Locked Loop
P/N Part Number
PNL Panel
POSTSL Post-Selector
PRESEL Pre-Selector
PTT Push-To-Talk
PWR Power
RCV Receive
REFD/REFL/
RFL Reflected
REV Revision
RF Radio Frequency
RFI Radio Frequency Interference
RMA Return Material Authorization
RMT Remote
RS232 Computer control, hardwired up

to 50 feet maximum

RS422 Computer control, hardwired up to 4000

feet maximum

RS485 Computer control, hardwired for

multiple users
RTTY Radio Teletype
RX Receive
RU Rack Unit
SDR Software Defined Radio
SEL Select
SINAD Signal to Noise and Distortion
SLO Slow
S MTR Signal Strength Meter
SPKR Speaker
SPLX Simplex
SRAM Static Random Access Memory
SSB Single Sideband
TCXO Temperature Compensated Crystal

Oscillator
TFT Thin Film Technology
TGC Transmit Gain Control
THD Total Harmonic Distortion
TTL Translator Transistor Logic
TX Transmit
USB Upper Sideband
UTC Universal Time Coordinated
VC Voltage Control
VCO Voltage Controlled Oscillator
VHF Very High Frequency
VRMS Volts Root Mean Square
VSWR Voltage Standing Wave Ratio
W Watt
WB Wide Band
WPM Words Per Minute
XMT Transmit

Abbreviations/Acronyms (Continued)

Use or disclosure of information from this document is subject to the restrictions xi
indicated on the proprietary/confidentiality page of this document.

CU-9150

Electrical Safe Work Practices

Accidents involving electricity can cause burns, explosions, shocks, and death. Only trained and
qualified personnel should service, install, or repair electrical equipment.

The general safety procedures for personnel servicing electronic and electrical equipment
include:

1. Always turn off or disconnect power before working on electric equipment, electronic

circuits, or any type of electrical item.

2. Turn off and disconnect power before checking or replacing fuses.

3. Locate and correct the cause of a blown fuse or tripped circuit breaker before replacing

the fuse or resetting the circuit breaker.

4. Never defeat the purpose of a fuse or circuit breaker. Always install a fuse with the

correct amperage rating for the circuit. Never install a fuse with a higher rating.

5. Always have a second trained and qualified person present when working on electrical

systems (protected or unprotected).

6. Always remove metal jewelry, watches, rings, etc., before working on electrical circuits

or any electrical equipment.

7. Do not work on electrical equipment in a wet area. Never place containers of liquid on

electrical equipment.

8. Do not touch an object that may provide a hazardous path to earth ground.

9. Safely discharge capacitors in equipment before working on the circuits (refer to ESD

procedures).

10. Inspect cabling for defects, including frayed wiring, loose connections, or cracked

insulation. Replace defective cords and plugs.

11. Always check the electrical ratings of equipment and verify that the ratings are correct.

12. Never overload circuits.

13. Verify grounding of equipment chassis/cabinets. Never cut off or defeat the ground

connection on a plug.

14. When working at any site, always observe all safety signs and safety procedures. They

exist to protect personnel from injuries.

15. All persons working on or around electrical/electronic equipment should have first aid

training, including resuscitation procedures and external cardiac compression.

xii Use or disclosure of information from this document is subject to the restrictions

indicated on the proprietary/confidentiality page of this document.

CU-9150

Electrostatic Discharge (ESD)

Electrostatic Discharge (ESD) can severely damage sensitive components located on printed
circuit cards. Electrostatic discharge measurements as high as 35,000 volts, can occur from
walking across a carpet.

To avoid potential damage to electronic equipment, follow correct electrostatic discharge
preventive procedures when handling or working with the hardware.

1. Always wear an electrostatic discharge wrist strap when handling electronic hardware.

2. Connect the electrostatic discharge wrist strap to a reliable earth ground.

3. Replace worn or frayed electrostatic discharge wrist straps and connecting cords.

4. Check your electrostatic discharge strap every month.

5. Do not use electrostatic discharge straps that are out of calibration.

6. Place printed circuit cards in an electrostatic discharge bag or other ESD container to

avoid damage from stray static charge.

7. Do not place printed circuit cards on any surface that is not an approved electrostatic

discharge surface correctly connected to earth ground.

8. Always handle printed circuit cards by the edges. Avoid touching any of the sensitive

circuits on the card.

Use or disclosure of information from this document is subject to the restrictions xiii
indicated on the proprietary/confidentiality page of this document.

CU-9150

Hazardous Materials

Hazardous materials are likely to be present at the maintenance facility. Many of the following
substances are toxic (causing illness or death): flammable materials, explosive materials,
corrosive materials that cause the skin or eyes to burn on contact, reactive materials that, when
exposed to heat, air, water, or certain other chemicals, can cause burning or release of toxic
vapors.

Some hazardous substances are obvious, for example, adhesives, solvents, abrasives, fuels, and
pesticides. Other substances are less obvious, for example, toner in office copiers and printers
and heavy-duty cleaning and disinfectant products. The list of substances identified as hazardous
in the workplace is constantly increasing as new processes and new technologies create new
chemicals.

Post a list of hazardous materials in each work area. In the United States, hazardous materials
include a material safety data sheet that describes the material, the health/safety risks, correct
usage procedures, recommended storage facilities, and the method(s) to treat exposure. If local
codes do not require use of a material safety data sheet, a simple list may describe the type of
material, correct usage and storage methods, and its hazard(s). Include emergency first aid
procedures in the event that personnel experience exposure to the material.

xiv Use or disclosure of information from this document is subject to the restrictions

indicated on the proprietary/confidentiality page of this document.

CU-9150

 Power supplies
 Transmitters
 RF equipment

 Motors
 Antennas

 Generators
 Fan systems

 New construction
 Installation or set-up

of equipment

 Equipment that is being:

 Adjusted  Serviced
 Inspected  Repaired

 Electrical
 Hydraulic

 Chemical
 Mechanical

 Pneumatic
 Thermal

Lockout/Tagout Policy

Lockout/Tagout refers to the complete isolation of equipment during maintenance or service
work. It is good practice to require use of locks or tags as warning devices to prevent injuries to
service personnel from accidental machine start-ups.

While servicing equipment, place a red or yellow tag on the equipment, indicating it is out of use
for repairs or maintenance. Treat these tags as a lockout tag. To obtain information regarding
when that piece of equipment will become available for use, contact the person who signed the
tag.

Examples of equipment/service to tag/lock out during servicing include:

Work situations where unexpected application of power or starting of equipment could occur
include:

Power types include:

Do not attempt to start, energize, or use a machine or equipment that

is locked out for service or maintenance.

WARNING

Use or disclosure of information from this document is subject to the restrictions xv
indicated on the proprietary/confidentiality page of this document.

CU-9150

Warnings, Cautions, and Notes

Warnings, cautions, and notes alert the user to special conditions regarding safety or correct
performance of a particular step(s).

WARNINGS  Used when a procedure, technique, or restriction could result in injury or death
to personnel.

CAUTIONS  Used when a procedure, technique or restriction could result in damage to
equipment.

NOTES  Used whenever emphasis or consideration for the performance of a procedural step
or steps are necessary.

Some personnel in the work place should be trained in rendering first aid. In those places where
high voltages are present, they should be familiar with methods of resuscitation.

Keep Away from Live Circuits

Operating personnel must observe at all times all safety regulations. Do not replace components
inside the equipment with the power supply turned on. Under certain conditions, dangerous
potentials may exist when the power control is in the off position due to circuit design or charges
retained by capacitors. Remove watches and rings before performing any maintenance
procedures.

Do Not Service or Adjust Alone

Under no circumstances should any person reach into or enter the enclosure to service or adjust
the equipment except in the presence of someone who is capable of rendering aid.

Resuscitation

Personnel working with or near high voltage should be familiar with methods of resuscitation.

xvi Use or disclosure of information from this document is subject to the restrictions

indicated on the proprietary/confidentiality page of this document.

CU-9150

Chapter I

1.0 General Information

1.1 Scope of Manual

This manual contains information necessary to install, operate, maintain and repair the CU-9150
1 KW Automatic Digital Antenna Coupler.

1.2 General Description

The CU-9150 is a 1000 watt high quality remotely controlled antenna coupler, capable of
providing efficient matching of antennas 23 feet and longer to a 50 ohm transmission line, over
the frequency range of 1.6 to 30 MHz. In addition, the coupler may be used as a 'line flattener' to
correct the VSWR of resonant antennas. The unit is designed as a companion to the Sunair LPA­9600 1 kW or LPA-9500 500 Watt Linear Power Amplifiers.

The CU-9150 is designed to operate at separations of up to 250 feet from the
Exciter/Transceiver. The coupler control is located on the front panels of Sunair 9000 Series
Exciters/Transceivers. Manual tuning cycles are initiated by pressing the CPLR TUNE
pushbutton on 9000 Series front panel. A meter for indicating forward and reflected power is
also located on the 9000 Series front panel. During a tuning cycle, the linear power amplifier is
disabled and tune power (35-45 Watts) is supplied by the Exciter/Transceiver. The operating
power and commands to the coupler are also supplied by the Exciter/Transceiver alone. The
coupler may be used directly with a 125 watt Exciter/Transceiver if low power operation is
desired or the linear amplifier is off-line.

1.2.1 Assemblies

1.2.1.1 Input Connector Assembly 1A1A2

The Input Connector Assembly 1A1A2 provides the required mounting surface for the various
electrical and mechanical components. It serves as interconnect for signals to and from the CU­9150, the Exciter/ Transceiver and the LPA-9600 kilowatt linear power amplifier.

1.2.1.2 CPU Assembly 1A1A3

The CPU Assembly 1A1A3 contains the microprocessor responsible for the operations and
functions of the CU-9150.

1.2.1.3 RF Detector Assembly 1A1A4A1

The RF Detector Assembly contains the magnitude, phase, reflected power detectors and a 50
ohm calibration source.

1.2.1.4 Input Capacitor Assembly 1A1A4A2

The Input Capacitor Assembly contains the input capacitance binary variable network element.

Use or disclosure of information from this document is subject to the restrictions 1-1
indicated on the proprietary/confidentiality page of this document.

CU-9150

1.2.1.5 Motherboard 1A1A1

The Motherboard 1A1A1 interconnects the CPU Assembly, RF Detector, Input Capacitor and
Network Relays.

1.2.1.6 Chassis Assembly 1A1

The Chassis Assembly contains three binary variable reactive network elements. These are the
series inductance (L series), output capacitance (C-out), and output inductance (L-out).

1.3 Technical Specifications

1.3.1 General

Frequency Range 1.6 to 30 MHz
Tuning Capabilities 35-foot Whip, 50 to 150 Long Wires

NOTE: Long Wire Adapter required; 23 foot Whip, 3 to 30 MHz.

RF Input Power 1.6 to 2.0 MHz 500 W average, 1 kW PEP

2.0 to 30 MHz 1 kW average, 1 kW PEP
Input Impedance 50 ohms
Duty Cycle Continuous
Tuning Time 1 second typical; 25 ms from memory. Channel Memory,

128 channels.
Tune Power Required 25 W RF delivered
Tune Accuracy 1.5:1 VSWR or better (99.5% of all operating frequencies)
Remote Capability Up to 250 ft. from Exciter/Transceiver
Power Input 28 VDC supplied from Exciter/Transceiver
Circuit Protection (A) RF Input Spark Gap

(B) Control Line Lightning Impulse
Weight 20.4 kg (45 lbs)
Size Height: 24.38 cm (9.6”)

Width: 45.47 cm (17.9”)

Depth: 73.15 cm (28.8”)
MTTR 15 minutes
MTBF 12,000 hours

1.3.2 Environmental

Temperature Range: Operating -50oC to +65oF (-58oC to +149oF)

Storage: -55oC to +85oF (-67oC to +185oF).

1-2 Use or disclosure of information from this document is subject to the restrictions

indicated on the proprietary/confidentiality page of this document.

CU-9150

Equipment

Sunair Part Number

CU-9150 Automatic Digital Antenna Coupler

8120000056 Gray
8120000099 Olive Drab

Button up

8120001052 Gray

Operation and Maintenance Manual

TM-8120000501

Connector Kit, consisting of:

8092000298

Bushing, Telescoping, .561 D

0700550054

Bushing, Telescoping, .621 D

0700550062

Bushing, Telescoping, .751 D

0700550071

Connector, Power, 37 Pin Round

0747640009

Connector, RF, N UG-21 B/U

0754140008

Equipment

Sunair Part Number

Control Cable Assembly

8092500096

Order by length. Contains:

Connector, Power, 37 Pin Round

8092000298

Connector, RF, N UG-21 B/U

0588680001

LPA-9600/LPA-9500 mating connector and hardware

User Supplied

Coax Cable Assembly

8104906097

Order by length desired. Contains:

Coax Cable RG-213

1010770021

Connector, RF, N UG-21 B/U 2 each

0754140008

Humidity: MIL-STD-810C, Method 507.1, Proc. II
Shock and Vibration: MIL-STD-810C, Method 516.2 and 514.2
Enclosure MIL-STD-810C, Method 510.1, waterproof

1.4 Equipment Supplied

Table 1.4-1 List of Equipment Supplied

1.5 Equipment Required, Not Supplied

Table 1.5-1 List of Equipment Required, Not Supplied

Use or disclosure of information from this document is subject to the restrictions 1-3
indicated on the proprietary/confidentiality page of this document.

CU-9150

Equipment

Sunair Part Number

Linear Amplifiers/Exciter/Transceiver

Consult Sunair Marketing Department

TS-9150 Diagnostic Test Set

8120907591

Depot Spares Kit

8120900090

Field Module Kit

8120905792

35 Foot Fiberglass Antenna

0715850008

Feed-Thru Antenna Mount, 1 kW

1004890001

Base Antenna with Flange

0715780000

KW Longwire Antenna Kit

1003090010

Control Cable Assembly - Used to connect coupler
directly to exciter/transceiver

8076004195
Long-Wire Adapter Kit

8120909003

1.6 Optional Equipment

Table 1.6-1. Optional Equipment

END OF CHAPTER I

1-4 Use or disclosure of information from this document is subject to the restrictions

indicated on the proprietary/confidentiality page of this document.

CU-9150

CHAPTER II – Installation

2.0 Installation

2.1 General

Section II contains all necessary instructions for the unpacking, inspection, and if necessary,
reshipping of damaged equipment or parts. In addition, further information regarding location
and mounting considerations, power requirements, antenna and ground system hook-ups and
installation test is also provided.

2.2 Unpacking and Inspection

As soon as you have received your unit(s), unpack and inspect all components and accessories.
Check the packing list to be sure you have received all items ordered and that all items necessary
for operation have been ordered.

NOTE: Be sure to retain the carton and its associated packing materials

should it be necessary to reship damaged equipment.

Do not accept a shipment when there are visible signs of damage to the cartons until a complete
inspection is made. If there is a shortage of items or any evidence of damage, insist on a notation
to that effect on the shipping papers before signing the receipt from the carrier. If concealed
damage is discovered after the shipment has been accepted, notify the carrier immediately in
writing and await his inspection before making any disposition of the shipment. A full report of
the damage should also be forwarded to Sunair’s Product Services Department. Include the
following:

 Order Number
 Model and Serial Number
 Name of Transportation Agency
 Applicable dates.

When Sunair receives this information, arrangements will be made for repair or replacement.

2.3 Return of Equipment to Factory

The shipping container for the CU-9150 has been carefully designed to protect the equipment
during shipment. The container and its associated packing materials should be used to reship the
unit. When necessary to return equipment to Sunair for warranty or non-warranty repair, an
authorization number is required. This number can be obtained from our Product Services
Department:

Telephone: [phone]
FAX: [phone]
e-mail: [e-mail].

Use or disclosure of information from this document is subject to the restrictions 2-1
indicted on the proprietary/confidentiality page of this document.

CU-9150

If the original shipping carton is not available, be sure to carefully pack each unit separately,
using suitable cushioning material where necessary. Very special attention should be given to
providing enough packing material around connectors and other protrusions from the coupler.
Rigid cardboard should be placed at the corners of the equipment to protect against denting.

When returning subassemblies or components for repair or replacement, be sure to pack each
item separately, using suitable cushioning material.

Shipment to be made prepaid consigned to:

Sunair Electronics, Inc.

Product Services Department

3131 SW 42 Street

Ft. Lauderdale, Florida 33312

U.S.A.

Plainly mark with indelible ink all mailing documents as follows:

U.S. Goods Returned For Repair

Value For Customs - $100.00

Mark all sides of the package:

FRAGILE - ELECTRONIC EQUIPMENT!

NOTE: Before shipping, carefully inspect the package to be sure it is

marked.

2.4 Power Requirements

All power necessary to operate the CU-9150 1 KW Automatic Digital Coupler is supplied from a
companion Exciter/Transceiver via the LPA-9600/LPA-9500 control cable. See Figure 2.11-1
for control cable connections.

2.5 Installation Considerations and Mounting Information

The satisfactory operation of the equipment will depend upon the care and thoroughness taken
during the installation.

2.5.1 General Installation Procedures and Requirements

1. Carefully plan radio/amplifier/coupler/antenna locations, observing the following

requirements before starting installation.

2. Provide best possible RF ground for all equipment. Use flat copper strap 1" wide or #6

(or larger) wire and make connections to the ground terminal of all system components.
Leads to ground system should be as short as possible.

After the system grounds have been installed, connect the station ground system to the
antenna coupler ground terminal. Bear in mind that the antenna ground lead is actually
part of the antenna itself, and therefore will have a marked effect on the antenna input
impedance. If a 35-foot vertical antenna is to be used, at least 12 separate 35-foot radials
connected to a common ground stake are recommended.

2-2 Use or disclosure of information from this document is subject to the restrictions

indicated on the proprietary/confidentiality page of this document.

CU-9150

3. Provide the maximum separation between coupler/antenna and the radio with its

associated wiring. 100 feet is the recommended minimum distance and up to 250 feet
separation may be used.

4. The antenna lead from the antenna coupler RF output insulator must be insulated for at

least 15 kV potential. As an alternative, copper tubing with an outside diameter of at
least 1/4" may be used, provided that it is routed to the antenna terminal so that it is
spaced at least six inches from any metal objects in its vicinity. It is important to keep
the length of this lead to an absolute minimum since it forms a part of the radiating
portion of the antenna. Three (3) feet would be the maximum distance if antenna
efficiency is not to be compromised.

5. Linear amplifiers with low level modulation such as used in Sunair exciters/transceivers

will sometimes oscillate if the high RF power level output is radiated or conducted into
the low level stages. Evidence of this situation is erratic or excessive power output. This
is caused by too close proximity of the coupler output and antenna to the transmitter
and/or inadequate RF grounds. Carefully following the above procedures will prevent
this from occurring.

2.5.2 Mounting Considerations

See Figure 2.11-2 for Coupler outline dimensions.
The mounting position for the CU-9150 is dependent on the available space for mounting. Four

mounting feet with 3/8" wide slots are provided on the coupler. If it is necessary to mount the
coupler on a wooden pole, simple angle-iron adapter brackets may easily be fabricated. Since
the total weight of the unit is only 45 pounds, two wooden 4 x 4s set in cement would provide
dependable support.

2.5.3 Installation of Remote Control and RF Cables

It is recommended that the remote control cable be procured from Sunair. However, if
necessary, the cable may be made from individual No. 20 AWG stranded wire with an overall
braided shield and PVC jacket. Interconnection cable details are given in Figure 2.11-1.

2.6 Antennas and Ground Systems

2.6.1 General

Sunair Exciters/Transceivers are designed to operate into a 50 Ohm resistive antenna system
with a maximum voltage standing wave ratio (VSWR) of 2:1. When used with the CU-9150 1
KW Automatic Digital Antenna Coupler alone or with the LPA-9600 Linear Amplifier, the
system will match antennas 35 feet and longer. The CU-9150 is placed close to the antenna
(within 3 feet or less) and controlled from the front panel of the exciter/ transceiver. This
optimizes both operator convenience and electrical performance. As there are numerous types of
antennas, a complete discussion is beyond the scope of this manual; however, some general DOs
and DON’Ts of antenna installation are listed below:

 The antenna should be clear of all large objects such as trees and buildings.

Use or disclosure of information from this document is subject to the restrictions 2-3
indicted on the proprietary/confidentiality page of this document.

CU-9150

 When using whip antennas, the ground system actually forms part of the radiating

system. Where space permits (such as in a base station installation) a good ground plane
or radial system should be installed at the base of the antenna. (See Figure 2.11-3.)

NOTE: An inadequate ground system is most often responsible for

disappointing performance when using a whip antenna.

2.6.2 Random Length Non-Resonant Antennas

See Figure 2.11-3, Figure 2.11-4, and/or Figure 2.11-5 as needed.
Whips and longwires are popular non-resonant antennas. The whip antenna is often used in

mobile, marine, portable or semi-portable installations because it is rugged and self-supporting.
The antenna impedance is strongly dependent on the operating frequency, and an antenna
coupler, therefore, must be used to match the antenna to the transceiver. Thirty-five foot whip
antennas offer a good compromise between practical height and good electrical performance at
low frequencies. The whip’s performance is greatly influenced by its ground system. For
temporary base station installations, a minimum of four 6-foot long ground rods should be driven
into the ground, symmetrically placed around the antenna base. The rods should be bonded
together with heavy strap and then connected to the antenna coupler ground by another short,
heavy strap. If the antenna is mounted on the roof of a building where a short ground lead to
coupler cannot be obtained, a minimum of four symmetrically placed ground radials should be
installed at the base of the antenna, bonded together, and connected to the antenna coupler
ground post. The radials should be made of number 12 gauge wire or larger and should be at
least 1/4 wave long at the lowest operating frequency. (Radial length in feet = 246/frequency in
MHz.) The whip’s radiation pattern is omni-directional in the azimuthal plane.

The longwire antenna, illustrated in Figure 2.11-5, is a popular base station antenna where a wide
range of operating frequencies are used. The antenna impedance varies greatly with frequency
and, therefore, must be matched to the transmitter with the antenna coupler. The CU-9150 will
efficiently match longwire antennas up to 150 foot in length. The radiation pattern of the
longwire antenna is also a strong function of operating frequency. The two most popular
longwire antennas, (75 and 150 foot) available from Sunair, exhibit excellent low frequency
radiation efficiency.

2.7 Long-Wire Adapter Kit (1A1A5) 8120909003

The Long-Wire Adapter Kit is required for wire antennas between 50 and 150 feet in length. See
Figure 2.11-6 for installation details.

Operation using a 23- to 35-foot whip antenna is still possible after installation of the long-wire
adapter kit. This is accomplished by changing the point at which the wire from K19 on the
chassis (1A1K19) is connected to the long-wire adapter kit. See Figure 2.11-7 for details.

A WHIP / LONG-WIRE identification plate is included with the long-wire adapter kit. It should
be secured to the top cover of the coupler by one of the cover hold-down screws. It is meant to
indicate whether the long-wire adapter kit is configured for whip or long-wire operation.

2-4 Use or disclosure of information from this document is subject to the restrictions

indicated on the proprietary/confidentiality page of this document.

CU-9150

2.8 TX Only Function

If the coupler is being installed in a system with separate transmit and receive antennas and
where two or more transmitters are using collocated antennas, the TX ONLY function should be
enabled. When this function is enabled, the coupler opens the RF path between the tuning
network and the radio system when the radio system is in receive mode. Therefore, high RF
voltages induced by adjacent transmitters are confined to the coupler.

The TX ONLY function is enabled by soldering a jumper wire between E4 and E4 of the
1A1A4A1 RF Detector Board.

2.9 Software Revision

In order for the CU-9150 to function properly, the software revision in the companion
transceiver or exciter and linear amplifier must be equal to or later than the following:

Equipment Software Revision

RT-9000 or RT-9000A D4
T-9400 B1
LPA-9500 B1
LPA-9600 B1

2.10 Checks after Installation

Follow steps outlined in Section 3.2 for your particular system configuration.

WARNING - HIGH VOLTAGE

The radio operator and service technician should exercise caution not to
contact the ANTENNA INSULATOR E2 output while transmitting.

2.11 Integration with Third Party Radio Systems

Refer to Section 4.9 for interface information required to integrate the CU-9150 with Third Party
Radio Systems.

Use or disclosure of information from this document is subject to the restrictions 2-5
indicted on the proprietary/confidentiality page of this document.

CU-9150

Figure 2.11-1. CU-9150 Control Cable P/N 8092500096

2-6 Use or disclosure of information from this document is subject to the restrictions

indicated on the proprietary/confidentiality page of this document.

CU-9150

Figure 2.11-2. Coupler Outline Dimensions

Use or disclosure of information from this document is subject to the restrictions 2-7
indicted on the proprietary/confidentiality page of this document.

CU-9150

THIS PAGE INTENTIONALLY LEFT BLANK

2-8 Use or disclosure of information from this document is subject to the restrictions

indicated on the proprietary/confidentiality page of this document.

CU-9150

Figure 2.11-3. LPA-9600 with CU-9150, 35-Foot Antenna (Roof Top Installation)

Use or disclosure of information from this document is subject to the restrictions 2-9
indicted on the proprietary/confidentiality page of this document.

CU-9150

Figure 2.11-4. LPA-9600 with CU-9150, Non-Resonant Antenna

2-10 Use or disclosure of information from this document is subject to the restrictions

indicated on the proprietary/confidentiality page of this document.