Tokyo Hy-Power HL-550FX User Manual

Users Manual

Solid-State HF/50MHz Band

550W Linear Power Amplifier

Model HL-550

FX

1

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. Cautions

2-1 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.

2-2 Keep the amplifier out of direct sunlight, in a cool dry environment.

2-3 Internal high voltages (AC, DC and RF), are present at all times, ON AIR or OFF.

Internal access should be limited to avoid injury.

2-4 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.

2-5 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.

2-6 To 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

2-7 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.

2-8 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.

2-9 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.

2-10 Before starting 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.

2-11 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.

2-12 Keep the aluminum heat sink and air openings free from dust and blockages.

Periodic cleaning will prevent degraded cooling efficiency.

2-13 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.

2-14 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. Features

3-1 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.

3-2 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 once the
operating band is selected.

3-3 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).

3-4 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.

3-5 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.

3-6 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.

3-7 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.

3-8 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

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.)
Output Power HF: 550W typ., 50MHz: 500W (RTTY, SSTV, FM 250W max.)

(When set to AC100V-120V, 500W on both HF and 50MHz)
Drain Voltage 44V
Drain Current 30A max.
Input Impedance

50Ω (unbalanced)

Output Impedance

50Ω (unbalanced)

Final Transistor VRF150 x 4
Circuit Class AB parallel push-pull
Cooling Method Forced Air Cooling

Output Power Pf 1kW

Reflected Power Pr 100W

Drain Voltage Vd 60V

Multi-meter (F.S.)

Drain Current Id 50A
Input/Output Connectors UHF SO-239 (Type M-J)

AC 200~260V, 50/60Hz 7.5A max. AC Power

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.
Accessories AC Power Cord x 1

Coax Jumper Cable (with PL259 at both ends) 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 F202, F203 of PC1662V power amp board)

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

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.

5-2 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 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 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.

① 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

6-A. Front Panel Description

PPPPOOOOWWWWEEEERRRR

OOOOFFFFFFFF

SSSSTTTTBBBBYYYY

OOOOPPPPEEEERRRR.... OOOONNNN AAAAIIIIRRRR OOOO....DDDDRRRRIIIIVVVVEEEE

OOOO....VVVVOOOOLLLLTTTT

FFFFUUUUSSSSEEEE OOOO....HHHHEEEEAAAATTTTPPPPRRRR

BBBBAAAANNNNDDDDMMMMEEEETTTTEEEERRRR

PPPPRRRROOOOTTTTEEEECCCCTTTT

FFFFXXXX

MMMMOOOODDDDEEEELLLL

TTTTOOOOKKKKYYYYOOOO HHHHYYYY----PPPPOOOOWWWWEEEERRRR

SSSSOOOOLLLLIIIIDDDD SSSSTTTTAAAATTTTEEEE LLLLIIIINNNNEEEEAAAARRRR AAAAMMMMPPPPLLLLIIIIFFFFIIIIEEEERRRR

1111

2222 3333 4444

5555 6666 7777 8888

9999

1111000011111111

11114444

HHHHLLLL555555550000

FFFFAAAANNNN

IIIIDDDD

11112222

11113333

①①①①POWER

POWERPOWER

POWER : Main power switch to turn AC power on and off.

②②②②POWER

POWER POWER

POWER

(LED)

(LED)(LED)

(LED)

: Green LED lights when power is turned on.

③③③③OPER

OPEROPER

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.

④④④④ON AIR

ON AIRON AIR

ON AIR

(LED)

(LED)(LED)

(LED)

: Green LED lights when the amplifier is in transmit (TX) mode.

⑤⑤⑤⑤O.DRIVE

O.DRIVEO.DRIVE

O.DRIVE

(LED)

(LED)(LED)

(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.
⑥⑥⑥⑥PR

PRPR

PR

(LED)

(LED)(LED)

(LED)

: LED lights when reflected power from antenna exceeds 70W to

indicate protection circuit has worked.

⑦⑦⑦⑦O.VOLT

O.VOLTO.VOLT

O.VOLT

(LED)

(LED)(LED)

(LED)

: When the DC drain voltage of the FET (Vd) is too high, the LED lights

to indicate the protection circuit has worked.

7

To reset protection, turn POWER off and turn on again.
⑧⑧⑧⑧FUSE

FUSEFUSE

FUSE

(LED)

(LED)(LED)

(LED)

: LED lights when the 15A glass fuse (F202,203) has blown from

excessive Id. (Two fuses are on the PC1622V PA board.)

⑨⑨⑨⑨O.HEAT

O.HEATO.HEAT

O.HEAT

(LED)

(LED)(LED)

(LED)

: 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.)

(Turn the main POWER switch to off, and then on again to reset the Protection Circuits.)(Turn the main POWER switch to off, and then on again to reset the Protection Circuits.)

(Turn the main POWER switch to off, and then on again to reset the Protection Circuits.)

⑩⑩⑩⑩BAND

BANDBAND

BAND : Select the desired operating frequency band.

⑪⑪⑪⑪METER

METERMETER

METER : To change the multi-meter scales. Meter reads Pf, Pr, Vd, and Id.

⑫⑫⑫⑫FAN

FAN FAN

FAN

(LED)

(LED)(LED)

(LED)

: LED lights brighter when fan is running at high speed. When the

heatsink reaches 50℃ the cooling fan will switch to high-speed mode to
cool the heatsink.

⑬⑬⑬⑬IIII

DDDD

(LED)

(LED)(LED)

(LED)

: 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.

⑭⑭⑭⑭

MULTIMETER

MULTIMETERMULTIMETER

MULTIMETER

: 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 ⑪METER select switch.

8

6-B. Rear Panel Description

AAAALLLLCCCC

AAAALLLLCCCC AAAADDDDJJJJ

SSSSTTTTBBBBYYYY

GGGGNNNNDDDD

AAAANNNNTTTT

AAAACCCC

FFFFUUUUSSSSEEEE

IIIINNNNPPPPUUUUTTTT

⑮⑮⑮⑮AC POWER

AC POWERAC POWER

AC POWER : AC Mains Socket. Socket for the AC power cord. (Socket is EMI

filtered.)

⑯⑯⑯⑯STBY

STBYSTBY

STBY : 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.

⑰⑰⑰⑰ALC

ALCALC

ALC : 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.

⑱⑱⑱⑱GND

GNDGND

GND : Ground Terminal

⑲⑲⑲⑲ALC ADJ

ALC ADJALC ADJ

ALC ADJ : 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.

⑳⑳⑳⑳FUSE

FUSEFUSE

FUSE : A pair of fuses for AC mains. 15A glass pre-installed fuse.

(Change to 8A fuses if 200V~230V line is used.)

○○○○

21

2121

21

IN

ININ

IN PUT (TX)

PUT (TX)PUT (TX)

PUT (TX) : RF Input Connector. Connect the coax jumper cable from the

transceiver.

○○○○

22

2222

22

ANT

ANT ANT

ANT (OUTPUT)

(OUTPUT)(OUTPUT)

(OUTPUT) : RF Output Connector. Connect the coax cable to the antenna.

9

① RF Power Detector and Send-Receive Switching Relay
② Inter-lock Switch
③ LPF Board
④ Main Power Source Unit (Switching Mode Power Supply)
⑤ Sub-Power Source Unit
⑥ Control Board
⑦ Power Amp Unit (PA board/heatsink)
⑧ Frequency Detector Board
⑨ Cooling Fan
⑩ AC Fuse