Tokyo Hy Power Labs HL 2500FX User Manual

INSTRUCTION MANUAL

HF ・50MHz LINEAR POWER AMPLIFIER

ON AIR

FAN

Pf/kW

Pr/VD/ID/ALC

PROT

HF SOLID STATE LINEAR AMPLIF IER HL-2500FX

POWER OPER.

OFF STBY

OUTPUT

METER

ALC

ANT

AUTO

MAN’L

BAND

3.5

1.8

MAN’L

14 18/21

24/28

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1.Introduction

Thank you for purchasing the HL-2500FX. This compact and lightweight desktop HF linear power amplifier has a maximum input power of 2.9 kW. Our solid-state broadband power amp technology makes it the smallest and lightest in the industry.

Typical output power is 1.5 kW PEP/SSB on HF (1kW on 50MHz) with the drive power of 85-90 W. The built-in band decoder will let you forget about the band setting when the amplifier is connected to your modern radio through such band data cables as ICOM CI-V, DC voltage (Yaesu and Elecraft K3), and RS-232C (Kenwood). These data cables are optional parts. The one that matches your radio should be purchased separately.

2. Cautions

2-1 Unpack the amplifier, check the fan guard at the rear panel fan to see if there is any damage caused by the physical shock during the transportation. Fan blades must be free to rotate when powered. 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, etc.,

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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 The amplifier has fast acting sophisticated protection circuits controlled by the latest microprocessor technology. 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. Also note that the full power CW (or carrier) drive under the erroneous MANUAL BAND SET leads to the failure of the final power FET’s (See page 14, Section 10. Trial). In this sense, it is highly recommended that the amplifier is connected to the radio with Band Data Cable.

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 internal 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 DC power supply selection is designed with wide AC line voltage technology and works with any voltage of 200V to 250V as well as 100V to 125V. 200V to 250V line, however, is recommended for the best stability and performance. Note that maximum output power is 1kW only, when 100V to 125V is connected. Prepare appropriate AC power cord plug that fits the outlet at your location.

2-10 Before powering on the amplifier, be sure to connect a dummy load (50 ohms, 1.5 kW 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 100 W to obtain the full

1.5 kW output. Do not attempt to operate with excessive drive from a high power transceiver. Transmitting high drive RF (over 100 W) into the amplifier will void the warranty.

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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 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 MUST be shipped using the original box and packaging materials.

3. Features

3-1 Our solid-state broadband design engineers worked to make the HL-2500KFX, the lightest and most compact 1.5 kW amplifier in the industry. This world-class compact 1.5 kW amplifier is the easiest to handle and operate.

3-2 The amplifier is equipped with a newly developed band decoder. The amplifier’s decoder changes bands automatically as the data signal is received from the associated HF transceiver’s frequency bands.

3-3The amplifier’s main PA section includes 6 high power MOS FET THP2933’s by Microsemi, resulting in 1.5 kW PEP (SSB max.). The amplifier’s broadband characteristics require no further tuning once the operating band is selected.

3-4 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).

3-5With 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.

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3-6 The amp utilizes an advanced 16 bit MPU (microprocessor) to run the various high speed protection circuits such as overdrive, high antenna SWR, DC overvoltage, band mis-set etc.

3-7 This amplifier is compatible with AC 200 V and 250 V as well as AC 100V to 125V.

3-8 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.

3-9 An analog multimeter allows the operator to monitor Pr (Reflected power), Vd (Drain voltage of power FET), Id (Drain current) and ALC voltage.

3-10 For future expansion, the amplifier rear panel is equipped with a control cable connection socket TUNER, this is for the upcoming model HC-1500AT, auto antenna tuner by Tokyo Hy-Power Labs. in

2013.

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4. Specifications

Frequency : 1.8 ~ 50 MHz all amateur bands including

WARC bands Mode : SSB, CW, RTTY RF Drive : 85W typ. (100W max.) Output Power : 1.5 kW PEP/CW (typ.)

(1 kW on 50 MHz band)

Matching Transceivers

for Auto Band Decoder : Most ICOM, Yaesu, Kenwood, Elecraft K3,

Ten-Tec Drain Voltage : 50 V (when no RF drive) Drain Current : 60 A max. Input Impedance : 50Ω(unbalanced) Output Impedance : 50Ω(unbalanced) Final Transistor : THP2933 x 6 (MOS FET by Microsemi) Circuit : Class AB push-pull Cooling Method : Forced Air Cooling MPU : PIC 18F8722 Multi-Meter : Output Power Pf 2.5 kW

Reflected Power Pr 250W Drain Voltage Vd 60V

Drain Current Id 80A Input/Output Connectors : UHF SO-239 with low loss Teflon insulator AC Power : AC 100V ～250V (wide range) AC Consumption : 3 kVA max. when TX Dimension : 370 x 145 x 422 mm (W x H x D)

14.6 x 5.7 x 16.6 inches Weight : Approx. 18 kgs. or 41 lbs. Accessories : AC Power Cord x 1

RCA Plug (Stereo Type Pair Cable) x 1 Spare Fuse 20 A

(for AC 200V～250V line) x 2

Spare Fuse 20A (In yellow plastic)

(DC58V, for FET drain) x 3

Spare Fuse 1.6 A (Black)

(Miniature Fuse for RF Absolute Over-drive)

x 1

Spare Fuse 3.2 A (Black)

(Miniature Fuse for + 12V Control Circuit Supply

and External AUX, Supply)) x 2 Instruction Manual x 1 Warranty Card x 1

Optional Items : Band data cable to radios

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5. AC Line Voltage

5-1 The amplifier is designed to work with any AC voltage world wide, (200- 250 V and 100-125V).

When connected to 100-125V line, maximum available output

power is 1kW on HF and 500W on 6m band.

5-2 The correct AC plug (not included in the package), must be obtained locally due to the AC plug variations worldwide.

5-3 For the best performance and stability, it is strongly recommended that you will connect to AC 230V line (200V～250V).

6.Front Panel Description

9 10 11

ON AIR

FAN

Pf/kW

POWER OPER.

OFF STBY

1 2 3

POWER Main power switch. At OPERATE, the amplifier is ready to go into

①

OUTPUT

Pr/VD/ID/ALC

METER

ALC

PROT

HF SOLID STATE LINEAR AMPLIFIER HL-2500FX

ANT

4 5 6

AUTO

MAN’L

BAND

3.5

1.8

MAN’L

14 18/21

18/21

24/28

ON AIR (TX) mode and at STBY, it is on STAND-BY mode.

OUTPUT To select High or Low Output levels. At LO, output is

③

approximately 60% of HI.

METER To change the multimeter scales. Meter reads Pr, Vd, Id and ALC.

④

ANT-A/B To Select antenna “A” or “B”. When main power switch is turned

⑤

off, it is switched to A.

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BAND-AUTO/MANUAL

⑥

To select band switching methods AUTO or MANUAL. When using AUTO, the manufacturer for the transceiver in use should be selected. When the band data cable is not used, MANUAL should be selected. (See page 19, 10 Operation / Setting)

BAND-MANUAL

⑦

Rotary switch for band change in the manual mode. While the transceiver is on Receive (RX) mode, turn to select the desired frequency band operate. The switches will not work when the transceiver and the amplifier are in Transmit (TX) mode.

METER (PF) Meter to read forward output power, PF. Full scale

⑧

is 2.5 kW, and it reads average power.

MULTIMETER

⑨

Pr (Reflected power from antenna), VD (FET drain voltage), ID (FET drain current) and ALC voltage are shown on the scale as selected by ④MANUAL select switch. Full scales are; PR: 250W, VD: 60V, Id: 80A, ALC: -10V.

ONAIR, FAN, ID, PROT (LED)

⑩

ON AIR : Lights when the amplifier is in transmit (TX) mode. FAN : Lights when cooling fan is running at high speed.

When the heat sink temperature reaches 35℃, cooling fan speed will continuously increase to enhance cooling capacity.

ID : Excessive ID Indicator (55A). Depending on the band and antenna situation, high drain currency may flow into FET’s. If 55A is exceeded, this LED lights to indicate that high ID is being drawn (This light does not necessarily mean a failure of the amplifier. However, if it lights too often, or too long, it is possible the drive power should be reduced and the antenna should be checked for SWR, to avoid stress to the FET’s)

PROT : Lights when protection circuit shuts down the amplifier. Various protection circuits are built in such as Over-drive, Band mis-set, high Ant-SWR, Over-temperature etc. Detailed explanations will follow.

LCD PANEL Displays modes of operation and protection circuit.

⑪

Detailed explanation will follow.

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7 Rear Panel Description

1 2 3 4 5 6

ANT B ANT A

INPUT

ALC ADJ

ALC

7 8

END

9 10 12 1611 13 14 15 17

SELECT

TUNER

CONT

SERIAL

USB

FUSE

FUSEFUSE

N D

REMOTE

DC OUT

DC OUT 12V2A

12V2A

USE

USEFUSE

FUSE

AC IN

ANT-B RF Output Connector. Connect coax cable to the antenna B.

①

ANT-A RF Output Connector. Connect coax cable to the antenna A.

②

TUNER DIN Socket. Connect the control cable from External Auto

③

Antenna Tuner, HC-1500AT and or HC-1.5KAT.

SELECT Switch to select the transceiver (i.e. “CI-V” for ICOM CI-V, “I”

④

for ICOM DC Voltage, “Y” for Yaesu, “K” for Kenwood, “Aux1-3” for three auxiliary positions of N.C./no connection.).

DC OUT 12V 2A, Auxiliary DC power supply terminal.

⑤

REMOTE Connector to switch the amp ON and OFF in the remote

⑥

location.

ALC ADJ. Potentiometer to adjust ALC voltage level. Minus 10 V is

⑦

available at maximum, when turned fully clockwise. Factory setting is 0 volts, with the pot turned fully counter-clockwise.

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ALC RCA Jack for ALC Voltage Output. Negative DC voltage

⑧

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 (Seen page 18, Section 9-C. 7 ALC Adjustment). Also consult with your HF transceiver’s user manual.

SEND RCA Jack. Connect the control cable from the ACC

⑨

terminal (or SEND, TX GND etc.) of the transceiver. Electrical conditions are 12V DC of open voltage at receive mode (RX), and short current of 35mA at transmit mode (TX).

INPUT RF input connector. Connect the coax jumper cable

⑩

from the transceiver.

CONT D-Sub (15pin) Socket. Connect the band data cable to

⑪

the transceiver/

SERIAL Serial connector for control. (D-Sub 9pin) To access

⑫

to CPU controller board through serial data bus.

USB USB Connector. To access to CPU board. This socket in

⑬

connected to serial connector ⑫.

GND Ground terminal.

⑭

AC IN 230V AC Main Socket. Socket for the AC power cord.

⑮

(Socket is EMI filtered.)

Fuse A pair of fuses for AC Mains. 250V/20A glass fuse.

⑯⑰

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７ LCD Panel Description

LCD displays the status of the amp in various situations. Capacity is 24 characters in two rows.

Basic Signs

Following s are the common signs to appear while amp is in operation.

*21MHz *28MHz

1.8MHz

3.5MHz 7MHz

10MHz 14MHz 18MHz 21MHz 24MHz 28MHz 50MHz

EXCD

BAND

Manual

AUT-CIV AUT-YAE AUT-KEN AUT-TEN AUT-ICM AUT-FLX AUT-ELC

AUT-FRQ

BAND SET

MODE

ANT-A ANT-B

ANTENNA

SELECT

1.8MHz AUT-CIV ANT-A

STBY Temp35C OUT_Hi

Other Signs

Initial Messages

TOKYO HY-POWER HL-2500FX V1.00

PLEASE WAIT CHECKING CONDITIONS

ACV is 198V Complete Initial Set-Up

OPERATION

STATUS

STB

Ｙ

OPER ONAR TRCK

TEMPERATURE

（℃）

Temp00C

｜

Temp99C

OUTPUT

SETTING

OUT_Hi

OUT_Lo

OUT_LoLIM

Protection Shutdown Message

24 MHz AUT-CIV ANT-A PROT BAND MISSET

Detailed explanation will follow.

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8-A Basic Connection

Following is a basic example of connection with the transceiver without using Band Data Cable.

Antenna

Caox. Cable

HL-2500FX

200V-

GND

SELECT

TUNER

CONT

SERIAL

USB

hite

black

green

FUSE

LC SEND

Transceiver

RCA plug cable

AN T B

ALC ADJAL

INPUT

ANT A

T B

INP

SE ND

AC200V

Note

SEND

■

SEND socket is named “RELAY”, “TX GND”, “SEND” etc depending on radio models. (Refer to user manual of the transceiver.)

ALC

■

ALC cable must be connected especially when driving the amp with high power transceiver. Otherwise shut-down will frequently occur.

REMOTE

DC OUT 12V1A

FUSE

AC IN

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+ 27 hidden pages

Tokyo Hy Power Labs HL 2500FX User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual