Yaesu SGC-500 User Manual

SGC, 13737 S E 26th Street Bellevue, WA 98 005 USA • Ph: 425-746 -6310, Fx: 425-746-6384, Ema il: [e-mail] m

www.sg cworld.com

SGC RESERVES THE RIGHT TO CHANGE SPECIFICATIONS WITHOUT NOTICE

 Copyright SGC 2007

S G -500 S M A RT P O W E RC UB E ™

LI N E A R P O WE R AM P L IF E R

Us er ’ s M an u al

SGC, 13737 S E 26th Street Bellevue, WA 98 005 USA • Ph: 425-746 -6310, Fx: 425-746-6384, Ema il: [e-mail] m

www.sg cworld.com

SGC RESERVES THE RIGHT TO CHANGE SPECIFICATIONS WITHOUT NOTICE

 Copyright SGC 2007

Table of Contents

Warning and Safety Guidelines Page 1

1.0 Introduction Page 2

2.0 Specifications Page 2

3.0 Cautions Page 3

3.1 DC Power Supply Considerations Page 3

3.2 Safety Considerations Page 3

4.0 Antenna Feedline Tips Page 4

4.1 Antenna Characteristics Page 4

4.2 Transmission Feed Lines Page 4

4.2.1 Coaxial Cable and Routing Tips Page 5

5.0 Power Supplies Page 5

5.1 Battery Power Supplies Page 5

5.2 Alternative Power Sources Page 5

6.0 Front Panel Description Page 6

6.1 RF Out and RF In Jacks Page 6

6.2 Power On/Off Switch Page 6

6.3 Power LED Page 6

6.4 Power Connector Page 6

6.5 Status LED Descriptions Page 7

6.6 Access Connector Page 8

7.0 Amplifier Operation Page 9

7.1 Test Transmission Page 9

7.2 PTT Keying Page 10

7.3 Mobile Installation Page 10

7.4 SG-500 and SG-235 Interconnection Page 10

7.5 Domestic vs. Export Page 11

8.0 Troubleshooting Guide Page 12

8.1 Fault Analysis Page 12

8.2 Troubleshooting Guidelines Page 12

Test Procedure Page 13

SGC SG-500 SmartPowerCube™ User’s Manual, Page 1

SGC, 13737 S E 26th Street Bellevue, WA 98 005 USA • Ph: 425-746 -6310, Fx: 425-746-6384, Ema il: [e-mail] m

www.sg cworld.com

SGC RESERVES THE RIGHT TO CHANGE SPECIFICATIONS WITHOUT NOTICE

 Copyright SGC 2007

Warning!

Safety First!
The SG-500 SmartPowerCube™ is a high power amplifier capable of producing output power levels
which can cause serious RF burns to anyone coming in contact with exposed antenna or feedline during
transmission. These RF power levels can also cause fire, explosion, injury or even death resulting from
improper or unsafe operation or installation. Observe all rules and precautions of electrical safety and
adhere to the operating and installation guidance provided in this manual.

Never operate the unit with hits protective cover removed, nor attempt to modify its original circuit
design and construction. Doing so may cause malfunctions and void the warranty. Ensure that any work
performed on the unit be done in the presence of another person who is thoroughly trained in first aid
techniques, including CPR.

Power Supply Warning!

SGC strongly advises against the use of any switched-mode or analog regulated power supply with the
SG-500 amplifier, and doing so may void the product warranty. Regulated analog supplies not designed
for use in the high RF fields may experience regulator circuit instability, producing damaging over­voltage conditions, or oscillation between supply and amplifier.

To remedy the power supply issue, SGC recommends the use of an unregulated 14 VDC, 50 Amp supply.
A lower cost option is to use a 100-Ah lead-acid automotive/RV battery floated with a low cost charger.

SGC SG-500 SmartPowerCube™ User’s Manual, Page 2

SGC, 13737 S E 26th Street Bellevue, WA 98 005 USA • Ph: 425-746 -6310, Fx: 425-746-6384, Ema il: [e-mail] m

www.sg cworld.com

SGC RESERVES THE RIGHT TO CHANGE SPECIFICATIONS WITHOUT NOTICE

 Copyright SGC 2007

1.0 Introduction

The SGC SG-500 SmartPowerCube is a professional grade HF amplifier designed to provide a maximum
of 500 watts PEP RF output when driven from virtually any HF transceiver – up to 150 W PEP input.
This provides on the air signal levels within 3 dB of a full kW amplifier at a much lower cost. The unit
has an operational frequency range of 1.6 to 24 MHz (to 30 MHz for Export version). This amplifier is
the result of extensive research and design to create an affordable unit, which provides dependable
operation with a minimum of controls and operator interface.

The SG-500 is ‘bullet-proof’ – fully protected by microprocessor control. This circuitry dynamically
monitors all amplifier parameters and provides adjustments and protection against high VSWR, under­voltage, over-current, and high-temperature conditions. Amplifier status is visible from a row of LED
indicators on the front panel. Professional-grade design and construction is utilized through the unit, with
all circuit assemblies encased within the massive die-cast alloy chassis/heatsink.

PTT Keying Mode and Band Output Filter Selection can be enabled automatically, or by manual control.
Band switching time is typically 15 msec or less. This automated capability is ideal for remote or
unattended operating site applications. SGC’s conservatively rated amplifier design uses 8 final power
transistors for full power output with minimal component stress. The small case dimensions (less than 1
cubic foot) and footprint size allow convenient desktop, mobile, and maritime installation. When used
with the matching SG-235 antenna coupler, it forms the heart of an automatic all-band 500 Watt HF
system.

2.0 Specifications

Power Output: 500 W PEP SSB, 500 W CW 10 min. maximum without fan
500W CW no time limit with fan (at 50% duty cycle)

Frequency Range: 1.6 to 24 MHz (1.6 to 30 MHz in export version)

Power Input: 50 to 90 Watts (auto) 150 Watts maximum

Band Switching: Manual (automatic in export version)

Input Voltage: 14.0 VDC (input range 10.0 to 18.0 VDC)

Input Current: 40A average (SSB), 90A peak (CW)

Cooling: Natural air convection (optional cooling fan available)

T/R Switching: 10 msec. nominal

Keying: PTT line (manual) or RF sensed (automatic)

Protection: Input overdrive, under-voltage, out-of-band frequency input, current imbalance,

over-current, over-temperature, high VSWR

Built-In Testing: Microprocessor controlled LED fault indicators

SGC SG-500 SmartPowerCube™ User’s Manual, Page 3

SGC, 13737 S E 26th Street Bellevue, WA 98 005 USA • Ph: 425-746 -6310, Fx: 425-746-6384, Ema il: [e-mail] m

www.sg cworld.com

SGC RESERVES THE RIGHT TO CHANGE SPECIFICATIONS WITHOUT NOTICE

 Copyright SGC 2007

Operating Modes: SSB, CW, RTTY, SITOR, ALE, SSTV, AM at 250 W

Dimensions: 4.9” H x 12.0” D x 10.8” W
(6.1” H and 13.2”D with feet)
(9.75” H with optional fan kit)

Case: Solid cast aluminum with matte black powder coat finish

Weight: 21 Pounds (9.5 Kg)

3.0 Cautions and Safety Considerations

Although you are probably anxious to get your SG-500 amplifier installed into your station and operating,
we highly recommend first taking a few moments to review the information presented in this manual. It
will help familiarize you with the proper preparation, installation, and operation of your new equipment.
The few minutes spent now will save you much time later when you begin the more involved process of
installation and getting on the air.

3.1 DC Power Supply Considerations

This amplifier is designed to be powered only from a high quality 14.0 VDC power supply providing
adequate reserve current capability for the desired operational application. At 500 Watts RF power, high
RF and DC current levels are present in and around equipment. We only recommend the use of high
quality linear power supplies designed for RF applications. We strongly advise against the use of a
switched-mode power supply for high RF application. Permanent damage to the power supply or other
station equipment may occur if an improperly designed switched-mode supply is used. It is also best to
use a separate, dedicated power supply for the exciter (transceiver).

A minimum of 40A, 14VDC is needed for SSB operation and 90A or better for carrier modes (AM, FM,
RTTY) or high duty cycle operation. In many cases, a battery can be paralleled or “floated” with a
charger or power supply for extended current reserve. However, please check with the manufacturer of
the power supply because high-current diodes are sometimes needed to accomplish this. SGC
recommends that only a 100-Ah, deep cycle marine/RV battery be used for this application. For
commercial or high duty-cycle operation, we recommend installing the optional SGC cooling fan kit for
continuous operation.

3.2 Safety Considerations

While all SGC equipment is designed with safety and ease of operation in mind, all safety and protective
considerations need to be adhered to. Follow the recommended installation instructions outlined later in
this manual. The 500 Watt RF energy can cause a painful burn to anyone coming into contact with a
radiating antenna element, whip or open transmission line. Ensure that no person or animal comes into
direct contact with the antenna or transmission line of your station.