Instruction Manual OM1006 Solid State 50 MHz Power Amplifier OM POWER, s. r. o. 930 30 Báč 126 SLOVAKIA E-mail: om-power@om-power.com
TABLE OF CONTENTS 1. GENERAL INFORMATION 1.1. Introduction.. 4 1.2. Specification... 4 1.2.1. Parameters. 4 1.2.2. Protection Circuits 4 1.2.3. Indicators.. 5 2. SAFETY INSTRUCTIONS 5 3. GENERAL DESCRIPTION. 6 3.1. HF part. 6 3.2. Power Supply.. 8 3.3. Safety Devices. 8 4. INSTALLATION 9 4.1. Grounding 9 4.2. Coaxial Cable... 9 4.3. Control Cable.... 9 4.4. Main Supply. 11 4.5. Cooling. 11 5. OPERATION 11 5.1. Operation Elements.. 12 5.2. Preparation for operation... 13 5.2.1. Display Menu 14 5.2.2. Settings Menu 15 5.2.2.1. Own text editing.. 16 5.2.2.2. Display delay... 16 5.2.2.3. Bias delay 17 5.2.2.4. Preamplifier delay 17 2
5.2.2.5. Bias SSB No.1.. 18 5.2.2.6. Bias CW No.1.. 18 5.2.2.7. Software version.. 19 5.2.3. Operating mode 19 6. MAINTENANCE. 23 6.1. Indication of Fault Conditions. 23 6.2. Fuse Replacement..... 24 6.3. Cleaning... 25 7. APPENDIX... 26 7.1. Block Diagram..... 26 3
1. GENERAL INFORMATION 1.1. Introduction The OM Power model OM1006 is a single band, solid state amplifier, designed for duty operation on 6 meter s amateur band with all modes and no time limit. It is equipped with a new Freescale high rugged N-channel double MOSFET. This amplifier is characterized by compact design, small size and a low weight. 1.2. Specification 1.2.1. Parameters Frequency Coverage 50 54 MHz Amateur Band Power Output 1000W in CW, 800W SSB (linearity), RTTY, AM, FM and digi, 50% duty cycle. Input Power 8 to 10W for full output power 1000W Input Impedance 50 Ohm, VSWR < 1.3 : 1 Power Gain Typically 23 db Output impedance 50 Ohm unbalanced Maximum output SWR 1.9 : 1 for full output power 1000W SWR protection: Automatic switching to STBY, when reflected power is 100W or higher Intermodulation distortion - 32 dbc Suppression of harmonics < -60 dbc MOSFET MRFE6VP61K25HR6 Cooler 3 axial fans + 2 axial fans (power supply) Supplying 100 250VAC, 50 60 Hz Power Supplies inside 50V DC switch mode PS 12V DC for logic and protection circuits Size 270 mm x 200 mm x 345 mm [10.6 x 7.9 x 13.6 ] (Width x height x depth) Weight 12 kg ( 26.5 lb ) 1.2.2. Protection Circuits There is several special protection circuits used in the amplifier. They are activated when one or more of next parameters exceed defined values or some unwanted occasion occurs. Output power too high Reflected power too high Drain current too high Gain to low DC voltage too low or DC voltage error Input power too high (hardware protection & software protection) Inside temperature too high Soft start for power supply protection (PS feature) 4
1.2.3. Indicators There are few visible LED indicators on the front panel for information on operating condition, a few buttons and a graphic display. LED Indicators STBY - Standby mode OPERATE - Operation mode CW - CW mode PREAMP - Control voltage +12V DC for optional RX preamplifier switching FAULT - Failure ON AIR - Transmit mode Buttons UP DWN - Listing in LCD menu - Scroll trough the alphabet in edit mode - Changing parameters OPER SET PRE CW/SSB - Operation mode - confirms parameters - Cursor to the right in edit mode - Settings menu - Preamplifier ON - Edit mode start, cursor to the left in edit mode - mode switch OSD Indicator 140 x 16 dot graphic display to view: - Display menu - Settings menu - Warning & fault messages 2. SAFETY INSTRUCTIONS WARNING! Before you will start to install and operate power amplifier, read carefully next safety instructions! WARNING! AVOID CHILDREN to play around PA or to touch power amplifier or connected cables in working condition, or to push anything into the fan holes! WARNING! Never turn the amplifier on without the upper lid in place. WARNING! The OM1006 amplifier should not be used in WET or HUMID environment or exposed to RAINFALL! 5
WARNING! Do not turn the amplifier on without having connected the ANTENNA or properly rated DUMMY LOAD! A hazardous HF voltage may build up on the antenna connector after turning the amplifier on with no antenna or dummy load connected! WARNING! Before opening the upper lid of the amplifier make sure that power supply has been disconnected. Take out power cord from the outlet! CAUTION! The amplifier must be installed in such a way that free flow of hot air from inside is allowed. The amplifier must not be installed in a constrained surrounding (i.e. tight shelves etc.) CAUTION! The amplifier must be properly grounded during operation. CAUTION! During operation the amplifier must be installed in such a way that the rear panel will stay accessible. CAUTION! The amplifier is an A category product. In a household it can influence other electric appliances. In such cases the user is to take proper actions to mitigate this disturbance. CAUTION! Read this manual carefully. Follow all of instructions during installation and operation to avoid damage to the amplifier not covered by manufacturer s warranty! Do not attempt to perform any change of hardware or software! 3. GENERAL DESCRIPTION 3.1. HF part OM1006 power amplifier was designed to achieve the RF performance of the MOSFET, when applied to the 50 54 MHz frequency band. Design was tuned for performance at 1000W CW output, 50VDC. It consists of no tune distributed element matching circuits designed to be as small as possible. For operating it is important that adequate heat sinking was provided for the design. 6
Look at the RF Board The coaxial transformer turns ratio was chosen to meet required impedance level and the length of the coax was tuned to achieve maximum efficiency and maximum power transfer between the device and its load impedance. Top view on the opened OM1006 Input / Output Relay HF Board Output LPF Supply Board for Control circuits Switch Mode Power Supply 7
3.2. Power Supply The amplifier uses two power supplies. A professional switch mode power supply 50V / 32A for power amplifier, and small 12V power supply for logic and protection circuits. Main power supply contains special soft start circuits, uses two fans, which are visible from the rear side of PA. It has its own logic to control these fans speed. Power amplifier should be connected to any external source of AC in the range from 100VAC to 250VAC, 50 or 60 Hz. It can be powered by a portable generator, for example. Switch Mode Power Supply and the Supply Board. Two fuses are visible. 3.3. Safety Devices Control and monitoring circuits ensure control and safety during malfunctions of the PA. These are on the Control board and the Protection board. Control board is located behind the front panel. Protection board is visible on the right hand side of PA, close to the input/output relay. Protection Board at the top Input/Output Relay in the middle Communication Board at the bottom (LAN) 8
4. INSTALLATION NOTE Read this chapter carefully prior starting with installation. Before unpacking inspect shipping carton first, if it is not damaged. Keep all of packing parts for possible future shipment. Check unpacked power amplifier. If you find some damaging, contact your dealer immediately to keep full warranty. During installation go step by step according to next parts. 4.1. Grounding CAUTION The amplifier has to be grounded properly! Connect the screw on the rear panel of the amplifier to your local grounding system with a copper cable; use a cross-section of 4 mm 2 at least. Connect your transceiver to the same grounding system of your shack carefully! Use minimum length of cables and make sure that the connections are both physically and electrically sound. With poor grounding, you may risk damaging to your equipment, having problems with TVI/BCI or your transmitted signal may be distorted. 4.2. Coaxial Cable The output of the transceiver is to be connected to the input of the amplifier via RG58 or similar cable. For the connection between the power amplifier and the antenna, RG213 or similar coaxial cable suited for high power is recommended. Both the INPUT and OUTPUT N sockets with Teflon insulation are used. 4.3. Control Cable Control cable maintains TX / RX switching of the PA (TX GND). The cable is shielded. On the side of the power amplifier a CINCH-socket is used. On the side of your transceiver you have to use a socket suitable for this transceiver. During transmitting the middle pin is connected to the ground. Amplifier uses one double coaxial relay for input and output (input and output are switched at the same time). It has to be switched earlier than HF is applied (cold switching). Modern transceivers have a time delay between PTT switching and power output. 9
Rear view of the amplifier OM1006 RF Output RF Input AC Power Socket PS Fans LAN - Local Area Network connection for REMOTE CONTROL of PA (for future use) PREAMP - RCA Phono, +12V / 100mA for an external RX preamplifier switching CAUTION If you are using an older transceiver or transmitters without time delay, we recommend to connect the PA in such a way that the transmit/receive switch (foot switch for example) is connected with the KEY IN socket of the amplifier. The KEY OUT socket is to be connected with the PTT socket at the transceiver. The amplifier is equipped with two safety devices, which ensure that the output relay is not switched under power mistakenly (hot switching). KEY IN - RCA Phono Input signal PTT (switching voltage / current 5V /2 ma) KEY OUT - RCA Phono Output signal PTT (maximum switching of 50V / 100mA) 10
4.4. Main Supply CAUTION Be sure you got PA with properly terminated line cable, corresponding with your power system s outlet. If not, contact your dealer. In such a case you should make the necessary changes using a licensed electrician. WARNING! Be sure that your power system is correctly wired and properly rated! To use adequately sized and connected grounding system is also very important. 4.5. Cooling CAUTION The amplifier must be installed in such a way that free flow of hot air from the amplifier is allowed. Do not obstruct air intake and exhaust areas of the PA. All of installed axial fans provide adequate cooling of the amplifier, even during long time operation. Three upper fans they are activated, when inside temperature exceeds 40 deg. Celsius. Their speed is gradually rising with increasing temperature. Two fans inside the power supply start to operate depending on the current drawn by the MOSFET. When the amplifier reaches inside temperature of 70 deg. Celsius, warning message Amplifier is too hot appears on the display. At 75 degrees protection circuit will automatically block transmitting. 5. OPERATION WARNING! Before switching PA on, make sure that amplifier is grounded, antenna or dummy load is connected, and line cord is putted to the outlet. CAUTION Do not turn PA on for at least 2 hours after unpacking it and moving in its operating location. Especially when amplifier was moved from a cold place to a warm one, because not visible condensation may develop inside, and this could result in damage of the PA. CAUTION Before switching PA on, check connections between PA and TCVR. 11
CAUTION Never try to change antenna during a transmission to avoid warranty loss. 5.1. Operation Elements There is couple of operational elements accessible or visible on the front panel. STBY - Standby mode LED OPERATE - Operation mode LED CW - CW mode LED PREAMP - Preamplifier ON LED (+12V control voltage output) FAULT ON AIR - Failure LED - Transmitting mode LED 12
OPER - short press to switch between Standby and Operation mode SET - long press (about 2,5 seconds) to enter the Settings menu (green LED is ON) - short press to release the Settings menu (green LED is OFF) - short press to confirm parameters in the Settings menu - short press to move cursor to the right in editing mode - long press to release editing mode and confirms Own text PRE - short press to switch preamplifier ON and OFF - short press to start editing mode in the Settings menu - short press to move cursor to the left in editing mode CW/SSB - long press to change between CW (CW LED is ON) and SSB mode (LED is OFF) UP DWN - short press to list in LCD menu - short press to change parameters - short press to scroll trough the alphabet in editing mode UP - long press to enter Hardware SETTINGS menu not available for users - short press to release the SETTINGS menu 5.2. Preparation for operation After turning on the power switch on the front panel power amplifier will automatically go into standby mode. NOTE Some of next preparation steps are accessible only in standby mode. 13
5.2.1. Display Menu The graphic display shows couple of parameters or texts. In every line user can select different ones, using UP/DWN buttons (UP for upper line scroll, DWN for bottom line scroll) : OM POWER amplifier - Own text Bar graph for output power PWR in watts + short bar graph - PWR in watts + REF in watts PWR in watts + SWR Pin in watts + SWR T1 in deg C Um1 in Volts + Im1 in Amps OM POWER amplifier -.. Have a look at some of combination examples: 14
5.2.2. Settings Menu Press SET button for about 2,5 seconds to enter Settings menu. Green LED in the button s corner will light. The top line will display Settings menu, in the bottom line user can scroll these parameters or texts: Own text Display delay Bias delay Preamplifier delay Bias SSB No.1 Bias CW No.1 Software version x.x Own text - Use UP/DWN button to select desired parameter for editing or viewing. 15
5.2.2.1. Own text editing Settings menu appears in the upper line. Select Own text in the bottom line. To open editing mode press PRE. Cursor will appear in the first position. You can move it to the right using SET, or to the left using PRE. Insert proper letter or number in the chosen start position using UP/DWN keys. Move cursor to the next position and then insert next letter, number, sign or space...etc. Maximum 20 characters. When you finish editing, press the SET button for about 2,5 seconds to confirm new text and to leave editing. New text replaces the original Own text in the Display Menu. 5.2.2.2. Display delay Display delay is the period during which the display remains lit when the PA will remain at rest (in standby mode for example). The default value is 140 seconds. Settings menu appears in the upper line. Select Display delay in the bottom line. To open editing mode press PRE. To change time use UP/DWN keys. Value can be changed in 20 seconds steps. Confirm the selected value by pressing SET. 16
5.2.2.3. Bias delay Electronic Bias Settings (EBS) is one of significant feature of the power amplifier. It allows to set low drain current after pressing the PTT regardless of whether you have CW or SSB mode, until RF signal is no present at the input. At the moment when RF signal comes to the input of PA, bias will automatically change its value depending on the selected operation mode. For CW it will stay low (Id = 200mA), for SSB it will move operating point to AB class ( Id = 2,7A)... EBS is default activated Bias delay is set to ON. To deactivate EBS you have to set Bias delay to OFF. I such a case bias value after pressing the PTT will depend on the working mode. Settings menu appears in the upper line. Select Bias delay in the bottom line. To open edit mode press PRE. Use UP/DWN buttons to change status. Press SET to confirm new value and to leave editing. 5.2.2.4. Preamplifier delay You can control switching of an external RX preamplifier from the PA using PRE button in operation mode. For reliable working condition and safety of preamplifier there is important to set some delay of its switching according to the PTT. Possible range is from 0 to 255ms. Default value is 20 ms. Settings menu appears in the upper line. Select Preamplifier delay in the bottom line. To open edit mode press PRE. Use UP/DWN buttons to change value. Confirm the selected value by pressing SET. 17
5.2.2.5. Bias SSB No.1 This parameter will be checked without the possibility to change it. When Settings menu appears in the upper line, select Bias SSB No.1 in the bottom line. To view SSB Bias press PRE. In couple of seconds you will see the value of drain current in the second line (about 2,7A). Do not leave this status active long time. Use the SET button to release checking. 5.2.2.6. Bias CW No.1 This parameter will be checked without the possibility to change it. When Settings menu appears in the upper line, select Bias CW No.1 in the bottom line. To view CW Bias press PRE. In couple of seconds you will see the value of drain current in the second line (about 0,2A). Do not leave this status active long time. Use the SET button to release checking. 18
5.2.2.7. Software version The last thing you can view in the Settings menu, is Software version, visible in the second line of the display. NOTE Do not forget to leave Settings menu by pressing the SET button. Green LED in the button s corner turns OFF. 5.2.3. Operating mode CAUTION In STBY the amplifier is in bypass-mode and your transceiver is directly connected to the antenna. Maximum allowed power in bypass mode is 100 Watts! Passing RF power is not measured or displayed if PA is either in standby mode or turned OFF. Push the OPER button to activate operation mode. At that moment 50V DC will be connected to the MOSFET. In the OPERATE mode you can select CW or SSB transmitting mode, you can scroll Display menu and select switching of an external RX preamplifier. You can not activate Settings menu. NOTE Setting of CW or SSB mode actually means only a bias adjustment (class C or class AB mode of PA) and is not strictly tied to the operating mode of the connected transceiver. 19
WARNING! Before you push PTT for the first time, set the RF power in your transceiver to the minimum (from 1 to 3 watts)!!! Select parameters in the Display menu as is visible in the previous or next picture and press PTT. You can check measured parameters of PA. 20
Previous picture shows input power 0.8W, output power 173W. Power gain from input to output of the PA was 23,5 db. When operation mode of the PA was changed from CW to SSB, output power increased (TCVR output power remained the same). This is because the operation class of PA was changed from class C to class AB. 21
Previous pictures show couple of different kinds of visual display during the same test. This test gave us result of power gain 25,3 db in class AB. If all looks good, you can increase RF power from the transceiver slowly and check important parameters of PA. Do not exceed the output power of 1000 watts in CW operation mode and about 800 watts in SSB, AM, FM and digi operation mode even if more is reachable. NOTE We recommend using the maximum output power of 800 watts to maintain good linearity of output signal in SSB or AM mode. CAUTION Never use CW mode in the PA, if this is driven by SSB signal, otherwise strong and unpleasant intermodulation distortion occurs! 22
CAUTION Check the temperature of PA during digi modes operation. Decrease the output power, when warning message Amplifier is too hot appears. Output power of about 800 watts should be ok for 50% of duty cycle. 6. MAINTENANCE 6.1. Indication of fault conditions If a fault condition appears during the operation of the amplifier, the safety circuits of OM1006 will react, the FAULT LED lights. There are several fault or warning messages possible to appear on the display, when some of the protection will be activated. The OM1006 power amplifier can show one of the following messages: 1. PowerOut is too high 2. Reflected power too high 3. PowerIn is too high or Overdrive error 4. Gain is too low 5. Voltage is too low 6. Amplifier is too hot 7. Current is too high When the output power of the PA exceed limit value, PowerOut is too high fault message appears on the display, the amplifier will stay in the operation mode, but transmitting will be blocked. Decrease the input power to allow transmits again. When reflected the power of the PA exceed 100 watts, Reflected power too high fault message appears on the display, amplifier will stay in operation mode, but transmitting will be blocked. In such a case try to decrease input power first, or improve matching and adapt better the impedance of your antenna. When the input power of the PA exceed limit value, PowerIn is too high fault message appears on the display, amplifier will stay in the operation mode, but transmitting will be blocked. Decrease the input power to allow transmits again. There are two limit values. First (20% above full driving level) is for software protection. In this case software will block transmitting; PA will stay in OPER mode. Second and very fast protection will be activated, when the input power exceeds 50% above full driving level. In this moment input RF signal will be switched immediately to the dummy load and PA will go to STBY mode. Message 23
Overdriving error appears. Decrease the input power under maximum driving level, set OPER mode again to continue transmitting. When one half of the double MOSFET will be broken for example, or some fault in the output circuit presents, output power of the PA will decrease rapidly. Fault message Gain is too low appears, amplifier will stay in OPER mode, but transmitting will be blocked. In this situation contact the manufacturer for the assistance. In the case of the main power supply failure, when voltage drops below 42 volts, fault message Voltage is too low appears, the amplifier will stay in operation mode and transmitting will be blocked. You have to check inside fuse first. If fault persists, contact the manufacturer or your dealer for the assistance. When the amplifier reaches inside temperature of 70 deg. Celsius, warning message Amplifier is too hot appears on the display. At 75 degrees protection circuit will automatically block transmitting (fault condition). You have to decrease the power or wait couple of minutes to be ready transmitting again. When current of the PA exceed the limit value, Current is too high fault message appears on the display, amplifier will stay in operation mode and transmitting will be blocked. Decrease input power first and try to transmit again. If this will not help and current will stay high, contact the manufacturer for assistance. If you turn the power amplifier ON and no LED will be illuminated, display stays dark, check mains first, and then check fuses inside the PA (see next part for more details). CAUTION If MOSFET is destroyed, do NOT attempt to replace it, in any case! Contact the manufacturer immediately. WARNING! Never try to change or move any part inside the amplifier except of internal fuses. Substitution of parts may void intrinsic safety! 6.2. Fuse Replacement There are two fuses installed inside the OM1006 power amplifier. They are located on the supply board on the left hand side of the PA, above the main power supply. The user is allowed to change these fuses. WARNING! Before opening the upper lid of the amplifier make sure that power supply has been disconnected. Take out power cord from the outlet! OM1006 uses one fuse 10 Amps T type 5 x 20 mm for main 50V DC power supply and one fuse 500mA T type for small 12V DC power supply. 24
6.3. Cleaning To prevent damage to the amplifier surfaces and the plastic components do not use aggressive chemicals for cleaning. Do not open the amplifier for cleaning. Outer surface may be safely accomplished by using piece of soft cotton cloth moistened with clean water or window cleaner. 25
7. APPENDIX 7.1. Block Diagram of OM1006 Power Amplifier 26