Icom_IC-PW1_serv.pdf

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1、HF/50 MHz ALL BAND LINEAR AMPLIFIER iC-PW1 INTRODUCTION This service manual describes the latest service information for the IC-PW1 HF/50 MHz ALL BAND LINEAR AMPLIFIER at the time of publication. To upgrade quality, all electrical or mechanical parts and inter- nal circuits are subject to change wit

2、hout notice or obligation. DANGER HIGH VOLTAGE! NEVER touch the antenna con- nector or the power supply section in the linear amplifier while connecting the IC-PW1 to an AC outlet. NEVER carry the linear amplifier by yourself. At least two persons must carry the linear amplifier since it weights ap-

3、 prox. 25 kg (55.12 lb). NEVER expose the IC-PW1 to rain or moisture since fire or shock hazard could occur. NEVER touch the IC-PW1 with metal strips, wire, etc. These materials may cause fires and electric shocks. ORDERING PARTS Be sure to include the following four points when ordering replacement

4、 parts: 1. 10-digit order numbers 2. Component part number and name 3. Equipment model name and unit name 4. Quantity required 1140003830S.ICTC4W66FIC-PW1 MAIN UNIT1 piece 8810003160SET Screw 3 6 ZKIC-PW1 CHASSIS6 pieces Addresses are provided on the inside back cover for your convenience. REPAIR NO

5、TES 1. Make sure a problem is internal before disassembling the linear amplifier or the remote controller. 2. DO NOT open the linear amplifier or the remote controller until the linear amplifier is disconnected from its power source. 3. DO NOT force any of the variable components. Turn them slowly a

6、nd smoothly. 4. DO NOT short any circuits or electronic parts. An insu- lated tuning tool MUST be used for all adjustments. 5. DO NOT keep power ON for a long time when the linear amplifier is defective. 6. READ the instructions of test equipment thoroughly before connecting equipment to the linear

7、amplifier. MODEL VERSION SYMBOL Europe Europe-1 IC-PW1 USA EUR EUR-1 U.S.A. TABLE OF CONTENTS SECTION 1 SPECIFICATIONS SECTION 2INSIDE VIEWS SECTION3 CIRCUIT DESCRIPTION 3-1 LINEAR AMPLIFIER CIRCUITS. 3 - 1 3-2 ANTENNA TUNER CIRCUITS . 3 - 2 3-3 PROTECTION CIRCUITS . 3 - 3 3-4 POWER SUPPLY CIRCUITS

8、. 3 - 4 3-5 PORT ALLOCATIONS . 3 - 4 SECTION 4ADJUSTMENT PROCEDURES 4-1 PREPARATION. 4 - 1 4-2 PAAND FRONT UNITS ADJSTMENT . 4 - 2 4-3 MAIN UNIT ADJUSTMENT . 4 - 3 SECTION 5PARTS LIST SECTION 6 MECHANICAL PARTS AND DISASSEMBLY SECTION 7SEMI-CONDUCTOR INFORMATION SECTION 8 BOARD LAYOUTS 8-1 ANT-SW UN

9、IT . 8 - 1 8-2 C-NET BOARD. 8 - 1 8-3 L-NET BOARD. 8 - 2 8-4 H-NET BOARD. 8 - 2 8-5 CONNECT BOARD . 8 - 3 8-6 COMBINR UNIT . 8 - 4 8-7 SPLITR UNIT. 8 - 5 8-8 PA UNIT. 8 - 6 8-9 DET BOARD. 8 - 7 8-10 JACK-1 UNIT. 8 - 8 8-11 SW BOARD . 8 - 9 8-12 FILTER UNIT. 8 - 11 8-13 MAIN UNIT . 8 - 13 SECTION 9 B

10、LOCK DIAGRAM SECTION 10 VOLTAGE DIAGRAM 10-1 WIRING DIAGRAM. 10 - 1 10-2 SPLITR, PA, AND COMBINR UNITS . 10 - 2 10-3 FILTER UNIT . 10 - 3 10-4 PA UNIT. 10 - 4 10-5 FRONT UNIT. 10 - 5 10-6 MAIN UNIT . 10 - 6 10-7 TUNER UNIT. 10 - 7 1 - 1 MGENERAL Frequency range:1.8001.999 MHz 3.5003.999 MHz 4.630 MH

11、z 7.0007.300 MHz 10.10010.150 MHz 14.00014.350 MHz 18.06818.168 MHz 21.00021.450 MHz 24.89024.990 MHz* 1 28.00029.700 MHz* 1 50.00054.000 MHz * 1The USA version can only be used the antenna tuner on the 2428 MHz bands. Duty cycle:Full duty Input connector:SO-239 2 (50 ) Output connector:SO-239 4 (50

12、 ) Power supply voltage:90 V132 V AC or 180 V264 V AC (single-phase; 50/60 Hz) Usable temperature range:10 C to +40 C; +14 F to +104 F Dimensions:Linear amplifier350(W)265(H)375(D) mm; (Projections not included)13.78(W)10.43(H)14.76(D) in Remote controller205(W)71(H)68.3(D) mm; 8.07(W)2.80(H)2.69(D)

13、 in Weight:25 kg; 55.12 lb(Included in the remote controller) (Included in the remote controller) MLINEAR AMPLIFIER Output power: * 1 EUR-1 version is 450550 W; * 2 EUR-1 version is 450550 W PEP Driving power:Max. 100 W Sprious emissions:Less than 60 dB (for HF bands) Less than 70 dB (for 50 MHz ban

14、d) MANTENNA TUNER Output matching range:16.7150.0 * 1 (for HF bands) 20.0125.0 (for 50 MHz band) * 1 Specifications of 1.9 MHz band guaranteed 1.851.95 MHz Auto tuning accuracy:VSWR 1.5:1 or less Min. required input power:60 W Insertion loss:Less than 1 dB (after tuning) SECTION 1SPECIFICATIONS All

15、stated specifications are subject to change without notice or obligation. MODE CW, RTTY SSB INPUT AC VOLTAGE 90132 V AC 450600 W* 1 450600 W PEP* 2 180264 V AC 9501150 W 9501150 W PEP 2 - 1 SECTION 2INSIDE VIEWS ANT-SW UNIT SW BOARD JACK1 UNIT COMBINR UNIT FRONT SIDE SPLITR UNIT PA-1 UNIT PA-2 BOARD

16、 PA-3 BOARD PA-4 BOARD FILTER UNIT FRONT UNIT POWER UNIT LOWPASS FILTER 2 - 2 TUNER UNIT CONNECT BOARD FRONT SIDE MAIN UNIT C-NET BOARD H-NET BOARD L-NET BOARD DET BOARD 3-1 LINEAR AMPLIFIER CIRCUITS 3-1-1 EXCITER INPUT SWITCHING CIRCUIT (SPLITR UNIT) The applied signal from the exciter (transceiver

17、) is passed through the exciter select circuit (RL1) then applied to the THROUGH/AMP switching relay (RL2). The switched signal is passed through the attenuator circuit (R3R6) when the amplifier is activated. The attenuated signal is applied to the power split circuit (L2L4, L6, R9R12). When “THROUG

18、H” is selected, the signal from the exciter select circuit is applied to the FILTER unit via J8. The attenuator circuit attenuates the switched signal approx. 1 dB to protect the amplifier circuits from excessive input power and stabilizes the amplifying operation. 3-1-2 POWER SPLITTER CIRCUIT (SPLI

19、TR UNIT) The power splitter circuit converts the antenna impedance to 14(12.5 ) at L2, then the applied RF power level is divid- ed at the hybrid circuit (L3, R9, R10). The divided RF signals are separately passed through another hybrid circuit (L4, R11 and L6, R12) to convert the impedance to 50 an

20、d divide the power level. The power level divided signal is applied to the one of four PA units (PA1PA4) via J4 to J7. The RF power level at J4, J5, J6 and J7 is approx. 15of applied power (from the exciter). 3-1-3 POWER AMPLIFIER CIRCUITS (PA14 BOARDS) The power level divided signal from the SPLITR

21、 unit is amplified at the power amplifier circuit (Q1a/b). The ampli- fied signal is applied to the COMBINR unit. Two power MOS-FETs (MRF150) and a negative feedback circuit are employed for each PA unit to obtain a stable 300 W or higher of RF power and to maintain response gain for all bands withi

22、n 3 dB. 3-1-4 POWER COMBINER CIRCUIT (CONBINR UNIT) The amplified signals from the PA1 and PA2 boards are combined at the hybrid circuit (L1, R1) to obtain a 500 W RF level and the impedance is converted to 25 . The amplified signals from the PA3 and PA4 boards are combined at another hybrid circuit

23、 (L2, R2). Both signals are again combined at another hybrid circuit (L3, R3) to obtain a 1 kW RF level and the impedance is converted to 12.5 . The combined signal is applied to the FILTER unit via the impedance convertor (L5) for conversion to 50 impedance. 3-1-5 FILTER CIRCUIT (FILTER UNIT) The s

24、ignal from the CONBINR unit is passed through one of 8 low-pass filters. The filtered signal is applied to the matching circuit. SECTION 3CIRCUIT DESCRIPTION C26 R3 R4 R5 R6 HV to PA1 board via the J11, pin 1 T8V to PA1 board via the J11, pin 5 and 6 GND F 5V TEMP IN DRIV J1 J2 RL1 C18 C19 D1 J9 L7

25、C2 R1 C4 L1L8 C3 D3 D2 R7 C7 R8 R2 C5L9 R17 C21R16R18 C22 IC1 L11 R14R15 R13 C9C10 D4 C8 L5 D5 L2 C17 L3 R9R10 C11 L4 R11 J4PA1 J5PA2 J6 J7 PA3 PA4 R12 L6 C14 J8 IN1 IN2 TRU SPLITTER CIRCUIT RL2 3 - 1 3 - 2 2-step (3-step for the 50 MHz band) Chebyschev low-pass filters are adopted, to obtain 60 dB

26、or less higher harmon- ic emissions for all HF bands or 70 dB or less for the 50 MHz band. The filtered signal is passed through or bypasses the anten- na tuner and is then applied to one of four antenna connec- tors via the antenna select relay (RL1RL4) on the ANT-SW unit. 3-2 ANTENNA TUNER CIRCUIT

27、S 3-2-1 MATCHING CIRCUIT (TUNER UNIT) The matching circuit is a T-network. Using 2 tuning motors, the matching circuit obtains rapid overall tuning speed. Using relays (TUNER unit; RL1RL10, L-NET board; RL1, RL2, H-NET board; RL1RL10), the relay control signals from the antenna tuner CPU (MAIN unit;

28、 IC12) via the relay driver (MAIN unit; IC14) ground one of the taps of L3L5 (L- NET board) or L11L15 (H-NET board) and add network capacitors (C-NET board). After selecting the coils and capacitors, 2 motors (TUNER unit; MF1, MF2) adjust C1 and C2 using the antenna tuner CPU and the motor driver (M

29、AIN unit; IC15) to obtain a low SWR (Standing Wave Ratio). 3-2-2 DETECTOR CIRCUIT (MAIN AND FILTER UNITS) (1) SWR detector Forward and reflected power are picked up by a current transformer (FILTER unit; L22), detected by D15 and D16, and then applied to the MAIN unit. The applied signals are amplif

30、ied at the SWR amplifier (MAIN unit; IC31a/b). The amplified voltages are applied to the antenna tuner CPU (MAIN unit; IC12, pins 2, 3). The CPU detects the SWR. (2) Reactance components detector Reactance components are picked up by comparing the phase of the RF current and RF voltage. The RF curre

31、nt is detected by L3 and R4 (DET board), and then amplified at IC1a and IC2d. The amplified RF current is applied to the phase comparator (DET board; IC4, pin 13). The RF volt- ages are detected at C1C3 on the DET board, and ampli- fied at IC1c and IC2a, then applied to the phase comparator (IC4, pi

32、n 1). The output signal from the phase comparator (IC4, pin 6 for RF voltage, pin 9 for RF current) is rectified at D13 and D14 for conversion into DC voltage. The rectified voltage signals are combined, then applied to the antenna CPU (MAIN unit; IC12, pin 64) after being amplified at IC9a on the M

33、AIN unit. ECL-IC is used for IC1 and IC2 on the DET board to ensure quick and stable signal detection even at low RF signal level input. (3) Resistance components detector Resistance components are picked up by L5, R14 and R21, and detected by Q1, D11 and D12 on the DET board. The detected resistanc

34、e components are amplified at IC9a on the MAIN unit, and then applied to the antenna CPU (IC12, pin 1). 3-2-3 MOTOR CONTROL CIRCUIT (MAIN UNIT AND C-NET, L-NET, H-NET BOARDS) The control circuit of the internal antenna tuner consists of the CPU, EEPROM, tuning motors and tuning relays. (1) CPU and E

35、EPROM (MAIN unit) The antenna tuner CPU (IC12) controls the tuning motors via the motor driver (IC15) and tuning relays via the relay dri- ver (IC14, Q9Q14). The CPU memorizes the best preset position and the contents are stored in the EEPROM (IC7) without the need for a backup battery. DETECTOR CIR

36、CUIT COUPLERCOUPLER L3, R4 L5, R14, R21 Impedance detector Phase detector Q1, D11, D12 D3, D4, D5, D6, D13, D14, IC2, IC4 IC9 Tuner CPU IC12 641 From FILTER unitTo C-NET board DET board MAIN unit 6 71 2 Amplifier 3 - 3 (2) Tuning controls (MAIN unit) A motor driver (IC15) rotates the tuning motors (

37、MF1, MF2) to obtain a low SWR. (3) Tuning relays (C-NET, L-NET and H-NET boards) According to the operating frequency band and antenna condition, tuning relays select the capacitors and coils. 3-3 PROTECTION CIRCUITS 3-3-1 GENERAL The IC-PW1 has two protection systems. One system bypasses the power

38、amplifier, and the other system shuts down the internal power supply activation. Protection activates when: a mismatched frequency band signal is transmitted. the ALC control level exceeds the control range. the power level balance between the 4 PA units becomes unbalanced. the output voltage of the

39、 internal power supply (VD) exceeds 55 V DC. the current of the power amplifiers (ID) exceeds 50 A. the heatsink temperature of the power amplifier exceeds +100C (212F). the applied AC voltage exceeds the specified value. The main CPU controls the THROUGH/AMP switch and internal power supply operation. 3-3-2 ALC CIRCUIT (MAIN UNIT) The ALC (Automatic Level Control) circuit automatically lim- its RF output power by controlling the input level of the exciter. (1) FOR-ALC The detected “FOR” volta