Ameritron Qsk-5 User manual

2.5KW

QSK

T/R

SWITCH

MODEL

QSK-5

INSTRUCTION

MANUAL

AMERITRON

116

Willow

Road

Starkville,

MS

39759

QSK-5

T/R

SWITCH

The

Ameritron

QSK-5

is

a_

self

contained

QSK

switch

that

adapts

non-QSK

amplifiers

to

full

break-in

operation.

The

QSK-5

is

housed

in

an

RF

shielded

enclosure

and

oper-

ates

on

120

VAC

power

lines

(QSK-5X

operates

on

200V

-

240V).

Inter-

face

connections

are

made

on

the

rear

panel

through

four

standard

phono

jacks

for

control

and

four

$0-239

connectors

for

RF.

The

QSK-5

will

handle

2000

watts

of

carrier

on

CW

and

2500

watts

PEP

on

SSB

in

normal

amateur

service

when

the

load

has

a

low

SWR.

An

optional

fan

is

required

for

continuous

carrier

modes

such

as

RTTY

and

Packet

at

power

levels

over

750

watts.

Internal

modifications

are

not

required

with

linear

amplifiers

that

use

less

than

25

volts

of

positive

polarity

on

the

"keying"

jack.

The

following

requirements

must

be

met

by

the

station

equipment

(amplifier,

antenna,

transceiver)

to

insure

proper

operation

of

the

QSK-5:

AMPLIFIER

REQUIREMENTS:

The

Ameri-

tron

QSK-5

(QSK-5X)

is

compatible

with

all

Ameritron

HF

Amplifiers.

The

keying

voltage

of

the

amplifier

used

with

the

QSK-5

must

be

a

positive

polarity

below

25

volts.

Most

popular

amplifiers

will

meet

this

requirement.

The

QSK-5

is

designed

to be

used

with

full

legal

limit

amateur

amplifiers

and

will

safely

carry

power

levels

up

to

2000

watts

on

CW

and

2500

watts

PEP

on

SSB.

The

SSTV,

RTTY

and

PACKET

rating

of

the

QSK-5

is

750

watts

average

power

with

5

minute

on

and

two

minute

off

duty

cycles

without

a

cooling

fan.

The

amplifier

output

rating

on

high

duty-cycle

modes

can

be

extended

to

1500

watts

with

the

optional

cooling

fan

installed.

ANTENNA

REQUIREMENTS:

The

antenna

SWR

must

be

low

if

the

QSK-5

is

operated

at

full

ratings.

To

calculate

the

safe

power

capability

of

the

QSK-5

use

the

following

formulas:

2800

divided

by

the

SWR

for

SSB

and

high

peak

to

aver-

age

power

modes.

2250

divided

by

SWR

for

CW

and

high

average

to

peak

power

modes.

1800

divided

by

SWR

for

RTTY

and

other

high

duty-

cycle,

high

average

power

modes.

NEVER

EXCEED

2000

WATTS

ON

CW,

2500

WATTS

ON

SSB

OR

1500

WATTS

ON

RTTY.

The

following

are

some

typical

SWR

values

and

power

ratings:

SWR

SSB

cw

RTTY

7:1

2500W

2000W

1500W

1.5:1

1875W 1500W

1200W

2.0:1

1400W

1125W

900W

3.0:1

950W 750W

600W

TRANSCEIVER

REQUIREMENTS:

The

QSK-

5

internal

relays

bypass

the

QSK-5

when

it

is

turned

off

or

if

trans-

missions

have

not

teen

made

within

the

seconds.

This

bypass

feature

allows

the

QSK-5

to

be

removed

from

the

circuit

for

tuning,

normal

VOX

operation,

and

other

times

when

QSK

is

not

de-

sired.

It

also

allows

the

amplifier

to

have

a

cool

down

period

between

transmission

periods.

The

factory

wiring

of

the

QSK-5

gives

the

user

flexibility

in

the

choice

of

trans-

ceivers

and

allows

tailoring

the

QSK-5

to

almost

any

application.

RX

FUSE

LAMPS

AMP

OUT

ANTENNA

© ©

KEY

1

KEY

2

°

co

.

AMP

RELAY

O

AMERITRON

AUX

STARKVILLE,MS

MADE

IN

USA

BACK

PANEL

RF

INTERCONNECTIONS

AMP

OUT:

This

SO-239

connector

should

be

connected

to

the

RF

output

of

the

amplifier

with

a

short

length

of

good

guality

coax.

This

is

also

one

of

the

places

to

locate

a

TVI

low-pass

filter.

ANTENNA:

This

S0O-239

connector

connects

to

the

station

wattmeter.

The

antenna’

switch,

tuner,

or

antenna

must

follow

the

wattmeter.

This

connector

should

have

the

cable

that

was

originally

connected

to

the

amplifier's

output

attached

here.

This

is

another

place

that

a

TVI

filter

can

be

located.

XCVR

OUT:

This

S0-239

connector

connects

to

the

transceiver's

antenna

connector.

This

is

the

cable

that

used

to

go to

the

ampli-

fier's

input

connector.

AMP

IN:

This

S0-239

connector

connects

to

the

input

connector

of

the

amplifier.

CONTROL

JACKS

AUX:

This

phono

jack

comes

factory

wired

to

an

open

collect

output

that

follows

the

KEY2

signal.

One

common

use

of

this

jack

would

be

to

connect

the

"“hand-shake"

output

to

the

transceiver.

O

*,

XCVR

AMP

fe}

oO

IN

OD)

POWER

VAC

ee

DESCRIPTION

KEY

2:

CAUTION:

NEVER

connect

any

circuitry

between

this

jack

and the

transceiver's

QSK

output

line.

This

phono

jack

connects

to

the

input

of

the

QSK

board.

This

jack

has

approximately

5

volts

DC

on

it

and

will

supply

one

mA

of

current

to

ground

when

pulled

low.

This

is

the

jack

that

must

be

pulled

low

(below

2

volts)

to

place

the

QSK

switch

in

the

transmit

mode

during

break-in

operation.

The

time

delay

from

the

keying

of

this

jack

to

the

application

of

RF

must

be

at

least

one

millisecond

to

prevent

clipping

of

the

leading

edge

of

the

wave-

form.

The

release

must

occur

at

or

beyond

the

point

that

the

RF

output

has

dropped

to

zero.

A

full

return

to

the

receive

mode

occurs

less

than

one

mS

after

this

jack

goes

high.

KEY

1:

This

jack

connects

to

the

VOx

relay

or

the

QSK

line

of

the

transceiver,

or

other

points,

as

required.

This

jack

will

pass

the

full

voltage

and

current

of

the

amplifier's

relay

along

to

the

transceiver

during

the

first

ten

mS

of

closure.

After

the

first

ten

mS

passes

the

holding

current

drops

to

10

mA.

This

jack

activates

the

amplifiers

internal

relay

via

the

AMP

RELAY

jack

even

if

the

QSK

switch

is

off.

This

jack

has

no

time

delay

at

the

beginning

of

transmissions.

It

holds

the

ampli-

fier

on

for

three

seconds

after

release

only

when

the

QSK-5

power

is

on.

AMP

RELAY:

This

line

connects

to

the

“amplifiers

key

(relay)

jack.

This

line

will

carry

up

to

one

ampere

at

25

volts

safely.

This

line

has

no

delay

when

activated

by

‘pulling

the

Key

1

line

to

ground,

it

has

a

one

mS

delay

when

activat-

ed

by

the

Key

2

line.

When

the

QSK

switch

is

turned

off

(bypassed)

the

amplifier

will

be

keyed

by

this

jack

when

the

Key

1

line

is

pulled

low.

When

the

QSK

switch

is

active

this

jack

has

a

three

second

re-

lease

delay

to

prevent

the

amplifi-

er'ts

internal

relay

from

chattering

and

distorting

the

signal

during

QSK

operation.

The

three

second

hold

delay

is

removed

when

the

QSK

switch

is

turned

off.

Wiring

diagrams

are

shown

in

Fig.

2,

These

circuits

cover

nearly

any

application

the

user

may

require.

Optional

FAN

Installation

A

small

volume

of

airflow

is

neces-

sary

to

cool

the

diodes

during

high

power,

high

duty

cycle

opera-

tion.

Ameritron

offers

a

fan kit

under

part

number

CF-5

that

con-

tains

instructions

and

all

hard-

ware.

This

kit

is

normally

not

required

unless

operation

on

RTTY

or

other

steady

carrier

modes

exceed

a

5

minute

on,

two

minute

off

time

period

at

power

levels

over

50%

of

the

RTTY

ratings

shown

on

page

1.

WIRING

DIAGRAMS

Figure

2a.

This

connection

diagram

PACKET,

CW,

or

SSB.

The

4

jack.

no

VOX

output,

If

the

transceiver

requires

a

"handshake"

line

use

the

layout

in

Figure

2b.

will

work

with

most

QSK

transceivers

on

"AUX"

line

must

be

plugged

into

the

Key

and

has

Figure

2b.

This

connection

diagram

is

for

transceivers

that

use

a

"hand-

shake"

line

to

verify

that

the

amplifier

is

ready

to

accept

power

but

do

not

have

a

relay

or

PIT

line

that

goes

low

other

than

the

QSK

line.

A

pair

of

diodes

(1N4001)

are

used

to

split

the

AUX

jack

output.

Figure

2c.

This

connection

diagram

is

for

transceivers

that

are

too

slow

to

key

the

QSK

switch.

The

primary

use

of

this

circuit

for

non-QSK

radios

would

be

to

eliminate

or

reduce

constant

relay

switching

in

the

amplifier

on

packet

or

CW

semi-break

in.

It

is

even

possible

to

use

some

non-QSK

radios

on

QSK

with

this

set

up.

Four

diodes

(1N4001)

are

used

to

split

and

isolate

inputs

and

outputs.

Keying

Circuit

Timing

transceiver

critical

The

timing

of

the

keying

circuit

is

with

any

QSK

switch,

transceiver

MUST

have

the

proper

sequencing

of

RF

and

QSK

output

lines.

The

trans-

ceiver

QSK

line

must

pull

low

BEFORE

RF

-

appears

on

the

output

connector

and

release

AFTER

the

RF

envelope

reaches

zero

to

operate

with

any

QSK

switch.

A

few

transceivers

do

not

meet

this

requirement

even

though

they

are

advertised

as

QSK

transceivers.

There

is

no

way

to

completely

correct

this

problem

without

modifying

the

transceiver.

One

indication

of

improper

timing

is

the

flashing

or

failure

of

fuse

lamps

LP1

and

LP2.

These

lamps

protect

the

transceiver

from

failure

of

the

receive

diodes.

Any

compo-

nent

failure

that

causes

the

receive

diodes

to

conduct

during

the

time

interval

the

transmit

diodes

are

conducting

will

connect

the

amplifier's

output

directly

to

the

input.

This

may

result

in

an

oscilla-

tion that

can

cause

damage

to

the

transceiver.

NEVER

REMOVE

OR

DEFEAT

THESE

LAMPS.

They

will

only

fail

if

there

is

a

timing

or

component

problem.

If

you

remove

the

fuse

lamps

the

transceiver

may

be

dam-

aged.

If

the

lamps

flash

or

fail

a

simple

test

can

be

made

by

sending

a

string

of

very

slow

dashes

with

a

keyer.

Slowly

raise

the

power

on

the

trans-

ceiver

until

the

lamps

begin

to

flash.

If

the

lamps

flash

at

the

beginning

or

end

of

each

dash

the

timing

of

the

QSK

line

from

the

radio

is

at

fault.

If

the

lamps

light

throughout

the

entire

length

of

the

dash

the

QSK_

line

should

be

unplugged

and

the

Key

2

jack

of

the

QSK

switch

should

be

grounded.

If

the

lamps

still

light

then

the

QSK

switch

has

a

circuit

problem.

If

the

lamps

do

not

light

the

problem

is in

the

radio

or

the

connection

to

the

radio.

Another

indication

of

improper

timing

is

the

generation

of

clicks

or

leading

or

trailing

edge

"chopping"

of

the

signal.

This

indicates

hot

switching

is

occurring.

This

is

strictly

a

timing

problem.

Timing

can

be

measured

with

a

dual

trace

scope.

The

trig-

gered

trace

should

be

connect-

ed

to

the

QSK

output

line

of

the

transceiver

(open

collec-

tor

lines

will

need

a

pull

up

resistor

connected

to

12

volts)

and

the

RF

_-

output

monitored

with

the

other

trace.

RF

must

not-

appear

until

at

least

one

half

milli-

second

after

the

QSK

line

is

low.

The

QSK

output

line

of

the

transceiver

must

not

go

high

before

the

RF

envelope

drops

to

zero.

QSK

Board

Operation

On

RECEIVE

the

functions

as

follows:

QSK

board

When

terminal

D

is

high,

R10

and

R16

bias

Q5

into

conduc-

tion.

This

holds

the

collector

of

Q5

below

three

volts.

IC1A

and

B

are

biased

at

50%

of

the

supply

voltage

with

the

inputs

arranged

so

that

IC1B

is

on

in

this

mode.

IC1B

turns

Q4

on

and

this

pulls

the

base

of

Q3

low

removing

the

high

voltage

from

the

receive

diodes

(D2,3,4

and

11)

and

grounding

the

junction

at

L6.

This

allows

12

volts

to

flow

through

the

diode

string

from

L5

and

L7

to

the

common

cath-

ode

point

at

L6.

This

turns

the

receive

diodes

on.

R17

and

C19

control

the

time

delay

of

the

receive

diode

turn

on

to

insure

the

transmit

diodes

have

time

to

turn

off

before

the

receive

diodes

are

turned

on.

IC1A

will

be

off

when

terminal

D

is

high

and

Q2

will

not

conduct.

This

allows

Q1

to

be

forward

biased

by

R5

and

pull

L2

up

to

400

volts.

This

voltage

cuts

off

D1

first

and

then

D10,9,8

and

/7.

This

disconnects

the

input

of

the

amplifier

before

disconnecting

the

output.

On

TRANSMIT

the

circuit

func-

tions

as

follows:

Point

D

is

held

below

2

volts.

This

removes

the

forward

bias

on

Q5

and

allows

the

collector

to

go

high.

ICiA

turns

on

after

a

slight

delay

caused

by

the

charge

time

of

R18

and

C20.

Q2

turns

on

and

dis-

charges

the

transmit

diode

string

through

D5.

Q1

is

forced

off

by

the

removal

of

base

bias

by

Q2.

The

12

volt

supply

then

flows

from

R27

through

the

diode

string

to

Q2.

This

places

the

transmit

diodes

in

conduction

by

bias-

ing

them

with

approximately

600

mA

of

forward

current.

The

receive

diodes

are

disa-

bled

when

Q5's

collector

voltage charges

C19

quickly

through

D13.

This

turns

IC1B

off

and

Q4

turns

off.

This

allows

R6

to

pull

the

base

of

Q3

high

and

the

voltage

at

the

emitter

of

Q3

rapidly

turns

the

center

junction

of

the

receive

diodes

off

by

applying

oe

volts

of

positive

bias

to

L6.

Voltage

divider

R8

and R12

allows

IC1C

to

compare

the

status

of

the

receive

diode

bias

to

the

voltage

obtained

through

R11

from

the

transmit

diode

string.

If

the

transmit

diode

string

is

off

and

the

receive

diode

string

is

on,

the

output

of

IC1C

will

be

low

and

Q6

and

Q7

will

be

off.

When

the

transmit

diode

string

is

on

and

the

receive

diode

string

is

off

Q6

and

Q7

are

biased

into

conduction.

Q7

can

be

used

to

switch

the

bias

in

an

=

amplifier,

The

source

(terminal

J)

must

be

within

3%

volts

of

ground

and

the

drain

(terminal

I)

must

be

below

25

volts

positive.

The

FET

will

safely

carry

two

amperes

of

current.

Q6

can

be

used

to

pull

up

to

100

mA

of

current

to

ground

(terminal

K).

The

open

circuit

voltage

must

be

below

25

volts

and

positive

polarity.

QSK-5

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QSK-5

PARTS

LIST

QSK-5

Power

Supply

PCB

Designation:

Description:

Part

#

C1,

2

-O1

uF,

250V,

Disc

200-2122

C3,

4

10

uF,

350V,

Elec

203-0310

C5

100

uF,

25V,

Elec

203-0564

C6

2200

uF,

25V,

Elec

2035-0207

C7

.01

uF,

50V,

Disc

200-0416

cs,

9

27

pF,

500V,

DM10

208-5404

CR1,

2,

3,

4,

5,

1N4007

300-0266

CR6,

R6

Q1

2N3906

305-0722

R2,

7

100K,

2W,

Metal

103-2181

R3

33

ohm,

1/4W

100-0403

R8

3.3K,

1/4W

100-0729

RLY1

Relay,

12V

DC,

DPDT

408-2135

RLY

Relay,

12V

DC,

3DPT

408-6140

QSK-5

Diode

Switching

PCB

Designation:

Description:

Part

#

C1,

2,

3;

4,

5,

6,

~.OT

uF,

1

KV,

Disc

200-2121

C7, 10,

11

c8

.001

uF,

1

KV,

Disc

200-2120

C12,

13, 14,

15

.005

uF,

1

KV,

Disc

200-3535

C16,

25

.01

uF,

250

V,

Disc

200-2122

C17,

18,

22, 23,

24

.01

uF,

50

V,

Disc

200-0416

C26,

27, 29,

30

C19

.022

uF,

50

V,

Mono

205-3220

C20

.O1

uF,

50

V,

Mono

205-3100

C21

.001

uF,

100

V,

Poly

201-2100

D1,

7,

8,

9,

10

4P4001B

300-5712

D2,

3,

4,

11

4PH301

300-5301

D5,

6

1N4007

300-0266

013,

14,

15

1N4148

300-5301

Li,

2,

3,

4

Choke,

100

mH

409-2150

L5,

6,

7

Choke,

2.5

mH

402-1162

Q1,

2,

3,

4

2N6740

305-0706

Q5

FET,

MTP-4NO8

305-6751

R1

330K,

1/4W

100-5330

R2,

3, 4,

11,

22,

1

Meg,

1/4W

100-0730

R23,

24,

25,

26

R5,

6,

8

3.3

Meg,

1/4W

100-6330

R10,

13,

14,

15,

10K,

a7

4W

100-4100

R17,

18,

21, 28,

29

R12

68K,

1/4W

100-4680

R16

4.7K,

1/4W

100-1470

R19

470K,

1/4W

100-0188

R20,

31

1K,

1/4W

100-0727

R27

10

ohm,

10W

103-9702

R30

68

ohm,

3W

103-3533

R32

100

ohm,

1/4W

100-2100

AMERITRON

116

Willow

Road

Starkville,

MS

39759

Limited

Warranty

Ameritron

warrants

to

the

original

purchaser

that

this

product

shall

be

free

from

defects

in

material

(except

tubes

and

RF

output

transistors)

or

workmanship

for

one

year

from

the

date

of

original

purchase.

During

the

warranty

period,

Ameritron

or

an

authorized

Ameritron

service

facility

wilt

provide

free

of

charge

both

parts

(except

tubes

and

RF

output

transistors)

and

labor

necessary

to

correct

defects

in

material

or

workmanship

To

obtain

such

warranty

service,

the

original

purchaser

must:

(1)

Complete

and

send

in

the

Warranty

Registration

Card.

(2)

Notify

Ameritron

or

its

nearest

authorized

service

facility,

as

soon

as

possible

after

discovery

of

a

possible

defect,

of:

(a)

The

model

number

and

serial

number,

if

any;

(b)

The

identity

of

the

seller

and

the

approximate

date

of

purchase;

(c)

A

detailed

description

of

the

problem,

including

details

on

the

equipment

(3)

Detiver

the

product

to

the

Ameritron

or

the

nearest

authorized

service

facility,

or

ship

the

same

in

its

original

container

or

equivalent,

fully

insured

and

ship-

ping

charges

prepaid.

Correct

maintenance,

repair

and

use

are

important

to

obtain

proper

performance

from

this

product.

Therefore,

carefully

read

the

Instruction

Manual.

This

warranty

does

not

apply

to

any

defect

that

Ameritron

determines

is

due

to:

(1)

Improper

maintenance

or

repair,

including

the

installation

of

parts

or

ac-

cessories

that

do

not

conform

to

the

quality

and

specifications

of

the

original:

parts.

(2)

Misuse,

abuse,

neglect

or

improper

installation.

(3)

Accidental

or

intentional

damage.

All

implied

warranties,

if

any,

terminate

one

(1)

year

from

the

date

of

the

original

purchase.

The

foregoing

constitutes

Ameritron’s

entire

obligation

with

respect

to

this

product,

and

the

original

purchaser

and

any

user

or

owner

shal!

have

no

other

remedy

and

no

claim

for

incidental

or

consequential

damages.

Some

states

do

not

allow

limita-

tions

on

how

long

an

implied

warranty

lasts

or

do

not

allow

the

exclusion

or

limitation

of

incidental

or

consequential

damage,

so

the

above

limitation

and

exclusion

may

not

apply

to

you.

This

warranty

gives

specific

legal

rights

and

you

may

also

have

other

rights

wich

vary

from

state

to

state.

PLEASE

RECORD

THIS

INFORMATION:

Model

__———Cs—CSC—SCSS

etal

Nl:

Date

of

Purchase

Purchased

From

Warranty

Card

Mailed

On

AMERITRON QSK-5 User manual

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