KOHJINSHA KL-1 User manual

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InstructionManual
HFALLBAND
LINEARAMPLIFIER
KL-1
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KL-1isdesignedtouseonlyforamateurradiopurpose.
Youneedproperlicensetousethisamplifier.
Pleasekeepthismanualafterreadingwell.
Youcanalsofindavailableoptionsinthismanual
Rev1.15.Nov.2013

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Thank you for choosing KL-1 as
youramplifier.
KL-1istheKohjinshaʼsstateofthe
artHFallbandlinieramplifier,which
haspresettuning,heavydutypower
supply,andremotecontroller.
Wewouldlikeyoutoreadthis
instructionmanualverywellbefore
usingyourKL-1.,whichshouldhelp
togetthemaximumperformance
from this amplifier. We would also
likeyoutouseKL-1forlongtime.
ACESSARIES
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Controller
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RemoteControlCable７ｍ
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CoaxialCablewithConnectors７ｍ
ACCable３ｍ
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ＲＣＡPlug1pc
LugTerminalsForPowerSupply ３pc
EarthLug2pc
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InstructionManual
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TableofContents
１．Foryoursafety・・・・・・・・・・・・・・・・・・2
２．MainUnit(PowerSupplyandRFDeck)・・・・・・4
３．Controller・・・・・・・・・・・・・・・・・・・・・7
４．InstallationandACWiring・・・・・・・・・・・・10
５．ExternalConnection・・・・・・・・・・・・・・・11
６．DisassemblingController・・・・・・・・・・・・・12
７．ControllerSetupandConnectionｓ・・・・・・・・13
SettingsforModels・・・・・・・・・・・・・・・15
8．ControllerProgramming・・・・・・・・・・・・・・22
9．AntennaSelector・・・・・・・・・・・・・27
10．PCConnectionandSetting・・・・・・・・・・・・29
１1．SteppIRConnectionandSetting・・・・・・・・・31
１2．Operation(CW,RTTY,SSB)・・・・・・・・・・・32
１3．TransformerWiring・・・・・・・・・・・・・・・33
１4．Specifications・・・・・・・・・・・・・・・・・・・34
１5．DisassemblingMainFrame・・・・・・・・・・・・35
１6．CircuitDiagrams
RFPowerDetector・・・・・・・・・・・・・・・・37
InputMatch・・・・・・・・・・・・・・・・・・・３8
TXInhibitMatrix(PCB3)・・・・・・・・・・・・・39
ServoMotorControl(PCB4)・・・・・・・・・・40
HVRectifier(PCB5)・OnDelay(PCB6)・・・・・・41
ServoControlMotor(PCB7)・・・・・・・・・・・42
ＲFＰＥＰMeter・・・・・・・・・・・・・・・・・43
ＲＦDeck・・・・・・・・・・・・・・・・・・・44
PowerSupply・・・・・・・・・・・・・・・・・・45
Controller・・・・・・・・・・・・・・・・・・・・46
１７．TroubleShooting・・・・・・・・・・・・・・47
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
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ReadThisPageForYourSafety
●Wewouldlikeyoutoread『ForYourSafety』verycarefullytopreventfrom
accident.
●Wewouldalsolikeyoutokeepthismanualatyourreachableplaceinorderto
readthisanytimeyouneedtocheck.
DANGERNegligenceofthissignmaycauseseriousinjuryordeath
ofoperatororpeoplearoundtheoperator.
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◎YoumustnotplaceKL-1inthenearbyareainwhichinflammableobjectisused.
Itmaycauseexplosionorfire.
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WARNINGNegligenceofthissignmaycauseseriousinjuryor
deathofoperatororpeoplearoundtheoperator.
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◎Negligenceofcautionslistedheremaycausegettingelectricshock,leakageofelectricity,
orshortcircuit.
●UseaproperplugtoconnectACwirewithACoutlet.Neverconnectwiredirectlywith
theoutlet.
●HaveagroundearthbeforeyouconnectACplugwiththeoutlet.
●Youshouldusepropergroundingmaterialstohavegroundearth.Donʼtusegaspipe,
waterpip,etc.,.
●YoumustnotusebrokenACwireorlooseACplug.
◎Negligenceofcautionslistedheremaycausefire,unusualheat,electricshock,ormajor
troublesofKL-1.
●YoumustbecarefulwithACpowerlinecapacity.Neveruseextensionsorpiggy
backedoutlet.
●Holdtheplugwhenyoupullouttheplug.Neverpullthewire.
●Donʼtsteponwiresorcoaxialcable.Youmustnotputthingsonwiresorcoaxial
cable.
●ACwiresorcoaxialcablemustnotbetwisted,pulled,broken,orgivenheat.
◎YoushouldpulloutACplugwhileyoudonʼtuseKL-1forlongtime.Otherwiseheator
firemayoccur.
◎Donʼtmakeanymetalorwiretouchthepartsintheamplifier,oryoumaycausefireor
trouble.
◎DonʼtuseproperprimaryAC,oryoumaycausefire,electricshock,ortrouble.
◎Donʼt use KL-1in the nearby area where medical equipments are used.The
interferenceontheseequipmentsmaycauseseriousaccident.
◎Ifyouarenoticedthunderstorm,removealltheconnectionsfromKL-1.Onceyouhear
thunderrolls,youarebetternottouchantennacables.
◎Just in case you hear usual noise, smell, or see smoke, stop using KL-1. If you continue using
under such conditions, you may cause fire, get electrical shock, or trouble. Remove AC plug
from the outlet, and make sure no more fire, smell, or smoke, contact us or our agent in your
area.
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CAUTIONNegligenceofthissignmaycauseyourinjurers,ormay
causetroubleswithKL-1.
◎NegligenceofCUASIONsignmaycauseabnormalheatinthemainunit,andthenmaymakeburnt,fire,
trouble,ormechanicallybroken
●DonʼtinstallKL-1intheareawithhighhumidity,dusty,airless.
●DonʼtinstallKL-1tooclosetoawall.
●DonʼtblocktheventholeofKL-1.
●DonʼtinstallKL-1intheareaofhavingdirectsunlight,orheatedaircomingout.
◎NegligenceofthisCAUTIONmaycausefalldownofKL-1,fire,injury,ortrouble.
●DonʼtmoveorinstallKL-1byonlyoneperson.
●Installontheveryhardandstableplace.
●DonʼtputanythingonKL-1.
◎DonʼtinstallKL-1closetotelevisionsetorradio.
Youmaycauseinterferences.
◎DonʼttouchKL-1orACplugwithwethands.
Youmaygetelectricshock.
◎Openthecaseonlywhenyouchangesettings.
Otherwiseyourmaygetinjury,electricshock,orcausetrouble
◎Donʼttransmitwithoutantennaordummyload.
Thatmaycausefire,ortrouble.
◎DonʼtdroporgivewhamKL-1.
Thatmaycauseinjury,ortrouble.
◎Donʼtusethinner,benzene,gasoline,orsuchfarmableliquidwhenyoucleanKL-1.
That may cause color change, distortion of case, or removing paint.
When you want to clean KL-1, use soft cloth with thinned kitchen detergent.
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２．MainUnit
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2-1 FrontPanel
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①PowerIndicator
KOHJINSHAlogoturnsonwithGREENlightwhenyou
connectACplugwithAC200V(220V,230V,or240V)
andturnonthecircuitbreakeronthelowerpartofrear
panel.
WhenyouturnonbypressingPOWERswitchonthe
controller,theKOHJINSHAlogoturnsRED,whichmeans
youhavehighvoltageonthetube.
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2-2 SidePanel(LeftandRight)
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②③SnapFastener
Theseareusedwhenyouneedtoremovesidepanels.
Pushdownthehookstounlock,thenliftapanelto
removeit. 
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2-3 UpperPanel
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④VentilationHole 
 Hotaircomesoutofthisholetokeepthetubeproper
temperature.Donʼtblockairflowatanytime.
Otherwiseyoumaygivedamagethetube.
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２．MainUnit
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2-４ RearPanel(UpperPart)
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⑤ANTConnectors(Output)
Therearesixantennaconnectorstouse
type-M(PL-259)connector.Youcanselect
which
outputtousefromthecontroller.
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⑥GNDterminal
UsethisterminaltoconnectKL-1toagood
earth
groundforsafety.
Goodearthgroundshouldpreventelectric
shock
accidentorRFinterferences.
UseaearthlugsuppliedwithKL-1.
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⑦INPUTConnector
Thisistoconnectwithyourtransceiver(transmitter)
RFoutterminal.
Usethe7mcoaxialcablethatissuppliedwithKL-1togetoptimumperformance.
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⑧REMOTE
ThisAmphenol5OPistoconnectwiththecontrollerbyusing7maccessorycablethat
issuppliedwithKL-1..Pushinfirmlyandmakesuretolockit.
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⑨ExtANTSelector
UsethisconnectortoconnectExtAntennaSelector(Option)
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２．MainUnit
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2-5 RearPanel（LowerPart）
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⑩Fuse
5Aand3Afusesareused.
Oncefuseisblown,resolvethecausefirst,andthenreinstallthesamevalueoffuse.
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⑪CircuitBreaker
CircuitBreakeristrippedbyequipmentassoonasitdetectsfailureofKL-1likeshort
circuitorovercurrent.Ratedcurrentis50A.
Pushuptheleverofthecircuitbreakeruntilyouheartheclicknoiseafteryoufixthe
trouble.
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⑫PrimaryACPowerConnectionTerminals
ApplyprimaryAC200V(220,230,or240V)tothis３Ｐterminal.Usethickerthat
AWG#8.Cable.CenterisforGNDconnection.ApplyACtobothside.
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⑬VentilationHole 
ThisisforKL-1tointakeoutsideair.Donʼtblockthiswithanything.
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３．Controller
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３-1 FrontPanel 
 
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①POWERSWITCH
Wholesystempowerismade“ON/OFF”byPowerSwitch.
ThisswitchtogglesON”“OFF”alternately.
 ThebluelampofthecircumferenceofabuttonlightsupwhenKL-1ʼspoweron.
ThebluelampofthecircumferenceofabuttongoesoutwhenKL-1ʼspoweroff.
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②OPERATIONSWITCH
WhentheKL-1isdetunedorchangedbandwithOPERATIONSWITCHisturnedon,
servo-motorautomaticallymovestotuneontheband.STBYlampwilllightwhentuned.
Setthe⑧FineTuneknobtostaycenter.
OperatewiththisOPERATIONSWITCHONusually.
IfyoudonʼtuseKL-1(throughtheamplifier),pressthisswitchtoputthebluelampout.
InthismodebandchangeoftheexciterwonʼtletKL-1totune.
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③CONTROLLERSWITCH
ThisswitchworkstoantennaselectionswitchwhileKL-1ispoweredoff.
YouneedtokeepthisswitchonforantennarelaystoworkduringKL-1ʼspoweroff..
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④DOWNSWITCH
Youcanmovebanddownwardwiththisswitch.Pressoncemovesdowntoonelower
band.

⑤UPSWITCH
Youcanmovebandupwardwiththisswitch.Pressoncemovesuptooneupperband.

⑥ANTSELSWITCH
Thisswitchchangesconnectorsontherearpanel.EachpresschangefromANT1to
ANT6sequentially.LED1toLED6worktogetherwiththisswitch.

- 7 -

３．Controller

⑦LOCKSWITCH
Youcannotselectantennasmanuallyifthisswitchisturnedon.Youcanchange
antennasfromyourtransceiverorPC.

⑧FINETUNE
Whenyouneedtofinetuning,turnthisknowtogetmaximumpower.Placethisknobat
centerpositionnormally.
Whenyoufinetune,youMUSTdrivewith50Worlittlelower.
Becauseinordertopreventcontactsofthevariableinductorgettingdamagedbybig
amountofpowerandcurrent.

⑨STANDBY
ThislampshowsgreenlightonwhenKL-1isreadytouseafterbandchange.

⑩ONAIR
Thislamplightsredwhiletransmitting.

⑪PLATEVOLTAGE
Platevoltagemeter.

⑫PLATECURRENT
Platecurrentmeter.

⑬GRIDCURRENT
Gridcurrentmeter.

⑭FORWARDPOWER5KW
Forwardpowermeter.

⑮REFLECTEDPOWER500W
Reflectedpowermeter.


- 8 -

３．Controller

３-２ RearPanel 










①RS232CConnector
 ThisisusedtoconnectwiththeradiothathasRS232Cinterface.
UseRS232Cstraightcable.

②PC⇔RIGSwitch
 YoucancontrolKL-1fromeitherPCortransceiver.
Usethisswitchtoselectyourfavoriteway.

③USBTerminal
 ThisistoconnectwithyourPC.
 JustconnectwithyourPC.KL-1workswithoutdrivers.

④CI-VTerminal
 YoucanconnectwithICOMradiosusingthisterminal.Usecablewith2pplug.

⑤SteppIRTerminal
 WhenyouconnectwithSteppIR,usethisterminal.
 Usethecabletouseforthispurpose.（2Pプラグ・D-Sub9P）
Moredescriptionregardingthiscableinpage33.

⑥REMOTEConnector
ForAmphenol50Pconnectorwiththesupplied7mconnectioncable.
Pushtheconnectortotheendandmakesureifitislocked.

⑦TXCONT
 Connectwithyourtransceiverʼsremoteterminal(TXGND).

⑧GNDTerminal
UsethisterminaltoconnectKL-1toagoodearthgroundforsafety.
GoodearthgroundshouldpreventelectricshockaccidentorRFinterferences.
UseanearthlugsuppliedwithKL-1.
- 9 -

４．InstallationandACWiring

Thereisaventilationholetotakeairinontherearpanel.
Donotblockthisholewithanything.
InstallingKL-1industyorhighhumidareamaycausehighvoltageleakage.




PrimaryACconnectingwireisrequiredthickerthanAWG#8.
Ifyoudonotuseproperwire,youmayhavefirefromtheheat.




PrimaryACConnection



- 10 -

５．ExternalConnections

Thisshowsexternalconnections.






- 11 -

６．ControllerDisassembling
Unscrew6nutsonthecover.Liftthecoverandyoucantakeitoff..

Becarefulinordernottogethurt.



















- 12 -

７．ControllerSetupandConnections

Youneedtosetupthecontrollersettingsandmemorysettingsbeforeyouconnectwith
yourtransceiver.
WewouldliketoexplainhowtosetupKL-1controllertogetfullcontrolKL-1withyour
transceiver.


7-1 BoardsintheController
YouneedtohaveproperjumperandmemorysettinginordertocontrolKL-1
coordinatingwithyourtransceiver.Thepictureshowspinheaderlocationsonthe
CPUboard.




- 13 -

７．ControllerSettingsandConnections

7-2 JumperPinSettingsandConnectionforDifferentTransceivers
Inthissectionweshowjumperpinsettingsandcableforconnectionwithdifferent
transceivers.
■showsjumperpinposition.
■doesn’teffectsettingswithorwithoutjumperpin.
Eachfigureʼsbottomsideisfrontsideofthecontroller.

（※）YoucannothavebothRS-232CconnectorandCI-Vconnectorontherear
panelofKL-1.Ifyouhavebothconnectors,controlfunctiondoesnʼtwork.You
shoulduseeitherinterface.














- 14 -

７．ControllerSettingsandConnections
7-3-1 ICOM（CI-V）
1.JumperPinSettingsonTrackingBoard
 

２.ConnectingwithYourTransceiver
ConnectremotejackofyourICOMtransceiverwithCI-VjackofKL-1
controller.
Use2pinplugonbothsidewithshieldedcable.



TransceiverREMOTEKL-1CI-V
φ3.52pplugφ3.52pplug
- 15 -

７．ControllerSettingsandConnections

7-3-2 YAESUFTDX9000・FT2000・FTDX5000・FT1000MP・MK-V

1.JumperSettingsonTrackingBoard
 
























2.ConnectingwithYourTransceiver
UsestraightcablewithDSUB9femaleconnectoronbothsides.Youneedtouse
onlypin2,3andGND.

Transceiver CATKL-1 RS-232C
D-SUB9(female)D-SUB9(female)
- 16 -

７．ControllerSettingsandConnections

7-3-3 YAESU FT-1000・FT-1021
1.JumperSettingonTrackingBoard
 





















2.ConnectionwithTransceiver
ConnectCATconnectorofyourtransceiverwithRS232CconnectorofKL-1.
UseDIN6pinconnectorfortransceiverandRS232C(female)forKL-1
Youneedtouseonlypin2,3andGND.

Transceiver CATKL-1 RS-232C
DIN6PinD-SUB9(female)
- 17 -

７．ControllerSettingsandConnections

7-3-4 KENWOOD TS2000・TS870・TS５90・TS480・TS990
1. JumperSettingsonTrackingBoard
























2.ConnectionTransceiverwithController
ConnectCOMconnectoroftransceiverwithRS232CconnectorofKL-1
  UsestraightcablewithDSUB9femaleconnectoronbothsides.Youneedto
useonlypin2,3andGND.
 
Transceiver COMKL-1 
D-SUB9(female)D-SUB9(female)
RS-232CRS-232C


- 18 -

７．ControllerSettingsandConnections

7-3-5 KENWOOD TS-950・TS-850
1. JumperSettingsonTrackingBoard
























2.ConnectionTransceiverwithController
ConnectACC1oftransceiverwithRS232CconnectorofKL-1.
Useonlypin2,3,andGNDwithDIN6pinfortransceiver,andRS232C
femaleforKL-1.


TransceiverACC1KL-1 RS-232C
DIN6pinD-SUB9(female)


- 19 -