Palstar COMMANDER HF-2500 EXPORT User manual

COMMANDER
HF-2500 EXPORT
Owner’s Manual
PALSTAR, INC.
Command Technologies Division
9676 N. Looney Road
Piqua, Ohio 45356
U.S.A.
Custome Se vice and Sales Telephone: [phone]
Inte national: 937-773-6255
Fax: [phone]
E-mail: info@palsta .com
Rev. 1.3 14 July 2010

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Table of Contents
Int oduction 3
Safety Wa nings and P ecautions 4
Unpacking Inst uctions 5
HV T ansfo me Installation 6
Connections 8
Rea Panel View 9
F ont Panel View & Tuning P ocedu e 10
Theo y of Ope ation & Adjustments 12
Wa anty, Se vice, and Retu ns 14
Specifications 15
RF Deck View 16
Access Plate Illust ation 17
HV Powe Supply Schematic 18
AC Mains & Step-Sta t Schematic 19
Cont ol Boa d Schematic 20
Tuned Input & T/R Switch Schematic 21
RF Deck Schematic 22
Amplifie Test Ca d 23
PHOTO APPENDIX
Dual Mete s Diag am 24
Mete Boa d 25
Step-sta t Boa d 26
Powe Supply 27

3
Int oduction
The Commande HF-2500 Expo t is class AB2 linea powe amplifie . It has been designed
fo ope ation on all amateu f equencies f om 1.80 MHz to 29.7 MHz, excluding the 30 mete
band.
Th ee Eimac 3CPX800A7 pulse ated ce amic-metal t iodes configu ed in a g ounded g id
ci cuit allow fo conse vative ope ation at 2800 watts continuous ca ie output. A p essu ized
fo ced ai cooled chassis, including the high voltage supply insu es cool ope ation with high
duty cycle emission modes.
The output ci cuit utilizes ext a heavy duty components with ve nie eduction d ives on all
tuning cont ols. Easily accessed ea panel cont ols allow fo ope ato adjustment of input
VSWR and ALC.
An automatic time delay ci cuit, insu es p ope cathode conditioning befo e RF d ive can be
applied. A p otective ci cuit shuts down the amplifie in the event of excessive g id cu ent. A
esisto located in the high voltage B+ ci cuit p otects the tube in the event of an inte nal tube
a c. Mete ing functions includes plate voltage, plate cu ent, g id cu ent and elative output.

4
CAUTION:
• DO NOT attempt any type of se vice o epai on this amplifie without fi st emoving the
AC powe and allowing AT LEAST 10 MINUTES FOR THE HIGH VOLTAGE CAPACI-
TORS TO BLEED OFF !
• DO NOT ope ate this amplifie with the top o bottom cove s emoved. THE VOLTAGES
INSIDE THE CABINET ARE DEADLY ! EXPOSURE TO UNSHIELDED RF AT
THESE POWER LEVELS IS HAZARDOUS TO YOUR HEALTH !
• Neve attempt ope ation without fi st connecting you amplifie to an app op iate antenna o
dummy load. The antenna SWR should not exceed 2:1. The dummy load should have an
impedance of 50 Ohms with sufficient powe handling capability. DAMAGE TO THE AM-
PLIFIER MAY RESULT IF OPERATED WITHOUT A CONNECTION TO A PROPER
LOAD.
• NEVER OPERATE THIS AMPLIFIER WITHOUT AN EARTH GROUND CON-
NECTED TO THE REAR PANEL GROUND TERMINAL.
• Do not obst uct the ventilation holes located on the top, bottom, and sides of the cabinet.
These holes p ovide sufficient intake and exhaust of cooling ai . SEVERE OVERHEAT-
ING AND SERIOUS DAMAGE WILL RESULT IF SUFFICIENT VENTILATION IS
NOT PROVIDED.
• Neve ope ate any amplifie using an extension co d.
!! WARNING !!
CONTACT WITH VOLTAGES IN THIS AMPLIFIER CAN BE
!!! FATAL!!!

5
UNPACKING
Ca efully emove the Commande HF2500 EXPORT Amplifie f om its shipping ca ton
making su e the e is no damage evident f om shipping. If the e is any damage, notify the deliv-
e ing shippe immediately, fully desc ibing the damage.
The HV powe t ansfo me was shipped sepa ately, as its weight would damage the cabinet
in t ansit.
Do not dest oy the packing mate ial since it may be eusable late , should you equi e fac-
to y se vice o need to t anspo t the Amplifie fo any othe eason.
TRANSFORMER INSTALLATION
Remove the top cove f om the amplifie chassis. Install the t ansfo me following the illus-
t ated p ocedu e beginning on next page.
SHIPPING BLOCK
The 3CPX800A7 tubes a e shipped installed in the amplifie , held in place by a Sty o-
foam block. Remove the block befo e use.
200/234 VAC Ope ation
The Commande HF2500 EXPORT comes facto y wi ed fo 234 VAC ope ation. Fo best
ope ation, you should use a dedicated 234VAC main capable of supplying 30 Amps of peak AC
cu ent.
Commande Amplifie s manufactu ed fo expo t a e wi ed fo 234 VAC o 200 VAC de-
pending on the final destination.

6
Hook the snap ings on the p ovided
lifting handle into the holes in the tabs
on eithe end of the t ansfo me
HF-2500 EXPORT
T ansfo me Installation
Position the t ansfo me ove the mounting holes
in the chassis and inse t the fou p ovided 1/4-20
Phillips head sc ews th ough the t ansfo me
mounting tabs and into the th eaded inse ts in the
chassis plate and tighten.
He e is the lifting handle attached and
eady fo use.
The t ansfo me is HEAVY, so ca efully
lift it into place in the chassis. BE CARE-
FUL NOT TO BUMP THE PC BOARD
ON THE BACKS OF THE METERS.

7
Plug the second connecto on the t ansfo me
into the mating one that comes f om the AC
cont ol boa d. It is keyed so that it cannot be
plugged in backwa ds. Make su e that the
connecto halves a e p essed togethe until the
lock tabs snap in place.
This completes HF-2500 EXPORT
t ansfo me installation.
Plug the fi st connecto on the t ansfo me into
the mating one on the chassis wi ing ha ness. It
is keyed so that it cannot be plugged in back-
wa ds. Make su e that the connecto halves a e
p essed togethe until the lock tabs snap in place.
D ess the wi es and connecto s down out of
the way as shown.
View of the completed t ansfo me installa-
tion

8
Connecting You Amplifie
• Connect the RF output of you t ansceive to the RF Input connecto on the ea of the HF-
2500 EXPORT with 50 Ohm coaxial cable.
• Connect the existing station antenna tune o a Wattmete and dummy load to the RF Output
connecto on the HF-2500 EXPORT with RG-8 o bette coaxial cable.
• Connect the Keyline jack on the ea of the HF-2500 EXPORT to the no mally open te minal
of the elay jack on you t ansceive . The Key jack on the HF-2500 EXPORT has positive 5
VDC open ci cuit and equi es the sinking of 15 mA of cu ent when pulled to g ound.
• Connect as sho t a g ound lead as possible f om a good RF g ound to the G ound Post on
the HF-2500 EXPORT.
• Connect the ALC phono jack to the ALC connection on you t ansceive using a shielded
cable. Consult you t ansceive manual fo p ope ALC connection details.
Key
ALC
RF Ouput
RF Input
RF Output
Ground
Antenna
Tuner
Ground
To Earth
Ground
ALC TX GND
To Antenna
Transceiver
HF 2500 Export Amplifier
Wattmeter
To
Dummy
Load

9
Rea Panel View
Tuned Input
Adjustments
(One fo each
band)
Automatic Level
Cont ol Adjust
RF Output
(to Wattmete
& Antenna
o Antenna
Tune )
RF Input
(f om
T ansceive )
G ound
Post
Key Line
(to t ansceive )
ALC
(to t ansceive )
AC Mains
Twistlock
Connecto
AC Powe Twistlock Connecto Wi ing
(View looking at ea panel)
GREEN
BLACK
}
WHITE
To Safety G ound
To 200/234VAC @ 30A
X
Y
G

10
TUNING PROCEDURE
Set the f ont panel cont ols to the following positions:
ON - OFF Switch. OFF
STANDBY - OPERATE STANDBY
BAND SWITCH DESIRED BAND
TUNE CONTROL PRESET TUNE SETTINGS (See test sheet)
LOAD CONTROL PRESET LOAD SETTINGS (See test sheet)
Afte the cont ols have been p eset and the amplifie is connected to a suitable RF load,
switch the On/Off switch to the On position. The following will occu :
A. The mete s will illuminate.
B. The step-sta t elay will actuate and the HV will begin to amp up.
C. Afte 2 seconds the step-sta t elay will disengage and the HV will now be at its no mal
no-load voltage level.
D. The 3 minute filament time will sta t. The g een “Status-T ip” LED will flash (1Hz
ate) du ing the 3 minute wa m-up inte val.
E. Afte 3 minutes the “Status-T ip” LED stops flashing and the amplifie is eady fo use.
Place the Standby/Ope ate switch in the Ope ate position. The amplifie will not switch to
the “Ope ate” state if the Keyline is active when the switch is th own (this p otects the amp in
Load Cont ol Standby/Ope ate
Switch
Powe
On/Off
Band Switch Tune Cont ol T ansmit
Indicato
LED
Status-T ip
Indicato
LED
Plate Cu ent/
Plate Voltage
Mete
G id Cu ent/
Relative Powe
Mete

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case it is inadve tently keyed when the switch is th own). Key the excite with no RF d ive ap-
plied. The ed t ansmit LED should illuminate, and the mete should indicate app oximately
150 mA of plate cu ent. Apply 5 to 10 watts of RF d ive, the plate cu ent should ise slightly.
If the plate cu ent ises above 1800 mA, educe d ive. Adjust the TUNE cont ol to peak the
g id cu ent and achieve maximum output powe as indicated on an exte nal Wattmete .. COM-
PLETE THESE ADJUSTMENTS AS QUICKLY AS POSSIBLE TO AVOID STRESSING
THE TUBES.
Adjust the LOAD cont ol to educe g id cu ent while maintaining output powe as indi-
cated on the elative output mete o an exte nal Wattmete . Next, inc ease the d ive in small
inc ements and adjust the LOAD cont ol fo maximum output while keeping the g id cu -
ent low. Unde no mal conditions the g id cu ent should not exceed 60mA.
Readjust the TUNE cont ol to again peak the eading on the g id mete . If the mete ises
above 150mA. quickly educe d ive and adjust the LOAD cont ol counte clockwise to educe
g id cu ent. Repeat these adjustments as equi ed to achieve the desi ed output up to 2800
Watts.
[NOTE: If the g id cu ent is allowed to each o exceed 180mA, the cont olle will imme-
diately un-key the amplifie and the “Status-T ip” LED will flash apidly, indicating that a g id
cu ent limit (a “G id-T ip”) has occu ed.
In o de to eset the G id-T ip ci cuit y, the excite must be un-keyed and the “Standby-
Ope ate” switch must be switched to “Standby” and then back to “Ope ate.” Once the G id-
T ip has been eset, the “Status-T ip” LED will stop flashing and emain illuminated.
Do NOT exceed 1800mA plate cu ent.]
Note that when inc easing output powe the tune scale will always ead highe and the load
will ead lowe . Also, the supplied inspection sheet has all of these settings and they should be
used as a guide fo this p ocedu e. If you settings va y widely f om these you have something
w ong and should sta t ove .
If you planned ope ation is on SSB, you should educe the load cont ol slightly counte -
clockwise, educing the TOTAL output slightly about 30 to 50 Watts. This adjustment is neces-
sa y to insu e that the amplifie is sufficiently loaded to handle the plate cu ent peaks caused
by the complex voice patte ns du ing SSB ope ation. Nominal plate and g id cu ent ead-
ings du ing SSB ope ation will be about 30 to 40% of the key down CW eadings.
CAUTION: THE TUNE AND LOAD AIR VARIABLE CAPACITORS MAY ARC IF
MAXIMUM DRIVE IS APPLIED BEFORE THE AMPLIFIER IS PROPERLY TUNED. AL-
WAYS FOLLOW THE DESCRIBED TUNE-UP PROCEDURE TO AVOID CAPACITOR
ARCING. ARCING MAY ALSO OCCUR IF YOU ATTEMPT TO TUNE INTO AN AN-
TENNA WITH A VSWR GREATER THAN 2:1.
Generally expect to tune by peaking grid current and
simultaneously dipping plate current.

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Theo y Of Ope ation
The Commande HF-2500 EXPORT uses th ee C.P.I. Eimac 3CPX800A7 pulse ated ce-
amic/metal t iodes in a class AB2 g ounded g id configu ation. Nominal d ive powe of 20 to
65 Watts.
This amplifie will ope ate on the following amateu bands: 160, 80, 40, 20, 15, 17, 12 and
10 mete s.
Mete ing Functions
The Commande HF-2500 EXPORT has two illuminated c oss-needle panel mete s. The left-
hand mete continuously displays 3CPX800A7 g id cu ent and elative output powe . Unde
typical ope ating conditions the g id cu ent will be 20-60mA.
Plate voltage and Plate cu ent a e continuously displayed on the ight-hand mete . The
typical plate cu ent unde nominal ated output (2800 Watts) should ange f om app oximately
1000mA to 1800mA, with an absolute maximum of 1800mA.
Tuned Input Ci cuits and Adjustments
The tuned input ci cuits utilize an π impedance matching ci cuit with a high Q design.
These ci cuits employ RF phase compensating capacito s to educe inte modulation p oducts.
The use of mica t imme capacito s allows adjustments to match the t ansceive to the ampli-
fie . The ea panel p ovides easy access to these t imme capacito s. A f ont panel band switch
selects the app op iate input filte .
You Commande amplifie has mica t imme capacito s which a e easily accessed th u
holes located on the ea panel. The tuned input ci cuits a e facto y tuned and should not be e-
adjusted unless necessa y. You can easily make adjustments fo any change in you p efe ence
fo ope ating f equency ange. Also, slight adjustments may be necessa y because of slight va i-
ances in impedances between you t ansceive and the tuned input ci cuit y of the amplifie .
1. Install a SWR mete between the t ansceive and the amplifie .
2. Make su e the Standby/Ope ate switch is in the Ope ate position and the band switch
is set to the same band as the one fo which you a e making adjustments. You ampli-
fie should also be p ope ly tuned and loaded (p efe ably onto a dummy load of suffi-
cient capacity).
3. Apply d ive, obse ve the SWR, and adjust the t imme capacito fo minimum SWR.
Be ca eful not to ove d ive the amplifie .
4. Repeat this p ocedu e fo each band.
Automatic Level Cont ol and Adjustments
An adjustable Automatic Level Cont ol (ALC) ci cuit limits the peak output powe . When
p ope ly set, this ci cuit insu es that the amplifie can not be ove d iven. Rea panel access al-
lows fo easy manual adjustment. A sample of the RF input de ives the ALC voltage.
You t ansceive 's inte nal ALC will maintain linea ity. The amplifie 's ALC will p event
ove d iving the amplifie . The HF-2500 EXPORT’s ALC ci cuit was designed fo negative going
ALC voltage. P ope adjustment is as follows:
1. Use an insulated tool when making these adjustments.
2. Tune the amplifie fo ope ation on the 20 mete band fo full 2800 watts output.
3. With you t ansceive set fo 20 mete SSB ope ation, set the t ansceive 's mic ophone

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gain fo no mal ope ation as specified in its owne s manual.
4. While speaking loude than no mal into the mic ophone, adjust the ALC pot th ough the
access hole on the ea panel . Adjust fo 2800 Watts maximum output as indicated on
an exte nal peak eading Wattmete .
5. On some newe model t ansceive s this adjustment can be made in the CW position. On
these models (with you output at 1500 Watts) simply adjust fo a slight d op in output.
Output Filte Ci cuit
The π va iable netwo k filte t ansfo ms the plate load impedance f om app oximately 2500
Ohms down to 200 Ohms, Two ai va iable capacito s and an associated inducto accomplish
this t ansfo mation. A heavy duty band switch selects the p ope inductance f om high Q induc-
to s with app op iate taps fo the desi ed band of ope ation.
A design Q of 14 allows fo good ha monic attenuation on all bands. A special eactance-
tuned fe ite co e 4 to 1 t ansmission line t ansfo me steps down the 200 Ohm output of the π
ci cuit to the 50 Ohm nominal antenna impedance. This also p ovides fu the ha monic attenua-
tion of the output in the same manne as an L coil in a π-L netwo k.
High Voltage Supply
The high voltage supply ope ates f om 200/234 VAC, 30 Ampe e line. The p ima y of the
high voltage t ansfo me is switched on and off with elays and inco po ates a step-sta t ci cuit
to limit in- ush cu ent while the high voltage filte capacito s cha ge. The f ont panel On/Off
switch applies AC mains powe to the cont olle ci cuit y which then cont ols AC powe to the
filament and HV t ansfo me s. 2400 VAC f om the t ansfo me is applied to a full wave b idge
ectifie . Mete ing of the tube anode and g id cu ent is accomplished by shunt esisto s located
in the negative etu n of the 3CPX800-A7 cathode. Plate voltage mete ing is accomplished by a
esisto divide netwo k in the B+ line of the high voltage ci cuit.

14
Limited Wa anty
Palsta Inc. wa ants the Commande HF-2500 EXPORT to be f ee f om defects in mate ial
and wo kmanship unde no mal use and se vice to the o iginal buye fo a pe iod of one (1)
yea f om the date of delive y to that buye (the “Wa anty Pe iod”). Palsta Inc.’s obligation
unde this wa anty is limited to epai o eplacement of the p oduct at it’s option at the Palsta
facto y in Piqua, OH.
This wa anty is effective only when the p oduct is etu ned to the facto y with all t anspo -
tation cha ges p epaid and examination of the p oduct discloses the p oduct, in Palsta ’s judg-
ment, to have been defective du ing the Wa anty Pe iod.
The Wa anty Pe iod shall not extend beyond its o iginal te m with espect to inte im in-
wa anty epai s by Palsta . This Wa anty Pe iod shall not apply to any p oduct which has been
epai ed o alte ed by anyone othe than Palsta without p io w itten autho ization. Wa anty
does not extend to any p oducts which have been subject to damage f om imp ope installation,
application o maintenance in acco dance with the ope ating specifications. Palsta neithe as-
sumes no autho izes any pe son to assume fo it any obligation o liability othe than he ein
stated.
Shipping You Amplifie Back to the Facto y
Due to the necessity of shipping the amplifie with the HV t ansfo me emoved, please
contact the facto y fo inst uctions befo e sending an amplifie back to us. The e a e ci cum-
stances in which it may not be necessa y to etu n the HV t ansfo me , the eby saving you ship-
ping cha ges. When you call, Palsta will info m you if t ansfo me etu n is necessa y. If
t ansfo me etu n is necessa y, emove it f om the amplifie cabinet and ship it sepa ately, and
must be in its o iginal packing.
Repai Policy
When sending in a p oduct fo se vice, see the section above. If not using the o iginal pack-
ing mate ials, please “double” box it ca efully with suitable padding and ship it insu ed fo you
p otection. Please include a note clea ly desc ibing the p oblem, how you wish the item e-
tu ned and how you wish to pay fo the se vice. Package you unit p ope ly. Palsta , Inc. is not
esponsible fo me chandise damaged in shipment. Ou se vice ate is $30 pe hou (1/2 h .
minimum).
Retu n Policy
All etu ns must eceive p io autho ization f om Palsta . Retu ned items must be eceived
in o iginal—AS SHIPPED—condition including the o iginal box, manuals, accesso ies, and
copy of sales eceipt. Retu ns must be within 14 days of pu chase. Retu ned items a e subject to
a 25% estocking fee. Shipping is not efundable.

15
Specifications
COMMANDER HF-2500 EXPORT
HF Linea Powe Amplifie
• Band Cove age: 160, 80, 40, 20, 17, 15, 12, and 10 mete amateu adio bands.
• Types of Emissions: SSB, FM, CW, AM, RTTY, SSTV.
• D iving Powe Requi ed: 20 to 90 Watts nominal at ated continuous ca ie output.
• Maximum Output Powe : 2800 Watts Continuous Ca ie .
• Duty Cycle: 50 pe cent in Amateu se vice at 2800 watts output powe
• Input impedance: 50 Ohm unbalanced
• Output Impedance: 50 Ohm unbalanced: SWR 2:1 o less
• Ha monic Supp ession: Exceeds all FCC equi ements
• Keying: Requi es contact closu e capable of sinking +5 VDC at 15 mA
• Mete ing: Plate voltage, plate cu ent, g id cu ent, and elative powe
• A.L.C.: Negative going, adjustable f om ea panel
• F ont Panel Cont ols: On/Off switch; Standby/Ope ate switch; Tune; Load; Band selecto
switch.
• Rea Panel Cont ols: Tuned input adjustment; ALC adjustment; RF input; RF output;
ALC output; Keying; g ound connection; AC powe inlet.
• Tube Complement: Th ee Eimac 3CPX800A7 pulse ated ce amic/metal t iodes.
• Cabinet Size: 18.25" W x 8.5" H x 20.75" D (46.3cm x 21.6 cm x 52.7 cm)
• Weight: 120lbs. ( 54.6 kg. ) (including t ansfo me )
• Powe Requi ement: 200/234 VAC, 50/60 Hz, 30 Ampe es

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HF-2500 Expo t TOP VIEW

17
Bottom View showing access plate
HV Powe Supply PCB Cathode and Filament Inte face PCB
Access Plate Removed

18
HF-2500 EXPORT HV Power Supply

19
AC Mains and S ep-S ar Board
/862-118

20
Con rol and Me ering Board