Palstar PM5K User manual

Palstar Incorporated
9676 N. Looney Rd.,
Piqua, OH 45356 USA
Customer Service and Sales Telephone:
1-800-773-7931
Fax:
1-937-773-8003
Email:
[e-mail]
© Copyright 2007 Palstar Inc.
Printed in the U.S.A.
PM5K DigitalWattmeter
Owner’s Manual

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TABLE OF CONTENTS
Unpacking and Setup 3
Introduction 4
Quick Setup 6
Installation 7
General Operation 8
Using the PM5K –Front Panel 9
Rear Panel Connections 16
Remote Coupler Mounting 16
Directional Coupler Mounting 17
Accuracy and Calibration 17
In Case of Trouble 19
Specifications 20
Warranty 22
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Notes:

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Limited Warranty
Palstar Inc. warrants products
manufactured by it to be free from
defects in material and workman-
ship under normal use and service
for a period of three (3) years for
the AT-AUTO, AT5K, AT4K,
BT1500A, R30, and ZM30 and all
other products for one (1) year
from the date of delivery to the
first buyer (the “Warranty Period”).
Palstar Inc’s obligation under this
warranty is limited to repair or re-
placement of the product at its op-
tion at the Palstar factory in Piqua,
OH.
Effective only when the product is
returned to the factory with all trans-
portation charges prepaid and ex-
amination of the product discloses
in Palstar’s judgment, to have been
defective during the Warranty Pe-
riod.
The Warranty Period shall not ex-
tend beyond its original term with
respect to interim in-warranty re-
pairs by Palstar. This Warranty Pe-
riod shall not apply to any product
which has been repaired or altered
by anyone other than Palstar with-
out prior written authorization. War-
ranty does not extend to any prod-
ucts which have been subject to
damage from improper installation,
application or maintenance in ac-
cordance with the operating specifi-
cation. Palstar neither assumes nor
authorizes any person to assume
for it any obligation or liability other
than herein stated.
Repair Policy
When sending in a product for ser-
vice, please “double”box it carefully
and ship it insured for your protec-
tion. Please include a note clearly
describing the problem, how you
wish the item returned and how you
wish to pay for the service. Package
your radio properly. Palstar, Inc. is
not responsible for merchandise
damaged in shipment. Our service
rate is $30 per hour (1/2 hr. mini-
mum).
Return Policy
All returns must receive prior au-
thorization from Palstar. Returned
items must be received in original—
AS SHIPPED–condition including
the original box, manuals, accesso-
ries, and copy of sales receipt. Re-
turns must be within 14 days of
purchase. Returned items are sub-
ject to a 25% restocking fee. Ship-
ping is not refundable.
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UNPACKING AND SETUP
INITIAL SETUP
Unpack the PM5K. The box should contain:
· One Display Head –Black enclosure
· One Directional Coupler –Gold colored box with connectors
· One shielded interconnect cable for the coupler and display
enclosure –6 feet long
· One DC 2.1mm coaxial plug power cable –6 feet long
· One CD Rom with the LITE version of software
· Manual
If anything is missing, give us a call and we'll remedy the problem.
The PM5K consists of two major components: The Display Unit
and the Directional Coupler. The Directional Coupler is installed in
series with the output of your transmitter and antenna. A six-foot
(1.8m) cable is provided for connection between the Display Head
and the Directional Coupler. You may use a longer cable if you
wish (consult the Special Applications section later in this manual).
The PM5K uses a standard 2.1mm coaxial power plug, center
pin is + V. Make sure your power source can supply at least
600 ma of current.
Recheck your cables/adapters and fasten them down appropri-
ately. Turn on the power to the Display Head. You should see the
firmware version number displayed, and then the PM5K will go to
its normal operational state.
Note that the display will become dimmer after 2 minutes of not
sensing power, and completely dark after 10 minutes of not sens-
ing power. This feature allows you to keep the meter on all the
time and not reducethe lifetime of the display.

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Introduction
Thank you very much for purchasing the Palstar PM5K Series RF
Power/VSWR Indicator. The PM5K represents a breakthrough in
features for measurement of the performance of your transmitting
system. Microprocessor control insures fast capture time and low
power consumption. With the ability to monitor your VSWR and
power levels at all times, you will know that your transmitter, RF
source, and load, or antenna systems are operatingeffectively and
safely. In addition, the power and VSWR relay alarms can quickly
shut down your power amplifier system and alert you to the alarm
condition. This places an additional layer of protection in your
transmitting system to help preserve expensive tubes and fi-
nals. The PM5K also features the ability to be monitored and con-
trolled from a PC via the bundled software, and the unique ability
to be monitored and controlled over a LAN or from the internet.
PM5K firmware updates will be made available for download from
the Palstar website as they become available. This means that the
user can take full advantage of features or enhancements just by
installing the firmware update. No need to return the meter to the
factory for updates.
There are many features introduced in the PM5K that have not
been seen before! We are very proud of our product and are inter-
ested in learning about your experiences with this meter. We also
want to know if you have ideas about new features we can bring
forth for the meter. We have built in the ability to enhance the me-
ter with software updates that you can download from the internet.
We think you will agree that this is a totally new concept in an RF
Wattmeter, and one that should extend its lifetime for a long time
to come.
We want you to be satisfied with your purchase. If you have any
type of problem, please check the Trouble Shooting section of this
manual. If your problem persists, call our Customer Service De-
partment at 1-800-773-7931. Updates are available for download
from the Palstar website as they become available. This means
that the user can take full advantage of features or enhancements
just by installing the firmware update. No need to return the meter
to the factoryfor updates.
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1.5 –30MHz, 50-54 Mhz
50 ohms nominal, <1.05 V.S.W.R. insertion
.05 dB or less
SO-239 female (Type-N, and 7/16 DIN optional)
1 to 3,005 watts (3KW HF)
1 to 9,999 watts (10 KW HF) - Limited by
VSWR to the limits of the connector
1.00 to 99.00
< ±5% as measured against NIST traceable cali-
brated instruments (see accuracy section on
how to achieve better accuracy)
10 Bit A/D –4 overlapping channels of auto
ranging = 12 Bit effective resolution
< 10 milliseconds
< 45 milliseconds
> 30Hz
Off, 1.5, 2.0, 2.5, 3.0 –relay programmable to
open or close on trip
Off, 5, 50, 100, 250, 500, 1,000, 2,000 watts -
NC and NO relay contacts are available
Off, 175, 225, 700, 1,100, 1,600, 2,600, 3,000
.5 Ampere 50 volts AC/DC
Manual front panel (stand alone) or via RS232 –
application software
12 - 15V DC at 600 ma
-35C to +25C
Exceeds FCC Class B (tested) and CE - both
emissive and conductive (tested) as well as
EMP 4 KV and 8KV on cables
Display 8 ¼”X 3 ½ “Face, 4 ¼”Deep
Coupler 2 ¾”X 2 ¾”X 6 ½”
5 lbs (2.3 kg)

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SPECIFICATIONS
Specifications subject to change without notice.
Frequency Range
Line Impedance
Insertion Loss
Line Connections
Power Ranges
VSWR Range
Accuracy
Resolution
Peak Power Capture Time
VSWR Alarm Relay Actuation time
Bar Graph Response
VSWR Alarm
Low Power Monitor Alarm
High Power Monitor Alarm
Alarm Relay Contacts
Control
Power Required
Temperature of Operation
Regulatory Testing and Certification
Dimensions
Shipping Weight
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Write your new PM5K serial number and calibration data for
your coupler here (see coupler sticker):
Serial Number __________________________________
Date of purchase __________________________________
Copyright and Trademark Disclosure
Palstar and PM5K Wattmeter are trademarks of Palstar Inc.
The firmware for the PM5K ©2007 by Palstar Inc.
The application software for the PM5K ©2005 by D. Kinsell,
All rights and media reserved 2007.
Coupler Calibration Table
Forward Power 30MHz
Reverse Power 30 MHz
Forward Power 50 MHz
Reverse Power 50 MHz

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QUICK SETUP
If you are currently using a wattmeter in your setup, you have eve-
rything you need for a test. If you are not using a wattmeter, then
you will need a suitable jumper to connect the Directional Coupler
to your station.
Connect the Directional Coupler as follows:
Using RG-8, RG213, or RG-58 or other 50 ohm coaxial cables
SOURCE goes to your transmitter or linear amplifier (directly)
ANTENNA goes to your antenna (or tuner)
For the 5 kW PM5K or 10 kW PM10K, plug the ¼”connector into
the Directional Coupler and Display Enclosure. Supply 12V DC
power by connecting a standard 2.1 mm coaxial plug to the DC
jack in the back of the Display Enclosure. The center pin is “+”
12V DC.
The PM5K is protected against polarity reversals, but be careful
just the same. Apply 12-15 volt DC power. You should observe
that the Vacuum Fluorescent Display becomes active and the firm-
ware version number will be displayed for a few seconds, then the
unit will display the operational mode screen. You are now ready
for a test.
Simply use your normal procedure to transmit. The PM5K will give
you an instant indication of your power and VSWR. If your trans-
mitter has an internal tuner, you might want to turn it off. The in-
ternal tuner will cause a 50 ohm impedance to be presented to the
finals of your transmitter, thereby changing the characteristic im-
pedance present at the antenna jack on the transmitter. This will
affect the accuracy of the PM5K (just as it would any other meas-
uring device).
If the PM5K is functioning with a display of your forward power and
VSWR number with a bar graph to indicate relative power, you
may now proceed to program it from the front panel buttons or the
control software. If you are having other problems, refer to the
Trouble Shooting section of this manual.
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IN CASE OF TROUBLE
The PM5K is well designed and should give you many
years of trouble-free service. Most of the problems you
will encounter usually occur during installation and startup.
If the items below aren't sufficient to help you solve your
problem, please give us a call.
Unit will not come on
Check power connections. Is the unit on? DC Polarity
OK?
High VSWR displayed; no forward power displayed
Be sure that the SOURCE input to the Directional Coupler
goes to your transmitter (or amplifier).
Be sure your interconnection cable is fully seated in both
the display and coupler.
VSWR doesn't change when adjusting a tuner
Be sure that you have installed the Directional Coupler
AHEAD OF the tuner. If your rig has an internal tuner,
you should turn it off to make the most accurate measure-
ments.

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instance, if you have a 2,000 watt amplifier, chose the
2,500 watt bar graph scale. This will result in the bar
graph displaying most of the graph at this power level. At
the highest scale the meter will display a resolution of 2.4
watts, but when you’re at exciter levels of 100 watts or
less the auto range scale can display resolutions of 1 watt
even though it is resolving .09 watts in the sampling cir-
cuit. We intentionally limit the display to 1 watt incre-
ments.
The PM5K is calibrated in two segments: HF (2-30MHz)
and at 50.1 MHz. It has better then +/- 5% accuracyon
our certified calibrated lab test equipment. We provide a
calibration table on each directional coupler just like the
calibrated sensors we use from our measurement system.
The ability to program the PM5K with this calibration “trim”
data assures you that you have the best calibration possi-
ble with yourmeter. The data supplied has two ranges:
1.5 to 30 MHz –HF Range noted as30MHz on the
coupler sticker
50 MHz –6 Meter Amateur Radio Band noted as50
MHz on the coupler sticker
Program the Forward and Reverse Power trim settings in
your meter to match your coupler for the frequencies you
will use. We typically see +/- 3% accuracyat HF and
even better at the 6 meter band.
If your application calls for better accuracy on a certain
band, you can easily recalibrate the unit to suit your needs
by adjusting the forward power and reverse power trim
settings. In this case, you can enjoy enhanced accuracy
since you have calibrated exactly to your test equipment.
There are no potentiometers or variable capacitors in the
coupler or the display enclosure to adjust. The calibration
values are held in non-volatile memory.
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INSTALLATION DETAILS
DISPLAY HEAD AND COUPLER LOCATION
The Display Enclosure is designed to be either table-top or 19-inch
rack mounted with the optional rack mounting plates. You can
mount one or two meters side by side in a standard 19-inch rack
with the available mounting plates in a 2U high space. If using the
Display Enclosure as a table top or shelf mount, simply place it
into a position that is easily seen, but be careful not to place it on
top of an amplifier in a way that it blocks the cooling of your ampli-
fier. Choose a suitable location for the Directional Coupler and
mount it as well. We suggest mounting it with an adapter right at
the output of your amplifier. Be sure that you mount the Direc-
tional Coupler close enough to the Display Head so that the sup-
plied cable can reach. If you require a longer cable, any shielded
¼”“Stereo”jumper cable will suffice. If you use a longer cable, test
it for accuracy and RF immunity.
Connect a 12-15V DC power supply cable with 2.1mm plug to the
Display Head. The center pin is the “+”side of the DC power plug.
Wire your cable to a clean DC power source. Remember that
some switch mode or cheap wall warts are RF “noisy”. The Dis-
play Head is protected against polarity reversal.
DIRECTIONAL COUPLER WIRING - Since the purpose of the
PM5K is to provide an indication of the match of your antenna sys-
tem to your transmitter, it is critical that the Directional Coupler be
installed as the first element after the antenna jack on your trans-
mitter or amplifier and before a tuner. Connect from your transmit-
ter's antenna jack to the SOURCE connector on the Directional
Coupler.
The standard Directional Coupler comes with SO-239 connectors.
You can order optional “N”connectors or 7/16 Din connectors for
very high power operation.
If you are using an amplifier, install the Directional Coupler after
your amplifier. Connect the cable that goes to your antenna sys-
tem to the ANTENNA jack on the Directional Coupler. You may
use the VSWR protection circuitry if desired.

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GENERAL OPERATION
In addition to the large vacuum fluorescent display, there are two
buttons on the front of the PM5K: “Menu”and “Mode Select.”
These buttons are used to select the operational mode, and to
program the meter’s several functions such as VSWR Alarm,
Power Monitor Alarm, Auto Ranging Scales, etc.
The following discussion shows you how to operate the meter. As
we add more features, you will be able to download more options
for your meter from the Palstar website. You will also find useful
information on the Array Solutions User’s Group on the website
of our partner company Array Solutions.
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being delivered. It also keepspossible RFI causing cables away
from your transmitter, audio, data and CW circuits, therefore re-
ducing the chance of RFI and distortion to your signal.
A Power/VSWR meter that requires you to run coax to it since it
has no remote coupler means you have to mount the meter very
close to your operating position. Since you’re routing your coaxial
cables through it, you are also bringing in possible RFI that can
affect your audio, CW tone, modulation, and also your PC. The
PM5K eliminates this possible source of RFI since the signals
passed to its display head are merely DC voltages from the re-
mote coupler.
The remote mounting capability is perfect for multiple transmitter
sites, remote power sensing for tuners, PA stages, broadcast tow-
ers, etc. The ability to have the meter report alarms via the relay
closures or the software makesit a very flexible instrument for re-
mote sites as well.
Remotely controlled radio applications over the internet should find
this meter readily adaptable with the PRO application software.
DIRECTIONAL COUPLER CONNECTORS
You may order the unit with SO239 (standard) connectors, Type-
N, or 7/16 Din.
The connectorsare field replaceable if you should need to do so.
ACCURACY AND CALIBRATION
The PM5K resolves 12 equivalent bits of analog to digital data.
There are 8 sampling channels: 4 forward and 4 reverse. A cali-
bration table is generatedfor each meter that resides in the proc-
essor’s non-volatile memory for each of these channels. This al-
lows the best accuracy possible over the auto ranging scales. This
results in a display that has 1024 steps for each auto ranging
scale.
Chose your bar graph scale so that it is the best choice of
resolution for the power your equipment is running. For

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REAR PANEL CONNECTIONS
REMOTE COUPLER MOUNTING, RFI, and REMOTE SITE
INSTALLATIONS
A remote mountable directional couplervs. a Power/VSWR meter
that is all in one box is ideal since the remote coupler can be
placed very close to the amplifier or source output. The effects of
coaxial transmission line losses are then minimized, and you get a
more accurate reading of the status of your antenna and power
Coupler cable input
Power Monitor Alarm –1/8”
stereo jack, relay will close
or open depending on how
you program it, these are .5
amp 50V contacts.
Tip - normally open
Ring - normally closed
Sleeve - common
DC 12-15V –2.1
mm coaxial DC
power jack used
to supply meter
with DC power,
center pin is
“+V.”
PTT IN and PTT OUT –
Route PTT through this
connector. or an ALC
voltage to the amplifier to
shut it down fast. .5 amp
50V contacts.
RS232 –connect a
DB9 cable to a PC
com. port to program
and read the meter
with the application
software.
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USING THE PM5K
Front Panel Controls
After Power-Up, the meter enters the Normal Operation Mode
Push the mode select button to choose from:
F –Fast hold of peak power, .2 second
M –Medium hold, 1 second
S –Slow hold of peak power, 2 second
V –VSWR is displayed on BarGraph –see next page

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VSWR Bargraph Mode
Used to allow easy adjustment of a tuner for minimum VSWR. Dip
it for minimum VSWR.
Pushing the menu button again takes us to the next menu item.
VSWR Alarm Menu
Push the mode select button to select the VSWR alarm trip point:
Off
1.5
2.0
2.5
3.0
Push the mode select button to reset the VSWR alarm and LED
Pushing the menu button again takes us to the next menu item.
Alarm Polarity Menu
(This option only displays if VSWR Alarm Limit is not set to off)
Select by pushing the mode select button:
ALARM OPENS Relay
ALARM CLOSES Relay
This applies to the PTT/ALC relay only –not the Power Monitor
relay.
Pushing the menu button again takes us to the next menu item.
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Other useful aspects of the meter:
VSWR is not displayed if the forward power is less than 5 watts.
VSWR alarm function is disabled if the forward power is less than
10 watts in normal modes or less than 50 watts in VSWR dipping
mode.
The minimum displayed power is 1 watt. The maximum displayed
power is 3005 watts (3 KW HF coupler).
The call sign/message which you can program into the display can
be up to16 characterslong.
The bar graph has80 segments and auto ranges in 3 ranges.
Display will auto dim after 2 minutes and automatically turn off af-
ter 10 minutes if no power is detected. Display lifetime is 35,000
hours at maximum intensity before it will reach 50% brightness.
This is a lifetime display in normal use.
The meter can have its internal firmware updated from the serial
port connected toyour PC. Just download the latest revision of
firmware from Palstar: www.palstar.com/pm5k.php. See the LIT
software manuals on the CD for the procedure.

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Reverse Power Trim Menu
Select with mode select button to scroll from
+15% to -10%.
Set the Reverse Power Trim factor to the settings indicated on
your coupler for HF (30MHz setting). It is now possible to get bet-
ter than 5% accuracy at 50 MHz if you use the setting in the cali-
bration table for 50 MHz.
Pushing the menu button again takes us to the next menu item.
Power Display Menu
Select with mode select button:
Net Power ( Forward Power –Reverse Power)
Forward Power only ( Reverse power is not subtracted)
Selects your preferred way you chose to display power and is
shown on the digital power readout and bar graph.
Pushing the menu button again takes us to the next menu item.
RS232 Port Baud Rate Menu
Select with mode select button (highest speed recommended):
9,600
19,200
38,400
Pushing the menu button returns unit to normal operation mode.
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Low Power Alarm Menu
Push the mode select button to choose trip point in watts:
Off
5
50
100
250
500
1,000
2,000
If the peak power remains below this setting for a few seconds the
power alarm LED will light and the power monitor relay will actu-
ate.
Push the mode select button to reset the alarm and LED
Pushing the menu button again takes us to the next menu item.
High Power Alarm Menu
Push the mode select button to choose trip point in watts: 0
0 (off)
175
225
700
1,100
1,600
2,600
3,000
If the peak power exceeds this setting the power alarm LED will
flash and the power monitor relay will cycle on and off. If the
“Alarm Trips Amp”, next menu, option is selected then the VSWR
alarm LED will also flash and the PTT/ALC relay will actuate but
will not cycle.
Push the mode select button to reset the alarm and LED
Pushing the menu button again takes us to the next menu item.

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Alarm Trips Amp Menu
Select with mode select button:
Yes
No
This menu option allows the high power alarm to actuate the PTT/
ALC relay just like a VSWR alarm does.
Pushing the menu button again takes us to the next menu item.
Alarm Polarity Menu
(This option only displays if VSWR Alarm Limit is not set to off)
Select by pushing the mode select button:
ALARM OPENS Relay
ALARM CLOSES Relay
Applies to the PTT/ALC relay only not the Power Monitor relay.
Pushing the menu button again takes us to the next menu item.
Show Call Text Menu
Select with mode select button:
Yes
No
This will display your call letters or any other text you programmed
into the meter via the software application program. You must use
the software to program the call text.
Pushing the menu button again takes us to the next menu item.
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Display Intensity Menu
Range: 1 - 4 (brightest)
Select with mode select button :
1
2
3
4
Pushing the menu button again takes us to the next menu item.
Bargraph Ranges Menu
Select with mode select button:
50 250 1250
100 500 2500
200 1000 3000
400 2000 3000
Pushing the menu button again takes us to the next menu item.
Forward Power Trim Menu
Select with mode select button to scroll from
+15% to -10%.
Set the Forward Power Trim factor to the settings indicated on
your coupler for HF (30MHz setting). It is nowpossible to get bet-
ter than 5% accuracy at 50 MHz if you use the setting in the cali-
bration table for 50 MHz.
Pushing the menu button again takes us to the next menu item.