Palstar AT5K 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:
in [e-mail]
REV 1.6 09.02.2010
© Copyright 2010 Palstar Inc.
Printed in the U.S.A.
AT5K 3500 Watt Antenna Tuner
Owner’s Manual

WARNING: TO PREVENT FIRE OR
ELECTRICAL SHOCK DO NOT
EXPOSE TO RAIN OR MOISTURE
1. Read Instructions—All the safet and
operating instructions should be read before
the appliance is operated.
2. Retain Instructions—The safet and
operating instructions should be retained for
future reference.
3. Heed Warnings—All warnings on the
appliance should be adhered to.
4. Follow Instructions—All operating and
use instructions should be followed.
5. Cleaning—Unplug this appliance from the
wall outlet before cleaning. Do not use liquid
cleaners or aerosol cleaners. Use a damp
cloth for cleaning.
6. Do Not Use ttachments—not recom-
mended b the manufacturer or the ma
cause hazards.
7. Water and Moisture—Do not use this
product near water—for example, near a
bathtub, wash bowl, kitchen sink, laundr tub,
in a wet basement, or near a swimming pool—
and the like.
8. ccessories—Do not place this product on
an unstable cart, stand, tripod, bracket, or
table. The product ma fall, causing serious
injur to a child or adult, and serious damage
to the appliance.
9. Ventilation—This product should never be
placed near or over a radiator or heat register.
This product should not be placed in a built-in
installation such as a bookcase or rack unless
proper ventilation is provided or the manufac-
turer’s instructions have been adhered to. An
slots or openings in the cabinet are provided
for ventilation. To ensure reliable operation of
the video product and to protect it from over-
heating, these openings must not be blocked
or covered. The openings should never be
blocked b placing the product on a bed, sofa,
rug, or other similar surface.
10. Grounding or Polarization—this product
is equipped with a 3-wire line cord receptacle.
It is intended for use with a 3-wire properl
grounded power socket. Do not defeat the
safet purpose of the supplied line cord and
plug.
11. Power Sources—This product should be
operated onl from the t pe of power source
indicated on the marketing label. If ou are not
sure of the t pe of power supplied to our
home, consult our appliance dealer or local
power compan .
12. Power-cord Protection—Power-suppl
cords should be routed so the are not likel
to be walked on or pinched b items placed
upon or against them. Pa particular attention
to cords at plugs, convenience receptacles,
and the point where the exit.
13. Lightning—For added protection for this
product during a lightning storm, or when it is
left unattended and unused for long periods of
time, unplug it from the wall outlet.
WARNING: TO REDUCE THE RISK OF FIRE OR ELECTRIC SHOCK, DO NOT
EXPOSE THIS APPLIANCE TO RAIN OR MOISTURE. DO NOT
OPEN THE CABINET WHILE OPERATING. REFER SERVICING TO
QUALIFIED PERSONNEL ONLY.
CAUTION: TO PREVENT ELECTRIC SHOCK, DO NOT USE THE THREE WIRE
CORD WITH AN EXTENSION CORD RECEPTIACLE OR OTHER
OUTLET UNLESS THE BLADES CAN BE FULLY INSERTED TO
PREVENT BLADE EXPOSURE.
An appliance and cart combination should
be moved with care. Quick stops, exces-
sive force and uneven surfaces ma cause
the appliance and cart combination to
overturn.
The lightning flash with arrow head
s mbol, within an equilateral triangle, is
intended to alert the user to the presence
of uninsulated “dangerous voltage” within
the product’s enclosure that ma be of
sufficient magnitude to constitute a risk of
electric shock to persons.
The exclamation point within an equilateral
triangle is intended to alert the user to the
presence of important operating and
maintenance (servicing) instructions in the
literature accompan ing the appliance.
1-800 -773-7931 WWW.PALSTA R.COM
2 Important Safeguards
1-800- 773-7931 WWW.PALST A R.CO M
Notes 19

1-800- 773-7931 WWW.PALST A R.CO M
18 Notes
1-800 -773-7931 WWW.PALSTA R.COM
14. Power Lines—An outside antenna s s-
tem should not be located in the vicinit of
overhead power lines, other electric light or
power circuits, where it can fall into such
power lines or circuits. When installing an
outside antenna s stem, extreme care should
be taken to keep from touching such power
lines or circuits as contact with them ma be
fatal.
15. Overloading—Do not overload wall out-
lets and extension cords as this can result in a
risk of fire or electric shock.
16. Object and Liquid Entry—Never push
objects of an kind into this product through
openings as the ma touch dangerous volt-
age points or short-out parts that could result
in a fire or electric shock. Never spill liquid of
an kind on the product.
17. Servicing—Do not attempt to service this
product ourself as opening or removing
covers ma expose ou to dangerous voltage
or other hazards. Refer all servicing to quali-
fied service personnel.
18. Damage Requiring Service—Unplug this
product from the wall outlet and refer servicing
to qualified service personnel under the fol-
lowing conditions:
a. When the power-suppl cord or plug is
damaged.
b. If liquid has been spilled, or objects have
fallen into the product.
c. If the product has been exposed to rain or
water.
d. If the product does not operate normall b
following the operating instructions. Adjust
onl those controls that are covered b the
operating instructions. An improper adjust-
ment ma result in damage and will often
require extensive work b a qualified
technician to restore the product to its normal
operation.
e. If the product has been dropped or the
cabinet has been damaged.
f. When the product exhibits a distinct change
in performance—this indicates a need for
service.
19. Replacement Parts—when replacement
parts are required, be sure the service techni-
cian has used replacement parts specified b
the manufacturer or have the same character-
istics as the original parts. Unauthorized sub-
stitutes ma result in fire, electric shock or
other hazards.
20. Safety Checks—Upon completion of an
service or repairs to this product, ask the
service technician to perform safet checks to
determine that the product is in proper operat-
ing condition.
21. Outdoor ntenna Grounding—Before
attempting to install this product, be sure the
antenna or cable s stem is grounded so as to
provide some protection against voltage
surges and built-up static charges.
a. Use No.10 AWG copper, No.8AWG alumi-
num, No.17AWB copper-clad steel or bronze
wire or larger, as ground wire.
b. Secure antenna lead-in and ground wires to
house with stand-off insulators spaced from 4
feet to 6 feet apart.
c. Mount antenna discharge unit as close as
possible to where lead-in enters house.
d. A driven rod ma be used as the grounding
electrode where other t pes of electrode
s stems do not exist. Refer to the National
Electric Code, ANSI/NFPA 70-1990 for infor-
mation.
e. Use jumper wire not smaller than No.6
AWG copper or equivalent, when a separate
antenna grounding electrode is used.
Important Safeguards cont’d 3

4 Table of Contents
1-800 -773-7931 WWW.PALSTA R.COM
Important safeguards 2
Table of Contents 4
General Description 5
Installation 6
Rear Panel Connections 7
Front Panel Description 8
Schematic 10
Operating Your T5K 12
Specifications 15
Service and Warranty 16
Thank ou for purchasing a
Palstar AT5K Antenna Tuner.
This antenna tuner has been
designed and manufactured to
high qualit standards, and will
provide reliable operation for
man ears.
Please carefull read the
Owner’s Manual in order to take
advantage of the man interest-
ing features that will provide
ears of enjo able amateur
radio operation.
1-800- 773-7931 WWW.PALST A R.CO M
17
NOTE:
NOTE: The Balanced/Coax control function is as
follo s:
Button Pushed In: -Coax Feed
-LED O
Button Released Out: -Balanced Feed
-LED On

16 Serv ce and Warranty
1-800 -773-7931 WWW.PALSTA R.COM
Limited Warranty
Palstar Inc. warrants products manu-
actured by it to be ree rom de ects
in material and workmanship under
normal use and service for a period
of one (1) year from the date of
delivery to the first buyer (the
“Warranty Period”). Palstar Inc’s obli-
gation under this warranty is limited to
repair or replacement o the product;
at its option at the Palstar actory in
Piqua, OH.
E ective only when the product is
returned to the actory with all trans-
portation charges prepaid and exami-
nation o the product discloses in Pal-
star’s judgment, to have been de ective
during the Warranty Period.
The Warranty Period shall not extend
beyond its original term with respect
to interim in-warranty repairs by Pal-
star. This Warranty Period shall not
apply to any product which has been
repaired or altered by anyone other
than Palstar without prior written
authorization. Warranty does not ex-
tend to any products which have been
subject to damage rom improper in-
stallation, application or maintenance in
accordance with the operating speci i-
cation. Palstar neither assumes nor
authorizes any person to assume or it
any obligation or liability other than
herein stated.
Repair Policy
When sending in a product or service,
please include a note clearly describing
the problem, how you wish the item
returned and how you wish to pay or
the service. Our service rate is $30 per
hour (1/2 hr. minimum).
Return Policy
All returns must receive prior authori-
zation rom Palstar. Returned items
must be received in original—AS
SHIPPED– condition including the
original box, manuals, accessories, and
copy o sales receipt. Returns must be
within 14 days o purchase. Returned
items are subject to a 25% restocking
ee. Shipping is not re undable.
NOTE:
Keep the packing your
AT5K as shipped in
case a return for repair
is necessary.
If you ship the tuner in
other than the original
packing, Palstar cannot
be responsible for ship-
ping damage, and you
ill be charged $25 for
replacement packing
hen e return it to
you.
General Descr pt on 5
1-800 -773-7931 WWW.PALSTA R.COM
The Palstar AT5K Antenna
Tuner is an American made im-
pedance matching network that
can provide unbalanced and
balanced output with a power
rating of 3500 watts (single tone
continuous) and 5000 watts
PEP at certain Z ranges (p.14).
The AT5K T-matching network
utilizes a 1:1 unbalanced to bal-
anced transformer in the input of
the network. When the network
is properl tuned, a 50 Ohm im-
pedance will be presented to
both the input and output of the
balun for maximum efficienc .
The AT5K optimizes the per-
formance of our antenna and
transmitter b providing adjust-
able impedance matching using
a T-t pe circuit configuration.
The AT5K also measures the
power and Voltage Standing
Wave Ratio (VSWR) which al-
lows ou to tune the SWR to the
lowest ratio for the selected
transmission frequenc .
Integrated into the AT5K is a
frequenc -compensated lighted-
dial dual-movement SWR me-
ter. The meter features the abil-
it to read True Active Peak and
Peak Hold.
Designed to handle both Bal-
anced line feeds and Coax
feeds the AT5K features a front
panel mounted switch to select
between feeds.
Tuning is achieved with the front
panel mounted controls. The
Vernier capacitor dials allow for
tuning with precision and accu-
rac , while the Inductor crank
handle facilitates coarse adjust-
ments.

W RNING: Balanced antennas will produce high
RF voltages at the output post connectors. RF
burns may result if touched during transmission.
6 Installat on
1-800 -773-7931 WWW.PALSTA R.COM
Unpacking
Carefull remove the AT5K from the shipping carton and inspect
it for signs of damage. If an damage is apparent, notif the trans-
portation carrier or dealer immediatel . We recommend keeping
the packing carton for moving, storing or reshipping the tuner
to us for repair if required.
Location
Select a location for the AT5K that allows the connectors to be
free from an possible contact with people, pets, or objects during
operation and with unrestricted air flow for cooling.
Installation Procedures
Connect a coax cable from our transmitter to the RF INPUT
connector on the rear panel. Keep the cable as short as possible.
If ou use a linear amplifier, connect our transmitter to the linear
amplifier input and the linear amplifier output to the AT5K.
Connect coax cable from our antenna to the COAX 1 or COAX
2 connector on the rear panel. These connectors are either direct
from the transmitter or through the tuned circuit, de-pending on the
setting of the OUTPUT SELECTOR switch on the front panel.
For coax feed (unbalanced) the BALANCED/COAX switch on the
front panel must be in the OUT position. This grounds the lower
end of the roller inductor, allowing coax feed.
For a balanced feed antenna connect a balanced feed line to the
white BALANCED OUTPUT posts (back panel). Note that for bal-
anced operation, the BALANCED/COAX switch on the front panel
must be in the IN position, and an LED above the switch will light,
indicating balanced feed.
Connect a dumm load to the BYPASS connector using a coax
cable. This lets ou select the dumm load from the DIRECT/
TUNED mode switch. An antenna that does not require the use
of an antenna tuner ma be connected to the BYPASS connector,
if desired.
Spec f cat ons 15
1-800 -773-7931 WWW.PALSTA R.COM
Front Panel Indicators and Controls
Metering Dual movement cross needle power and frequenc
compensated coupler
Controls
Input Tuning Variable capacitor (600 pF, 6kV Peak)
Antenna Tuning Variable capacitor (600 pF, 6kV Peak)
Inductance 35 µH roller inductor 10 ga. plated copper wire
rated at 10 amps and 5kV
Antenna Selector Switch 6 position: Coax 1 tuned and tuner b pass;
Coax 2 tuned and tuner b pass;
B pass coax connector;
Balanced antenna
Switch wafers are ceramic (7kV/10A rated)
Power Range Switch 2 position 300 W /3000 W
Rear Panel Connectors
Coax SO239 connector (silver/gold/TFE)
Balanced Line Dual High Voltage N lon66TM terminal post
12 VDC Input For meter light and rela s -- 2.1mm conn. (center +)
Other
Frequenc Coverage 1.8 — 29.5 MHz
Power Maximum 5000 W PEP SSB, 3500 W single tone continuous
Impedance Range 10 to 2000Ω NOTE: Power Range p.14
Balanced Output 1:1 current t pe Balun at input-Ferrite
Dimensions 16” Wide x 8” High x 18” Deep (incl. terminals)
Weight 25 lbs.
Materials Chassis, brackets, and top cover are gold chem-film
coated aluminum (.090) & powder coated.
Front Panel Front panel is matte powder coated and screened.

14 Operat ng Your AT5K cont’d
4. Any time a new or di erent antenna is connected, it is necessary to repeat
the tuning procedure or the new antenna.
Troubleshooting
You hear a sp tt ng sound wh le tun ng your AT5K at h gh power.
You are probably tuning into an impedance that is on the low side (20Ω – 40Ω).
In this event, either reduce transmitter/ampli ier power to a lower setting or
change to a higher antenna impedance by using a di erent antenna or modi ying
the existing antenna.
Also, try to ind the highest capacitance setting (i.e. closer to 100 on the dial) on
the output knob. This will probably require re-adjustment o the inductance
setting.
An antenna capacitance setting that is too low under these conditions will result
in excessivly high voltages, high losses, and poor e iciency.
For example: at 1500 Watts into a 25Ω load @ 3.5Mhz will produce the
ollowing:
In the irst instance the tuner will arc and su er almost 16% loss o which 80%
will be dissipated in the roller inductor.
8 Ω − 15 Ω
Ω − 15 ΩΩ − 15 Ω
Ω − 15 Ω 1000 watts (all bands)
15 Ω − 25 Ω
Ω − 25 ΩΩ − 25 Ω
Ω − 25 Ω 1500 watts (all bands)
25 Ω − 50 Ω
Ω − 50 ΩΩ − 50 Ω
Ω − 50 Ω 3500 watts (all bands)
50 Ω − 2000 Ω
Ω − 2000 ΩΩ − 2000 Ω
Ω − 2000 Ω 160M — 3500 watts
80M - 15M—3500 watts
10M — 1500 watts (29.5 MHz max)
Po er Specifications (assuming single tone key down)
Antenna Impedance Max Po er Rating
Output Cap Inductor Voltage Loss
100pF 11.7 µH 4550 16%
200pF 6 µH 2400 8%
300pF 4 µH 1600 6%
Rear Panel Descr pt on 7
1-800 -773-7931 WWW.PALSTA R.COM
12 VDC INPUT (2.1
mm plug) or 12VDC
@ 500mA to power
the metering, lamp,
relay and an.
RF INPUT coaxial
connector or input
rom transmitter or
ampli ier.
GROUND post/wing nut
ground connector.
BALANCED OUTPUT two
nylon High Voltage post
connectors or output to RF
balanced twin-lead antennas.
Relay switched rom ront
panel control.
COAX 2 coaxial connector
or output to Antenna Two.
COAX 1 coaxial connector
or output to Antenna One.
BYPASS coaxial connector or
output to dummy load or reso-
nant antenna. Bypasses tuner,
but meter circuits are on i
12VDC adaptor is connected
to jack located on rear panel.
FIGURE 1 REAR PANEL CONNECTORS

8 Front Panel Descr pt on
1. POWER/SWR METER Dual needle meter displa s
FORWARD and REFLECTED power in watts. SWR
is measured where the two needles intersect on the
red scale.
2. PE K ND PE K/HOLD Active circuitr is used to
offer peak reading for SSB. This peak feature is
also translated to provide an approximate 2 second
hold at the peak level for eas viewing. NOTE: The
PEAK/HOLD will function onl if the PEAK button is
pressed in as well.
3. R NGE The power range is 300 watts on low and
3000 watts on high (push button in for high).
4. F N The IN position turns on the fan which cools the
internal components of the tuner when using a ser-
vice that requires constant carrier operation (for e.g.
AM or RTTY).
5. B L NCED/CO X Selects either coax feed or bal-
anced feed. A LED shows when balanced mode is
selected.
1 2 3
7 8 9 10
4 5 6
See Corrections For Balanced/COAX Settings on Page 17
Operat ng Your AT5K cont’d 13
7. Key your transmitter and adjust the power level or a reading o 100-150
watts on the FORWARD scale. Adjust the INPUT, OUTPUT and INDUC-
TOR controls or a minimum REFLECTED reading while maintaining a FOR-
WARD reading o 100-150 watts using your transmitter power control. Use
the supplied chart o approximate tuning control locations or the di erent
bands located at the back o the manual.
8. Read the SWR on the red scale at the point where the two needles intersect.
Repeat TUNING the input and antenna controls until the lowest SWR read-
ing is obtained.
This procedure takes patience the first time The input and an-
tenna controls vary the capacitors and provide fine adjustments
The roller inductor crank control provides coarse adjustment
9. When you have tuned your antenna to the best SWR, record the settings o
the INPUT, ANTENNA and INDUCTANCE controls on the chart above or
uture re erence. When you retune, use these settings as your starting point.
Notes
1. An SWR o 1:1 is best, but an SWR as high as 2:1 may be acceptable. Check
your transmitter/ampli ier manual or details.
2. I you cannot get an acceptable SWR, lengthen or shorten your antenna and/
or eedline and retune.
3. Very high or very low impedance loads are to be approached with extra cau-
tion especially when you are going to use high power and the use o an RF
analyzer (e.g. the Palstar ZM30 Antenna Analyzer) would be advisable to
check and understand the kind o load you attempting to use.
4. I you get low SWR readings at more than one setting, use the setting that
gives:
- highest FORWARD power reading
- lowest REFLECTED power reading
- uses the largest capacitance (highest number) on the OUTPUT control.
It is important to remember that consistent with low SWR indicated on the
tuner meter you must have and adjust or the largest capacitance (highest
number) on the output control to keep the losses low and the voltage that
would appear on the antenna capacitor within the 5kV rating;
I you hear a spitting sound while tuning at high power you are probably tun-
ing into an impedance that is on the low side (20Ω - 40Ω). Please see the
troubleshooting section or more detailed instructions.
CAUTION: When approaching the end stops of the
roller inductor, (readings of Zero or 229) SLOW
DOWN. Slamming the roller heel into the mechani-
cal end stops on either end of the roller inductor can
damage it.

12 Operat ng Your AT5K
Before Operating
1. To avoid possible damage to the AT5K set INPUT, OUTPUT, INDUCTOR,
and POWER RANGE switches as outlined in the chart be ore applying trans-
mitter power.
2. Begin tuning with your transmitter/lamp into the tuner set at a low output
power setting (50-150 Watts).
Tuning
1. Select the band and requency o desired operation.
2. Set TUNE and INDUCTOR controls to the suggested setting be ore applying
transmitter power (see chart). Actual settings will vary rom antenna to an-
tenna.
3. Set your transmitter/ampli ier to a low power output (100-150 watts). I your
transmitter/ampli ier combination has a LOW POWER position, select that
position to obtain the 100-150 watts or the initial tune-up.
4. Preset the INPUT, OUTPUT, and INDUCTOR values shown in the chart
supplied or each band or on the label on the ront panel. Select the type o
antenna eed you require (BALANCED or COAX) with the pushbutton on
the ront panel. Note: BALANCED shows red LED.
5. Set the POWER RANGE switch to 300 W (with POWER range switch meter
button out).
6. Set the OUTPUT SELECTOR switch to the position matching your antenna
connection. To tune your antenna, the switch selection must be set to:
COAX 1 TUNED, COAX 2 TUNED or WIRE (BALANCED ANTENNA).
Selecting COAX 1 DIRECT, COAX 2 DIRECT or BYPASS bypasses the tun-
ing selection.
WARNING: DO NOT OPERATE THE AT5K
WITH THE COVER OFF.
BAND INPUT OUPUT INDUCTOR
SUGGESTED ACTUAL SUGGESTED ACTUAL SUGGESTED ACTUAL
160 M 32 32 20
80 M 31 33 148
40 M 28 35 202
20 M 34 32 208
15 M 44 14 218
10 M 100 10 229
Note: end of the roller (max turns clock ise) is 229 = minimum in-
ductance. Maximum inductance is ZERO (0) on the mechanical
counter.
Front Panel Descr pt on 9
6. POWER ON The IN position provides power for the
Peak and Peak Hold metering circuit, rela and
meter illumination.
7. INDUCTOR 28 µH continuousl variable ceramic
roller inductor driven b a crank handle. Coupled to
the crank handle is a gear-driven precision me-
chanical counter. (Max.= 0; Min. = 229)
8. OUTPUT Continuousl adjustable output capacitor.
Min. capacitance=0. Max capacitance = 100.
9. DIRECT-TUNED MODE SWITCH Six-position rotar
switch selects an output coaxial connector.
a. DIRECT BYP SS selects BYPASS COAX connec-
tor b passing the impedance matching circuit but
providing SWR, FORWARD and REFLECTED
power meter readings.
b. DIRECT CO X 1 selects COAX 1 connector b -
passing the tuner matching circuit but providing
SWR, FORWARD and REFLECTED meter read-
ings.
c. DIRECT CO X 2 selects COAX 2 connector b -
passing the tuner matching circuit but providing
SWR, FORWARD and REFLECTED meter read-
ings.
d. TUNED CO X 1 selects COAX 1 connector
through the impedance matching T circuit.
e. TUNED CO X 2 selects COAX 2 connector
through the impedance matching T circuit.
f. TUNED B L selects the END FED WIRE connec-
tor through the impedance matching circuit. For
balanced antennas, the balanced coax switch (5)
must be IN.
10. INPUT Continuousl adjustable input capacitor.
Min. capacitance = 0. Max = 100.

10 AT5K Schemat c
AT5K Schemat c 11
Balanced Line COAX