Yaesu VL-1000 Manual

VL-1000
HF & 50-MHz Band Linear Amplifier
Technical Supplement
(Includes AC Power Supply VP-1000)
VERTEX STANDARD CO., LTD.
4-8-8 Nakameguro, Meguro-Ku, Tokyo 153-8644, Japan
VERTEX STANDARD
US Headquarters
10900 Walker Street, Cypress, CA 90630, U.S.A.
YAESU EUROPE B.V.
P.O. Box 75525, 1118 ZN Schiphol, The Netherlands
YAESU UK LTD.
Unit 12, Sun Valley Business Park, Winnall Close
Winchester, Hampshire, SO23 0LB, U.K.
VERTEX STANDARD HK LTD.
Unit 5, 20/F., Seaview Centre, 139-141 Hoi Bun Road,
Kwun Tong, Kowloon, Hong Kong




Cut out the label at the right, and place it behind the
clear plastic window in the spine of a binder.
Contents
Introduction .......................................................................................................... 1-1
Specifications........................................................................................................ 1-2
Chip Component Information ........................................................................... 1-3
Mechanical Details (Exploded Views & Mechanical Parts) ........................ 2-1
VL-1000 .................................................................................................................................... 2-1
VP-1000..................................................................................................................................... 2-3
Alignment .............................................................................................................. 3-1
Block & Interconnection Diagrams .................................................................. 4-1
PCB Diagrams & Parts List
CNTL Unit ............................................................................................................................ 5A-1
Tuner Unit ............................................................................................................................. 5B-1
LPF Unit ................................................................................................................................ 5C-1
Divider Unit ......................................................................................................................... 5D-1
PA Unit ................................................................................................................................... 5E-1
Display Unit .......................................................................................................................... 5F-1
ANT-SW Unit ....................................................................................................................... 5G-1
Connector Unit..................................................................................................................... 5H-1
Liner-Filter Unit ................................................................................................................... 5 I -1
Sensor Unit ........................................................................................................................... 5 J -1
Jack Unit ................................................................................................................................ 5K-1
Relay Unit .............................................................................................................................. 5L-1
AC Power Supply VP-1000 PCB Diagrams & Parts List
Filter Unit .............................................................................................................................. 6A-1
Power Supply Unit PB1 ....................................................................................................... 6B-1
Power Supply Unit PB2 ...................................................................................................... 6C-1
VL-1000
Technical Supplement

VL-1000 Technical Supplement
Introduction
covered by warranty. For the major circuit
boards, each side of the board is identified by
the type of the majority of components installed
on that side. In most cases one side has only chip
components, and the other has either a mixture
of both chip and lead components (trimmers,
coils, electrolytic capacitors, packaged ICs, etc.),
or lead components only.
While we believe the technical information in
this manual is correct, Yaesu assumes no liabili-
ty for damage that may occur as a result of typo-
graphical or other errors that may be present.
Your cooperation in pointing out any inconsis-
tencies in the technical information would be
appreciated. Yaesu Musen reserves the right to
make changes in this transceiver and the align-
ment procedures, in the interest of technological
improvement, without notification of owners.
This manual provides technical information
necessary for servicing the Yaesu VL-1000 HF &
50-MHz-Band Linear Amplifier. It does not in-
clude information on installation and operation,
which are described in the VL-1000 Operating
Manual provided with the transceiver, or on ac-
cessories which are described in their manuals.
The VL-1000 is carefully designed to allow the
knowledgeable operator to make nearly all ad-
justments required for various station conditions,
modes and operator preferences simply from the
controls on the panels, without opening the case
of the Linear Amplifier. The VL-1000 Operating
Manual describes these adjustments, plus certain
internal settings.
Servicing this equipment requires expertise in
handling surface mount chip components. At-
tempts by unqualified persons to service this
equipment may result in permanent damage not

VL-1000 Technical Supplement
Specifications
VL-1000 Specifications
General
Frequency Coverage:
Power Output:
Continuous Transmission Period:
Case Size (WHD):
Weight (Approx.):
Supply Voltage:
Power Consumption (Max.):
Linear Amplifier Section
Excitation Power:
ALC Voltage (output) Range:
Spurious Radiation:
Third-order IMD:
Input/Output Impedance:
Automatic Antenna Tuner Section
Impedance Matching Range:
Frequency Range:
Matching Time:
Matched SWR:
Tuning Memory Register:
VP-1000 Specifications
Output Voltage:
Output Current:
Input Voltage:
Current Consumption:
Operating Temperature Range:
Case Size:
Weight:
160 ~ 6 Meter Amateur Bands
(USA Version: 160 ~ 15, 6 Meter Amateur Bands)
1000 Watts @ 220V AC Input to VP-1000 Power Supply
100% @ 500 W for 1 hour
410 ×135 ×410 mm
21 kg
+48 VDC, +12 VDC, –12 VDC
48 A @ +48 VDC, 3 A @ +12 VDC, 0.1 A @ –12 VDC
50 ~ 80 Watts
0 ~ –10 V (Nominal –4 V @ 1000 W output)
less than –60 dB
less than –30 dB @ 1000 W PEP (Typical)
50 Ohms, unbalanced
16 ~ 150 Ohms, unbalanced
160 ~ 6 Meter Amateur Bands
less than 10 seconds
1.5:1 or better
50 channels
+48 VDC, +12 VDC, –12 VDC
+48 V: 48 Amps
+12V: 3 Amps
–12V: 0.1 Amps
100 ~ 234 VAC, 50/60 Hz
14 Amps @ 200/220/234 VAC Input
18 Amps @ 100/117 VAC Input
–10 °C ~ +50 °C
410 ×135 ×369 mm (W ×H ×D)
13.5 kg (Approx.)

VL-1000 Technical Supplement
Chip Component Information
(Unit: mm)
Type L W H
P 2.0 1.25 1.2
A 3.2 1.6 1.6
B 3.4 2.8 1.9
C 5.8 3.2 2.3
Examples: 100=10Ω
222=2.2kΩ
473=47kΩ
Marking* 100, 222, 473...
473
Tens Ones Multiplier
0 0 100
1 1 101
2 2 102
3 3 103
4 4 104
5 5 105
6 6 106
7 7 107
8 8 108
9 9 109
(Unit: mm)
Type L W H
1/10 2.0 1.25 0.5
1/16 1.6 0.8 0.45
1/16S 1.0 0.5 0.35
(Unit: mm)
Type L W H
2125 2.0 1.25 0.35 ~ 0.5
1608 1.6 0.8 0.65 ~ 0.95
1005 1.0 0.5 0.45 ~ 0.55
The diagrams below indicate some of the dis-
tinguishing features of common chip compo-
nents .
Capacitors
Tantalum Capacitors
Resistors
Indicated Letters

VL-1000 Technical Supplement
Chip Component Information
Replacing Chip Components
Chip components are installed at the factory
by a series of robots. The first one places a small
spot of adhesive resin at the location where each
part is to be installed, and later robots handle
and place parts using vacuum suction.
For single sided boards, solder paste is applied
and the board is then baked to harden the resin
and flow the solder. For double sided boards, no
solder paste is applied, but the board is baked
(or exposed to ultra-violet light) to cure the resin
before dip soldering.
In our laboratories and service shops, small
quantities of chip components are mounted man-
ually by applying a spot of resin, placing the com-
ponents with tweezers, and then soldering by
very small dual streams of hot air (without phys-
ical contact during soldering). We remove parts
by first removing solder using a vacuum suction
iron, which applies a light steady vacuum at the
iron tip, and then breaking the adhesive with
tweezers.
Special vacuum/desoldering equipment is
recommended if you expect to do a lot of chip
replacements. Otherwise, it is usually possible
to remove and replace chip components with
only a tapered, temperature-controlled solder-
ing iron, a set of tweezers and braided copper
solder wick. Soldering iron temperature should
be below 280°C (536°F).
Precautions for Chip Replacement
 Do not disconnect a chip forcefully, or the
foil pattern may peel off the board.
 Never re-use a chip component. Dispose of
all removed chip components immediate-
ly to avoid mixing with new parts.
 Limit soldering time to 3 seconds or less to
avoid damaging the component and board.
Removing Chip Components
 Remove the solder at each joint, one joint at a
time, using solder wick whetted with nona-
cidic fluxes as shown below. Avoid applying
pressure, and do not attempt to remove tin-
ning from the chip’s electrode.
 Grasp the chip on both sides with tweezers,
and gently twist the tweezers back and forth
(to break the adhesive bond) while alternate-
ly heating each electrode. Be careful to avoid
peeling the foil traces from the board.
Dispose of the chip when removed.
 After removing the chip, use the copper braid
and soldering iron to wick away any excess
solder and smooth the land for installation of
the replacement part.

VL-1000 Technical Supplement
Chip Component Information
Installing a Replacement Chip
As the value of some chip components is not
indicated on the body of the chip, be careful to
get the right part for replacement.
 Apply a small amount of solder to the land
on one side where the chip is to be installed.
Avoid too much solder, which may cause
bridging (shorting to other parts).
 Hold the chip with tweezers in the desired
position, and apply the soldering iron with a
motion line as indicated by the arrow in the
diagram below. Do not apply heat for more
than 3 seconds.
 Remove the tweezers and solder the electrode
on the other side in the manner just described.

VL-1000 Technical Supplement
Chip Component Information
Notes:

VL-1000 Technical Supplement
VL-1000 Exploded View & Miscellaneous Parts
Non-designated parts are available
only as part of a designated assembly.
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
YAESU P/N
U00306002
U00520002
U02304001
U02315001
U02406007
U03306001
U03308001
U03325007
U03450002
U04306001
U04306002
U04310002
U05306002
U20406007
U22416007
U24306001
U30312001
U34306001
U44308002
U44406001
U60300301
U65500102
U66300001
U66300002
U66400001
U66500002
U70005002
U73005002
Description
PAN HEAD SCREW M3×6Ni
PAN HEAD SCREW M5×20Ni
SEMS SCREW SM3×4
SEMS SCREW SM3×15
SEMS SCREW SM4×6B
SEMS SCREW ASM3×6
SEMS SCREW ASM3×8
SEMS SCREW ASM3×25B
PAN HEAD SCREW ASM4×50Ni
SEMS SCREW HSM3×6
SEMS SCREW HSM3×6Ni
SEMS SCREW HSM3×10Ni
CAP SCREW TM3×6Ni
BINDING HEAD SCREW M4×6B
SEMS SCREW HM4×16B
TAPTITE SCREW M3×6
FLAT HEAD SCREW M3×12
TAPTITE SCREW M3×6
TAPTITE SCREW M3×8Ni
TAPTITE SCREW M4×6
HEX NUT N3
WING NUT N5Ni
FLANGE NUT N3
FLANGE NUT N3Ni
FLANGE NUT N4
FLANGE NUT N5Ni
PLAIN WASHER FW5Ni
TOOTHED LOCK WASHER IW5Ni
Qty.
2
1
6
14
6
1
1
2
8
79
2
5
4
26
2
52
12
4
24
3
1
1
4
5
8
1
2
2
RA002870A
BOTTOM CASE
Display Unit
RA0027400
NET (2pcs)
RA0056700
BLIND SHEET (2pcs)
RA002730A
WINDOW
RA002720A
PUSH KNOB
RA0054900
SUB PANEL
RA0038100
FRONT PANEL
RA0052500
PUSH KNOB (12pcs)
S4000042
CASE LEG (2pcs)
R3514220
LEG (2pcs)
R3133080
COLLAR (2pcs) R0133740
COIL SPRING (2pcs)
R3514230
CASE LEG (2pcs)
RA0028600
TOP CASE
CNTL Unit
R7133800
WASHER (2pcs)

VL-1000 Technical Supplement
VL-1000 Exploded View & Miscellaneous Parts
Non-designated parts are available
only as part of a designated assembly.
M2190024
STEPPING MOTOR (2pcs)
K90000051
VARIABLE CAPACITOR 200pF (2pcs)
M2090022
FAN
PA Unit (2pcs)
M2090021
FAN (2pcs)
Connector Unit
ANT-SW Unit
RA0028300
REAR FRAME
S5000202
FAN COVER (2pcs)
P1090984
CONNECTOR (2pcs)
Jack Unit
Divider Unit
Tuner Unit
LPF Unit
Line-Filter Unit
T9206667
T9206667A (Lot. 2~)
T9206667B (Lot. 5~)
WIRE ASS'Y
R6124610
SUPPORT (12pcs)
T9206666
T9206666A (Lot. 5~)
WIRE ASS'Y

VL-1000 Technical Supplement
Alignment
Introduction
The following procedures cover adjustments that
are not normally required once the amplifier has left
the factory. However, if damage occurs and some
partsmust be replaced, realignment may berequired.
If a sudden problem occurs during otherwise normal
operation, it is most likely due to component failure;
realignment should, therefore, not be attempted un-
less normal amplifier operation is thoroughly under-
stood, the cause of the malfunction has been clearly
diagnosed to involve part failure, and the faulty com-
ponent has been located and replaced.
We recommend that servicing be performed by
authorized Yaesu service technicians, who are ex-
perienced with the circuitry and fully equipped for
repair and alignment. If a fault is suspected, con-
tact the dealer from whom you purchased the am-
plifier for instructions regarding repair. Authorized
Yaesu service technicians will, at the completion of
the repair process, perform a complete performance
check to ensure compliance with all factory specifi-
cations.
Those who undertake any of the following align-
ment procedures are cautioned that they are doing so
at their own risk. Problems caused by unauthorized
attempts at realignment are not covered by the war-
ranty covering this product. Also, Yaesu must neces-
sarily reserve the right to change circuits and/or align-
ment procedures, in the interest of improved perfor-
mance, without notifying owners.
Required Test Equipment
The following test equipment (and thorough fa-
miliarity with its correct use) is necessary for com-
plete realignment. Correction of problems caused by
misalignment resulting from unauthorized adjust-
ments and/or made with improper test equipment is
not covered by our warranty. Although most align-
ment procedures documented below do not require
all of the listed test equipment at any one time, the
interaction of some adjustments may require that
more complex procedures must be accomplished lat-
er. Do not attempt to perform only a single step un-
less it clearly is isolated electrically from all other
steps. It is better to have all test equipment ready
from the beginning, and follow all of the steps in a
section in the order they are presented.
The following test equipment is required:
ÌVP-1000 Matching Power Supply
ÌFT-920 or other 100W transceiver
ÌDC Ammeter
ÌControl Cables
ÌALC (RCA-RCA) Cable
ÌIn-line Wattmeter (50 Ω, 2 kW)
(Connect between Antenna Jack 1 and 50 Ω
Dummy Load)
Ì50 ΩDummy Load (2 kW)
(Connect to In-Line Wattmeter)
Ì75 ΩDummy Load (2 kW)
(Connect to Antenna Jack 2)
Preparation & Precautions
A 50 ΩDummy Load and the in-line Wattmeter
must be connected to Antenna Jack 1 during most
all procedures (except for the Reverse ALC Adjust-
ment procedure, which utilizes a 75 ΩDummy Load,
which can be connected to Antenna Jack 2). Correct
alignment is not possible using an antenna. Except
where specified otherwise, the exciting transceiver
should be set to 14.2500 MHz, FM or (key-down)
CW mode, and the VL-1000 controls should be pre-
set as indicated:
ÌOPERATE and REMOTE switches: both ON.
ÌDIM, LOW, ATT, and TUNER: all OFF.
ÌDISPLAY SELECT: MULTI-METER 1.

VL-1000 Technical Supplement
Alignment
Read each step to determine if the same test
equipment used in the previous step will be required.
If not, remove the test equipment (except the Dum-
my Load and Wattmeter) before proceeding.
The in-line Wattmeter is not used for any specif-
ic alignment procedure. However, it is extremely
useful for the purpose of verifying proper signal
flow from the rear panel antenna jacks.
Correct alignment requires that the ambient tem-
perature of the VL-1000, the exciter, and the test equip-
ment all be the same, and that this temperature should
be between 20° and 30° C (68° ~ 86° F). If any equip-
ment is brought into the shop from an environment
that is hotter or colder than this temperature range, it
should be allowed time for thermal equalization be-
fore alignment is begun.
Amplifier alignment must only be performed
with all circuit boards firmly in place. All voltages
shown in alignment procedures are nominal (±10%
tolerance).
PA Unit Idling Current
The adjustment of the PA Idling Current must
be performed twice, as there are two identical 500W
PA Units in the VL-1000. When performing align-
ment steps, be certain that you confine your work
to one PA Unit at a time.
ÌWith the transceiver, power supply, and ampli-
fier all turned off, connect all interconnection
cables required for normal operation. Connect
the DC Ammeter in the +48-Volt line between
the VL-1000 and VP-1000.
ÌWith the front panel of the VL-1000 facing to-
ward you, align the PA Unit on the left side of
the amplifier (immediately behind the left fan)
first; after completing this alignment, repeat the
process on the right PA Unit, as instructed be-
low.
ÌDisconnect the wires connected to J5001 and
J5007 of the right PA Unit, and move them safe-
ly out of the way.
ÌTurn on the power supply, amplifier, and trans-
ceiver. Preset VR5001, VR5002, VR5003 and
VR5004 on the left PA Unit fully counterclock-
wise. Key the transmitter in the SSB mode (with
zero drive power), and adjust VR5003 for 210 mA,
VR5004 for 400 mA,VR5001 for 610 mA, and
VR5002 for 800 mA on the DC Ammeter. Try to
make these adjustments in order, and as quick-
ly as possible. When done, turn off the power
supply, amplifier, and transceiver.
ÌNow remove both +48V wires (one each from
J5001 and J5007) from the left PA Unit.
ÌThe next steps will be performed on the right PA
Unit.
ÌConnect both +48V wires (one each to J5001 and
J5007) on the right PA Unit. Turn on the power
supply, amplifier, and transceiver. Preset
VR5001, VR5002, VR5003 and VR5004 on the
right PA Unit fully counterclockwise. Key the
transmitter in the SSB mode (with zero drive
power), and adjust VR5003 for 210 mA, VR5004
for 400 mA,VR5001 for 610 mA, and VR5002
for 800 mA on the DC Ammeter. Try to make
these adjustments in order, and as quickly as
possible.
ÌNow connect both +48V wires (one each to J5001
and J5007) on the left PA Unit. All +48V wires
should now be connected on both PA Units.

VL-1000 Technical Supplement
Alignment
Forward ALC Adjustment (High Power)
ÌTune the transceiver to 14.050 MHz, FM mode,
and set the DRIVE or RF PWR control fully
clockwise.
ÌPress and hold in the INPUT switch on the front
panel of the VL-1000 for ½ second. This initiates
the “ALC Alignment” mode.
ÌStart with the transceiver’s DRIVE or RF PWR
control fully counter-clockwise, then rotate the
DRIVE or RF PWR control to the fully clock-
wise position while transmitting.
ÌIf the power output from the amplifier (as dis-
played on the AVG PWR meter) does not reach
1000 W because of the effect of the VL-1000’s ALC
voltage at full excited drive, keep the transceiv-
er’s DRIVE or RF PWR control fully clockwise,
then press and hold in the DISPLAY 2 key until
the power output from the amplifier reaches 1000
Watts.
ÌIf, on the other hand, the ALC voltage from the
VL-1000 does not cause the exciter drive to be
controlled such that the power output from the
amplifier limits at 1000 Watts, reduce the setting
of the DRIVE or RF PWR control to that the out-
put power is 1000 Watts. Now press and hold in
the DISPLAY 2 key until you observe the ampli-
fier output just begin to fall below 1000 Watts. At
this point, advance the DRIVE or RF PWR con-
trol fully clockwise, and press/hold in the DIS-
PLAY 1 or DISPLAY 2 key so as to achieve 1000
Watts of power output.
ÌIf the above adjustments are not successful, it is
possible that the Forward ALC potentiometer,
VR1001, is maladjusted. While transmitting,
slowly rotate VR1001 in the direction that pro-
vides improved output control (either more or
less ALC voltage, as observed on the transceiv-
er’s ALC meter). When 1000 Watts of output
VR5004: Idling Current (800 mA)
VR5003: Idling Current (610 mA)
VR5002: Idling Current (800 mA)
VR5001: Idling Current (610 mA)
J5001: Remove this wire when adjusting the other PA Unit
J5007: Remove this wire when adjusting the other PA Unit
PA Unit Alignment Points

VL-1000 Technical Supplement
Alignment
VR1002: Reverse ALC (Slight power turn-down into 75Ωdummy load)
VR1001: Forward ALC (High Power)
(PO=1000 W on AVG PWR meter)
CNTL Unit Alignment Points
powerare obtained, the FT-920 transceiver’sALC
meter should have six bars illuminated. Other
transceiversshouldshow mid-scale indication on
their ALC meter.
ÌUnkey the transmitter when adjustment is suc-
cessful. Now press and hold in the INPUT switch
on the VL-1000 front panel for ½ second to exit
the ALC alignment mode.
ÌIf your VL-1000 is after prod. lot 002, key the
transmitter with the DRIVE or RF PWR con-
trol fully clockwise, adjust VR2001 for 1000 Watts
on the AVG PWR meter.
Forward ALC Adjustment (Low Power)
ÌThe transceiver should be left at 50.100 MHz in
the FM mode, with the transceiver’s DRIVE or
RF PWR control fully clockwise.
ÌPress the LOW switch on the front panel of the
VL-1000. Now press and hold in the INPUT
switch for ½ second so as to enter the “ALC Align-
ment” mode once again.
ÌKey the transmitter, and press the DISPLAY 1
(to increase the power) or the DISPLAY 2 key
(to decrease the power) so as to achieve 500
Watts output power as displayed on the AVG
PWR meter.
ÌReturn the transceiver to the receive mode. Press
and hold in the INPUT switch for ½ second to
exit the ALC Alignment mode.
Reverse ALC Adjustment
ÌPress the ANT switch on the front panel to select
ANTENNA 2 (to which the 75 Ωdummy load is
connected).
ÌWith the transceiver still set to 50.100 MHz in
the FM mode, set the DRIVE or RF PWR con-
trol of the transceiver fully clockwise. If neces-
sary, press the LOW switch to select high power
operation.
ÌPress and hold in the INPUT switch for ½ sec-
ond to enter the “ALC Alignment” mode.

VL-1000 Technical Supplement
Alignment
ÌKey the transmitter, and adjust VR1002 such that
the power output (as indicated on the AVG PWR
meter) just begins to fall below 1000 Watts of
power output. You may also watch the exciter’s
ALC meter, and adjust VR1002 to the point
where the ALC meter just begins to deflect be-
yond the point set in the “Forward ALC” sec-
tion. This sets the threshold for SWR protection
at 1.5:1 SWR.
ÌUnkey the transmitter, and press and hold in
the INPUT switch for ½ second to exit the ALC
Alignment mode.
Antenna Tuner Variable Capacitor Alignment
If a new Antenna Tuner Unit must be installed,
or if the tuning capacitors and/or motors must be
replaced, the position of the capacitors on the mo-
tor shafts must be aligned. The procedure is auto-
mated, and follows this simple procedure. Start with
the VL-1000 turned off.
ÌLoosen the two screws affixing each variable ca-
pacitor to the motor shafts. Be sure that both
variable capacitors rotate freely on the shaft.
ÌWith the amplifier off, press and hold in the OP-
ERATE and DIM switches; while holding them in,
turn the VL-1000 power on. Release the switches;
the motors will rotate to a “Reset” position.
ÌOnly one screw on each motor shaft coupling
will be easily accessible at this point; tighten these
screws snugly.
ÌWith the TUNER switch set to on, switch the
amplifier to the 10 MHz band by pressing the
“10 MHz” band key on the transceiver.
ÌThe motors will now rotate approximately 90
degrees, allowing access to the remaining two
shaft coupling screws (one on each shaft). Tight-
en these screws snugly. Capacitor alignment is
now complete.

VL-1000 Technical Supplement
Alignment
Notes: