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Service Manual
COURIER ML100
MOBILE LINEAR AMPLIFIER |
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NOTICE
FCC Rules and Regulations requires that only those persons possessing a valid
First or Second Class Radio Telephone Operator's license are permitted to make
repairs or adjustments in the transmitter section of any Transceiver.
NOTE
This unit is illegal for use on the 26.965 - 27.255 MHz class
(D) Citizens Band Radio Service.
FCC Type acceptance number is: ML-100
INSTALLATION
To install the COURIER ML-100, remove the knurled screws securing the mounting
bracket. Using the mounting bracket as a template, drill the three holes for
the self-tapping screws. Secure the bracket with the self-tapping screws and
replace the COURIER ML-100 with the knurled screws.
signed for NEGATIVE ground operation only.
The COURIER ML-100 is de-
Connect the fused wire to the positive terminal of the battery with a No. 12
wire. Connect the ground wire to clean vehicle body ground.
cable between transceiver and transmitter connector of the ML-100.
the antenna cable to the antenna connector of the ML-100.
Connect a coax
Then connect
MOUNTING DIAGRAM
TO
POSITIVE FUSE
12 VOLT
BATTERY
CONNECTION
a
CHASSIS GROUND
ANTENNA
TRANSMITTER ML 100
CONNECTION DIAGRAM
FIGURE I, INSTALLATION DIAGRAMS
= ANTENNA LOAD
PLATE
© OR TUNING
® @ ® ©) ©
©. Si
Ed >
FIGURE 2, TUNING CONTROLS
PLATE COIL CHANGE
To use your ML-100 on frequencies other than PLATE en
25 - 30 MHz, disconnect plate tuning capacitor TUNING 4
(C5) lead from existing tap on 11 to tap of ni 30-38%
desired frequency range as shown in diagram 35-45=
at right. ANTENNA +9 907
TUNING 50-54
For best results use grid-drip meter to C8 = Е
find the correct tap, if power output сап-
not be obtained when tap is changed.
FIGURE 3, PLATE COIL
LOWERING POWER INPUT
The power input to the final amplifier can be lowered by changing the power
transformer output connection from Pin 4 to Pin 3. This is done on the 27.235
to 27.275 MHz band where the power input is limited to 30W. (See schematic
diagram Figure 7, notes 1 and 2.
ANTENNA OR TRANSMITTER CHANGE
For best operation all tuning procedures should be repeated after any change
of antenna or driver unit.
MAINTAIN 13.8 VDC INPUT
Measure the DC voltage at the fuse (during transmit with engine running). If
voltage is higher than 13.8 volts, adjust the voltage regulator.
INTRODUCTION
This Service Manual, together with the Owner's Instruction Manual provides a
complete set of instructions necessary to install, operate and service the
ML-100 Mobile Linear Amplifier.
The service instructions given are intended to be used by service personnel
who are familiar with communication equipment. Therefore, detailed information
on basic electronic circuitry, service procedures and test equipment setups
are not included.
SERVICE and FACTORY MAINTENANCE
Should the ML-100 Mobile Linear Amplifier require service, write or call the
FANON/COURIER Service Department, 990 South Fair Oaks Avenue, Pasadena, Cali-
fornia 91105, and request Return Authorization. When shipping the unit to
the factory, please enclose a complete description of the problem with the
unit and pack all articles well enough to withstand rough handling during ship-
ping. Follow the instructions given in the Return Authorization Form which
will be sent to you.
GENERAL DESCRIPTION
The COURIER ML-100 Mobile Linear Amplifier is designed for use with FCC accepted
Low Power transceivers operating in the 25 to 54 MHz frequency range to increase
their power output up to 60 watts.
SPECIFICATIONS
Dimensions: Tubes - 2
Width = 7-1/4"
Depth = 8-1/2" Transistors - 5
Height = 2-3/4"
Diodes - 6
Weight = 5-1/2 pounds
DC Power Consumption: At 12.6VDC
Minimum Drive Power Required: Receiving (standby): 1.2 amp
1 watt Transmit: 12 amp
Drive Power Input:
1 to 15 watts
Maximum Power Output:
60 watts
Frequency Range (With change of
taps on tank coil)
25 to 54 MHz
SERVICE ‘INSTRUCTION
The ML-100 Linear Amplifier is very easily serviced with standard test equipment.
The power supply should be adjustable so that the voltage at the amplifier may
be set to 13.6 +0.2 volts DC. A regulated power supply is recommended.
The ML-100 may be used with AM, FM or SSB (Single Side Band) transmitters.
NOTE
The maximum input power to the amplifier should
be limited to 15 watts in FM, CW and SSB Mode and
to 4 watts in AM Mode.
TEST EQUIPMENT REQUIRED
(Or Equivalent)
Driver unit capable of producing 1 and 3.5 watts at 27 MHz.
(Driver unit must be approved by the FCC).
Regulated DC Power Supply, Adjustable from 10 to 15 volts DC,
at 20 amperes.
Wattmeter, Bird Model 43.
Dummy Load, 100 watt, 50 ohm impedance.
Oscilloscope, Tektronix Model 453A.
DC Voltmeter, Simpson Model 260.
Prepare 11 feet 9 inches of RG-58/U jumper cable with PL259 connectors on each
end as shown in Figure 4, to match the transmitter to the amplifier.
UG-175/U
Г ADAPTER y 8
STEP 2 STEP 4
FIGURE 4, JUMPER CABLE FABRICATION DIAGRAM
TROUBLESHOOTING CHART
TROUBLE
PROBABLE CAUSE
Unit does not operate. a. Fuse blown.
(No RF output. No Keying. b. 51 defective.
V1 and V2 filaments do с, Cl/ shorted.
not light).
Unit does not operate. a. K2 defective.
(Relays do not operate. b. 01, 02, Q3, defective.
V1 and V2 filaments glow. с. CRI shorted.
High voltage power supply
operates. 690 to 725 volts).
(See test procedure below).
Unit does not operate. a. Relay K2 defective.
(V1 and V2 filaments glow. Ъ. (Q4 or 95, C10, 615, CI6
High voltage power supply does defective.
not operate). c. CR3, CR4, CRS or CR6
defective. (open)
d. Tl defective.
e. R11 open.
f. CRS or CR6 open.
Low RF power output. a. Vl or V2 defective.
b. Low DC power source,
less than 12 volts DC.
c. High voltage too low
(Q4 or Q5 defective).
d. CS, Cll or C12 shorted.
e. C9 defective.
DC voltage present at J2. a. C6 shorted.
Low high voltage (less than a. Q4 or Q5 defective.
690 volts). b. C9, C1S, C16 or 610
defective.
c. CRS or CR6 open.
4. Cll or Cl2 defective.
Relay chatters during modulation a. C18 open.
on SSB Mode. b. C14 or 01 defective.
c. Low DC voltage.
No reception of signals on the a. Kl contacts dirty (in
driving transceiver.
normal closed mode).
TEST PROCEDURE
High Voltage Power Supply
№
А. Remove the top cover from the ML-100 and set the POWER switch to OFF.
B. Connect a DC voltmeter positive lead to the POWER ON/OFF switch.
Connect the negative lead to the ML-100 chassis. Adjust the meter
to measure 12 to 15 volts.
Amplifier Adjustments for AM Operation
A.
Connect the ML-100 DC power leads, red (+) and white (-) to a 12.6VDC,
20 ampere DC power source. Adjust the DC voltage to obtain 12.6 volts
on the DC voltmeter.
Turn the DC power source to OFF and connect the DC voltmeter to the
12JB6 (V1 and V2) plate connectors. Adjust the meter to measure 1000
volts.
Turn the power source voltage to ON and the ML-100 POWER switch to ON.
With an insulated screwdriver or tuning wand, hold K2 (Relay RL9 closed
and measure the high voltage on the DC meter. If the high voltage
transformer Tl is wired for HIGH POWER operation, the DC voltage read-
ing should be 700 to 940 volts. If the transformer is wired for LOW
POWER operation, the DC voltage reading should be 400 to 500 volts.
See Figure 3,7 and modification notes.
Turn the power source voltage to OFF and the ML-100 POWER switch to OFF.
Connect an oscilloscope, 10:1 probe to Tl, Pin 4. Adjust the sweep to
50 usec/cm, and the vertical gain to 20 v/cm.
Turn the source power supply to ON and the ML-100 POWER switch to ON.
Hold K2 closed as in step E and observe the wave pattern shown in Fig-
ure 5. Turn the power source supply and the ML-100 to OFF.
Connect the FCC approved RF driver +
through a RG-58/U coax jumper | ES |
cable to the ML-100 input con- +
nector, Jl. HH HH HEHE HE
> 80|V
Connect an RF wattmeter terminated | En :
in 50 ohms or a PORT-A-LAB to the =-300 to 400 4 sec.»
ML-100 output connector (Antenna | L Li &]
connector). Set the meter to read Horizontal Sweep = 50 us/cm
10 watts. Vertical Amplitude = 20 v/cm
FIGURE 5
Turn the RF driver power to ON and HIGH VOLTAGE POWER SUPPLY
read the RF wattage on the watt- OSCILLATOR WAVE PATTERN
meter.
The RF driver power should be adjustable from approximately 1 watt to
3.5 watts. If a conventional transceiver is used, the carrier output
power may be varied by adjusting the DC source voltage to the trans-
ceiver.
Before turning the ML-100 POWER ON, turn the RF driver power ON and ad-
just to obtain 1 watt on the RF wattmeter.
Turn the RF driver power OFF and set the RF wattmeter to measure 50 watts.
Turn the ML-100 POWER switch to ON and allow 1 minute for the 12JB6
filaments to heat.
H. Turn the RF driver ON (Without modulation) and observe that the ML-100
relays close. An indication of RF Power should be observed on the
wattmeter. The level of power will depend upon the adjustment of the
PLATE TUNING and the ANTENNA LOADING capacitors C7 and C8.
I, While making the observation in step H, adjust the ANTENNA LOAD and
the PLATE TUNING capacitors for maximum power output as indicated on
the RF wattmeter. Adjustments are located on the right side of the
ML-100; use an insulated screwdriver.
J. Turn the RF driver and ML-100 POWER to OFF. Adjust the RF wattmeter
to measure 5 watts.
K. Turn the RF driver power ON and adjust to obtain 2 watts on the RF
wattmeter. Turn the RF driver OFF.
L. Turn the ML-100 POWER switch to ON and allow 1 minute for the unit to
Stabilize. Adjust the RF wattmeter to measure 50 watts.
M. Turn the RF driver power ON and adjust PLATE TUNING and LOAD to max-
imum RF power output on the RF wattmeter. Approximately 50 watts
should be indicated.
N. Modulate the RF driver carrier, either by voice or by a 1 KHz audio
Signal, and adjust the ANTENNA LOAD and the PLATE TUNING capacitor to
a minimum of power output drop when modulation is applied to the driver
unit. DO NOT USE THE RF INDICATOR LIGHT FOR AN INDICATION OF MAXIMUM
POWER.
Amplifier Adjustments for FM Operation
A. Connect an FCC approved FM/RF driver to the ML-100 input connector, Jl,
through a RG-58/U coax jumper cable.
B. Connect an RF wattmeter, terminated in 50 ohms, to the ML-100 antenna
connector and set the meter to measure 10 watts.
C. Turn the FM/RF driver power to ON and adjust the output to obtain 1 watt
on the RF wattmeter.
D. Turn the ML-100 power to ON and adjust the PLATE TUNING and the ANTENNA
LOADING capacitors for maximum output indication on the wattmeter.
POWER OUTPUT TABLE
Input Watts Output Watts
1 16.5
2 32
3. 48
(Readings taken from a typical production unit)
cS
CIS a Q 4 ClO QS
CI6
CR3
R7
: Fe | 3
[R8
TOROID
RQ TRANSFORMER
RIO ré
Е -^ мини |; | PLATE
; т .
val
ANTENNA
LOAD ADJ.
a C8
PLATE
COIL
L |
CI8
CHI RF OUTPUT
CONNECTOR
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RS RELAY POWER
11 R3 K2 ON/OFF:
RF INDICATOR LIGHT SWITCH
| S |
FIGURE 6, COMPONENT LOCATION DIAGRAM
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119
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4
SYMBOL
Q1,2
03
04,5
L1
dd
CH1 , 2
Kl
K2
C2
63.15.18
С9,11,12
C14
Cl
C4
C5,10
C6
C14
С15,16
C7
C8
51
CR1
CR2,3,4,5,6
V1,2
21
31,2
Fl
REPLACEMENT PARTS LIST
DESCRIPTION COURIER PART NUMBER
TRANSISTORS
2N3567 TR6
2N4037 TR38
TR43B TR43B
CHOKES, COILS and TRANSFORMERS
Pl Network C020
Transformer Toroid TP10
RF Choke, Ohmite Z-50 CH14
RELAYS
12 volt DC, 120 ohm 5 amp. DPDT RL15
12 volt, DPDT RL9
CAPACITORS
imfd, 25WV Tantalum CESZ
10mfd, 25WV Electrolytic CE6
10mfd, 450WV " CE28
2000mfd, 25WV |! СЕЗ9
7mfd, 500V Disc CG]?
5mfd, " Ceramic Disc CC15
0.002mfd, 2KV " ds CC3/
0.001mfd, 3KV " " CCT 1
O.lmfd, 25V à ds CC93
0.0lmfd, 500V "' a CCS
45pfd, Variable Ceramic CV3
100-500pfd, Ceramic (air) CV25
SWITCHES
DPDT Toggle SW1
DIODES
IN662 DI3
IN4005, 600PIV, 1 amp RE7
TUBES
12JB6A TU12JB6
MISCELLANEOUS
Tube Socket e, 5014
Light Bulb 65mA | BUS
Light Bulb cap (Red) N Bull
Transistor Socket S013
Transistor Insulator, for TR43B WA4
Antenna Connector S0239 CN1
Fuse holder and 72' leads FH5
Fuse, 20 amp FUS
| O
SYMBOL
REPLACEMENT PARTS LIST
DESCRIPTION
MISCELLANEOUS
Terminal Strip
Terminal Strip
Tube Plate Clip
Nylon Screw #10/32 x 3/8"
Thumb Screw, for Mtg. Bracket
Case, Top
Heat Sink, Right
Heat Sink, Left
Bezel
Mounting Bracket
COURIER PART NUMBER
TS4231
TSL5232
HS23
HS24
HS 37
MS85
MS89R
MS89L
MS90
MS 20K
STANDARD WARRANTY
Adopted and Recommended by Electronic
Industries Association
FANON/COURIER CORPORATION warrants each new electronic
product manufactured by it to be free from defective material and
workmanship and agrees to remedy any such defect or to furnish a
new part (at the Company's option) in exchange for any part of any
unit of its manufacture which under normal installation, use and service
disclosed such defect; provided the unit is delivered by the owner to
us or to our authorized distributor from whom purchased, or authorized
service station, intact, for our examination, with all transportation
charges prepaid to our factory, within 90 days from the date of sale
to original purchaser and provided that such examination discloses, in
our judgment, that it is thus defective.
Written authorization must be obtained before any merchandise is
returned to the factory.
This warranty does not extend to any of our electronic products
which have been subjected to misuse, neglect, accident, incorrect wiring
not our own, improper installation, unauthorized modifications, or to
use in violation of instructions furnished by us, nor units which have
been repaired or altered outside of our factory, nor to cases where the
serial number thereof has been removed, defaced or changed, nor to
accessories used therewith not of our own manufacture.
This warranty is in lieu of all warranties expressed or implied and
no representative or person is authorized to assume for us any other
liability in connection with the sale of our electronic products.
990 SOUTH FAIR OAKS AVENUE
PASADENA, CALIFORNIA 91105
SUBSIDIARY OF
RESDEL INDUSTRIES
FANON/COURIER CORPORATION
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