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G8MNY > TECH 07.03.26 19:25l 448 Lines 25160 Bytes #8 (0) @ WW
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From: G8MNY@GB7CIP.#32.GBR.EURO
To : TECH@WW
By G8MNY (Updated Oct 24)
(8 Bit ASCII graphics use code page 437 or 850, Terminal Font)
A few years ago I bought an old large commercial Trans World Electronics Inc,
12V HF Amp, for "MEDIUM POWER Air/Ship/Army" use, at a local ham junk sale.
(actually used in BBC Engineering Vans, and cost around 2k UKP in 1977 & 3k5
with PSU). Zane M1BFI says they are also badged as Metron & AEL.
///////////////////////ｳ 2-30MHz, 4x 150W push pull amps in parallel.
/////////////////////// ｳ > 10dB gain, 70W max drive. (typical 15-40W)
/////////////////////// /ｳ IMD 3rd Order >-32dB @-500W, >-36dB @ 400W.
/////////////////////// / ｳ PA harmonics to better than -43dB.
/////////////////////// / ｳ 13.6V @ 75 Amps needed for full 600W output!
/////////////////////// / / 1kW DC input, Infinite SWR rated, <2:1 recom.
ｳｳｳｳｳｳｳｳｳｳｳｳｳｳｳｳｳｳｳｳｳｳｳｳ / / 15A charger & car battery will power it (SSB).
ﾚﾁﾁﾁﾁﾁﾁﾁﾁﾁﾁﾁﾁﾁﾁﾁﾁﾁﾁﾁﾁﾁﾁﾁﾁｿ / Thermal 70 heatsink shutdown. CW/SSB use!
ｳT500M __ ____ ｳ / Over current 75A trip (high SWR & over drive).
ｳ o<� [__] [____] ｳ/ Manual & Remote operation (On & Band select).
ﾀﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾙ Weight 8kg.
It was cheap as it had a fault, it came with the handbook, so I expected a
problem or two. On examination it basically worked OK "no blown amps", but it
had a faulty band switch. That was just a "light contact" on the double pole 6
way switch, causing non operation, due to no "band filter relays selected" (no
RF output path!) and easily fixed by bending the contact, once the switch was
stripped right down.
S C H E M A T I C
Rx & through path
1 DriveﾚﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄｿAnt
RIG____/ ﾚﾄﾄﾄﾄﾄｿ50Rﾚﾄﾄﾄﾄﾄﾄﾄﾄｿ ﾚﾄﾄﾄﾄﾄﾄﾄﾄｿ50R ﾚﾄﾄﾄﾄﾄﾄｿ \___ANT
|ﾀﾄﾄﾄｴAttenﾃﾄﾄﾄｴSplitterｳ ｳCombinerﾃﾄﾄﾄﾄﾂﾄ/ﾄｴFilterﾃﾄ\ﾄﾂﾙ|
| 70Wﾀﾄﾄﾄﾄﾄﾙ30Wﾀﾄﾂﾄﾂﾄﾂﾄﾂﾙ ﾚﾄﾄﾄｿ ﾀﾂﾄﾂﾄﾂﾄﾂﾄﾙ600Wｳ | ﾀﾄﾄﾄﾄﾄﾄﾙ | ｳ |ptt
| Max Max ｳ ｳ ｳ ﾀﾄﾄｴPA1ﾃﾄﾄﾙ ｳ ｳ ｳ ｳ ﾚﾄﾄﾄﾄﾄﾄｿ ｳ
| ｳ ｳ ｳ200Rﾀﾄﾄﾄﾙ200Rｳ ｳ ｳ ﾃﾄ/ﾄｴFilterﾃﾄ\ﾄｴ
| ｳ ｳ ｳ ﾚﾄﾄﾄｿ ｳ ｳ ｳ ｳ | ﾀﾄﾄﾄﾄﾄﾄﾙ | ｳ
PTT>ﾄﾄﾄﾙ Drive ﾚﾄﾄﾄﾄｿ ｳ ｳ ﾀﾄﾄﾄﾄｴPA2ﾃﾄﾄﾄﾄﾙ ｳ ｳ ｳ ﾚﾄﾄﾄﾄﾄﾄｿ ｳ
/ﾄｴBiasﾃﾄ> ｳ ｳ 200Rﾀﾄﾄﾄﾙ200R ｳ ｳ ﾃﾄ/ﾄｴFilterﾃﾄ\ﾄｴ
ｳ ﾀﾄﾄﾄﾄﾙ ｳ ｳ ﾚﾄﾄﾄｿ ｳ ｳ ｳ | ﾀﾄﾄﾄﾄﾄﾄﾙ | ｳ
Trip DCｳ ｳ ﾀﾄﾄﾄﾄﾄﾄｴPA3ﾃﾄﾄﾄﾄﾄﾄﾙ ｳ ｳ ﾚﾄﾄﾄﾄﾄﾄｿ ｳ
ﾚﾄﾄｿ ONｳ ｳ 200Rﾀﾄﾄﾄﾙ200R ｳ ﾃﾄ/ﾄｴFilterﾃﾄ\ﾄｴ
12V__ｳ/_ｳ__/ ﾁﾄ> ｳ ﾚﾄﾄﾄｿ ｳ ｳ | ﾀﾄﾄﾄﾄﾄﾄﾙ | ｳ
ﾀﾄﾄﾙ | ﾀﾄﾄﾄﾄﾄﾄﾄﾄｴPA4ﾃﾄﾄﾄﾄﾄﾄﾄﾄﾙ ｳ ﾚﾄﾄﾄﾄﾄﾄｿ ｳ
| 200Rﾀﾄﾄﾄﾙ200R ﾀﾄ/ﾄｴFilterﾃﾄ\ﾄﾙ
Band Switch| | ﾀﾄﾄﾄﾄﾄﾄﾙ |
or Remote> ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
L A Y O U T (Bottom cover off)
ﾚﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄｿ
ｳ ﾄﾄ ﾄﾄ ﾄﾄ ﾄﾄ ﾄﾄ ﾄﾄ ﾄﾄ ﾄﾄ ﾄﾄ ﾄﾄ ﾄﾄ ﾄﾄ ﾄﾄ ﾄﾄ ﾄﾄ ﾄﾄ ﾄﾄｳSO239
ﾞｳ~~~~~ﾄﾄ Pot PushPull | ﾚﾄﾄﾄﾄﾄｿ ﾚﾄﾄﾄﾄﾄｿﾚﾅﾄｿRig
ﾝｳ100 ｳ Bias =()=ｴｱｱｱｱｳOutput ｳRelayｳ >15MHz FilterｳRelayｳﾀﾅﾄﾙ
ﾝｳAmp ｳCircuit [ｱ] PA1 Transformers ~~~~~ ~~~~~ ｳ
ﾞｳMeterｳ [ｱ] =()=ｴｱｱｱｱｳ | ﾚﾄﾄﾄﾄﾄｿ ﾚﾄﾄﾄﾄﾄｿ ｳ
ﾃ-----~~5R [ｱ]Input 1mF ｳRelayｳ8-15MHz FilterｳRelayｳ ｳﾜﾛ 13.6V
ｳ [ｱ]Spliter=()=ｴｱｱｱｱｳ | ~~~~~ ~~~~~ /ｳ+ﾟ DC 75A
ﾃﾄﾄﾄﾄﾄﾄ. [ｱ] [ｱ] PA2 ｳﾚﾄﾄﾄﾄｿ ﾚﾄﾄﾄﾄﾄｿ ﾚﾄﾄﾄﾄﾄｿﾝｳ-ﾜ Wing
ｳ75A DC ﾃﾄﾄ[ｱ] [ｱ] =()=ｴｱｱｱｱｳｳ DC ｳ ｳRelayｳ 5-8MHz FilterｳRelayｳﾛｳﾟﾛ Nuts
ﾞｳTRIP & ﾃ()shuntﾜﾜﾜﾜﾜﾜﾜﾜﾜﾜﾜﾜﾜﾜﾜRelayｳﾜﾜﾜﾜﾜﾜﾜﾜﾜﾜﾜﾜﾜﾜﾜﾜﾜﾜﾜﾜﾜﾜﾜﾜﾜﾜﾜﾜﾜﾜﾛｳ
/ｳON/OFF ｳ__ﾜﾟﾟﾟﾟ =()=ｴｱｱｱｱｳﾀﾄﾄﾄﾄﾙ ﾚﾄﾄﾄﾄﾄｿ ﾚﾄﾄﾄﾄﾄｿﾚｴ12 Way
ﾟﾆ======' PushPull[ｱ] PA3 ｳ | ｳRelayｳ 3-5MHz FilterｳRelayｳｳｳJones
ｳDriveｳ Driver[ｱ] =()=ｴｱｱｱｱｳ [ｱｱ]Output~~~ ~~~~~ ｳｳSocket
ｳRelayｳ Transformers 1mF [ｱｱ]Combinerﾄｿ ﾚﾄﾄﾄﾄﾄｿﾀｴ
ｳ~~~~~ =()=ｴｱｱｱｱｳ [ｱｱ]| ｳRelayｳ 2-3MHz FilterｳRelayｳ ｳ
ｳ| ThermSw [ｱ] PA4 ｳ [ｱｱ] ~~~~~ _____ ｳSO239
ﾛｳ|Band [ｱ] =()=ｴｱｱｱｱｳ | ｳ Ant ｳﾚﾅﾄｿAnt
ｳ|Switch P.A. PCB 1mF :RF lead: FILTER PCB ｳRelayｳﾀﾅﾄﾙ
ｳ ﾄﾄ ﾄﾄ ﾄﾄ ﾄﾄ ﾄﾄ ﾄﾄ ﾄﾄ ﾄﾄ ﾄﾄ ﾄﾄ ﾄﾄ ﾄﾄ ﾄﾄ ﾄﾄ ﾄﾄ ﾄﾄ~~ﾄﾄｳ
ﾀﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾙ
Front Rear
PA protection is from a 75A fast magnetic trip for bad SWR and over drive, it
has an external calibrated shunt, and a thermal 70 auto resetting cut off
switch. The 100A meter uses 10cm of the thick DC lead as its calibrated shunt.
The bias supply is a simple 2 transistor thermally tracked circuit that
provides up to 2.2A of current @ 0.69V, for the 4 class AB push pull amps.
Excluding other currents, total PA quiescent current should be 1.6-2A, (which
gives the best two tone linearity results at around that level. See 5/)
P A R A L L E L A M P S
Four identical push pull Amps (>150W/Amp) use 2x PT9847 100W HF transistors
with large very well rated input & output matching transformers (no saturating
IMD products!) consisting of Fe dust rings stacked on each of the 2 brass tubes
for the 1 turn low Z side of the 5:1 turns ratio. Transformers with 2x 3 rings
are used for the driver and much larger 2x 5 ring ones for the outputs. A large
amount of RF NFB (for good linearity) is provided by 47R 5W & u1 C between each
collector & base of the 8 transistors.
ONE of 4 PA AMPS INPUT & OUTPUT TRANSFORERS
NFBﾚﾄ47Rﾄｿ 1:5 I/P 3 rings/side, O/P 5 rings/side
200R 5:1 u1=== ﾃﾄﾄﾂﾄﾄﾄﾄﾄｿ ______ Collectorﾄﾄﾄｴｱｱ ｱｱ ｱｱ ｱｱ ｱｱﾃ+PCB
ﾄﾄﾄﾄﾄｿ ﾚﾄﾄﾄﾄﾄﾄﾁﾄﾄﾄｴ< e ｳ ｳ|( 200R or Base tube~~~~~~~~~~~~~~tube
5W 5 )|ｳ ﾁ ｳ1n2 _)|( 5 Turn /////______________ \\\\\
Turn )|(__ NFB === ｳ )|( Output 5 turns|||||ｳｱｱ ｱｱ ｱｱ ｱｱ ｱｱｳ |||||
Input)|( ｳ u1ﾚﾄ47Rﾄｿ ｳ ｳ ｳ|( >150W for ||||| ﾃ+|||||
)|ｳ ｳ === ﾃﾄﾄﾁﾄﾄﾄ)ﾄﾙ|( 200ohm|||||ｳｱｱ ｱｱ ｱｱ ｱｱ ｱｱｳ |||||
)|ﾀﾄﾄ)ﾄﾄﾄﾁﾄﾄﾄｴ<PT9847 ｳ ﾁ ====\\\\\~~~~~~~~~~~~~~~/////
ﾁ ﾃﾄbias ｳe ﾃﾄﾄﾄﾂﾄﾄﾄﾄ+12V tube______________tube
.6V @.7A ===2u2 ｳ u1=== ===1mF @18A Collectorﾄﾄﾄｴｱｱ ｱｱ ｱｱ ｱｱ ｱｱﾃ+PCB
ﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾁﾄﾄﾄﾄﾄﾄﾄﾄﾄﾁﾄﾄﾄﾄﾄﾄﾁﾄﾄﾄﾁﾄﾄﾄﾄﾄ or Base Fe dust ring stack
The inputs & outputs are wired up from the drive splitter & output combiner
with staggered wire lead lengths, so all the RF signals ends up exactly in
phase.
ﾚﾄﾄﾄﾄﾄﾄ>PA1>ﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄｿ Splitter & combiner both have out of
(|_100R_ _100R_|) balance dump 100R to soak up any amp
_(| 1W ｳ 200R ｳ 5W |)_ differences, for best stability &
ｳ (|_100R_ｳ AMPS ｳ_100R_|) ｳ linearity. Fe dust ring & tube
ｳ (| 1W ｳ ｳ 5W |) ｳ construction like the transformers.
50R ｳ ﾀﾄﾄﾄﾄﾄﾄﾄ)ﾄ>PA2>ﾄﾄﾄﾄ)ﾄﾄﾄﾄﾄﾄﾄﾙ ｳ 50R ﾚﾄﾄﾄﾄﾄﾄﾄﾄﾄﾂﾄﾄﾄﾄﾂﾄﾄﾄﾄﾄﾄﾄﾄﾄｿ
Drive>ｴSPLITTER ｳ ｳ COMBINERﾃ>O/P 100R 100R 100R 100R 1 or
25W ｳ ﾚﾄﾄﾄﾄﾄﾄﾄ)ﾄﾄﾄﾄ>PA3>ﾄ)ﾄﾄﾄﾄﾄﾄﾄｿ ｳ 600W ｳ ___ ___ ｳ ｳ ___ ___ ｳ 5W
ｳ (|_100R_ｳ ｳ_100R_|) ｳ _ｳ|___X___|ｳ_ _ｳ|___X___|ｳ_
ｳ_(| 1W ｳ 200R ｳ 5W |)_ｳ ｱｳ|ｳｱ ｱｳ|ｳｱ ｱｳ|ｳｱ ｱｳ|ｳｱ
(|_100R_ｳ AMPS ｳ_100R_|) ｱｳ|ｳｱ ｱｳ|ｳｱ ｱｳ|ｳｱ ｱｳ|ｳｱ 50ohm
(| 1W 5W |) ~~|~~~~~~~|~~~~~~|~~~~~~~|~~\Drive/
ﾀﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄ>PA4>ﾄﾄﾄﾄﾄﾄﾙ PA1 PA2 PA3 PA4 Output
F I L T E R S
10 relays that in pairs, switch in 1 of 5 QRO 2 section (30dB/O) Pi low pass
band filters, and reduce the quite high PA harmonics to >-43dBc. N.B. there is
no PA RF output path without a pair of band relays operated!
Filter In Filter Out
______Relay Relay______ Band C1/C3 C2
From /oﾄﾂﾄﾄ())))ﾄﾄﾂﾄﾄ())))ﾄﾄﾂﾄo\ To 2-3MHz 390+430p 750+680+270p
Combinerｳ ｳ L ｳ L ｳ ｳ Aerial 3-5MHz 390+120p 750+270p
ｳ === === === ｳ Relay 5-8MHz 270+47p 430+200p
ｳ ｳC1 ｳC2 C3ｳ ｳ 8-15MHz 82+82p 200+150p
ﾄﾄﾄﾄﾄﾄﾁﾄﾄﾁﾄﾄﾄﾄﾄﾄﾄﾄﾄﾁﾄﾄﾄﾄﾄﾄﾄﾄﾄﾁﾄﾄﾁﾄﾄﾄﾄ 15-30MHz 82p 56+120p
The Ls are wound on 2cm dust core rings, or air for the highest range. The Cs
are all 2-3kV RF types. Using several Cs in parallel not only gets the odd
filter values needed, but also gives greater current handling, reduced lead
inductance and swamps any self C resonances. The 4 unused filters get shorted
to ground.
H E A T S I N K
At 25 ambient in free air, the very large heatsink does not need a fan on 30%
duty SSB Tx cycle, despite only the front part getting quite hot. But carrier
modes are to be avoided (input attenuator overheats on lower bands!) or the
temperature might rise above the heatsink thermal 70 auto resetting trip.
M O D I F I C A T I O N S
1/ LED INDICATORS, REDUCES STANDBY CURRENT, AND GIVES RELAY SEQUENCING.
Rx mode current was quite high (band relays), I found all the relays would
operate OK down to 7V. So I added series Rs to reduce the currents by 25%
needed for the "slow to operate" ones, and I used the R's added voltage drop
to light 2 status LEDs too.
SWITCH ﾚAmmeterｿ ON Drive
+12V>ﾄTRIPﾄﾁﾄShuntﾄﾁﾂﾄﾄﾄﾄﾄﾄﾄﾄﾄ\ﾄﾄﾂﾄﾄﾄﾄﾄﾄﾂﾄﾄﾄﾄﾄﾂﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾂﾄﾄﾄﾄﾄ\ﾄﾄﾄﾄ>Bias
75A _ｳ_Polarity ｳ 3mF=== PAs Over\Temp Regulator
\_/diode ｳ _ｳ_ ﾚﾄﾄﾄﾁﾄﾄｿ
ﾚﾄﾄﾄﾄﾁﾄﾄﾄﾄｿ ﾚﾄﾄﾁﾄﾄﾄｿ /// ﾚﾄﾄﾁﾄﾄｿﾚﾄﾄﾁﾄﾄｿ
ｳ DC ON ｳ ｳFilterｳ ｳDriveｳｳ Ant ｳ
ｳContactorｳ ｳRelaysｳ ｳRelayｳｳRelayｳ
ﾀﾄﾄﾄﾄﾂﾄﾄﾄﾄﾙ ﾀﾄﾂﾂﾂﾂﾂﾙ ﾀﾄﾄﾂﾄﾄﾙﾀﾄﾄﾂﾄﾄﾙ
ﾚﾄ100Rﾄｴ ｳｳｳｳｳ Red ﾚﾄ100Rﾄｴ ｳ Relay RF Cs
Green _ｳ_ 1W oooooo Tx _ｳ_ ｳ ｳ not shown
ON <=\_/ 75R /ｳ\ LED<=\_/ 33R ｳ
LED ﾀﾄﾄﾄﾂﾂﾅﾂｿ ﾃﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾁﾄﾄﾄﾄﾄﾄﾙ ｳ
oooooo e\ｳ ｳ
OFF/ｳ\ PNP ﾃﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾂﾄﾄﾁﾄﾄﾄﾄﾄﾄ<PTT
& BANDｳ 2N2905/ｳ Fbead ﾚﾄﾄﾄﾄｴﾃﾄﾄ270Rﾄﾙ 80mA
_ｳ_ _ｳ_ _ｳ_ 10u + Back EMF
/// /// /// Zobel
Added components mounted on or near the band switch.
Input & output filter relays (not in Rx path) are now only operated when the
PTT is active, from the added PNP emitter follower. The drive relay also puts
on the PA Bias, and is last to operate with a series LED too is also buffered.
But the Ant relay must be faster, so it is left direct to the PTT line!
These modifications save 160mA on standby and helps keeps the filter relay
contacts clean! It also reduces the PTT current from 250 to 80mA (limited PTT
current on my exciter's reed relay). And the slight voltage differences on
identical relays, is all that is needed to ensure the relays all operate in
the right sequence order Aerial, Band, and then Drive/Bias relay, so no QRO RF
relay contact splats.
2/ RIPPLE SMOOTHING AND RF on DC LEADS
Only 3x 1000uF was fitted on my PA's +12V rail, the diagram showed 3x 2200uF,
and having a large bag of similar 1000uF caps, I added 7 more symmetrically
stacked up around the 4 amplifiers to give 10,000uF in all. Much more than
that, might weld up the DC contactor! Each of these Caps can give a few amps
at audio, reducing some of the battery lead AF ripple current.
PA 12V Bus now has 10x 1mF contactor _____ Trip
Other<ﾄo-oﾄﾄﾂﾄﾄﾄﾂﾄﾄﾄﾂﾄﾄﾄﾂﾄﾄﾄﾂﾄﾄﾄﾂﾄﾄﾄﾂﾄﾄﾄﾂﾄﾄﾄﾂﾄﾄﾄﾂﾄo\___/ Amp \__X_______<+12V
kit 3A +ｳ +ｳ +ｳ +ｳ +ｳ +ｳ +ｳ +ｳ +ｳ +ｳ \meter/ ｳ ｳ
see 3/ === === === === === === === === === === ~~~~~ .5u=== ===1u
ﾁ ﾁ ﾁ ﾁ ﾁ ﾁ ﾁ ﾁ ﾁ ﾁ ﾁ ﾁ
To stop RF on the DC leads (don't want any in the shack), I also added a 1uF
non electrolytic internally across the DC terminals, and another 0.5uF from
+12V to the nearby "RF In" SO239 ground.
3/ DC FUSE
There was no low current fuse! So I soldered in a 3A one in the small wiring
feed (to the band switch) to reduce the risk of an internal fire!
4/ DC LOSSES
This QRO amplifier has very high currents, and a drop of 1V = 100W less peak
RF power! DC lead losses, and the use of unsoldered crimp connectors all adds
up. So with the amplifier into a dummy load, I used a DVM on 2V range from
battery -ve and then the +ve to highlight where the voltage was being lost..
drops on the leads, contactor, and tags. (If RF gets up your meter use 1K R in
series as an RF stopper at probe end.)
Metal case connection of the -ve terminal had not been used, it could reduce
the internal earth wire loss to near zero. It was just bolted on the painted
panel. So I ground off the paint around the earth post, greased the bare
aluminium to keep the air away, and bolted it up tightly. I did the same to
the back panel to heatsink screws with lock washers etc.
External DC cables, I use short heavy leads to a 75A SMPSU, or "starting grade
1m cables" to a large battery, or 2 sets of 30A leads to, 24AH battery, and to
30A PSU. See "battery leads" below.
5/ BIAS
R4 turns on Q2, when Q2 emitter > 0.6V, Q1 turns on reducing Q2 base drive.
Value of R3 low value preset is used to set the exact bias voltage, R4 and
supply voltage also affect the bias slightly. R5 limits the max current, D2 is
a safety feature. Q1 & D2 are thermally connected to the PA (on the same
heatsink).
PTT Switched (from Drive relay)
+12V ﾄﾄﾄﾄﾂﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄｿ
ｳ R5 This circuit was slightly
R4 Added 5R unstable when scoping
270R 47n 20W Scope for R5 (5R), so I added a small
ｳ ﾚｴﾃ---ｳ <--1MHz oscillation! capacitor base to collector
ｳ | ｳ/c on the large NPN to stop it.
ﾃﾄﾄﾄﾄﾄﾂﾄﾄﾄﾄﾄｴ TIP33A It only has to handle DC-3kHz.
ｳ C6 === Q2ｳ\e NPN +690mV @ 2A
ｳ 2u2_ｳ_ ﾃﾄﾄﾄﾄﾂﾄﾄﾄﾂﾄ> via RFC to
ｳ /// ｳ ｳ ｳ Amp input
NPN c\ｳ ｳ ｳ ｳ transformers
TIP29 ﾃﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄｴ ｳ ｳ
e/ｳQ1 _ｳ_ +ｳ 2R2
PA BIAS ｳ \_/ === ｳ Components used were not the
Quescentﾀ>5R D2 ｳ C7ｳ ｳ same as original diagram!
Set 1-2A R3 ｳ 2u2ｳ ｳ
ﾄﾄﾄﾄﾄﾄﾄﾄﾁﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾁﾄﾄﾄﾄﾁﾄﾄﾄﾁﾄﾄ
6/ ALC
There is no ALC system on this AMP, and I am used to an old Valve amp with a
power front panel ALC control. With PA ALC, the driver power is automatically
set to the wanted level, and with the PA turned off you are back to full bare
foot power. So I designed this 1 Transistor ALC circuit for this PA...
+12V Tx>ﾂﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾂﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄｿ
R4 R5 ｳ
270R PA 5R 10W 15K
ﾀﾄﾄ>Bias<ﾄﾄﾁﾄﾄﾄ270Rﾄｿ 2n2 ｳ
Circuit ﾃﾄﾄｴﾃｿ ｳ Front panel
e\ｳ ｳ 10K between Trip & Meter
2N3703 PNP ﾃﾄﾄﾁﾄ>POWER 50W-600W
mounted on POT/ｳ POT ALC Control
ﾚﾄﾄﾄﾄﾄｴ _ｳ_
4K7 |ｳ| ///
ｳ ｳFbead Mounted on 12 way JONES plug
Input -veｳ ｳ Fbeed spare Pin
RF on >ﾄﾄ1Kﾄﾄｴ<ﾃﾄｴ<ﾃﾄﾄｴ ﾀﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄｳ<ﾃﾄﾂﾄﾄﾄﾄﾂﾄﾄﾄ>ALC to rig
Drive 2x 1N4148 ｳ-20V long wire 1N4148ｳ 100R 0V to -10V
Atten === with DC leads ｳ ｳ -
2n2ｳ 4K7 === 4u7
_ｳ_ _ｳ_ _ｳ_+20V
/// /// ///
The -ve supply for the ALC is derived from the RF on the attenuator after the
DRIVE relay. The -ve after the 4K7 it is normally clamped to +ve by the PNP.
But when the PA bias current (limited to 2.2A by 10W 5R) reaching the 8 PA
bases, gives a voltage lower than that set on POWER POT, the clamping stops,
letting the -ve through. The series 1N4148 diode & 4K7 load, ensures only -ve
voltages are given to the exciter to reduce power drive. The 4K7, 4u7 & 100R
give a sensible fast ALC time constant action.
MY CLEVER ALC DESIGN!
The ALC works very well compared with manually keeping the drive power always
low enough at all times, so the PA never clips, or accidently over driven! By
using bias current demand, it is quite effective at keeping the PA operating
in it's linear region, by reducing the driver power in time. This is down to
the large amount of NFB used in this commercial PA, that increases the PA's
drive power, as the amp gain falls off at full power. This sudden increase in
bias current, occurs just before the PA actually hard clips. So a very useful
and accurate maximum drive threshold point, that caters for SWR, supply
voltage, and over-riding a higher Rig power setting.
7/ INPUT SWR
The input frequency compensating attenuator circuit was not as the diagram and
the SWR was not all that good, despite all components testing out OK.
SWR Original Input Match SWR Improved Input Match @ 50W
1.7ｴ .�'�. 1.7ｴ
1.5ｴ''''''''''' '�.. 1.5ｴ
1.3ｴ ''''洄洄� 1.3ｴ ..�''�. ..�'
1.1ｴ 1.1ｴ'''''''''' ''''''''
ﾀﾂﾄﾄﾄﾂﾄﾄﾂﾄﾄﾂﾄﾄﾂﾄﾄﾂﾄﾄﾂﾄﾄﾂﾄﾄﾂﾄﾄﾂﾄ ﾀﾂﾄﾄﾄﾂﾄﾄﾂﾄﾄﾂﾄﾄﾂﾄﾄﾂﾄﾄﾂﾄﾄﾂﾄﾄﾂﾄﾄﾂﾄ
1.8 3.5 5 7 10 14 18 21 24 28MHz 1.8 3.5 5 7 10 14 18 21 24 28MHz
L1 39p 25W L1 39p 25W
>ﾄﾄ())ﾄﾄﾄﾂﾄﾄﾄﾄﾂﾄﾄﾄﾄﾄﾂﾄﾄｴﾃﾄﾄﾂﾄ>Drive >ﾄ())ﾂﾄﾄﾄﾄﾄﾄﾂﾄﾄﾂﾄﾄﾄﾄﾄﾂﾄﾄｴﾃﾄﾄﾂ>Drive
40W L2( === ﾃﾄ220Rﾄｴ Splitter 40W ｳ L2( === ﾃﾄ200Rﾄｴ Splitter
( ｳ56p ﾃﾄ220Rﾄｴ === ( ｳ56p ﾃﾄ200Rﾄｴ
ﾚﾄﾄﾄﾄﾂﾁﾄﾄﾄﾂﾁﾄﾄﾄｿ ﾀﾄ220Rﾄｴ 100pｳ ﾚﾄﾄﾁﾂﾄﾁﾄｿ ﾃﾄ200Rﾄｴ
200R 200R 200R 200R 220R ｳ 220R 220R 220Rﾀﾄ200Rﾄﾙ
_ｳ_ _ｳ_ _ｳ_ _ｳ_ _ｳ_ _ｳ_ _ｳ_ _ｳ_ _ｳ_
Actual Circuit New Circuit
There was a bump @ 10MHz and that is from the drive splitter load. L2 & 56pF
disconnects the added load, as the 39pF bypasses the series attenuator Rs on
the higher frequencies, to flatten the amp gain. The original diagram did not
have 220R to ground, but had 20pF to ground @ the L1/2 junction. I found
making this a 100pF (Tx grade) was better on 10m band and changing the load Rs
around gave a better lower band input match.
Flat gain with an ALC, is less important than driver rig linearity, due to
poor load. The input SWR will change with drive level (higher Z at more power)
as the RF NFB level reduces, correcting each amplifier gain, as each amplifier
works harder.
T E S T I N G
At a club meeting, 2 of these amplifiers (modified & unmodified) were tested
with 2 tone linearity test and with a spectrum analyser for harmonics. Both
amps performed well up to the sudden (like AF Amps) 600W hard clipping level.
This was due to the effective NFB keeping good linearity until it fails. But
even brief full carrier testing on lower bands did provide smoke from the
underrated input attenuator!
The 2 tone test showed very good linearity to 400W PEP, so I think the quoted
IMD figures look right. On air tests with SDR displays show the amp is very
clean and no other sidebands/spatter could be detected @ S9+30dB etc.
The harmonics tests on a spectrum analyser showed the need to have the "right"
low pass filter selected, as these un-tuned broadband amps are quite harmonic
rich otherwise!
dB Topbands with dB Topband with
0_ｳ f1 15-30MHz Filter 0_ｳ f1 2-3MHz Filter
-10_ｳ ｳ -10_ｳ ｳ
-20_ｳ ｳ f3 -20_ｳ ｳ
-30_ｳ ｳ f2 ｳ -30_ｳ ｳ
-40_ｳ ｳ ｳ ｳ f4 f5 -40_ｳ ｳ f2
-50_ｳ ｳ ｳ ｳ ｳ ｳ f6 -50_ｳ ｳ ｳ
-60_ｳ ｳ ｳ ｳ ｳ ｳ ｳ f7 -60_ｳ ｳ ｳ f3
ﾀﾄﾄﾁﾄﾄﾁﾄﾄﾁﾄﾄﾁﾄﾄﾁﾄﾄﾁﾄﾄﾁﾄ ﾀﾄﾄﾁﾄﾄﾁﾄﾄﾁﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄ
On Topband the 2-3MHz LPF is not really that good for the 2nd harmonic! Higher
bands faired better with filter performance. Of course no problem at all after
a good ATU.
On actual testing into aerial via a high Q QRO ATU, I found it was possible to
get slight PA parasitic oscillation (of the RF envelope) at very high power. It
never did this into my dummy load or an actual aerial on Spectrum Analyser! But
with the final tweak to the input attenuator, it tested OK across all bands,
with ATU tuning over a range of SWRs. So sudden high SWR in a T tuner might be
indicating a Tx PA "parasitic" or tuner/aerial "arcing"!
H A Z A R D S
Current Loops:
Although 12V is fairly safe (compared to 230V or 3kV), with high currents
anything metal is a hazard! This includes the PL259 plug & mains earth wiring!
I put large heat shrink sleeving on 259 plug rig lead near the +12V terminal.
Care must be taken to ensure the "75A" does not flow around unsuitable leads in
parallel e.g. Mains PSU IEC lead earths and Rig power leads!
Battery leads:
With single battery, use short "starter gauge" cables, with soldered on copper
tabs/lugs, made from thin Copper sheet 0.5mm, wound on a 8mm drill 1.5 turns.
Then flatten one end, with flux added solder to cable (on cooker).
__________ heat shrink
Drilled ___ _____________
Hole ____/ ｳ~STARTER CABLE
~~~~ﾄﾄﾄﾄﾙ~ﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄﾄ
~~~~~~~~~~~~
Clean up and apply heat shrink sleeve or tape. Drill hole for PA & battery
connections. Mark up + & - with coloured tape. Apply water/acid repellent
grease to tabs, bolt tread, washers etc.
Lead Acid Batteries:
Other than high current & fire hazard of melted leads, batteries have Sulphuric
Acid that always seems to get out & damage clothes etc, you can replace clothes
but eyes are something else! Take care!
H2 Anti Explosion Tip:
Always "blow" at the battery, before making/unmaking connections, this "simple
action" reduces the chance of hydrogen being around for sparks to ignite!
High Power RF:
At these powers RF leakage from loose PL259, high Filter & Aerial voltages are
dangerous! Double check connectors and everything is SAFE before keying up, and
RF testing is essential. Otherwise you will soon learn about deep RF burns and
gain "Respect for the RF" the hard way!
RF Chokes:
Wind coax or balanced aerial leads, to make "RF chokes" near shack end, this
helps keep shack RF fields and RF lead currents down!
I N U S E
Running it /P for 9 days at a summer camps on HF with autocaller and plenty of
pile ups, I did find a fan system was useful, to cool the front part of the PA
(used a small Germanium transistor to sense temp and a high gain Tip Silicon to
operate 12V fans in series.)
A 25A linear PSU floating batteries worked well. The rig was floated on another
battery & PSU. This did allow a much smaller petrol generator (650W 2 stoke) to
be used rather than a 2.3kW 4 stroke for QRO Valve Amp. (That was used for cold
night to keep the operating tent warm!)
In my shack I now use a DEL 13.8V 75A SMPSU with thick short leads to the PA.
Reports were all pritty fantastic, good clear comms quality AF from the old
IC735 with its hard AF clipper mic processor, 2.4kHz SSB filter, and a strong
signal. A local looked at the remote Hack Green SDR website radio, only to
comment "my /P station much was stronger than he was and it was narrower!"
LOW POWER FAULT
After many years of use, I noticed only 350W peak output and lower DC current
drawn occasionally. Investing all the Rs were OK, and the combiner balancing 5W
100Rs were getting quite hot. Scoping each of the 8 transistor bases showed the
RH output PA4 pair was different. Removing the NFB on this pair and a little
RF drive I notice a spark on the 8th collector. It had developed a difficult to
see crack in the solder joint. Resoldering fixed this OK, and I was very lucky
it did not need a replacement old transistor. This fault has occurred twice now
on the other end of the row of PA transistors, where there is maximum thermal
expansion stress on large PCBs, with bolted down bits and loads of heat cycles,
or /M & /P kit!
See my Tech buls on "AF 2 Tone Test Osc Design", "Transistor PA Biasing", "Lead
Acid Batteries", "Variable Speed Thermal Fan", "DEL A870P7 SMPSU 12V 70A","12V
75A Del SMPSU Mods", "2nd Car Battery for /M & /P", "Rig DC Power & RF Hazards"
"Using 2 HF PAs" & "NORTHERN 650W 2 Stroke Genny".
Why Don't U send an interesting bul?
73 de John, G8MNY @ GB7CIP
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