The Good, The Bad and The Ugly. ACøC Alpha 76pa. One Man s Modernization - or Unforgivable Butchering - of a Classic Workhorse Amp
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- Mavis Alberta Parks
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1 The Good, The Bad and The Ugly ACøC Alpha 76pa One Man s Modernization - or Unforgivable Butchering - of a Classic Workhorse Amp Jeff Blaine ACØC Presented to the KC DX Club 27 June 2011
2 Beginnings: The Good It s not your SB200 Functional on all bands Power output within expected limits Great reliability history Fit on the bench slot Ceramic tube complement Reasonably quiet fan Jeff Blaine AC0C 2011, all rights reserved 2
3 Beginnings: The Bad Rode hard and put away wet Intermittent power out under some cases Clunky open-frame TR relay Transformer hum under load (common for the EI) Unobtanium tube type (8874) No grid drive protection 120V PTT switching input Jeff Blaine AC0C 2011, all rights reserved 3
4 Beginnings: The Ugly Rode hard and put away wet (paint) Alpha s famous non-drying paint Incandescent functional but dim lighting Jeff Blaine AC0C 2011, all rights reserved 4
5 The Mods
6 Mod: New Faceplate + Screws Jeff Blaine AC0C 2011, all rights reserved 6
7 Mod: Case Prep and Painting Interior tube vents were chamfered to improve flow Case roughed, degreased and painted with plastic matte-finish paint Jeff Blaine AC0C 2011, all rights reserved 7
8 Mod: LED for Meter Illumination Stock incandessent lamps replaced with a string of white and blue LEDs The board is temporary mounted and ties into existing control circuit Jeff Blaine AC0C 2011, all rights reserved 8
9 Mod: Plate Choke Swap Stock choke is resonant on the 12m band Replaced with an Ameritron unit with added turns Jeff Blaine AC0C 2011, all rights reserved 9
10 Mod: Coupling Cap Swap Replaced stock ceramic with TV type door knobs Coupling caps are one of the heating spots observed with the SB200 mod Jeff Blaine AC0C 2011, all rights reserved 10
11 Mod: TR Relay Swap Stock open frame swap with Panasonic RF reed input relay + GV vac output relay Sound deadning: 1. Foam mounted 2. Braid connected 3. Hot glue Jeff Blaine AC0C 2011, all rights reserved 11
12 Mod: Replacing the Missing Solder Solder braid on tube clamps and on bandswitch had serious solder voids The tube cap opens were easy to find the bandswitch intermittent opens were not Jeff Blaine AC0C 2011, all rights reserved 12
13 What about the Grid Protection? Amp has overcurrent protection SWR limit provided by external LP100 + PTT line Grid protection capability needed Jeff Blaine AC0C 2011, all rights reserved 13
14 Considering the K6XX Solution Uses voltage across existing resistor + opto iso as current source to trigger a timer Problems: Ckt errors and lack of warning level Jeff Blaine AC0C 2011, all rights reserved 14
15 A up Alternative The opto iso sampling method for the grid current is really an elegant idea Stick same sensor onto the ADC of a up, and could read grid current directly The up also opens the door to a lot of cool features including QSK, relay sequencing, temp monitoring, fan speed control, others. Oh my Jeff Blaine AC0C 2011, all rights reserved 15
16 up Control Board Functional Overview Real-time grid current measurement - warning and lockout 3 ms QSK switching speeds with rig inhibit output Automatic fan speed control - based on tube and transformer temperatures 4x20 LCD display on a remotely mounted control head Real-time measurement of tube and transformer temps - peakhold function to indicate the max temps reached Standby function Morse code beeps provide audio clues for key events Jeff Blaine AC0C 2011, all rights reserved 16
17 Inputs: - Grid current sense - PTT from transmitter - Tube temp sensor - TX temp sensor - Amp power ON - AC line sensor - Reflected power sense Outputs: - Bias line - TR relay - LCD - LED - TX inhibit - Speaker up Control Board Operation Summary Jeff Blaine AC0C 2011, all rights reserved 17
18 Schematic Page 1 Jeff Blaine AC0C 2011, all rights reserved 18
19 Schematic Page 2 Jeff Blaine AC0C 2011, all rights reserved 19
20 Schematic Page 3 Jeff Blaine AC0C 2011, all rights reserved 20
21 up Control Board Fit into amp sitting over the power supply and control board Jeff Blaine AC0C 2011, all rights reserved 21
22 up Control Board - Mounting Jeff Blaine AC0C 2011, all rights reserved 22
23 up Control Board Temp Sensors Tube Jeff Blaine AC0C 2011, all rights reserved 23
24 up Control Fan System up controls internal blower, rear-mounted muffin and desk mounted muffin above the amp Fan speed determined by tube and transformer temps Jeff Blaine AC0C 2011, all rights reserved 24
25 up Control Board Construction PCB by K0RU Double sided SMT construction Size of space available and connections were a challange Jeff Blaine AC0C 2011, all rights reserved 25
26 up External Control Head Control head sits on shelf above amp Jeff Blaine AC0C 2011, all rights reserved 26
27 Amp + Control Head Shack Layout Jeff Blaine AC0C 2011, all rights reserved 27
28 Remaining Tasks Replace TV doorknobs with proper RF type Paint the not so beautiful pink relay foam LED mount convert from breadboard to PCB Intermittent RCA jack on PTT line Faster grid protection trigger with 200W input slam Jeff Blaine AC0C 2011, all rights reserved 28
29 Lessons Learned 120V blows up parts very well!!! Jeff Blaine AC0C 2011, all rights reserved 29
30 Special Thanks To: o o o o o Lew Ward, K0LW Charlie Matzoch, W5VJN Rob Underwood, K0RU Matt Erickson, KK5DR Bob Wolbert, K6XX Jeff Blaine AC0C 2011, all rights reserved 30
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