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For the third time in three years, I've had a problem with my Alpha 8410 1500-Watt amplifier. I first bought an Alpha 8410 in February 2012.
IT LASTED A WHOLE THREE WEEKS!! I was able to reach the president of Alpha and convince him that my amplifier was a lemon and so he had Alpha personnel ship me a brand-new 8410 amplifier.The second 8410 lasted two years and then in June 2014,some of the components on the 'output' circuit board burned up while I was transmitting on 80 Meters into a dipole antenna. Since my second Alpha was under warranty, Alpha gave me a RA number and asked me to send the defective amplifier back to Alpha for repairs. That cost me $120.00 for FEDEX Ground shipping and then Alpha charged me a $35.0 'Laboratory' fee.I got my Alpha back after waiting a month and it worked fine for three months. Then last week, the exact same defect happened again and my Alpha went belly-up for the second time in three months.After looking at the Alpha 8410 schematics, I came to realize that the so-called 'output' board is a misnomer because it is really the amplifier's input/output board where the PL-259 from the transceiver is connected and the PL-259 from the antenna coax is also connected. Thus, this circuit board is an input/output circuit board. Anyway, I discovered an engineering design flaw in the board schematic.
The part that burned up in my amplifier was called a 'spark arrestor' or a 'spark-gap arrestor.' This device is rated at 1000 Volts at 20 Amps and is located just before the output SO-239 on the circuit board.The problem is: THE DEVICE SHOULD BE RATED AT 5000 Volts-AND NOT 1000 Volts!!!! Using the equation: E=W/I, where E= Voltage and W= Watts and I equals current in the antenna output circuit, I measured the 'normal' output current for a 1,500-Watt transmission and it was 0.3 Amps. Using this formula, the voltage is 5000 Volts and not 1000 Volts so naturally the spark-gap device exploded when subjected to five-times the amount of the rated voltage- voltage that it was NOT designed to withstand.Now I have to convince the people at Alpha that they made an engineering and/or design mistake with this amplifier and they need to replace the 1000-Volt spark-arrestor with a 5000 Volt spark arrestor. Oh yes, the other half of this equation is the 20 Amp rating for the spark-arrestor. IT WOULD BE ALMOST IMPOSSIBLE FOR 20 AMPERES OF CURRENT TO FLOW THROUGH THE ALPHA-8410 ANTENNA CIRCUIT. Such high current would melt the coax cable connected to the SO-239 and it would probably cause my four-element Yagi to glow bright red.
At least someone at Alpha should have caught this error!!! Not sure how you've done your math and at what point in the circuit.At 1500 watts the antenna has delivered to it 273 volts of RF at 5.47A. That's with a 50 ohm load.So a 1000 volt spark arrestor is about right unless something is breaking down in your antenna causing a rapid pulse that triggers the spark arrestor.It would be next to impossible to ask the unit be placed on a dummy load all the time. That just isn't going to happen.But the fact a protective device is triggering means there is something amiss.
May not be the amplifier at all.Hope this helps73Gary. For the third time in three years, I've had a problem with my Alpha 8410 1500-Watt amplifier. I first bought an Alpha 8410 in February 2012. IT LASTED A WHOLE THREE WEEKS!! I was able to reach the president of Alpha and convince him that my amplifier was a lemon and so he had Alpha personnel ship me a brand-new 8410 amplifier.The second 8410 lasted two years and then in June 2014,some of the components on the 'output' circuit board burned up while I was transmitting on 80 Meters into a dipole antenna. Since my second Alpha was under warranty, Alpha gave me a RA number and asked me to send the defective amplifier back to Alpha for repairs. That cost me $120.00 for FEDEX Ground shipping and then Alpha charged me a $35.0 'Laboratory' fee.I got my Alpha back after waiting a month and it worked fine for three months.
Then last week, the exact same defect happened again and my Alpha went belly-up for the second time in three months.After looking at the Alpha 8410 schematics, I came to realize that the so-called 'output' board is a misnomer because it is really the amplifier's input/output board where the PL-259 from the transceiver is connected and the PL-259 from the antenna coax is also connected. Thus, this circuit board is an input/output circuit board. Anyway, I discovered an engineering design flaw in the board schematic.
The part that burned up in my amplifier was called a 'spark arrestor' or a 'spark-gap arrestor.' This device is rated at 1000 Volts at 20 Amps and is located just before the output SO-239 on the circuit board.The problem is: THE DEVICE SHOULD BE RATED AT 5000 Volts-AND NOT 1000 Volts!!!! Using the equation: E=W/I, where E= Voltage and W= Watts and I equals current in the antenna output circuit, I measured the 'normal' output current for a 1,500-Watt transmission and it was 0.3 Amps.
Using this formula, the voltage is 5000 Volts and not 1000 Volts so naturally the spark-gap device exploded when subjected to five-times the amount of the rated voltage- voltage that it was NOT designed to withstand.Now I have to convince the people at Alpha that they made an engineering and/or design mistake with this amplifier and they need to replace the 1000-Volt spark-arrestor with a 5000 Volt spark arrestor. Oh yes, the other half of this equation is the 20 Amp rating for the spark-arrestor. IT WOULD BE ALMOST IMPOSSIBLE FOR 20 AMPERES OF CURRENT TO FLOW THROUGH THE ALPHA-8410 ANTENNA CIRCUIT.
Such high current would melt the coax cable connected to the SO-239 and it would probably cause my four-element Yagi to glow bright red. At least someone at Alpha should have caught this error!!! Click to expand.An amp running 1500 watts into an antenna that should be about 50 ohms will be this.P=I2(R) 1500= I2(50) 1500/50=I2 =30 square root of, so the current will be about 5.5 amps The voltage will be E=IR E= 5.5 X 50= about 275 volts. Your math is way off. Now if your antenna has an impedance that is much higher than 50 ohms than these numbers will rise.
I would think if your antenna system is in good order and you are not running a condition that will raise the antenna line voltage, you should never exceed the rating on that device. If you are blowing that same device repeatedly, I would think you are running the amp outside the rated limits of tolerable SWR. Does the amp have a 'tolerable' SWR rating? The spark gap burning up isn't the problem, it's a symptom of the real problem. What's firing the spark gap? Is the antenna arcing?
Are the coaxial connectors arcing? Is the choke open?The spark gap fires on peak, not RMS, voltage.
The peak voltage for 1500 watts into 50 ohms is 390 volts. To achieve 1 kV peak at 1500 watts the resistive load impedance needs to be 330 ohms.The spark gap is paralleled with a 1 mH choke which prevents the antenna from slowly charging up and firing the spark gap. If the spark gap fires, the voltage drops to around 30 volts. If RF is applied continuously after the spark gap fires it can burn up. Note that when the source of current is removed the spark gap takes time to deionize; longer than an HF RF cycle. So, once the spark gap fires with RF applied it will continue to conduct. Yeah, I'd go over all the connections from the amp to the antenna to look for the loose one.
Short one end and set up a beeping meter across the other end. Flex the cables as they go into the connectors and listen for the beep to interrupt. It's easy to make a test jig SO239 'T' with the meter in it to use as you move along.
I bet there's a broken wire/loose connection somewhere. This is all assuming that the system is presenting less than 2:1 or so at the frequencies of interest.
What band were you on when the trouble happened the last time? What does the antenna system measure in that band? What's in the line from the amp to the antenna? Check every connection carefully, including inside tuners, etc.Oh yeah, and tell us if you find something! We're curious.cheerios,chris. The 1000V is a bit marginal.With a perfect (1:1) SWR, of course the voltage should never exceed 387.24Vpk at 1500W output power. But if you operate way off resonance on 80m, as a lot of us frequently due because no conventional 80m antenna has an SWR of 1.0 over more than about 20 kHz of the band, the peak voltage can certainly exceed 1 kV under some conditions and fire the device.I didn't study the 8140 schematic or theory of operation at all, but I'd suspect when the suppressor faults, that's intended to trip some protection circuit and put the amp into standby/bypass immediately.
Sounds like that isn't really happening.I've never been a fan of complex protection circuits. In the model 87 I had for a while, the only thing in the amp that ever failed were the protection circuits. The RF circuitry and power supply never failed in any way. But the 'protection' circuit failures would take the amp down instantly and it would remain down until stuff was replaced - in the protection circuitry. Click to expand.When I was in the market for a legal limit amp, I looked at some used Alpha's, but it was exactly this issue that turned me off them.
It's great to have protection, but it seems the Alpha's have a reputation of being off the air more often because the protection circuitry failed - not the amp it's supposed to protect.I went with a QRO Technologies HF-2500DX instead - new - for the price of a used Alpha. The only IC it has is a 555 timer for the warm-up. There is a grid current protection circuit, and I have tripped it multiple times (like when forgetting to turn down the exciter to 15W), but a quick push of a button and I am back on the air.That, and the plate and filament transformers weigh more than an Alpha 89. You can never have too much power supply.SteveKV6O. When I was in the market for a legal limit amp, I looked at some used Alpha's, but it was exactly this issue that turned me off them. It's great to have protection, but it seems the Alpha's have a reputation of being off the air more often because the protection circuitry failed - not the amp it's supposed to protect.I went with a QRO Technologies HF-2500DX instead - new - for the price of a used Alpha.
The only IC it has is a 555 timer for the warm-up. There is a grid current protection circuit, and I have tripped it multiple times (like when forgetting to turn down the exciter to 15W), but a quick push of a button and I am back on the air.That, and the plate and filament transformers weigh more than an Alpha 89. You can never have too much power supply.SteveKV6O. Click to expand.The 'older' Alphas never had these problems and were built like tanks. I've owned a 77DX, a 374, a 78.all had 'zero' protection circuitry of any kind and just worked and worked and worked. The only thing that could make one fail was if someone turned the bandswitch while transmitting (a common multiop contest station problem!) - don't ask how I know that.But basically, they never failed.Then.I picked up a pristene but used model 87.
I had to fix it four times in two years, and each time it was 'control circuitry.' I sold it.My 'very dumb' homebrew 4-1000A amp has never failed at all and I built it in 1984.
It uses a 'pull' tube that was surplus from an FM BC station in 1983. The 'pull' tube is still in there and still runs 1500W output power. No protection circuitry of any kind. It's grid-driven so only needs about 20W drive. So, I built a 6 dB resistive attenuator into the input circuit, inside the T-R relay path. Now it's almost impossible to overdrive and I just watch the screen current for tuning. I really don't watch anything else.My 'equally dumb' Ameritron AL-80B has been in service 13 years, daily, and other than replacing the 3-500Z a few years ago has never failed in any way at all.
The original tube didn't fail, but got weak.took more grid current to make the suds, and I could tell it was going downhill. The new 'RF Parts' tube purchased in 2010 is still fine.My old original Alpha 374 (3 x 8874s) is now about 36 years old or something and still runs full power with its original tubes, per the second owner who I sold it to. That was my 'miracle amp,' in that it was an old original 374 that actually used only one single muffin fan to cool three 8874s. I never, ever thought that would actually work well. Evidently, it did! If you don't overdrive those tubes, they're bulletproof.
Not sure how you've done your math and at what point in the circuit.At 1500 watts the antenna has delivered to it 273 volts of RF at 5.47A. That's with a 50 ohm load.So a 1000 volt spark arrestor is about right unless something is breaking down in your antenna causing a rapid pulse that triggers the spark arrestor.It would be next to impossible to ask the unit be placed on a dummy load all the time. That just isn't going to happen.But the fact a protective device is triggering means there is something amiss. May not be the amplifier at all.Hope this helps73Gary.