Ameritron 2WUALS606 User Manual

Ameritron ALS-606

600-Watt 160-6 Meter

T-MOSFET AMPLIFIER

The Ameritron ALS-606 is 600-watt nominal output, 160- through 6-meter amateur radio band, solid-state amplifier. The ALS-606 uses four 50-volt linear RF MOSFETS. These MOSFET’s are specifically designed for linear power amplifier applications, rather than non-linear or pulse service. They provide lower SSB distortion when compared to non-linear application solid-state devices in SSB service. Fan speed is regulated by temperature sensors; assuring conservative cooling with minimal noise.

Nominal driving power is 75-watts for 600-watts output (approximately 9 dB gain) on most bands. The compact 9-1/2” wide by 7” high amplifier package (depth only 14”) fits nearly any station configuration. This attractive desktop amplifier unit weighs approximately 14 pounds.

An external 50-volt 25-ampere CCS power supply powers the ALS-606. Two different supplies are available, the ALS-600SPS switching regulated supply and the ALS-600PS unregulated supply. These supplies operate on all standard residential powerline voltages.

Exhibit VIII Manual ALS-606 HO82WUALS606

Ameritron Engineering 371 Dean Rd. Barnesville, GA 30204 Ph 770-358-3335 Cell 770-596-3514 Email W8JI@W8JI.com

Quick Start

Thank you for purchasing this amplifier system.

The ALS606 is a compact 600-watt nominal PEP output amplifier. It uses an external power supply system. This amplifier covers 160-6 meters. Nominal drive power is 75-watts or less. NOTE: This amplifier excludes

all operation between 25 and 28 MHz.

The ALS606 interfaces with most modern amateur radio transceivers. Supported band data input includes ICOM compatible analog voltage, Elecraft and Yaesu BCD band data, and Kenwood serial data. With proper interface cables and data, this amplifier will automatically change bands in step with transceiver band changes. Automatic band selection using a band data port or band decoded bus requires purchasing an Ameritron interface cable for your radio.

Carefully unpack this amplifier and power supply. Please inspect everything for physical shipping damage; this includes cabinets and chassis. Ameritron does not package dented or damaged units. Cabinets and controls can be broken, bent, or dented with rough handling. If a new unit arrives mechanically damaged, including broken knobs or switches, it is always from handling somewhere between Ameritron and the end user. In the event of cabinet damage or broken controls, please contact the dealer immediately. To permit claim processing, retain all boxes and packing materials.

Installation and Operation

WARNING: Do not block ventilation holes. Do not expose to moisture, water, or external heat.

This power amplifier system consists of two units, a power supply and an amplifier section. The amplifier section has metering and operator functional controls. Locate the amplifier section at a convenient place with proper space for airflow, within the operator’s reach and view. The power supply can be placed anywhere within cable length limits. Do not extend the amplifier power supply dc power cable.

Power Line or Mains Connections

There are two distinctly different power supplies available for the ALS-606. The ALS-600PS is more basic unregulated choke input supply. The ALS-600SPS is a state-of-the-art regulated switching mode supply. Please read the appropriate sections below. For non-export use, each supply comes with a standard NEMA 5-15P twoblade 120V 15A plug with round safety-ground pin.

Overall amplifier operation remains similar with either supply; except the linear supply has a RTTY and Normal voltage switch. The RTTY position allows higher amplifier efficiency at reduced power. See the power supply details included with the particular power supply for details specific to each supply. This includes operation on various line voltages, power supply operation, fuse selection, location, and power supply trouble shooting.

Non-export versions of Ameritron ALS-600 series power supplies are wired and fused for 120Vac USA power mains, but all are modifiable to other standard power mains voltages.

ALS-600SPS

1.) The USA standard version ALS-600SPS is supplied wired for 95-135 Vac, 50-400 Hz, 15-ampere or larger electrical service. Reconfiguring internal jumpers on the power supply board will allow 185-260 volt operation.

2.) The ALS-600SPS is internally regulated. Beyond 120 or 240V concerns, the ALS-600SPS does not require voltage tap changes. There should be very little change in HV1 (PA voltage) with amplifier power and line voltage. Less than 3 volts change from the 50Vdc nominal voltage is acceptable

3.) Do not operate with line voltage below 95 or above 135 volts (185-260 volts when wired for “240

volts”).

4.) Unless power mains fall below 100 volts, the ALS600SPS switching supply provides the same performance on 120-volts as on 240-volts. The only function reasons for 240-volt power mains are light dimming and unintentional line breaker opening. If outlet wiring is already loaded heavily, or if house wiring is sized too small for the distance to the mains supply, you may have to use a dedicated 120-V amplifier line, or rewire the supply and use 240-volt mains

5.) With 120Vac mains at 600-watt nominal RF output, current draw is approximately 12 amperes on steady carrier. Peak line current is typically much less than 8 amperes at 600 watts PEP on SSB voice

6.) The ALS-600SPS can be located anywhere, within reach of interfacing cables, convenient to your operating setup. The location must be dry, airflow must not be restricted, and outside temperature must not be over 120F (49C). You must not extend or shorten the amplifier to power supply cable

7.) Exceeding safe power supply load current forces the switch mode supply into shutdown. Restore operation by turning the main power switch off for a brief time. If the power supply detects a permanent overload or the supply has failed, the supply will not reset

ALS-600PS

The ALS600PS uses a standard transformer with choke input filter system. It weighs significantly more than the ALS-600SPS, and is not voltage regulated.

1.) The ALS600PS requires a 100-130 Vac, 50-60 Hz, 15-ampere or larger mains supply. This supply is reconfigurable for 210-250 volts by moving internal jumpers. The line cord uses a standard USA NEMA 5-15P two-wire male plug with safety ground

2.) This supply is unregulated. Voltage range includes all typical residential power line voltages, but the internal buck-boost winding must be reconfigured if output voltage is more than 58 volts no load. Operation with no load voltages over 58 volts can compromise FET reliability

3.) With 120Vac mains, current draw with steady 600-watt carrier is typically around 12 amperes. Line current is typically less than 8 amperes at 600 watts PEP SSB voice.

4.) The ALS600PS normally provides the same performance at 120-volts as at 240-volts, unless the power mains have excessive voltage drop. If you experience light dimming or line breaker opening, move the supply to a dedicated 120-V line, or reconfigure the supply for, and use, 240-volts

5.) This supply does not have overload protection, other than standard fuses

Radio and Antenna Connections

WARNING: Forcing connector engagement can result in permanent connector damage. Solder on the outside of center pins or bent pins are primary causes of female connector damage. External solder or bent center pins can permanently damage the female.

Do not use Line Isolators on amplifier RF cables. The chassis of the amplifier should be at the same RF potential as all other desk equipment. Shield isolators allow equipment to float to different RF chassis potentials. Different chassis potentials are exactly what we do not want, and isolators on desk coaxial cables encourage differing enclosure RF voltages. It is better to cure RF problems outside the operating position.

1.) RF connections are through standard UHF female connectors. Use 50-ohm coaxial cables with quality, properly soldered, UHF male (PL259) connectors. The output cable must safely handle at least 600 watts

2.) Examine the RF connectors. Female SO-239 UHF connectors have notches on the outer threaded-area edge. PL259 UHF males have protruding tabs on the metal outside the center-pin insulator. These tabs and notches prevent unwanted connector rotation. The male tab or tabs must align and fit into female notches. This interlocking prevents connector rotation. It is best achieved by slightly wiggling or rotating the cable while hand-tightening the male’s shell to seat the male tab in the female notch.

3.) With a firm handgrip, while making sure the PL259 male connector tab interlocks with the amplifier’s SO239 chassis connector notch, gradually tighten RF connectors. Do not use excessive force on connectors. Check for proper tightness and seating by wiggling and flexing the cable and watching for any male connector movement on the female. Properly seated, connectors will be solidly locked without use of pliers or tools

4.) ALC and Relay (keying or TR line) connectors are standard phono females. Phono males from external cables should push directly in with a snug, but not overly tight, fit

5.) The Relay line operates with low voltage (<12V) and low current (<20 mA). Transmit is enabled by pulling the Relay line to ground with a relay contact or transistor. Read your radio manual. Unless you have a very unusual radio, your radio should directly key this amplifier. Avoid using external interfaces with relays. Amplifier relay switching time is approximately 10-12 mS

6.) The remote and radio band data connectors are specialized connections. They are for use with Ameritron supplied cables only

Operation

Before attempting operation:

1.) This amplifier is optimized for 50-ohm loads. Be sure your antenna system 50-ohm SWR is as low as possible. As SWR increases from 1:1, either heat or distortion will increase

2.) Be sure your antenna system, including any switches, baluns, matching circuits, or lighting protection devices, are in good condition and will safely handle high power

3.) Connectors, cables, and antennas must not have loose connections or insulation failure issues

4.) Your exciter must be adjustable to significantly less than 100-watts output. Start at 50 watts maximum drive power and increase or decrease drive to reach desired power. Do not exceed 25 amperes or 600 watts, and do not drive into non-linearity on SSB. A trapezoid scope pattern is recommended for drive adjustment. Overdriving results in an excessively wide signal, and overdriving can damage the amplifier

5.) Power mains should be reasonably stable and match power supply voltage wiring

6.) The low pass filters cut off just above the traditional primary amateur bands. A primary band’s filter is used on the next lower WARC band. For example, the 20-meter low pass filter is used on 30 meters. Some radios do not supply enough band data to know the exact band. With these radios, amplifier band data displays the next higher primary band above the radio’s WARC band. If you are using such a radio, do not be alarmed if 15 meters illuminates when the radio is on 17 meters. This is still the correct filter

7.) The amplifier will automatically attempt to reduce power if it appears thermal limits will be reached

8.) The amplifier will shut off with an incorrect band selection, high antenna SWR (even for an instant), if safe thermal limits are reached, or with catastrophic failures.

9.) The ALS-606 reads peak envelope power on forward and reflected RF power scales

Alerts

This amplifier has front panel alert codes using the SWR, PA, TX, warning LED’s and bandswitch band indicators. When a fault code appears, the amplifier is disabled. When an operating problem is corrected, operation is restored and alerts canceled by moving the front panel Standby/Operate switch to Standby. The following table applies to faults:

Warning light

Steady

Warning light

Flash

Fault

Cause or Cure

SWR

Antenna Reflected Power

High antenna SWR or intermittent antenna

or feedline connection

SWR, PA

Band

Wrong filter

Filter input SWR

Exciter or amplifier on incompatible band,

filter failure

PA, TX

PA FET too hot

Excessive power for duty cycle or SWR,

lack of proper airflow

10M, PA, TX

Illegal 11 meter

Excessive 27 MHz signal level

REM, PA

No data or bad band data when

on remote

Defective or improper remote cable, or bad

radio band data information

With proper station installation, and with low antenna SWR, amplifier operation is straightforward:

1.) Set the bandswitch to the desired band. This happens automatically in the REM position with a suitable radio interface cable. Set ALC full clockwise. Turn the amplifier power switch ON, but leave the amplifier in STANDBY

2.) Set the exciter or transceiver to 50 watts carrier power. This power should show on the amplifier’s FORWARD POWER meter. REFLECTED power should be very low

3.) Move the amplifier standby-operate switch to OPERATE

4.) Transmit while watching the Forward Power reading, quickly adjust exciter power for less than 25 amps Id current, or less than 600-watts power output

5.) For high duty cycle modes and long transmissions, or if linearity is a problem, reduce power. The amplifier has overload protection circuits, and will also attempt to reduce power if the FET’s approach safe limits, but it is best to not rely on protection

6.) Adjust ALC to limit either forward power or amplifier PA current to a desired value at or below maximum ratings, counterclockwise reduces power and current. The ALC light should just flicker if ALC is limiting power properly. If the ALC light is on almost continuously, reduce the transmitter’s power output setting

Typical Wiring

Table of Contents

TABLE OF CONTENTS .......................................................................................................................6

AMPLIFIER FEATURES ......................................................................................................................7

POWER SUPPLY...............................................................................................................................10

Power Line Requirements ...................................................................................................................................................................11

Power Supply Features........................................................................................................................................................................10

Power Supply Location .......................................................................................................................................................................11

GENERAL INFORMATION ................................................................................................................11

Amplifier.............................................................................................................................................................................................12

INSTALLATION..................................................................................................................................12

INTERCONNECTION WIRING...........................................................................................................15

AMPLIFIER REAR PANEL ................................................................................................................17

FRONT PANEL ..................................................................................................................................19

OPERATION.......................................................................................................................................15

MARS OR CAP OPERATION ............................................................................................................15

INITIAL OPERATION .........................................................................................................................20

CIRCUIT BOARDS.............................................................................................................................22

TECHNICAL INFORMATION.............................................................................................................22

Amplifier Features

This amplifier provides the following standard features:

 160- through 6-meter operation, full-power on six meters  Four conservative linear-service rated 50-volt MOSFET transistors  New push-pull stripline PA layout with exceptional VHF performance  Energy-efficient solid-state design greatly reduces heat, <100-watts power line draw on receive  Exceptional harmonic suppression  Operational in a few seconds, no long filament warm-up time  Clean layout with easy-to-service modular construction  Quiet variable-speed forced-air cooling system  Power module current and voltage meters with LED illumination  Accurate PEP Forward and PEP Reflected output power metering  Reflected power protection  Thermal overload protection  Bandswitch error protection  Easy to understand front panel LED indicators for rapid fault-error diagnosis  Standard negative-going ALC output with front panel adjustment  ALC metering and ALC LED indicator  Fully-regulated external switch mode power supply, or linear unregulated supply  Compact size 14” deep x 7” high x 9.5” wide  Weight amplifier section 15 pounds

Power Supply

ALS-600PS

Power Supply Features

 Normal operating range is from 100 volts up to 130 volts 50/60Hz (12-amperes typical full carrier

power) or between 200 and 250 volts, 50/60Hz (6 amperes typical at full carrier power)

 A unique "buck-boost" winding allows compensation for up to six different power line voltages centered

on 115 and 230 volts. This versatile Ameritron feature maintains optimum voltages on the amplifier components for maximum performance and life

 The ALS-600PS standard power supply uses an input choke to provide low power factor loading on

power lines. This reduces the peak currents drawn from the line and improves the voltage regulation of the supply. This makes the ALS-600PS generator and inverter friendly within the acceptable powerline frequency range of 50 to 60 Hz

 Step-start to limit stress on power supply components  An illuminated cross-needle meter monitors 50V line output voltage and current  Weight 33 lbs.

ALS-600SPS

Power Supply Features

 Efficient operation from 100-130 volts ac (12 amperes typical at full output power) or  Low standby and receive power drain, typically less than 100-watts  Generator and inverter friendly with acceptable powerline frequency range 40 to 400 Hz  Fully-regulated current-limited outputs  Excellent voltage regulation  Exceptional filtering and RFI suppression eliminates receiver birdies common to most SMPS  Light weight 13 lbs.  Inrush protection  An illuminated cross-needle meter monitors 50V line output voltage and current.

The ALS-606 external power supplies contain 14-volt positive and negative supplies, as well as a 50-volt 25ampere continuous (30-ampere peak) main supplies. The ALS-606 PA (power amplifier) module operates from 50-volts, giving a total dc supply rating of 1250 watts average power and 1500 watts peak dc power. The 12volt supplies are for illumination, bias, and control functions.

Power supply to amplifier interconnections are through a heavy-duty cable using reliable Cinch Jones connectors.

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