Procedure 4-1, “Unpack the amplifier and transformer,” page 4–1
Procedure 4-2, “Install the transformer,” page 4–3
Procedure 4-3, “Connect the transformer,” page 4–4
Procedure 4-4, “Connect the cables,” page 4–7
Procedure 4-5, “Connect the transceiver keying line,” page 4–10
Procedure 5-1, “Start up the amplifier,” page 5–5
Procedure 5-2, “(Optional) Change the antenna settings,” page 5–7
Procedure 5-3, “Autotune the amplifier,” page 5–8
Procedure 5-4, “Manually tune the amplifier,” page 5–9
Procedure 5-5, “Program the amplifier memory,” page 5–11
Procedure 5-6, “Operate the amplifier,” page 5–12
Procedure 6-1, “Set up to operate from a PC,” page 6–1
Procedure 7-1, “Clean the amplifier,” page 7–1
Procedure 7-2, “Replace the tube and fuses,” page 7–3
Procedure 7-3, “Upgrade firmware on the primary board,” page 7–4
Procedure 7-4, “Upgrade firmware on the secondary boards,” page 7–7
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Product Release 1
Introduction
1
1
1.1 Product Description 1–1
1.2 Product Capabilities 1–2
1.3 Safety Considerations 1–2
1.4 Related Products 1–3
1.5 Assistance 1–3
Congratulations on your purchase of a professional-quality Alpha 9500
linear amplifier.
1.1 Product Description
The Alpha 9500 (see Figure 1-1) is an self-contained autotune HF linear
power amplifier. It is capable of continuous operation at 1500 W peak
power output on single sideband (SSB), keyed continuous wave (CW),
slow-scan television (SSTV), radioteletype (RTTY), digital modes or
FM, with no time limit.
CAUTION
!
CAUTION! Study this manual carefully before operating your
amplifier for the first time. In particular, it is extremely important that
you thoroughly review the installation and operation sections. Failure
to do so could result in serious damage not covered under warranty.
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Figure 1-1 Alpha 9500
1.2 Product Capabilities
Product capabilities include:
1.3 Safety Considerations
Continuous RF output. The Alpha 9500 is capable of 1.5 kW
•
continuous RF output on all commonly used modes and on any
authorized amateur frequency from 1.8 to 29.7 MHz (other than the
60-meter band).
Compatibility with popular amateur transceivers and exciters. The
•
Alpha 9500 requires approximately 50-65 W peak RF drive for 1.5kW output.
Capable of full CW break-in, QSK, and all digital modes when used
•
with any appropriate transceiver.
Built-in protective functions. The control system incorporates
•
protective functions that minimize the probability of accidental
damage to the amplifier or its power tubes. In most cases, when one
of the protective functions is tripped, the amplifier goes to standby.
USB and serial interface allow for remote operations, diagnostics,
•
and firmware upgrades.
Page 1–2February 2010
Locate the Alpha 9500 where there is good air circulation all around
•
and on top of the cabinet. The unit may become hot during operation.
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Use proper lifting techniques and two people when moving the Alpha
•
9500. The Alpha 9500 weighs approximately 69 pounds when the
transformer is installed.
Although the Alpha 9500 meets international safety standards and
•
FCC regulations, remember that the equipment works with high
voltages that can be LETHAL!
This operating manual holds information, cautions, and warnings that you
must follow to ensure safe installation and operation. Read Chapter 1
before attempting to unpack or operate the Alpha 9500. Failure to perform
procedures properly may result in amplifier damage, fire hazard, or
electric shock.
11
1
IMPORTANT
!
1.4 Related Products
Never open the amplifier case without unplugging the unit
•
from the wall outlet.
Never stick objects into holes in the case.
•
Never touch an antenna during transmission.
•
Never attempt to turn on the amplifier without the cover
•
securely in place (all attachment screws reinserted).
Never turn the amplifier back on after a hard fault without
•
waiting at least 20 seconds.
Never press the ON (AMP) button after the amplifier faults to
•
power off.
Never allow liquids to enter the amplifier through the cover
•
holes.
Never cover or obscure the exhaust holes in the cover of the
•
amp.
Other products available to enhance your use of the Alpha 9500 include:
1.5 Assistance
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Alpha 2100 full-1500 W-rated 50-ohm dummy loads
•
Alpha 4500 series SWR meters and wattmeters
•
For more information, go to www.rfconcepts.com or call 303-473-9232.
Technical assistance from RF Concepts is available from several sources.
11
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Alpha 9500 Linear Amplifier User ManualRF Concepts, LLC
IntroductionProduct Release 1
Go to our website at www.rfconcepts.com and click Support. On
•
this site you can get the following assistance:
FAQs
•
Legacy equipment information
•
Manuals
•
Repair information
•
Software downloads
•
Tech tips
•
Technical support
•
E-mail us at service@rfconcepts.com.
•
Fax us at 303-473-9660.
•
Phone us at 303-473-9232.
•
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Amplifier Components and Specifications
2
2.1 Cathode (Input-Match) Board 2–2
2.2 Center-Partition Board 2–3
2.3 Controls and Display 2–3
2.4 Display Board 2–4
2.5 Firmware 2–5
2.6 Master-Control Board 2–5
2.7 Output-Tank Circuit 2–5
2.8 Power Connections 2–5
2.9 Power Supply 2–6
2.10 Tube and Tube Deck 2–8
2.11 Specifications 2–8
2
The Alpha 9500 uses a single 3CX1500 (8877) high-mu external-anode
triode ceramic tube for amplification. The main power supply is an
unregulated transformer/rectifier/capacitor power supply for the highvoltage (HV) and heater circuits. All other power supplies are regulated.
The biasing and tank circuits are similar in most respects to those of the
Alpha 9500’s predecessor, the Alpha 77. The unit has thoroughly modern
computer-controlled power supply and control circuitry. Extensive safety
measures protect the amplifier against most off-nominal conditions. It has
USB and RS-232 interfaces to aid in remote operation. All front-panel
features are accessible via these interfaces.
There are six main circuit boards in the amplifier. Communications
among these is via an I2C bus.
The amplifier front and back are shown below (see Figure 2-1 and
Figure 2-2). Amplifier components are listed alphabetically and described
below.
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Figure 2-1 Amplifier front and interior
Figure 2-2 Amplifier back
2.1 Cathode (Input-Match) Board
The cathode board, housed in the tube deck, consists of a set of Pi filters
controlled by a set of five relays that are enabled based on the band-switch
setting.
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2.2 Center-Partition Board
The center-partition board contains the RF decoupling circuit on the B+
line as well as the crowbar safety circuit. When you remove the top cover
of the Alpha 9500, the spring metal of this safety device shorts out the B+
line.
2.3 Controls and Display
The Alpha 9500 controls enable you to adjust and monitor the amplifier
as needed (see Figure 2-3).
IMPORTANTNote that the front panel has, in the upper-right corner, a 7-segment
LED display. The display contains 4 digits.
!
The buttons below the display control what kind of value is displayed:
FLT, Fwd, Ig, Ip, SWR, or Vp.
ANTENNA SELECTDetermines which one or two of the four antenna output ports to use.
BANDSelects an amateur band, designated in megahertz (MHz).
DELDisplays the delivered power from the amplifier to the selected antenna
port in watts (W).
DIMControls the brightness of the display LEDs.
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FLTSets the 7-segment display to show the last fault. Also loads new
firmware.
FwdSets the 7-segment display to show forward power in W.
GAINDisplays the gain in decibels (dB).
GRID CURRENTDisplays the grid current in milliamperes (mA).
IgSets the 7-segment display to show grid current in mA.
IpSets the 7-segment display to show plate current in mA.
LOADControls the load capacitor.
MEMORYSelects one of three sets of segment memories:
DEF — factory-default settings
•
1, 2 — User 1 and User 2 memories
•
AUTO — autotune
•
ON (AMP)Turns the amplifier tube and voltage on.
ON/OFF (ANT SEL)Turns antenna select on; the amplifier tube is not on.
OPERSets the amplifier to the operate position.
PEPToggles between peak power (PEP) and average power.
PLATE CURRENT meterDisplays the plate current in milliamperes (mA).
PLATE VOLTAGE meterDisplays the plate voltage in volts (V).
RCL(Currently nonfunctional)
RF POWER kW meterDisplays the forward power in W.
SAVESaves the current settings.
SEGMENTSelects different frequencies within each band.
SNDControls the sound volume (not yet implemented).
STBYSets the amplifier to standby (bypass).
SWR meterSets the 7-segment display to show SWR.
TUNE (UP or DOWN)Controls the tune capacitor.
VpSets the 7-segment display to show plate voltage in V.
2.4 Display Board
Page 2–4February 2010
The display board is the largest board in the amplifier and spans the entire
inside front panel. It has three microcontrollers, one each to control the
stepper motors; the LEDs and 7-segment display and push buttons; and
the sound controller.
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2.5 Firmware
The Alpha 9500 firmware controls and implements most amplifier
features and functions.
You can upgrade the master firmware via a serial or USB connection to a
Microsoft Windows PC. For information, see
and Upgrading the Amplifier.”
Chapter 7, “Maintaining
2.6 Master-Control Board
The master-control board monitors all critical voltages and currents in the
amplifier, as well as the input power and output forward and reflected
power. It uses these converted values to control the amplifier’s operation
and to send data to the front panel, so that the correct LEDs are lit and the
stepper motors move to the correct positions. A standard 9-pin RS-232
serial port is provided for control and monitoring and is found on the back
of the Alpha 9500. A USB port is also provided. Either port may be used,
but only one may be active at any one time.
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2
2.7 Output-Tank Circuit
2.8 Power Connections
The amplifier automatically senses when a PC is attached to the USB port,
and uses that port. If nothing is connected to the USB, the amplifier
automatically switches back to the RS-232 serial port.
The output-tank circuit provides reliable high-efficiency, low-distortion
performance in a very compact volume. The basic topology is “pi-L”,
which provides harmonic attenuation adequate to meet the requirements
of all countries globally that permit power outputs of 1500 W.
Band switching is under automatic control, accomplished by a 4-wafer
band switch. These wafers are used as multifunction tap selectors, which
simultaneously select band taps on the inductors and include varying
amounts of capacitance to provide band spread on the tune and load
capacitors. The wafers are in the RF tank area. The band-switch position
is controlled by a stepper motor in the front subchassis.
When the Alpha 9500 is powered up, it measures the line voltage and
chooses, then sets the appropriate tap setting for the transformer primary.
After it is powered up, it does not reset the tap. The amplifier can be set
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to override autotaps election and use any primary tap; it may be useful to
do so if your line voltage is unsteady or on the edge of a tap setting. For
more information, contact RF Concepts technical support.
Figure 2-4 Primary connections
2.9 Power Supply
The power supply has two major sections: a switch-mode supply for the
logic circuitry and a conventional transformer supply for all other
voltages.
When the amplifier is plugged into the AC line, the switch-mode supply
is always on and all the microprocessors are active. It is usual for some of
the front panel LEDs to blink momentarily when the unit is first plugged
in.
The remaining voltages are produced by the mains and HV boards,
described below.
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Mains Board
Figure 2-5 Mains board
22
2
Power-supply functions are split between the mains board and the HV
board. The mains board deals mostly with the primary side of the
transformer. The various taps for the transformer primary are routed
through this board and so is the AC line input. Relays on the mains board
connect the AC line to the appropriate taps on the transformer primary.
When the ON (AMP) button is pressed, the microprocessor on the mains
board samples the line voltage and determines which tap to select. That
voltage tap remains selected until the amplifier is turned off, and does not
change even if the line voltage fluctuates.
If you install your amplifier in a location where the line voltage is not
steady, you can force the tap selection via the serial or USB port. For
information on how to force tap selection, contact RF Concepts technical
support.
Also on the mains board is a step-start circuit. This circuit consists of a
relay and a resistor, which are time-sequenced to limit the inrush current
into the amplifier when it is first turned on.
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HV Board
The main high voltage for the amplifier is created on the HV board using
a full-wave bridge rectifier and a bank of capacitors. This power supply
has two 10-ohm resistors, one in the positive (B+) lead and one in the
negative return to the tube cathode. This combination of resistors limits
the surge current in the case of a B+ arc.
When the power-supply current exceeds about 2.5 amps, a latching relay
opens the coil circuit of the mains tap relays on the mains board, causing
the amplifier to go to the power-off state. This hard-fault circuit operates
independently of microprocessor control.
All power-supply filter capacitors on this board have bleeder resistors that
discharge the capacitors in less than 60 seconds. If you must work on this
board, confirm the discharged condition with a voltmeter, due to the
remote possibility of bleeder resistor failure.
2.10 Tube and Tube Deck
The Alpha 9500 uses a single 8877 triode tube. The tube operates well
within its published ratings. It is operated in Class AB1, with a plate
voltage of 3300 V (nominal, full output, key down) and a cathode voltage
of 9.4 V.
The tube deck is a mechanical assembly that houses the tube socket and
the cathode (or input match) printed circuit board (PCB).
A temperature sensor mounted on the cathode PCB measures the
temperature of the air immediately below the tube socket. This
temperature measurement is used by the master controller as part of the
fault-detection software.
2.11 Specifications
The Alpha 9500 linear amplifier specifications are as follows.
Table 2-2 Alpha 9500 linear amplifier specifications
ParameterValue
Frequency coverageAll amateur frequencies in the range 1.8–29.7 MHz
Power output1500 Watts minimum
3rd Order IM<–30 dBc
SWR tolerance3:1
Drive power65 Watts nominal
Tube3CX1500/8877
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Table 2-2 Alpha 9500 linear amplifier specifications (Continued)
ParameterValue
CoolingForced air
Antenna outputs4xSO-239 connectors
Antenna selection1 or 2 outputs per band/segment
InputSO-239 connector
Tuning/Band switchingAutomatic; manual override possible
Power100, 120, 200, 220, 240V AC, 50/60 Hz
Power tap selectionAutomatic
InterfaceSerial port with full remote-control capability
ProtectionProtected against all common faults
DisplayBar graphs as well as digital panel meter
T/R switchingVacuum relays; QSK (full break-in)
Bypass capability1500 Watts
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2
Wattmeter and antenna selector active in ON1 to allow use with exciter.
HV and tube come on in ON2 for linear use.
Width17.5 inches
Height7.5 inches
Depth19.75 inches
Weight76 pounds
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Preparing Your Station
3
3.1 Prepare Your Station
3
3.1 Prepare Your Station 3–1
3.2 Limitations of Operation at 90–130 VAC 3–3
The Alpha 9500 is capable of dramatically improving the performance of
your amateur station. It is important that you observe good engineering
practices to achieve all the benefits of such a station in a safe and reliable
manner.
This chapter provides a few important operational considerations. We
recommend that you also consult a good source of general information
such as the latest Amateur Radio Relay League (ARRL) Handbook for
Radio Amateurs, especially if this is the first high-power amplifier that
you have used.
Procedure 3-1 Prepare your station
Step 1 Provide 220 VAC power.
The amplifier runs best when powered by a 200–240 VAC circuit. If you
do not have a 220 VAC outlet in your station, have a licensed electrical
contractor install one. A minimum of a 20 A capacity is required. A 20-A
breaker on your 220-V circuit is sufficient.
When you size the circuit, be sure to include the current drawn by other
equipment that may be on the same circuit.
Select a location for the outlet as close as possible to where you expect to
operate the amplifier. If you are not sure or contemplate moving the
amplifier, consider installing two outlets.
There are many styles of power plugs, some of which are country-
specific. For this reason, the amplifier is not shipped with a plug. Ask your
contractor for two or three matching plugs during installation.
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Ask the contractor to measure the voltage and record it for reference.
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Preparing Your StationProduct Release 1
3
Although the amplifier can run when connected to a 110 VAC outlet, you
WILL NOT achieve full-legal-limit output in this case. Rather, you
should not expect more than 1000 W output. For more information on the
limitations of operation when connected to a 110 VAC outlet, see
3.2, “Limitations of Operation at 90–130 VAC,” page 3–3.
Note that, when the amplifier is plugged in and turned on, it is normal to
hear the capacitors and band-switch zero themselves and a slight “clunk”
as the transformer comes up to full load.
Step 2 Provide proper airflow.
It is critical that airflow around the amplifier remain unimpeded at all
times and that the top of the amplifier remain clear of any restrictions.
Maintain at least 3 inches of clearance around the amplifier to allow for
unobstructed airflow.
If you are mounting the amplifier in a console, ensure that the exhaust air
is properly and fully removed from the console. If outlet air is drawn back
into the amplifier air intake and recirculated, the amplifier gets hotter and
hotter, resulting in degraded performance or even failure. If you are
designing your own console, consider putting in additional fans and/or
ducting to deal with waste heat.
Section
Minimize the possibility of dust or other contamination getting drawn into
or falling on the amplifier. Periodically (at least annually) clean the dust
out of the amplifier, paying particular attention to the tube fins. We
recommend the use of compressed air for dust removal.
Step 3 Ready your antenna for 1500 W.
Ensure that all antennas are rated for 1500 W and that they are carefully
tuned and installed for minimum voltage SWR.
Many antennas that are suitable for general use are unsuited for operation
with a full 1500 W of power. At this power level in a 50-ohm circuit, the
RMS current is 5.5 A and the peak RF voltage is 387 V. For SWR = 2:1,
these values double to 11 A and 775 V. The actual voltage and current at
various points in or on your antenna may actually be many times these
values.
Step 4 Provide adequate RF cabling.
The importance of a well-constructed feed-line system cannot be
overstated.
Use good-quality low-loss coaxial cable of size RG/8 or larger. The Alpha
9500 is intended for a nominal 50-ohm load. With proper matching (50
ohms) between amplifier and feedline, open-wire feeders or lines of other
than 50 ohms may be used.
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Use new, clean connectors and install them according to manufacturer
recommendations. Clean the connectors after soldering them and before
mating them with the amplifier.
Install system feedlines following good engineering practice and
according to manufacture recommendations.
33
NOTE: The FCC requires users to check their installations for
compliance with published values for allowable exposure to RF fields.
This information is available in ARRL publications, FCC printed rules,
and on the web. We strongly recommend that you do this for any
installation, both fixed and at an expedition or contest site.
If you have any questions regarding engineering your amplifier into
your amateur radio station, go to www.rfconcepts.com and click
Support.
Step 5 Provide surge protection.
Induced energy from nearby electrical storms or other power transients
may damage components. Such damage is not covered under warranty. It
is therefore important to use a good lightning arrestor. However the only
lightning-proof solution available is to disconnect antenna feedlines and
AC power when the equipment is not in use.
NOTE: Whenever the amplifier is online — either off, in standby
(STBY), or in warm-up with the WAIT LED lighted — the amplifier is
bypassed and the exciter is connected directly to the antenna. The
throughput limit in all cases is 1500 W.
3.2 Limitations of Operation at 90–130 VAC
3
Electrical-power equipment draws twice as much primary current from
120 V mains as from 240-V mains. Therefore, if you operate the Alpha
9500 on typical 120 V/20 A household circuit without exceeding the 20-
A circuit rating, you limit maximum peak power output to about
600–1000 W.
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3
If your line voltage is below 110 V under load, do not expect to be able
to get 1500 W output (see
Table 3-1 Amplifier behavior with nonstandard line voltages
Line voltageExpected behavior
Low: 90–110 VPower outputs above 1000 W are not expected.
Normal: 110–130 V 1500 W PEP operation (CW or SSB) may be
High: >250 VLifetime of the tubes may be reduced. Ask your
Table 3-1).
possible if your AC line service has sufficient
current capacity (30-A circuit recommended).
However, 1500 W continuous should not be
expected.
utility company if they can reduce your line
voltage. If this is not possible, consider placing
your own step-down transformer in line between
the AC outlet and the amplifier. A transformer
with at least 4-kVA rating is required, due to the
nature of the current waveform in the primary.
Another choice for voltage control, a ferroresonant
voltage regulator, is an expensive solution, but is a
good way to stabilize primary voltage.
NOTE If you intend to operate the amplifier at ~120 V or if other equipment
draws current from the same circuit as the amplifier, the following
apply:
1. If you replace the factory-shipped 20 A/250 V fuses with 25 A/250
V “slo-blo” fuses (for line voltages of less than 100 V), be aware
that the higher current at the lower voltage significantly warms the
amplifier’s power cord. The cord (as well as fuse holders and
some internal connectors) are operating near their maximum
ratings due to the current demand at lower voltages.
2. Ensure that the AC cord is not coiled too tightly or placed where
normal air flow is restricted, causing it to overheat.
3. You must change the two lower 2A fuses on the rear panel to 5A
fuses to allow for the increased in-rush current.
Page 3–4February 2010
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