Ameritron ALS watt NO TUNE

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1 Ameritron ALS watt NO TUNE TMOS-FET AMPLIFIER The Ameritron ALS-300 is 60 through 5-meter amateur radio band 200-watt output solid-state amplifier. It uses eight 50-volt conservatively rated linear RF MOSFETS. 50-volt linear FET s designed for transmitting service produce an exceptionally clean signal compared to other solid-state amplifiers. Fan speed is regulated by temperature sensors; assuring conservative cooling with minimum noise. Nominal driving power is 90 watts for 200-watts output (approximately db gain) on most bands. The compact wide by 6-/2 high amplifier package (depth only 8 ) fits nearly any station configuration. The attractive desk-top amplifier unit weighs only 22 pounds. An external 50-volt 50-ampere regulated power supply powers the ALS-300. The supply is wired for 230 VAC ( VAC, Hz, 5 amperes), but can be rewired for 20 VAC operation for lighter duty operation.

2 Table of Contents TABLE OF CONTENTS...2 AMPLIFIER FEATURES...3 POWER SUPPLY...4 Power Line Requirements...4 Power Supply Features...4 Power Supply Location...4 GENERAL INFORMATION...5 Amplifier...5 Power Supply...5 INSTALLATION...5 Airflow...6 INTERCONNECTION WIRING...7 AMPLIFIER REAR PANEL...8 FRONT PANEL...9 OPERATION...0 MARS OR CAP OPERATION...0 INITIAL OPERATION... CIRCUIT BOARDS...2 CB

3 Amplifier Features This amplifier provides the following standard features: Eight conservatively rated, very linear, 50-volt MOSFET transistors Operational in a few seconds, no long filament warm-up time Clean layout with easy-to-service modular construction Front panel indicators including wrong band and other fault errors Quiet variable-speed forced air cooling system Power module balance metering Power module current and voltage metering with LED illumination PEP forward output power and PEP reflected output power metering Reflected power protection Bandswitch error protection Standard negative going ALC output with front panel adjustment control ALC metering and an ALC LED indicator Fully regulated external power supply Compact size 7.5 deep x 7 high x.5 wide Weight amplifier section 23 pounds 3

4 Power Supply The power supply for the ALS-300 is a voltage regulated current limited supply. It contains 4-volt positive and negative supplies as well as dual 50-volt 25-ampere continuous (30-ampere peak) fully current limited supplies. Each PA (power amplifier) module in the ALS-300 operates from the separate 50-volt sources, giving a total dc input power rating of 2500 watts to the power amplifier modules. Power supply to amplifier interconnections are through a heavy-duty cable using a large Cinch Jones connector. Power Line Requirements This amplifier ships wired for Vac. The maximum average power line current is 2 amperes at 240 volts. Two 250-volt 5-ampere fuses fuse the power line. Note: 20-volt power mains operation is possible with a reduction in CW or RTTY power. Because average power is very low, SSB operation is unaffected by 20 volt operation. Fuse size would be 25 amperes maximum. Power Supply Features Efficient operation from volts ac (2 amperes minimum) and 0-35 volts (20 amperes minimum) Wide range of power line frequencies, Hz Fully regulated current-limited outputs Step-start to limit stress on power supply components Exceptional filtering and RFI suppression Compact light-weight design Power Supply Location Locate the power supply in a convenient ventilated area near the amplifier location. Do not place the power supply next to sensitive equipment like audio processors, transceivers, or microphones. For safety ground the wing nut stud on the supply rear to the station ground buss. The station ground buss should comply with national electrical codes. These codes dictate that station grounds must be bonded to the power mains entrance ground. A station ground that is not bonded to the mains ground does not offer lightning protection! 4

5 General Information Amplifier The Ameritron ALS-300 is a solid-state 200-watt nominal RF output power.8-22 MHz amplifier. This power is peak envelope power, which is the same as actual carrier power on CW. It uses eight exceptionally very low distortion push-pull parallel MRF-50 or equivalent RF power TMOS transistors. The ALS-300 meets or exceeds all FCC rules governing amateur radio external power amplifiers. Two temperature sensors on each PA (power amplifier) module, with bias tracking FET temperature and fan speed tracking heatsink temperature, control bias and fan speed. Harmonic suppression comes from push-pull operation of linear devices, and a series of high quality 5-pole low-pass filters. This amplifier exceeds all FCC mandated harmonic restrictions. Antenna switching is through a sequenced pair of miniature relays on a plug in board. Relay switching time is approximately five milliseconds. This amplifier s relay jack sources 2 volts when open circuit, and the relay jack current upon closure is less than 20 ma. This amplifier includes two dual-movement cross-needle meters. This is the equivalent of having four panel meters. The left hand meter is a dual power amplifier current meter. The right hand meter continuously displays forward RF peak envelope power on one dedicated scale, while the second movement in the right hand meter switches between reflected power, combiner mismatch voltage, ALC, and each power amplifier s voltages. While this amplifier will run more than 200 watts PEP output, linearity will suffer. Ameritron recommends running 200 watts peak power for maximum linearity, at which point this amplifier will have comparable IM performance to the best vacuum tube linear amplifiers. The characteristics of linear high-voltage FET s are very much like those of triode vacuum tubes. Power Supply The ALS-300 has an external power supply. This power supply normally operates from volts at Hz. It connects to the amplifier through a single cable. The power supply should be located in a cool spot away from sensitive audio systems or cables. Installation Please look your amplifier and power supply over carefully. Observe the air inlet and outlet ventilation holes. Locate the air inlet and outlet areas of the amplifier. Facing the amplifier front panel, the cooling air inlet is on the right side. The warm air outlet is on the left side of the amplifier as viewed from the normal operating position (front view). While the outlet air won t be particularly warm, it is never a good idea to have it blow into heat sensitive equipment such as transceivers or other power amplifiers. Have the same consideration for your new amplifier and power supply. Be sure the air inlet temperature isn t substantially above normal room temperature. Ideally the air inlet should be kept below 32 C or 90 F, although temperatures up to 4 C or 6 F are permissible. If ambient temperatures exceed these limits it might become necessary to reduce duty cycle or power. Warning: Do not block cooling air inlets and outlets! Never expose the amplifier to water or mist. 5

6 Airflow The amplifier must have a clear area to the sides and top for proper airflow, and to the rear for interconnection wiring. It is especially important to avoid obstructions that block the air inlet on the top left and both lower sides. Two inches clearance is normally adequate for full ventilation. Keep any papers or loose objects that might impede airflow away from the air inlets and outlets. Locate the amplifier and power supply away from sensitive equipment such as microphones, audio processing equipment, or low level audio or radio frequency amplifiers. Generally the best location for the power supply is below the operating desk and away from antenna feedlines. This will keep fan noise and any RF coupling to a minimum. The power supply is factory wired for Vac. It uses a standard NEMA-6-5P 5-ampere 240-volt plug. The round center pin is the safety ground. Do not remove the safety ground. CAUTION! Before connecting the power supply to an electrical outlet, always be sure you have completed the following four steps:. Insert the 5-ampere 250V fuses into the two black fuse caps. 2. Insert the fuse and cap assemblies into the power supply s fuse holders. The fuses lock in place with a slight turn. 3. Connect the power supply to the amplifier. 4. Be sure the amplifier power switch is turned off. Caution! Fuses have both voltage and current ratings. Use only 250V rated fuses in this device. The voltage rating generally is marked on fuses. DO NOT use automotive-type low voltage fuses in any power line application. For 240- volt operation 5-ampere fast blow fuses are required. Warning: Never insert the power supply cord into the outlet unless the above four steps have been completed!! Position the amplifier at the desired location on your operating desk, position it so you have access to the rear panel, and connect the rear panel cables. Do not connect the power mains at this time! 6

7 Interconnection Wiring POWER SUPPLY ANTENNA, ANTENNA TUNERS, SWITCHES, FILTERS FUSE FUSE OUT IN REMOTE ALS A B RLY ALC TRANSMITTER / TRANSCEIVER ALC RLY ANT Figure Interconnections INTERCONNECTIONS 7

8 Amplifier Rear Panel PWR SUPPLY To prevent connecting the power plug wrong, the large black multi-pin connector is indexed by the offset in two round pins. One round index hole is closer to the outer connector edge. Mate the round pins and holes and seat the male plug fully onto the amplifier rear panel pins. ALC RLY GND IN OUT Optional connection. Connects to radio ALC input. Mandatory if using a radio over 0 watts. Connect to radio amplifier keying line. Radio must pull this line below 2 volts to transmit. Connect to station ground buss. This connection is for safety. Connect through good 50-ohm coaxial cable to radio s antenna output connector. This can be a smaller cable like RG-58/U. To 50-ohm antenna, antenna tuner, power meter. This is the high power output. 50-ohm coaxial cable must safely handle 200-watts..) Connect the station electrical safety ground to the rear panel wing nuts. National safety codes require the station ground be bonded to the power mains safety ground at the building entrance. 2.) Connect the power supply to the amplifier. 3.) Connect the RLY line to the transceiver s accessory RELAY or XMT port. This port must pull low for transmit, and be open circuit when receiving. Relay control voltage from the ALS-300 is 2 volts positive with only 5 ma current. You should always check your transceiver s manual, but almost any standard transceiver directly interfaces to this amplifier. 4.) Connect the OUT (output) port to the appropriate point in your station. This is the high power RF output cable. This connection would go to your 500-watt rated Power/SWR meter, antenna, or antenna matching device. Good quality Mini-8 or RG-8X cables are acceptable for anything but RTTY use, although larger RG-8 style cables are normally preferred. Your antenna matching system must connect to this port. 5.) Connect the IN connector to your transceiver. Do not install any active antenna matching devices on this port. In general the shortest and most direct cable connection is best, although high quality cables can be very long without adverse effect on performance. RG-58/U or Mini-8 (RG-8X) style cables are acceptable. You should never use a tuner of any type on the amplifier input, nor should you drive this amplifier with over 0 watts peak envelope power. Never use a non-fcc accepted device with this amplifier. 6.) The ALC line is optional. In general the internal ALC in the transceiver is all that is needed. The ALC monitors the RF output power and reflected power supplied by the ALS-300 to the load. 7.) Operate the bandswitch manually during initial testing. Do not connect band decoders or computer interfaces until initial tests are completed. 8

9 Front Panel Figure 2 Amplifier Front 9

10 Operation This amplifier is very simple to operate. Once you have established proper connections please set the amplifier (Fig. 2, ref 3) to one of the following bands: Band Frequency Range Notes MHz MHz MHz MHz Operation locked out in domestic model. Export Only MHz MHz MHz MHz Operation locked out in domestic model. Export Only MHz Operation locked out in domestic model. Export Only. Caution: This amplifier is not suitable for 27 MHz. Damage to expensive components such as power amplifier transistors will occur if attempts are made to use this amplifier in the MHz frequency range. MARS or CAP Operation For licensed amateur radio operators participating in Military Affiliate Radio Systems, this amplifier is suitable for MARS and CAP operation on all frequencies between.8 and 22 MHz with some precautions. The upper frequency limits are in bold type in the table above. Do not operate above the bold-type frequency limits in the table above or PA (power amplifier) damage may occur. It is permissible to operate below those limits if you provide additional external harmonic suppression for authorized services such as MARS and CAP. When operated outside the frequency limits above, harmonic suppression might not meet acceptable limits. You may have to use additional external 2 nd harmonic filtering. Ameritron guarantees to exceed FCC part harmonic suppression standards only inside the frequency ranges listed above. Contact Ameritron with your specific requirements. Ameritron requires proof of a valid MARS or CAP license as well as your own amateur radio license for technical assistance.

11 Initial Operation Double check all wiring and connections (fig. ) before turning power on. It always pays to be safe. If you are sure you have connected your amplifier correctly, follow the procedures below. The following steps only need to be done on an initial checkout:. Place the MULTIMETER switch (fig.2 ref 7) in the HV2 position. Place the ALC SET control (fig2. ref 5) full clockwise ( on scale). 2. With the STANDBY/OPERATE switch (fig.2 ref 8) on STANDBY, turn the power switch (ref 9) ON. 3. There will be a slightly delayed click from the power supply. HV2 (fig.2, ref 2) should immediately rise to nearly full scale, and after a slight delay you should hear another click. The meters and BAND LEDS (fig.2, ref 4) will light up. 4. The HV meter (fig.2, ref 2) should read between 45 and 55 volts. 5. Change the meter switch (fig.2 ref 7) to HV. The voltage should be the same as in step Rotate the BAND switch (fig.2 ref 3) through all positions. For any model purchased in the USA, only the 60, 80, 40, 20, 7, and 5-meter bands will actually operate. 7. Change the meter switch (ref 7) to REF. This will read reflected power. 8. With no modulation in the FM, AM, RTTY, or CW mode adjust your exciter power to low power, around ten watts. This is to have a steady unmodulated carrier. Verify you have very low power, ideally around watts carrier (not critical), and that VSWR of the antenna system is low. You should see almost no deflection on the reflected power scale (fig ref 2). If you see reflected power deflection, check your RF cables. Note: You cannot use a tuner in your radio or between your radio and this amplifier to match the antenna system. Any antenna matching must be between the amplifier and the antenna, and the antenna tuner must be safely able to handle at least 200 watts of carrier or peak envelope power. 9. Place the amplifier in OPERATE position (fig.2 ref 8). Be sure the BAND on the amplifier matches the band selected on the transceiver.. Place the transmitter or transceiver into transmit in FM, AM, RTTY, or CW modes. The green TX LED (fig.2 ref 6) should light. The forward power (fig.2 ref 2) should increase to approximately ten times the initial reading, the reflected power should remain low, and the PA current should increase slightly on both scales of the current meter (fig.2 ref ). No other lights should illuminate.. Briefly increase power to 200 watts output. 2. After you have verified all of this, the amplifier is ready to operate.

12 Circuit Boards There are basic circuit boards plus two power amplifier modules in the ALS-300. The text below gives a brief description of each board s function. 2KWF The 2KWF is a high power low pass filter. It is the very large board with large toroid and a few air wound inductors. This board contains filter SWR fault detection, power amplifier unbalance detection, and multiple high power low pass 5-pole filters. Additionally two smaller boards, the antenna relay board RLY and the PA combiner board CMB, attach directly to the low pass filter board. BS The BS is located behind the BAND switch. It provides all band selection functions as well as band indicators. CB The CB is located near the front of the amplifier just behind the meters. The CB control board provides most control functions. This includes bias, fan speed, overload protection, and transmit-receive relay sequencing. It is the hub for nearly all functions, including interfaces. CMB This board combines the outputs of two 600-watt PA modules. It is a traditional 50-ohm magic T combiner with an output-matching transformer. FL The FL is optional and only appears in export models. It enables ten meter and twelve-meter operation. MB- The MB- is located behind the front panel below the meters. It contains peak-envelope-power detection circuits, multi-meter switching, fault indicators, and ALC circuits. There are four power meter adjustments on this board, two for calibration of forward and reflected power and two for forward and reflected peak hold time. Shunts on a header located on the board s upper edge adjust panel meter brightness. PA Boards PA boards are located on top of the heatsinks under the filter board shield panel. There are no user adjustments on these boards. PD8 The PD8 is located on the right side of the amplifier just above the panel containing the cooling fans. It contains a power splitter and two 5 db attenuator pads. The splitter and attenuator pads isolate the two power amplifiers from each other, and terminate the PA inputs in 50 ohms over a wide range of frequencies. This is necessary to stabilize the PA modules. Do not remove or bypass the attenuators. 2

13 RJ45 The RJ45 board mounts on the rear panel. It contains two RJ-45 jacks for remote control interface. RLY The RLY board contains two transmit and receive relays, one for RF output switching and the other for RF input switching. T/R relays activate with a low on terminals K (key) J-3 and RJ-7. The CB board contains the relay timing controls. SWR The SWR board is on the rear panel in front of the RF output connector. It is a traditional 50-ohm directional coupler. The null adjustment is accessible through a rear panel hole. Schematics Filter 2KWF PA Comb Out PA B PA A 2KWF-R 082 Gimmik D N96 C2.00uf Ant J2 T R Rly D2 J3 T2 50 N96 R3 R4 k C R2 C29.0 C99 C98 pf RLY RLY3 RLY5 RLY7 RLY9 C 500 C5 680 C9 360 C3 270 C7 80 L 6T L3 T L5 2T L7 8T L9 6.5T C3 C L4 T C7 680 C 360 C5 270 C9 80 C6 680 C 360 C4 L2 6T 270 L 6.5T C8 80 L6 2T L8 8T C8 680 C2 360 C6 270 C20 80 RLY2 RLY4 RLY6 RLY8 RLY RLY RLY2 FL FL FL C4 500 RLY RLY3 RLY5 RLY7 RLY9 RLY 2VDC RLY2 RLY4 RLY6 RLY8 RLY RLY2 C22 C23 C24 C25 C26 C27 J Gnd Gnd PA IN J4 PA Out Rly RADIO rev 03 Mar 2009 Figure 3 3

14 4 Bandswitch BS / Remote 2V 7 July V G 2V G 2V 2V SW rear view BS - J3 D N400 D2 N400 D3 N400 D4 N400 D5 N400 D6 N400 J J2 LED 60 LED2 80 LED3 40 LED6 7 LED5 20 LED4 30 LED8 2 LED7 5 LED9 R Figure 4

15 5 Control Board CB CB rev Bias A Bias A Bias B Bias B K F S P T RS A R F K - G CL A S P T R F - G X X 2 S CL G G G X X S S FAN CLK5 60 REAR PANEL FILTER TO MB J STBY MISC IN OUT GND HS HS FA FB FAN FAN FET FET RL2 ANT RL INP BAND FILTER 60 GND Bias B RL INP RL2 ANT Bias A Bias SW BAND SWITCH DC2V Upin4 Upin S DC2V 4042 U3 DC2V DC2V DC2V DC2V DC2V DC2V DC2V J8B J8A C28 C29 Q Q Q 3906 C8 RJ Q Q Q 3904 C30.47 C3.47 Q 3904 J J5 F2 A F A D3 D4 D2 D7 D5 D6 C3 C2 /50v C4.0/50v UD UB UA J2 J4 C.0 C5.0 C9 S S C2.0 C6 J7 C35 C9 U2B U2D U2A U2C C2.47 Q Q Q Q C.0 VR 25k 40% C4.0 C /50v C6 J6 C27 C26 C25 C24 C23 C36 C32 47/50v VR 40% VR2 40% VR4 40% VR3 40% VR8 40% VR7 40% VR6 40% C33 47/50v VR5 40% C37 C34 J3 D 96 C3 Q C7.0/50V C7 C8 C20.47 U5 LM7809 U4A LM358 U4B LM358 D9 D8 C22.47 C5.47 U4pin8 U4pin4 U2pin U2pin4 DC2V Switched DC2V ZD 5v R59 k R58 k R4 R55 0 R54 0 R57 R50 K R49 R5 R6 R9 k R 0 R29 27k R5 0 R3 R7 R5 k R2 k R25 R28 0 R24 R8 R22 R20 6.8k R6 0k R7 R32 k R3 R40 R4 k R43 k R42 R2 0 R4 0 R45 R44 R47 R46 R30 R36 2.2k R35 R38 k R8 R3 0 R9 R23 R53 0 R56 0 R33 R37 2.2k R39 k R34 k R52 R48 K R 0 R27 4.7K R26 4.7K R2 6.8k R Figure 5

16 Combiner 2000 watt CMB CMB 0827 rev0a 50 OHMS IN PA A T6 T OHMS IN PA B 50 OHMS OUT Figure 6 Filter FL FL 082 L L2 Out In C 30pF C2 30pF C3 30pF C4 30pF Figure 7 6

17 Metering Board MB -2V FWD SPEED R5 m 40% REF SPEED R6 m 40% CTRL J Gnd - Fwd Ref T C S A CL -2V R28 k C6 ALC k % -2V R2 R24 47k C R20 R39 C6 D LED3 R8 R U2A 3 2 C C8.0 D9 N96 R36 R34 220K R35 0k R33 220k R23 47k 8V C5 Q Q2 2N3904 2N3904 R4 R40 D2 LED2 UA 3 2 D7 N96 R25 LM324 R29 C4 4 D N96 2 D3 LED C3 2.2 D2 N96 D3 N D8 N96 U2B LM R R3 m R32 R37 R22 R6 m R5 k C7 UB 7 R7 2V 8V D4 LED4 R9 CAL R2 2.5k 40% C9.0 8V 2 3 R2 0 R3 5.6k C2 UD D4 N96 4 R30 6.8k R8 M R9 k D6 N96 D5 N96 C4 2.2uF 3 A 4 V - SW R 7 MB Rev R C V2 6 UC R38 4.7K 2 V2 A 9 C PEAK METER / ALC 8 REF CAL R 2.5k 40% C 8 V C2 C7 R4 5.6k C3 C5 CTRL J PIN...GND FWD PWR 5...RFLCTD PWR 6...TRANSMIT LED 7...COMBINER LED 8...SW R LED 9...ALC VOLTAGE OUT...COMBINER LVL R7 R3 R 68K R 68K R4 2V MULTI METER J2 Gnd F - L G CURRENT J3 METER BRIGHTNESS J4 MULTI METER J2 PIN...GND 2...FW D 3...MM MM 5...LMP 6...GND CURRENT J3 PIN...V2 2...V2 3...V 4...V METER BRIGHTNESS J4,2 low 2,3 high Figure 8 7

18 PA Boards PAM Revision 0a R5 C2 Yel 8 R3 R uF Q C3 470pF uf C C4 uf R6 8 C6.33uF R7 R NTC 0 R2 NTC 0 Org 8R C8 uf C5 uf R R8 8 C7.33uF R2 R9 C9 Q2 T3 PA Out P CONN PA In T C 470pF C 330pF R3 22 R4 22 R5 22 R uF X T2 T4 R7 22 R8 22 R2 C3 Brn Red 8 R9 C2 uf C8 uf 8 R26 C5 uf R20 C4 uf R27 R22 8 R C6.33uF C7.33uF R28.00uF R23 R25 C9 Q3 Q4 C2.33uF C20 470pF C22.33uF C23.33uF FB C24.33uF FB2 C25.47uF C26 0uF VRed 50VDC uF Figure 9 Power Divider PD8 0 R7 Out R2 27 T2 R5 27 Out R 200 R3 200 T R4 200 R PD8 rev0-8db splitter In Figure 8

19 Interface Connections RJ45 - J - RJ45 Rev J2 - Pin8 Pin6 Pin4 Pin2 Pin8 Pin6 Pin4 Pin2 Pin7 Pin5 Pin3 Pin Pin7 Pin5 Pin3 Pin R2 560 /2W R D D2 C 0uF J3 CONN Figure 9

20 Relay Board PA IN HD RLA 082 HD4 RADIO RL4 ANTENNA PA OUT RL MAY 2, 2008 Figure 2 Reference figures and drawings Figure Interconnections... 7 Figure 2 Amplifier Front... 9 Figure Figure Figure Figure Figure Figure Figure Figure... 8 Figure... 9 Figure

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