Amplifiers
Life’s too short for QRP.
ELDICO, HEATHKIT, KENWOOD, HENRY, HOMEBREW & A STRING OF ETO ALPHAS
How I've gotten 6-12 dB over the years, without changing antennas
Commercial Amplifiers -
HF (160m–10m & 80m–10m)
There have been many HF amplifiers in my shacks over the years, and they have been a combination of good value, utility, and fun. With one exception, all were used, and the homebrew ones had the added enjoyment of "tinker-factor" and were strong performers. Still, once I sprung for my first Alpha, a 76CA, reliability and headroom became the norm, and I haven't really looked back, but I haven't always achieved that goal either.
After a partially built 4 x 811A amplifier (I ran out of funds, before building the power supply), and an ill-fated purchase of a Johnson Courier amplifier, which never did work, I purchased an Eldico SSB-1000 while in college. I had my Drake B-Line set up in our dorm room, and met a guy whose dad was a ham who had the Eldico for sale. I bought it for $250 and set it up in the dorm room, earning the coveted WAS (worked all stereos) award. Somehow, I got away with it for over a year. That amp introduced me to ceramic, external anode tubes, a pair of 4CX250Bs (until 2021, I still used a pair on 6M), which I got back to in the Alpha series of amplifiers, 10 years later.
In the interim, I sold the Eldico to buy tires for my car, and later picked up a Heathkit SB-200. I didn't have the 200 all that long, but a boyhood friend, WA3OYA, had built one back when we were still in high school, and I always liked it's compact size and reasonable price.
My first amplifier, an Eldico SSB-1000 in my shack, in my parents' home in Wilmington, Delaware, circa 1974. This later became my dad's shack when I finished college, got married, and moved out.
As I set up my first shack in our first house, the old Drake B-Line got a little help from a Heathkit SB-200. I had some experience with this amp at a friend's shack, and it was affordable for a new homeowner. The shack was pretty sparse with a tuner, antenna switch and a mic., headphones, and paddles. Soon to follow was my first tower, tribander, 2m yagis, and a 40m wire yagi and 160M dipole.
The Heathkit SB-200, my first "newer" amplifier, in my shack in our first house in Woodbridge, Virginia
The Kenwood TL-922A powered by a pair of prized 3-500Zs and covering 160M. It was a great, matching accessory to my TS-180S.
Then, in 1980, I got the tube compliment I had wanted for a long time, a pair of 3-500Zs, in the form of the Kenwood TL-922A. It had die-cast side panels with handles, a solid top (and other poor ventilation/cooling features that melted the solder in a tube pin within a couple weeks), but really looked the part and did a good job overall. It also had the advantage of 160M coverage, and despite some component failures, including a bandswitch wafer, it served me pretty well for 3 years. The Eldico, Heathkit, and Kenwood comprised my experience with HF amplifiers, prior to my string of Alphas.
The Alpha Era UNRIVALED IN THEIR DAY
The beginning of my series of Alpha amplifiers, the 76CA. It matched the TS-930S paint scheme, and was a true workhorse still in operation to this day at W4ACM, now converted to a pair of 3CX800s.
Alpha 76CA
I don't remember where the ad appeared, but I came upon a one-year-old 76CA, that had been used as a test platform to "exercise (read, try to blow up)" antennas but was otherwise unused. I still remember receiving the package at work (it was cheaper to have packages shipped to a commercial address) and being sorely disappointed. Although in like-new condition, I hadn't yet embraced the simple clean lines of the Alphas. The Kenwood, with its die-case side panels and fold-out handles, made the Alpha look too plain. The 76CA had the infamous "sticky paint" but it was still in perfect condition when I received it, with the look of gray suede, and it wasn't too long before I began to appreciate the flush meters, elegant vernier knobs, unique push buttons, T/R meter illumination color changes, and the fit and finish of the cabinet, chassis, and front panel. What was easy to get used to was the quiet operation, and willingness of the amplifier to make power, seemingly without effort.
For those unfamiliar with the differences, the 76CA featured 3 x 8874s, and a hipersil transformer. It also included 160M as did the TL-922A which was a key band for me in those days, with the power restrictions removed, and nearly daily operation with a group on 1.858. With a simple dipole antenna at about 60 feet. the extra power helped especially in the winter months. Also, my contesting was hitting full stride, and the repeatable, smooth tuning and hour-after-hour power let me concentrate on operating. I had only a meter shunt and a couple of pilots lamps fail in the 9 years I owned the amplifier, which is still running strong at my cousin's QTH on the Eastern Shore of Virginia. The paint on the front panel finally turned more gooey than sticky, and rubbed off in places, but otherwise, the amp is still in great shape.
Alpha 78
A BROWN AMPLIFIER WITH BROADBAND TUNING?
YOU KNOW IT!
I became interested in the Alpha 78, based on the solid foundation of the 76CA, and a desire to have quicker band changes, and quieter T/R operation, with the possibility of QSK. A friend, Bob, W4JNN and later K4JN (now SK), had one of these, and encouraged me that I'd get used to a two-tone brown amplifier, and he was so right. I now consider the 78 to be the most attractive amateur amplifier that I've owned. I had two of them, over a span of probably a dozen years. The first was in great shape, but was misrepresented by the seller, having 3 tired 8874s. It also had one noticeable ding in the front panel. I ran my spare tubes, and sold it later for $1,300, disclosing the weak tubes to the buyer. I met him many years later, and he told me it was still running (no surprise to me.) The second one was in collector-quality condition, and the tubes were also fresh. It had been a backup amp, and I drove to Baltimore and bought it out of the trunk of the owner's car. Although there are logistical problems with retrofitting the 78 with 3CX800s, that was what I should have done, in retrospect. The Alpha 89 that replaced it, although now basically solid and reliable, gave me many problems for a couple years, as described below.
Alpha 89
LOW DRIVE REQUIREMENTS? 3.5KVA TRANNY? KW RTTY FOR HOURS? SILENT QSK (UNTIL THE PIN DIODES FAIL)? YEP.
As we began to plan to move, I decided to part with the 160M monobander (shown below), and the Alpha 78, in favor of a single amplifier. I wanted one with 3CX800s to gain additional headroom for digital modes and long stretches of CW (like contesting), and also a lower drive requirement to better suit the K3. The 87As were still selling for more than my budget, but based on outstanding reliability and usability of the 76CA and the 78s, I wanted to stay with an ETO Alpha. My friend Chris, W2PA, had and 89 and was well pleased with it. I knew the 86s were problem-prone, and leaned toward the US-made Alphas to avoid the GU74s, although the 91b and the Acoms which use them are highly prized. Those tubes are also much less expensive, and were generally available on the used market, but some from international sources were problematic. In fact, I had a pair of them and matching sockets, which I had intended to build into a single tube 6M amp, but that project never materialized. My current Alpha 89, one of 408 built, was from a local ham, who offered to deliver it and allow testing before purchase. I think the "stars in my eyes" effect made me overlook the high grid current to make serious power, and only in the next day or so, did I realize that one tube had an open filament. The amp included spares, which are medical pulls, so substitution proved that the amp was otherwise fine. The seller did, somewhat reluctantly, purchase another tube for it, and we finalized the deal. Not too long afterwards, the wheel in the blower fell off the motor shaft, which made quite a racket. After removal, I found that the original wheel was wildly off square with the shaft mount, which set up extensive vibration. Added to that, the wheel is simply pressed onto the motor shaft. I shimmed the wheel mount to correct the balance, and used a tap to pull threads through the mounting plate to increase the "bite" on the shaft. I also used red Locktite, and based on the difficult of pressing it onto the shaft, I think it will stay put.
The next series of problems were all centered on the PIN diode QSK board in the amplifier. It is an excellent performer, when it's right, but in my case, the receive diodes blew on three separate occasions. Although they are reasonably inexpensive ($12 each), they are somewhat difficult to replace, and each failure also shorted the drivers in my K3, and I reluctantly decided to ship it to RF Concepts for repair. To ship it, I needed to buy a box, and after the resulting repair, which included some post-production modifications to other problematic components, and over $600 later, I got less than a year's use before the next failure, including damage to the K3. That time (late 2012), I decided to take another approach. I built an outboard QSK box, based on the W7RY QSK driver board for the L-4/L-7, vacuum and reed relays. Luckily, the 89 worked perfectly on transmit, including bias switching and the expensive transmit PIN diodes were still fine. That allowed me to use the RELAY OUT from the amplifier to key the external box. With internal sound-deadening foam, and floating the relay on foam tape, and braid to connect to the coax connectors (added after this picture was taken), the operation is all but silent, and fast enough for QSK operation. I had an RJ-1 and also a suitable 21VAC transformer, so the entire project cost under $100. The cost for all the parts, including a new Gigavac GH-1 from MaxGain Systems, is just a couple bucks short of $200. I built a second one for the station at KP2M, owned and operated by longtime friend and CW Maestro, KT3Y, who experienced the same failures with his 89.
Oldies but Goodies — American Classics: Collins, Heathkit and Henry (details below)
SHOWING THEIR AGE BUT STILL GOING STRONG
After getting the boatanchor bug, and picking up a Drake B-Line to match my college-era station, I decided I wanted a Collins S/Line as well. This is documented elsewhere on this site. The S-1/Line from W4HYB included a mock station console (later converted back to a 312B-3), and, obviously, the 75S-1 receiver, 32S-1 transmitter, and 516F-2 power supply. What was not part of his station which I purchased, was a matching amplifier. Needless to say, the 30S-1 has always been a favorite of mine (all the Collins aesthetics including escutcheon, meters and knobs but BIGGER), but the size, weight, and expense just didn't fit for me then (or now). I was not really shopping for one, but friend and neighbor Frank, K3TRM, had one that his wife had found at a yard sale, along with a 312B-4! These are shown in these Google Photos albums, 312B-4 Basket Case and Collins RE 30L-1 Found at a Yard Sale (bought by a friend's wife). Frank said he felt like the amplifier "belonged" in my shack along with the S/Line, and a trade/cash transaction ensued that I couldn't say, "No" to. Thanks again Frank! While the 30L-1 wasn't quite the "basket case" that the 312B-4 was, it was a tired piece of gear, deployed in the Vietnam-era, and in need of TLC. It refurbished nicely, with the most unconventional part of the process being me walking on the opened top of the cabinet in my socks, on short, dense carpet, to flatten it out. The rest of the process was basically cleaning, and replacement of the HV board (details in the album) and other aging caps, along with a set of Taylor (Chinese) 572Bs. The result is shown in this photo, and the amp now graces the Rockwell Collins page on Wikipedia, placed there by my friend Chris, W2PA. It's an easygoing, no-strain 500-600W amplifier, and even makes 400W on 17M without retuning. It really is "just right" in the line of gray cases on the Collins operating desk.
Here's a classic I wanted when I first upgraded to General in 1971. A pair of 3-500Zs was THE tube complement to have, and relatively speaking, was an affordable piece of gear. I say "relatively speaking" because back then it was decidedly unaffordable by me. As you can see from the history of amplifiers I've owned, I skipped over the 220. After a couple tube failures with my homebrew 6 meter amplifier, I decided to get an SB-220 for single-band 6 meter conversion. After it got spruced up a bit, I found the ability to have an instant on, 200-400W at the main operating position, instead of waiting 3 minutes for the Alpha 89 to warm up, too good to give up, I haven't gotten around to single-banding it, opting for converting 10M to 6M by changing the coil tap and making changes to the input circuit, per an old QST article. Initial tests showed about 450W, but further testing revealed a lot of plate color and much lower output. I never debugged it, deciding to wait and just do a monoband conversion but that was overtaken by events, with a more suitable chassis (different amp with heftier parts) becoming available. Also, the old 6M homebrew amp continues to work at about 450W. After a disappointing summer E-skip season in 2020 (heard new countries I couldn't work!), I need to find at least 3dB in the amplifier, then look at my trusty 6M5X antenna, perhaps building an LFA from scratch, or extending the boom of the 6M5X and adding elements. Time will tell. I have since undone the mods and restored 10M. That will leave me an instant on (with the Harbach step-start circuit), 80-10 amp for use with my HW-101, perhaps. I have run 1100W with the HV in the SSB position, so these 3-500Zs still have some life left in them. An interesting front panel overlay prettied up the face, and a couple new knobs and inserts finished the facelift. The case received an overspray to complete the quick refresh. Inside, I replaced some of the nominal HV wires with silicon HV cable, and cleaned things up inside. Later upgrades include a new Harbach filter capacitor stack (screw type and a circuit board, and the Harbach soft-key module to provide a safe PTT port for any of the rigs in the shack.
More American Muscle — Henry Radio 2KD-Classic
This near mint Henry desktop has been in my shack for many years, first in our former home in Nokesville, VA. It originally belonged to my cousin's wife's uncle. My cousin received it when the uncle passed away, and it with no room for it in his shack, he loaned it to me and I used it with my Drake B-Line for many years. Although not an L-4B, it's a very high-quality unit. Even though it's a desktop, this model uses a squirrel cage blower and chimneys for cooling the tubes, and a variable inductor with fixed, doorknob capacitors along with a conventional air variable in the tank circuit. This is now used with my B-Line and also my Heathkit HW-101 now. I have had a couple small problems with the amp, but they were easily taken care of. The vitreous enamel series resistor in the HV lost its outer shell twice, and I replaced it with a more modern silicon coated power resistor rated at 50W instead of 25. End of problem.. You'll find a description of the repair, and some shots of the interior of this amplifier in my Google Photos album, O Henry (with apologies to William Sydney Porter). One of the power supply HV caps failed, as well as a small ceramic cap in the input circuit for 40M. That makes it a very reliable unit compared to some of the amplifiers I've had. Only the Alpha 78 had a perfect track record, but it stayed here far too short a time. Thanks Art, for this great addition to my shack!
Homebrew Amplifiers
80m–10m, 160m, & 6m
THE FIRST HOMEBREW AMPLIFIER I had was actually built by WA8SAJ. Jeff, still a guru and the go-to guy for all things Drake, just retired from active Drake repair in 2021. This amplifier was a 5-bander and employed a 4-1000. It had first passed through the hands (and shack) of my cousin, W4ACM, and Art made me a deal I couldn't resist. He ended up with the Alpha 76CA shown above, which is still in regular use at his station, albeit with the 2 x 3CX800 modification which he performed. I repackaged the amplifier into a small rack/cabinet provided by N2FB, and enjoyed what I dubbed "Da Fridge" for many years. Built as a grounded-grid design with only 4KV on the plate, it was hungry for drive, which my FT-1000D provided, but not really compatible with the K3 or other 100W radios. Since we were planning to move, it was a good time to move it along.
"Da Fridge" in its last iteration in my shack. I sold it to W3SOX, who uses it as part of his club station. It has undergone some PS changes, but looks mostly the same at Dave's QTH. It was time for me to downsize, and it served me very well for many years. Jeff, WB8SAJ, did an excellent job of construction and most of the changes I made were minor and /or cosmetics. I repainted the front panel and re-lettered it.
The owner after Jeff added a tuned input, which you can see next to the bat handle switches, and I increased the plate voltage to around 4KV with the variac below. I also added verniers to the plate tune and load controls, which especially helped on the higher bands.
The RF deck, as built by Jeff, WA8SAJ. He is a top gun Drake
tech. these days. You can see that Jeff was a Drake man,
even back in the 1970s. Some of the labeling was damaged
when I got it, and I decided that the front panel could use
paint and relabeling.
This is the power supply for Da Fridge, after replacement of the
original capacitor bank, which had begun to spit and spark after
30+ years of use. Although this is a voltage doubler circuit, the transformer
secondary was rated at 2A, so it was a very sturdy supply.
160m Monobander with a 4-1000A
Concurrently, with "Da Fridge," and based on the success of the 4-1000 for my operating, I rebuilt a smaller-chassis 5-band 4-1000 amplifier as a monobander for 160 meters. That amplifier came from KT3Y, who found its initial construction not up to his level of contesting needs, and I saw an excellent opportunity to rebuild it into a very durable single-band amplifier. I basically took it down to the chassis, repainted it, and retained the most basic wiring, and the excellent metalwork, tube socket, tube, chimney, filament transformer, and metering and bias circuits. I replaced the filament choke, plate choke, tank coil, T/R relay, blower, and tuned input circuits, and added capacitance to the load side of the tank circuit. Monobanders are inherently simple, and everything can be optimized. It has the same hunger for drive power, and so it also didn't suit the newly acquired K3, and was sold to N1WR, who was looking for a 160M RF deck. I retained the power supply, which I built from scratch, and still use it with a variac on my smaller, lower-voltage 6M amplifier, shown below.
The use of the old Model 28 teletype stand allowed me to mount the blower directly under the tube socket, providing excellent cooling. The filament transformer was an early Peter Dahl model, which had a mailing label as its identification. I had the pleasure of a chat with Peter about its vintage and he said the label showed it was built when he was living in an apartment, and was very early production. I repainted it, with the old metal case having succumbed to some rust, but never had a moment's trouble with it.
The RF deck of the 160M monobander showing the back of the Peter Dahl filament transformer, and homebrew tank coil and plate choke. As I say, without bandswitching components, an amplifier is remarkably simple, especially if you don't incorporate a lot of protective circuitry. This was strictly the basics, but did a great job for me, and is still running at Wayne's QTH, last I checked.
Underneath the RF deck, showing input circuit, vacuum T/R relay, and coupler for the blower. The plate loading control was padded with doorknobs to bring it down to 160 meters. The bias switching relays were also vacuum relays, just to quiet the T/R transitions.
A look inside the power supply for the 160M monobander, which is still in use at K4SO. Simple construction, with a full-wave bridge, with K2AW blocks, oil-filled capacitor, large bleeder,
and a Basler transformer from a Harris commercial transmitter (one of three from a 3-phase power supply.) This was built from a bare chassis, as was the 6M amplifier, shown below.
6m Monobander with 2 x 4CX250Bs
When I got on 6 meters in 1999, with a small antenna, and only 8 watts from a transverter, it became apparent that I'd need a bit more oomph, to work much DX, at least in a more rapid fashion. Finally, I drew on the experience of the last two amplifier projects, to build something entirely from scratch. A cabinet provided by my cousin, W4ACM, determined the overall dimensions and I fitted a chassis, then started looking for schematics. 4CX250Bs took me back to my old Eldico HF amp, shown at the top of this page, and I knew that with screen voltage on them, the 8 watts from the transverter would be sufficient to drive them. I found a reasonable (read "simple") design in the ARRL Handbook, and although it was for a single tube, I figured I could adapt it. That proved a little more challenging than I originally hoped, but a solvable problem, ultimately. Using hand tools, including a hole saw designed for wood, to punch the holes for the meters and tube sockets, I built the amp shown below. It's still cookin' at my present QTH, helped me achieve DXCC, and take advantage of sometimes brief openings (the magic band, indeed), to work over 700 grids by 2019. It was a satisfying project, because it used some materials that were on-hand, and challenged me to solve problems along the way, given compromises in budget, and mostly by my limited expertise!
Completed 6m amplifier, shown producing
about 550W output. It runs 324V on the
screens, and about 2200V on the plates.
Screen regulation is via 3 x OB2s, and it
is a very "no frills" design, proving useful
and reliable for over two decades until it was
replaced in 2021 with a modified BTI LK-2000
which uses a single 4-1000A.
The tube end of the 6m amplifier. I have a
divider, mostly for airflow reasons. You can
see the loading capacitor, input circuit, and
T/R relay in this picture, as well as the
opening for the blower, and HV input.
This is the other end of the amplifier, with the screen, bias, and relay supplies, as well as the filament adjustment potentiometer.
6m Amp with a Big Bottle OLD FAIITHFUL (ABOVE) GETS A BREAK - OLDIE GETS A NEW LEASE ON LIFE
After a disappointing season of seasonal e-skip, I decided that just hoping Cycle 25 would improve things might not be enough. So, although my receiving conditions are pretty good, I felt that improving receive and transmit performance were in order. That means, first, a bigger, better antenna. That took the form of an InnovAntennas 7 el. LFA, detailed on the Antennas page. My homebrew pair of 4CX250Bs had been a real workhorse, with one significant failure caused by a Penta 4CX350 simply burning out, and then another by my accidental extreme overdrive by its Eimac replacement. I felt that the 500W (more or less) ceiling needed to be bumped up by a foot or two, (2-3 dB). With the exception of a possible extreme modifications to the existing chassis, perhaps fitting a 4CX800 GU74, for example, it was time to move on. The SB-220, originally purchased as the successor, was still a candidate, and having had a King Conversions (QRO King) amp go through my shack, for repairs and as part of estate sale, that was still on the table. I had all the specifications by pictures, measurements and observation on deck to "do it myself," and also Lou (the King himself) had been so helpful to me, that I considered having him simply do the conversion. Still, the power supply, especially the transformer, worried me for use for an FT8 duty cycle. I did have the option of the overly robust full wave bridge, oil-filled capacitor supply as an external option, but had grown used to some "instant on" HF power for FT8 DXing.
While in email correspondence with Charlie, K3ICH, he mentioned that he'd converted a BTI LK-2000 (late 60s vintage) with a 3-1000Z, and putting out 1KW on the workbench. I mulled it over for a month or so, then decided to pursue it, based on familiarity with tube-type amplifiers and their associated circuitry, and proven ruggedness. Also, is was much less expensive than a wholesale move to solid-state. It was a tough call. It was still pre-vaccine COVID season for me, but I texted my friend Jake to get some additional muscle. One part of a "solid foundation," when you're talking about power supplies and even steel cabinets, is weight. No switching supplies here folks. So we headed up to Charlie's place with my 1990 Isuzu pickup and masks after final details were worked out. It was February and still chilly, with a little snow on the ground at Charlie's QTH and he had the amp in his woodstove-heated basement shop. It gently put the Bird 43 meter up to the top with a 1KW slug, and we got it ready to bring down in elevation (he's on a hillside) and south. (BTW, that's my own little nametag on the panel. There's a new one now with "4-1000 ALPHA" in place of "3-1000ZED." So, I went seemingly backwards from ZED to ALPHA.)
Once at my QTH, we brought it around the house to minimize steps, and delivered it to my shack. Rewiring proceeded apace, and that evening I was ready for initial testing. The dual, 110V DowKey relays that Charlie had installed were a nice, low SWR path both through and in and out of the amp, but I decided to add an additional relay buffer to my KeyAll buffer. After some arc-suppression measures, I was ready. Within a few minutes, there was HV capacitor arcing and I shut down for the night. Visual inspection showed the worst of the 50+-year-old caps, and I cobbled in a replacement, and put the amp on a variac to ease the voltage down a bit. Being a latching relay power chain, I had to bring the voltage up enough for latching, but found a good threshold. No arcing in the PS or the T/R relay chain, and the old boy was making good power.
But, it was clear the 3-1000Z was "feelin' it" however, with a bright orange plate after 13 seconds of FT8 transmit cycling. A little correspondence with W3LPL, who has run 3-1000Zs at his Superstation multi "forever," revealed that the internal structure of the 3-1000Z wasn't likely to hold up this service terribly long. Hmmmmm. That was not anticipated. With SSB and CW activity slowly rising on 6M, but FT8 likely to snag the new, hard-to-get Qs, I decided to try a 4-1000A, thanks to W3TIM. This required a new chimney, but the cabinet had enough headroom, even with a larger plate cap added later. But I knew from past experience with this "bulletproof" tube (as noted in the writeups of both amps above), it would be much harder to drive. It also wants 4-5 KV vs. the 3.2-3.4 KV that the 3-1000Z is happy with. Tests showed that 550-600W is possible, even with no additional B+, and there is NO plate color in FT8 operation. The 3-1000Z and chimney were sold, and my plans now are to cobble in the external supply, or maybe a couple more capacitors in a full retrofit of the old ones. Plan B to the partial rescue.
So, the 2021 summer e-skip season has yielded only one new country confirmation, but about 70 new grids at this writing (June 23). The antenna is a total delight, and on we go. A newer K3, SN6359 (vs. 2861 for my first), and its PRE2, lower noise preamp for 12-6, has also perked up what I can hear. There's still time on the Magic Band for some surprises this year.