KPA100 - Low Voltage output from High Voltage Bias Supply Circuit

[Michael Haygood]

Hi,

I've been using my K2/100 for many months with great results.  After a
recent storm containing lightning the next time I fired up the K2/100 I
received the "HI CURR" message and the "HI REFL" messages upon initial
transmit.  This was unusual, so the next thing I did was consult the
troubleshooting guide in the KPA100.

Using a wattmeter and connected to a dummy load, I measured the output power
of the K2/100 with the power outupt contol set to less than 11 watts and
noticed that for a setting of 5 watts the output of the K2/100 was about 10
watts.  For a power output setting of 15 watts, the output was very high -
about 100 watts.

The troubleshooting guide indicates that for a HI CURR message the steps are
to set CAL CUR to at least 3.50 Amps and verify the KPA100 T-R component,
R21 - R22, T1 and nearby components.  I verified that all of these
components were good; the CAL CURR was already set to 3.50.

Additionally, I re-calibrated the power out using R26 and R27.  When
performing this procedure, I recalibrated at 5 watts output on the
wattmeter.  I had to change the original setting of R26 alot to
re-calibrate.  After completion of this procedure, I verified the output at
various power levels.  The output was too low on all bands when the power
output setting was set to 100 watts - so I re-calibrated using an output
power of 50 watts.  The results revealed that the power output was still off
by alot when setting output power to 5 watts and 100 watts.

The next thing I did was verify that the bias current was properly set.  I
followed the Bias Current Adjustment procedure step-by-step from the KPA
manual.  The bias current was set properly, but upon performing the last
step in this procedure I noticed that the voltage on the left side of R12
was only 49.7 voltage instead of 100 to 110 volts when the power knob was
set above 11 watts!  This gave me a clue that perhaps something was wrong in
the high voltage bias circuit.

I then consulted the circuit description for the high voltage bias circuit
and learned that the 18.432 MHZ crystal oscillator, Q8 and T3 are used to
derive the T-R switch bias voltage (90 - 150V).  D1 - D8 are used for
rectification and voltage doubling.

I connected an oscilloscope to the 18.432 MHZ crystal and verified that it
was "oscillating" on the scope - although it did have a weak signal using a
1X probe on the scope.  I then consulted the DC voltage chart for Q8 and D1
through D8.  Additionally, I did a diode check using my DMM and D1 through
D8 all passed the diode check - no open or shorted diodes.

Knowing that the voltage form the high-voltage bias supply circuit was about
one half the minimum designed voltage of 90 volts, I suspected that perhaps
one of the diodes in the high voltage supply circuit may not be working
properly since the diodes are used for rectification and voltage doubling.  
I measured the anode and cathode voltages with respect to ground for D1
through D8 and here are my measurements:

D1:  Anode  15.7 V  Cathode  49.7 V
D2:  Anode  34.9 V  Cathode  15.7 V
D3:  Anode  14.5 V  Cathode  34.9 V
D4:  Anode  19.7 V  Cathode  14.5 V
D5:  Anode  14.9 V  Cathode  19.7 V
D6:  Anode  13.5 V  Cathode  14.9 V
D7:  Anode  -4.5 V  Cathode  -1.2 V
D8:  Anode  -1.2 V  Cathode - 0.00 V

The D4 cathode and the D3 anode connect to the output of T3 - the voltage
measured at this juntion was 14.5 volts; the DC voltage chart reveals that I
should have measured about 21 volts.  So I verified that T3 had no open or
damaged windings and verified the 18.432 MHZ crystal waveform across the
"input and output" windings of T3.  Is 14.5 volts too low at the D4/D3
junction?  This seems to be one of the "input" voltages to the diode
rectification and doubling circuitry.

I next checked the voltage on the Q8 EBC.  Voltage readings for Q8 were E -
zero volts; B was -200 millivolts; C was 11.6 volts.  These readings seem
reasonable with the exception of the Q8 base which should have read
approximately -2.5 volts.  Perhaps the output of the crystal is too low - R4
has a value of 39K (connected between the base and collector of Q8).

After all of this work "troubleshooting" and measuring voltages in the high
voltabe bias supply circuit I have the following questions:

1.  Could the 18.432 MHZ crystal output be too low, thus not generating
enough "derived" voltage for the high voltage supply circuit?

2.  Could Q8 - which seems to "amplify" the crystal waveform be bad or not
biased properly to amplify the crystal signal?

3.  Could one of the diodes in the rectification and doubling circuity be
bad?  However, all the diodes did pass the diode check using the DMM.

I'm stumped, and feel as if I'm close to solving this problem.  Perhaps
there is someone on this board who could provide some feedback about this
problem.

Thanks in advance.

73,

Michael Haygood
KI5E

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[Vic K2VCO]

Michael Haygood wrote:
> Hi,
>
> I've been using my K2/100 for many months with great results.  After a
> recent storm containing lightning the next time I fired up the K2/100 I
> received the "HI CURR" message and the "HI REFL" messages upon initial
> transmit.  This was unusual, so the next thing I did was consult the
> troubleshooting guide in the KPA100.

I would check the t/r switch components, D11, 12, 13, and 14 as well as
Q6-Q7. If something is shorted it would load down the HV power supply.

Also diodes D16-17 in the power/swr bridge could be damaged.
--
73,
Vic, K2VCO
Fresno CA
http://www.qsl.net/k2vco
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[Don Wilhelm-3]

Michael,

You said the 'magic words' - HI CUR, Hi REFL messages and lack of power
control (other than low and high power selection) *after* a lightning storm.

That is an indication that the lightning surge zapped diodes D16 and D17
in the KPA100 wattmeter - the result is that the base K2 microprocessor
*thinks* there is no power output and increases the drive until it 'runs
out of gas' - the K2 will produce max power output under those conditions.

Replacement of D16 and D17 is in order as a first step.  If that does
not cure things, then we can help you troubleshoot it further.

73,
Don W3FPR

Michael Haygood wrote:

> Hi,
>
> I've been using my K2/100 for many months with great results.  After a
> recent storm containing lightning the next time I fired up the K2/100 I
> received the "HI CURR" message and the "HI REFL" messages upon initial
> transmit.  This was unusual, so the next thing I did was consult the
> troubleshooting guide in the KPA100.
>
> Using a wattmeter and connected to a dummy load, I measured the output
> power of the K2/100 with the power outupt contol set to less than 11
> watts and noticed that for a setting of 5 watts the output of the K2/100
> was about 10 watts.  For a power output setting of 15 watts, the output
> was very high - about 100 watts.
>

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[Michael Haygood]

Don,

I replaced D16 and D17 which fixed the HI CUR, HI REFL messages and lack of
power control.

However, I am still reading a low output voltage from the high voltage bias
supply.  When receiving, the high bias supply voltage at D1 cathode and
R12/R11 is about 67 volts.

I've further investigated the low voltage output from the high voltage bias
supply as follows:

1.  De-soldered the high bias voltage side of resistors R12 and R11, then
remeasured the high bias output voltage - about 69 volts.  I did this to
ensure that nothing in the T/R circuit was draining the high voltage supply;
resoldered R11/R12 back into the circuit.

2.  Desoldered the D7 anode in the high voltage bias circuit, which connects
to the VSS supply pin of the MAX1406 (RS232 Interface), then measured the
high voltage bias output voltage at D1 cathode - measured 154 volts!  
Re-soldered the D7 anode back into the circuit and the high voltage bias
supply dropped back down below 70 volts.

The high voltage bias supply output should be between 90 and 150 volts.  Is
it possible that the MAX1406 is somehow draining this circuit?  Seems
strange that it would be because it cuts the output voltage more than 50%
when the MAX1406 VSS is connected into the circuit.

I've verified that D1 through D8 are good.

Any further thoughts or info concerning the low output voltage would greatly
be appreciated!

Michael Haygood
KI5E

>From: Don Wilhelm <[hidden email]>
>Reply-To: [hidden email]
>To: Michael Haygood <[hidden email]>
>CC: [hidden email]
>Subject: Re: [Elecraft] KPA100 - Low Voltage output from High Voltage Bias
>Supply Circuit
>Date: Thu, 19 Jul 2007 18:26:59 -0400
>
>Michael,
>
>You said the 'magic words' - HI CUR, Hi REFL messages and lack of power
>control (other than low and high power selection) *after* a lightning
>storm.
>
>That is an indication that the lightning surge zapped diodes D16 and D17 in
>the KPA100 wattmeter - the result is that the base K2 microprocessor
>*thinks* there is no power output and increases the drive until it 'runs
>out of gas' - the K2 will produce max power output under those conditions.
>
>Replacement of D16 and D17 is in order as a first step.  If that does not
>cure things, then we can help you troubleshoot it further.
>
>73,
>Don W3FPR
>
>Michael Haygood wrote:
>>Hi,
>>
>>I've been using my K2/100 for many months with great results.  After a
>>recent storm containing lightning the next time I fired up the K2/100 I
>>received the "HI CURR" message and the "HI REFL" messages upon initial
>>transmit.  This was unusual, so the next thing I did was consult the
>>troubleshooting guide in the KPA100.
>>
>>Using a wattmeter and connected to a dummy load, I measured the output
>>power of the K2/100 with the power outupt contol set to less than 11 watts
>>and noticed that for a setting of 5 watts the output of the K2/100 was
>>about 10 watts.  For a power output setting of 15 watts, the output was
>>very high - about 100 watts.
>>

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[Don Wilhelm-4]

Michael,

Congratulations on finding the faulty diodes.  The failed diodes
indicate that you may have suffered a static surge of some type -
disconnect those antennas when not in use.

You have also confirmed that the MAX1406 at U8 is damaged - take it out
and your KPA100 should work for you.

If you do not have an immediate replacement for the MAX1406, remove it
right now and the KPA100 will function as an amplifier just fine without
it - of course the computer connection part of the AUX I/O will not
function, but all else should work.

73,
Don W3FPR

Michael Haygood wrote:

> Don,
>
> I replaced D16 and D17 which fixed the HI CUR, HI REFL messages and
> lack of power control.
>
> However, I am still reading a low output voltage from the high voltage
> bias supply.  When receiving, the high bias supply voltage at D1
> cathode and R12/R11 is about 67 volts.
>
> I've further investigated the low voltage output from the high voltage
> bias supply as follows:
>
> 1.  De-soldered the high bias voltage side of resistors R12 and R11,
> then remeasured the high bias output voltage - about 69 volts.  I did
> this to ensure that nothing in the T/R circuit was draining the high
> voltage supply; resoldered R11/R12 back into the circuit.
>
> 2.  Desoldered the D7 anode in the high voltage bias circuit, which
> connects to the VSS supply pin of the MAX1406 (RS232 Interface), then
> measured the high voltage bias output voltage at D1 cathode - measured
> 154 volts!  Re-soldered the D7 anode back into the circuit and the
> high voltage bias supply dropped back down below 70 volts.
>
> The high voltage bias supply output should be between 90 and 150
> volts.  Is it possible that the MAX1406 is somehow draining this
> circuit?  Seems strange that it would be because it cuts the output
> voltage more than 50% when the MAX1406 VSS is connected into the circuit.
>

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