Tetrode Manual

THE TETRODE BOARDS
Control and Protection for your Tetrode RF Power Amplifier All the hard work done! Screen supply Grid bias Tube protection TX/RX sequencing ALC output Versatile!
TM
For one or two tetrodes, including: 4CX250350400 (all types), 4CX800/

GU-74B, 4CX1000, 4CX1500B, 4CX1600A, 4CX1600U/GS-23B, YL1050/52/56, GU-73B, GU-78B, GU-84B... and more.
'Universal' DC grounding use with grounded cathode, grounded screen or

grounded control grid.
Ideal for your new amplifier or as an upgrade for your existing tetrode PA.
Tetrode Boards: AN-1 Issue 1.21, May 2006
1998-2006 IFWtech Limited
WARNING
These notes are intended for users who have sufficient experience to work safely with high-voltage circuits. Use at your own risk! We cannot accept responsibility for any damage or injury.
DANGER - AC mains voltage and high DC voltages!
The names of tag connections on the boards are shown underlined, as in the G2-REG OUT tag. On the PC boards and the Interconnections diagram, some labels had to be shortened to save space, e.g. G2-REG OUT is labeled G2REG on the board and the Interconnections diagram.
CAUTION DO NOT use the Tetrode Boards with a screen supply derived from the anode high voltage through a dropper resistor it will cause serious component damage! Always use a separate transformer winding for the screen supply.
REVISION NOTES
AN-1 Issue No 1.0, April 1998 G2-CONTROL board Issue No 3B REC-G1-ALC board Issue No 3B See earlier versions Not issued 3B 3B 3D 3D Major revisions, to give more help on the wider variety of tetrodes that are now in use. R106 changed to 470. Many changes to Farnell stock codes. Changes (where significant)
Intermediate changes 1.11.17 1.18, 1.19 1.20, Nov 2004 1.21, May 2006
Any trademarks mentioned in this manual that are not the property of IFWtech Ltd are acknowledged to be the property of their respective owners.
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CONTENTS
1. Features......................................................................................................... 4 2. Introduction................................................................................................... 4 2.1 What You Get....................................................................................... 4 2.2 What Youll Need.................................................................................. 5 2.3 Choosing Configuration Options .......................................................... 5 3. Tetrode Grounding Connections ................................................................ 6 3.1 Grid Driven, DC-grounded Cathode ..................................................... 6 3.2 Cathode Driven, DC-grounded Screen Grid......................................... 7 3.3 Cathode Driven, DC-grounded Control Grid ........................................ 7 3.4 Screen-grid Components ..................................................................... 8 4. Screen-grid Supply Configuration .............................................................. 9 4.1 Examples of Tubes............................................................................... 9 4.2 Off-board Component Calculations .................................................... 11 4.3 On-board Component Changes ......................................................... 15 4.4 Further Information............................................................................. 15 5. Control-grid and Relay Supply Configuration ......................................... 16 5.1 Control-grid Supply............................................................................. 16 5.2 Relay Supply....................................................................................... 16 6. Basic Inter-board Connections ................................................................. 17 7. Power and Control Options ....................................................................... 19 7.1 TX/RX Changeover Sequencing ........................................................ 19 7.2 Coax Relay Voltage............................................................................ 21 7.3 HV Supply Control .............................................................................. 21 7.4 G1 Switching ...................................................................................... 21 7.5 Automatic Level Control (ALC) ........................................................... 22 7.6 Additional Fault Monitoring ................................................................. 22 8. Building the Kit ........................................................................................... 23 8.1 Mounting the Boards .......................................................................... 23 8.2 Assembling the Boards ...................................................................... 23 9. Initial Power-up ........................................................................................... 26 9.1 Procedure ........................................................................................... 26 9.2 Problems? .......................................................................................... 27 9.3 Screen Supply Adjustments ............................................................... 29 9.4 Screen-current Trip ............................................................................ 30 9.5 Control-grid Protection and ALC......................................................... 31 9.6 Warm-up Timer .................................................................................. 32 10. Power-up Your Amplifier............................................................................ 33 10.1 Final Checks....................................................................................... 33 10.2 RF Testing.......................................................................................... 33 10.3 Final ALC Adjustment......................................................................... 33 10.4 False Alarms ...................................................................................... 34 10.5 Thats All !........................................................................................... 35 11. Updates and Product Support................................................................... 36 Schematics ................................................................................................. 3742 Parts List..................................................................................................... 4348
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1. Features
Universal control unit for almost any amateur-size Tetrode Power Amplifier and its High Voltage supply. Carefully designed to help your tetrodes deliver a high-quality signal. Suitable for either one or two tubes. Two compact PC boards (both 5in x 4in boards can be stacked). Regulated and adjustable screen-grid supply. Regulated and adjustable control-grid supply. Sequenced relay switching with transceiver RF drive inhibit. Screen-grid currents monitored for sensitive fault detection. No risky grid fuses! Fault conditions disable PTT and HV supply for safety just press RESET to recover. Comprehensive metering. User-configurable for special requirements, with help from these detailed Instructions.
For a general introduction to these circuits and the ideas behind them, see Power and Protection for Modern Tetrodes by Ian White, G3SEK, in QEX for October 1997 (PDF version downloadable from the Tetrode Boards website see Section 11).
2. Introduction
The full Tetrode Boards kit includes all the components for the PC boards, and some of the hard-to-find accessories. To give you the best possible value for money, we do not supply expensive off-board components such as meters and large heatsinks. You can probably find these components much more cheaply as surplus, or out of the junk-box.
2.1 What You Get

The full Tetrode Boards kit includes: 1. Two PC boards, tinned, ready-drilled, and with printed component locations 2. All the on-board components premium quality for reliability 3. Power MOSFET (Q2) and mounting washers 4. Push-on tags for the on-board connectors 5. Two extra VDRs for mounting directly at the tube sockets 6. Complete schematics and these Instructions.
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2.2 What Youll Need

This is a summary of the additional components that youll need. Most of these are easier to buy surplus than at new prices, so we didnt include them in the kit. 1. Mains transformer(s) to supply screen grid, control grid, relays and heaters. For the 4CX250/350/400 family, the transformer ratings should typically be: Screen grid: minimum AC voltage depends on requirements for regulated screen voltage and current. Typical ratings are at least 0330V AC, at least 100mA, but may need to be higher for large tubes check Section 4.2.3 before ordering a transformer. CAUTION If the AC voltage of the screen supply transformer is too low, the voltage regulator will not be able to function correctly. Control grid: 0105V AC (anywhere in the range from 100 to 150V AC) at 50100mA. Relays etc: 15015V AC 1A min for 12V coax relays, higher voltage for 24V relays. Note: a center-tapped winding is essential here. Heaters: the appropriate AC voltage and current for the tube(s). Allow for voltage drops in the heater wiring, and adjust for exactly the correct on-load voltage at the tube pins. 2. RESET switch: SPST momentary push-button (low-voltage). 3. ALARM LED: ordinary 20mA red LED. 4. Heatsink for Q2: see notes on page 48. 5. Mounting pillars and hardware for the two PC boards. 6. M1: typically 050mA or 0100mA moving-coil meter for screen grid current. The G2CONTROL board has provision for an optional meter shunt resistor R17. 7. M2: 010mA moving-coil meter for control grid current. The REC-G1-ALC board has provision for an optional meter shunt resistor R108. 8. RF choke wound on a 100 resistor, for mounting near the tube (see Section 3.4). 9. Screen-cathode bleeder resistor Rs (see Section 3.4 for values and ratings). 10. Power resistors R12 and R14 (see Sections 4.2.4 and 4.2.5 for values and ratings). You will also need some temporary resistors for the setting-up procedures.
2.3 Choosing Configuration Options

Every power amplifier is different, so there are many possible options for voltages, metering, TX/RX control etc. CAUTION Please read ALL of Sections 3, 4, 5, 6 and 7 BEFORE you switch on the soldering iron!
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3. Tetrode Grounding Connections

CAUTION Do not start to build the kit until you have read all of Sections 3, 4, 5, 6 and 7, and have decided on the options you need to install.
You can use the Tetrode Boards with any configuration of DC and RF grounding of the tube(s). Remember that RF grounding and DC (chassis) grounding are different! For example, the screen grid of a tetrode is always RF-grounded, but in most configurations the screen is not DCgrounded to the chassis. This section explains the three practical combinations of DC and RF grounding, and shows you exactly how to connect the Tetrode Boards. Note that some configurations require additional components, shown in the schematics below as Rs, Cs, RFC, Rd, VDR see Section 3.4 for more details of these components. Two-tube Amplifiers The Tetrode Boards can handle either one or two tubes, though only one tetrode (V1) is shown in these examples. If yours is a two-tube amplifier, use the connection points marked V2 on the schematics below. Also see the note on page 10 about Matched Pairs of Tubes.
3.1 Grid Driven, DC-grounded Cathode

G1
ToV2 V2
IF V2 ISRFC, Rd, VDR and Cs atR2, VDR1 Repeat USED, REPEAT RFC1, each tube RFC1 RFC TEXT SEE
V1
G1 BIAS
G2
Rd 100 1W R2 100R 1W Rs R1 Rs SEE TEXT
INPUT CIRCUIT
RF
CATHODE
VDR VDR1 Cs C1
RF drive is to the control grid, and the screen grid is bypassed by Cs (usually built into the tube socket). The tube cathode is grounded to chassis (maybe through a small RF feedback resistor at X). Connect both of the CATHODE tags on the G2-CONTROL board and on the REC-G1-ALC board to chassis ground as shown above. Do not connect the G1 OUT and G2-REG OUT rails to chassis! Note that the G1 meter is at control-grid potential below chassis ground, and the G2 meter is at VG2 potential above chassis ground. Your anode-current meter in the B-minus rail will be at chassis ground potential.
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3.2 Cathode Driven, DC-grounded Screen Grid

G1 If V2 IF V2 IS USED, Ca at eachVDR1, C1 is used, repeat REPEAT tube
V1 G2 V2 Rs R1 SEE TEXT Ca C1 VDR VDR1 V2
CATHODE C2 Cb 10n
INPUT CIRCUIT
RF
B-MINUS
RF drive is to the cathode, the screen grid is DC-grounded (so there is no screen bypass capacitor Cs). The control grid is bypassed to chassis ground by Ca. The RF bypass capacitor for the input circuit is shown as Cb. Ca and Cb should both be 10-100nF; VHF/UHF amplifiers may need additional capacitance here. Connect the G2-REG OUT tag on the G2-CONTROL board to chassis ground as shown above. Do not connect the CATHODE or G1 OUT rails to chassis! Note that the G2 meter is close to chassis ground potential, but the G1 meter is at (VG2 + VG1) potential below chassis ground. Also your anode-current meter in the B-minus rail will be at VG2 potential below chassis ground.
3.3 Cathode Driven, DC-grounded Control Grid

G1 To V2 V2 Repeat RFC, Rd, VDR and Cs at each tube
IF V2 IS USED, REPEAT RFC1, R2, VDR1, C1 RFC1 RFC TEXT SEE
V1
G2 Cs C1 R2 100R 1W Rd 100 1W Rs R1 SEE TEXT VDR VDR1
V2
CATHODE Cb C2 10n
INPUT CIRCUIT
RF
B-MINUS
RF drive is to the cathode, the control grid is DC-grounded and the screen grid is bypassed by Cs (usually built into the tube socket). The RF bypass capacitor for the input circuit is shown as Cb, and should both be 10-100nF; VHF/UHF amplifiers may need additional capacitance here. Tetrode Boards: AN-1 Issue 1.21, May 2006 7
Connect the G1 OUT tag on the REC-G1-ALC board to chassis ground as shown above. Do not connect the CATHODE or G2-REG OUT rails to chassis! Note that the G1 meter is close to chassis ground potential, but the G2 meter is at (VG2 VG1) potential above chassis ground. Also your anode-current meter in the B-minus rail will be at VG1 potential below chassis ground.
3.4 Screen-grid Components

This section describes the components that are common to all of the schematics above.
RFC1 RFC TEXT SEE G2 Rd 100 1W R2 100R 1W Rs R1 SEE TEXT CATHODE VDR1 VDR C1 Cs V1
Screen-cathode bleeder resistor Rs Rs serves two purposes: 1. To prevent the screen grid from floating when the screen switching relay K1 is changing over. 2. To provide a bleed current which makes the screen current meter read up-scale by about 10mA. This allows negative screen currents of up to 10mA to be indicated in an ordinary lefthand-zero meter. A 050mA meter will read screen current from 10mA to +40mA. To obtain a bleed current of about 10mA, R1 = VG2 / 10 k, e.g. 35k for a 350V screen supply, 40k for 400V etc. The value doesnt have to be exact because you can zero the meter to any major scale mark using the mechanical adjustment. Section 4.2.1 gives some recommended values and component ratings. VDR This VDR is identical to the two VDRs on the G2-CONTROL board. It is the first line of defence to protect the screen grid, the screen bypass capacitor and the power supply in the event of a flashover. Connect the VDR directly from the screen tag on the tube socket to the nearest cathode tag, with short leads to minimize inductance. There are already two VDRs on the G2-CONTROL board, but an extra VDR will be needed right here at the screen grid of the tube. Because a two-tube amplifier needs a separate VDR at each tube, two extra VDRs are provided with the kit (making four in total). If you are only using a single tube, connect both VDRs in parallel for extra protection. Cs - RFC - Rd Cs is the screen bypass capacitor, and is usually built into the tube socket. RFC and Rd prevent spurious resonances between Cs and the LF bypass capacitor C9 on the G2-CONTROL board, which could lead to the screen grid becoming un-bypassed at HF. Rd is a 100 1W carbon or metal-oxide resistor (not wire-wound) and RFC is about 40 turns of 24gauge enameled wire, scramble-wound over the body of R2. If you use two tubes, you need a separate Cs-RFC-Rd network at each tube. If the screen grid is directly DC-grounded, as described in Section 3.2, then Cs, RFC and Rd are not necessary.
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4. Screen-grid Supply Configuration

The Tetrode Boards can be used with many different tubes that have a wide range of screen voltage and current requirements. For correct operation, you will need to select certain component values, depending on the following factors: Type of tube

regulated voltage required maximum positive screen current (without losing voltage regulation) per tube maximum negative screen current (without losing voltage regulation) per tube screen trip current, per tube
Number of tubes simply multiply the current requirements by the number of tubes Mains transformer

AC voltage current capability and/or winding resistances.
4.1 Examples of Tubes

The following are examples of the wide range of tubes that have been used with the Tetrode Boards, with some typical operating conditions and suggested settings for the screen current trip. Tube Typical operating conditions (SSB, Class AB1) * Screen voltage (V) GS-15B 4CX250B 4CX250R / 8930 4CX350A 4CX400A 4CX800 / GU-74B 4CX1000A 4CX1500B 4CX1600A / GU-91B 350 350 375400 375400 375400 350 325 225 350 240 Peak screen current (mA) 1 5 5 3 20 30 35 15 48 21 Suggested current trip level (mA)
8 15 15 15 20 40 35 20 55 30 continued...
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Tube
Typical operating conditions (SSB, Class AB1) * Screen voltage (V) Peak screen current (mA) 23
Suggested current trip level (mA)
4CX1600U / GS-23B GU-73B GU-78B GU-84B YL1050/1052/1056
520
23
360380 500
40 26
60 35
These values are taken where possible from manufacturers data sheets, or selected from information developed by amateur users. Data given here are in no way warranted by IFWtech Ltd.
The screen current of a tetrode is a very sensitive indicator for a wide range of fault conditions, including: Incorrect plate-circuit tuning Loading too light, or too heavy Too much RF drive Loss or major change in anode, screen or control grid voltage RF and DC arcs, flashovers and other glitches Blower failure, resulting in overheating of the tube(s). All of these faults will result in too much screen current, either positive or negative. Continuous electronic monitoring of the screen current is thus one of the most important features of the Tetrode Boards. The suggested current trip levels are normally about 2025% above the typical peak screen current recommended by the manufacturer. This is generally high enough to avoid false alarms during normal operation, but still low enough to give adequate protection to the screen grid. However, for some tubes the manufacturers recommended typical screen current (at the recommended screen voltage) equates to the maximum allowable power dissipation. Where this limit applies, the typical screen current is given as a value in the table above, and the suggested trip current is given as a value. The screen trip in the Tetrode Boards is very fastacting if anything goes wrong, so in practice it may be OK to set the screen trip current to 20% above the manufacturers maximum recommended current. Matched Pairs of Tubes Two-tube amplifiers require tubes that are well matched in terms of DC and RF characteristics. New tubes from the same manufacturer should start out well-matched, but they must then experience the same operating history. Tubes from different manufacturers (even new) may not be well-enough matched for use in a two-tube amplifier. Unless you are very lucky, used tubes with different operating histories will have very different characteristics and should not be paired together.
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4.2 Off-board Component Calculations

This section gives simple worksheets to calculate the voltages, currents and off-board component values for the screen regulator. Here is a very simplified schematic:
Standing current
R14 + METER R12 K1
Screen current +
Unregulated input voltage

Q2
R12/Q2 current
Bleed currentRS
Rs
Regulated screen voltage
VDR
+30V
Each of the worksheets below contains an example column based on 2 x 4CX800/GU74B tubes, and a blank column where you can enter the values for your particular amplifier. (If your calculated values are dramatically different from the example values at any stage, you need to 1 check your arithmetic!)
4.2.1 Screen bleeder resistor, Rs

Rs is the resistor connected between the screen supply and cathode potential, close to the tube(s). The purpose of Rs is to ensure there is always a DC return path for the screen, even while the relay contacts of K1 are changing over. Rs is calculated to bleed about 10mA of current, but this value is not critical (and need not be changed if using two tubes). Suggested values are: Screen voltage range Up to 250V 250400V 400550V > 550V Rs 22k 5W 33k 7W or 10W, or 2 x 15k 5W in series 2 x 22k 5W in series Above the voltage limit of the Tetrode Boards
If in doubt, use the next recommended lower value of resistance here.
There is also an Excel spreadsheet on the Tetrode Boards website. The spreadsheet approaches the problem in a different way, but the results are equivalent.
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4.2.2 Calculate the Trip Current and the Standing Current

The standing current is the current that flows through R14 all the time the amplifier is in the TX condition (K1 energized as shown above). Fill out this worksheet: Calculation steps A Suggested current trip level, mA (from table above, based on 2025% above manufacturers recommended peak screen current) Multiply A by 1.1 Multiply B by number of tubes Round C upward to the next multiple of 10mA This is the trip current E Add 20mA to D This is the standing current through R14 90 + 20 = 110mA Your amplifier Example: 2 x 4XC800/GU-74B 40mA
B C D
40 x 1.1 = 44mA 44 x 2 = 88mA 88 rounds up to 90mA
4.2.3 Calculate the transformer AC voltage requirement

Fill out this worksheet: Calculation steps A B C D E F Recommended regulated screen voltage (from table above, or tube manufacturers data) Add 50V to A Required standing current through R14 (= E from Section 4.2.1 worksheet above) Multiply C by 0.75, and add to A Choose whichever is larger, B or D Round E upwards to the next multiple of 10 This is the minimum unregulated input voltage that will meet your requirements G Divide F by 1.2 This is the minimum transformer voltage (RMS AC) estimated to meet your requirements Your amplifier Example: 2 x 4XC800/GU-74B 350V 350 + 50 = 400V 110mA (110 x 0.75) + 350 = 432.5V D is the larger = 432.5V 432.5 rounds up to 440V Continued... 440 / 1.2 = 367V AC
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CAUTION The transformer voltage is an ESTIMATE based on typical transformers. The suitability of any particular transformer cannot be guaranteed until the practical testing stage. If in doubt, choose a transformer giving a higher RMS AC voltage than estimated here. Notes on transformer AC voltage Maybe the minimum AC voltage is higher than you expected? Remember that the unregulated DC input contains 100/120Hz AC ripple, so the instantaneous minimum voltage can easily be 30 50V lower than the average voltage that you measure with a multimeter. If the instantaneous minimum voltage is too low, the voltage regulator will drop out during the negative part of the ripple cycles, and the regulated DC screen voltage will have negative spikes at 100/120Hz. An oscilloscope will show this very clearly. In the worksheet above, the factor of 1.2 on line G is an allowance for the difference between the average DC voltage and instantaneous value at the minimum of the 100/120Hz ripple cycle. However, the actual minimum voltage will depend on the transformer winding resistances, so the suitability of your particular transformer cannot be guaranteed in advance. The only way to be certain is to check the screen voltage using an oscilloscope, and make sure it is a clean, constant DC voltage with no negative 100/120Hz spikes. If you see small spikes, you may be able to adjust R12 to remove them see below.
4.2.4 Calculate R14

The purpose of R14 is to deliver the required standing current (= E from Section 4.2.1 worksheet above) into the shunt regulator circuit. We do not know what the actual value of your unregulated input voltage will be, so this calculation is only a first estimate. The exact value of R14 will be adjusted on test (see later, in Section 9.3.1). To calculate R14, fill out this worksheet: Calculation steps A B C D E Unregulated input voltage (= F from Section 4.2.3 worksheet above) Recommended regulated screen voltage (= A from Section 4.2.3 worksheet above) Voltage drop across R14 = A B Required standing current through R14 (= E from Section 4.2.1 worksheet above) R14 = C x 1000 / D This is the estimated value for R14 F W R14 = C x D / 1000 W This is the minimum power rating for R14 use a higher-rated component for better reliability 90 x 110 / 1000 = 9.9W Your amplifier Example: 2 x 4XC800/GU-74B 440V 350V 440 - 350 = 90V 110mA 90 x 1000 / 110 = 818
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Notes on R14 The recommended component for R14 is an Ohmite adjustable wirewound resistor. The adjustment feature allows simple setup (Section 9.3.1) without having to swap resistors.
Ohmite part number D50K1K0 (1k 50W max) will be suitable for R14 in almost all cases (see Components List for ordering information). This resistor can be adjusted to any value below 1k. The power dissipation is up to 50W, proportional to the length that is actually being used. The resistor is air-cooled, and with good ventilation it will run reliably at a moderate temperature.
4.2.5 Calculate R12

The purpose of R12 is to remove some of the heat load from the power MOSFET Q2. To calculate R12, fill out this worksheet: Calculation steps A B C Recommended regulated screen voltage (= A from Section 4.2.3 worksheet above) Required standing current through R14 (= E from Section 4.2.1 worksheet above) Maximum value of R12 = (A - 80) x 1000 / (B + 20) This is the maximum value for R12 D E Round this resistance value down to the nearest standard value W R12 = (B + 20) x R12 / 10
2 6
Your tube(s)
Example: 2 x 4XC800/GU-74B 350V 110mA (350 - 80) x 1000 / (110 + 20) = 2076
2000 (110 + 20) x 2000 / 6 10 = 33.8W

2
This is the minimum power rating for R12 use a higher-rated component for better reliability Notes on R12 R12 can be either a large wirewound resistor mounted with good ventilation, or a 50/100W metalclad resistor mounted on a large and well-cooled heatsink. If you choose the second option, the heatsink for R12 must be separate from the heatsink for Q2!
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4.3 On-board Component Changes

Very few on-board component changes are needed to configure the G2-CONTROL board for different tubes.
4.3.1 Screen voltage

You should normally use the screen voltages suggested in the table on page 9. The following table shows the on-board changes that may need to be made for screen voltages from 210V up to the maximum limit of 550V. (OK means you should use the standard values in the component list.) Voltage range 210260V (4CX1500B, 225V) 275350V 320420V 410560V VDR1, 2 * V250LA40B (marked 250L40B) OK (V320LA40B) OK (V320LA40B) V420LA40B (marked 420L40) LK3 shorted shorted shorted 150k 1W (use the resistor listed as R10) R9 47k 33k OK (27k) OK (27k) R10 100k 1W metal film OK (150k) OK (150k) 220k 2W metal film
* Also use the same components for the two VDRs that are connected at the screen(s).
A total of four VDRs will be needed. In recent issues of the Tetrode Boards kit, Q2 has been changed from an IRF840 (500V) to a higher-voltage MOSFET, STP4NB100 (1000V). See the Components List for further details.
4.3.2 Screen current sensing

Resistor R15 sets the working range of the screen-current trip circuit. Choose a value for R15 so that your trip current (D from the Section worksheet) falls about in the middle of its working range. R15 should be a 1W power metal oxide resistor. Trip current range 10mA (GS-15B) 3060mA 50100mA 70140mA 100200mA R15 220 82 47 33 22
4.3.3 Control-grid voltage

See Section 5.1.
4.4 Further Information

There is more detail about screen voltages and currents in Application Note 3, available from the Tetrode Boards website: http://www.ifwtech.co.uk/g3sek/boards/tetrode/tetrode3.htm click Downloads.
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5. Control-grid and Relay Supply Configuration

5.1 Control-grid Supply

The control grid bias is generated from a negative supply that delivers approximately 10mA via R105. The fixed shunt voltage regulator consists of zener diode D114 and transistor Q101, and the grid bias potentiometer RV102 gives an adjustment range of about 5V (from the nominal zener voltage to about 5V more negative). For different grid bias voltage requirements, change the 33V zener diode D114 (1N5364B) to another voltage in the 1N53xxB series. For example, 4CX250s with a screen voltage of +360V typically require about 55 to 60V of grid bias, so change D114 to a 1N5370B (56V). Depending on your transformer voltage, you may need to change R105 (and possibly also R103) to deliver approximately 10mA DC into the bias regulator (approximately 5V measured across RV102). Also see Section 7.4 for information about optional control-grid bias switching.
5.2 Relay Supply

The bridge rectifier BR101 provides both positive and negative DC voltages, so you must use a center-tapped winding (or two equal windings correctly phased). The input tags are labeled 18-018V AC; the center-tap connects to the center tag. 18018V AC is a universal input voltage that will usually work with both 12V and 24V relays. For 12V relays only, 15015V AC is recommended, though transformer voltages down to about 12012V AC may work with some relays. Do not use transformer voltages lower than 12012V; such low AC input voltages will not give a regulated +12V DC supply from U101. Do not use transformer voltages higher than 25025V AC; they will exceed the voltage ratings of C105 and U101.
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6. Basic Inter-board Connections

This section deals with the basic inter-board connections that all configurations will need. The Interconnections diagram on page 37 shows all of these basic interconnections, and also some of the Power and Control options (Section 7). Basic Interconnections 1. Wire the REC-G1-ALC board and the G2-CONTROL board together as shown in the Interconnections diagram (page 37). 2. Wire the CHASSIS GROUND points on the two boards to a secure chassis ground. Do not rely on board mounting pillars for chassis ground connections. 3. Always wire the CATHODE tags on the two boards together. Also re-check Section 3 to confirm you are using the correct DC-grounding options. Now connect the following off-board parts: 4. Mains transformer The tags on the REC-G1-ALC board are marked for typical input voltages. Connect the transformer windings to the following tags on the REC-G1-ALC board:

Screen supply: 330V AC Control grid supply: 105V AC Relay supply: 18-0-18V AC.
Do use these transformer windings for any other purposes. 5. G2 current meter M1 The full-scale deflection of the meter should be a round number, above the maximum trip current suggested in the table on page 9. Typically the meter movement will need to be either 050mA full-scale for small amplifiers, or 0100mA full-scale for larger amplifiers. Observe correct meter polarity as marked on the G2-CONTROL board. R17 is an optional meter shunt for calibration. A typical 050mA meter will indicate screen current from approximately 10mA to +40mA (see Section 9.3.3 for a detailed explanation, and page 29 for a typical meter scale). 6. G1 current meter M2 For class-AB1 operation, this meter must normally be 010mA full-scale. Observe correct meter polarity as marked on the REC-G1-ALC board. R108 is an optional meter shunt for calibration. 7. RV102 This is the G1 bias control potentiometer, usually mounted on the rear panel. 8. ALARM LED and RESET switch Mount these components on the front panel. Observe correct LED polarity.
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9. Q2 Mount Q2 on its own heatsink. There are a number of options, depending on the screen voltage, the regulator standing current (Section 4.2.2) and the MOSFET you have selected for (see further notes on page 48): An area of chassis that is cooled directly by cold air from the PA blower A finned heatsink of outside dimensions at least 4in x 3in x 1in, in a well-ventilated location with the fins vertical A heatsink with direct fan cooling even a small fan helps a lot. Use the insulated mounting hardware provided. The special thermally conductive washer requires no grease, but make sure there are no burrs on the heatsink they can easily cut through the washer. Connect the body of the heatsink to chassis ground for safety. Take care to connect the MOSFET correctly to the GATE, DRAIN and SOURCE tags as marked on the G2-CONTROL board, and do not expose the MOSFET to electrostatic voltages. CAUTION If the total standing current (Section 4.2.2) is greater than about 100mA, you may require two MOSFETs connected in parallel with equalizing resistors. If this may apply to your amplifier, e-mail boards@ifwtech.co.uk for further details. 10. R12, R13, R14 R12 and R14 are large power resistors, and generate a lot of heat in the TX condition. If you use metal-clad resistors, they must be mounted on a large heatsink using thermally conductive grease (mounting on the chassis will usually not be good enough, and will cause overheating). You can use a heatsink about the same size as the one for Q2 (4in x 3in x 1in) but do not make Q2 share the same heatsink!. In the RX or Standby condition the power dissipation is much lower than on TX. No current flows through R14, and only a small keep-alive current flows through R13 and R12. If the RX/Standby voltage across R13 is more than about 150V (unusual), use two identical 10k 3W resistors in series. 11. PTT This is the ground-to-transmit connection from the transceiver. Check that your transceivers PTT output is capable of switching 12V at 140mA to chassis ground. You can connect a SPST switch in series with the PTT line to disable the amplifier on Standby.
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7. Power and Control Options

The Tetrode Boards offer a wide range of user options. You will need to configure these options while you are assembling and interconnecting the boards. CAUTION Do not start to build the kit until you have read all of Sections 3, 4, 5, 6 and 7, and have decided on the options you need to install.
7.1 TX/RX Changeover Sequencing

7.1.1 General options
This section gives you an overview of the options for TX/RX changeover sequencing. Sequencing Requirements The two DPCO relays K2 and K3 give you several options for TX/RX changeover sequencing. When you press and release the PTT, K2 operates quickly but K3 operates slowly. This combination of fast and slow changeovers can generate all the necessary TX/RX sequencing by inter-linking appropriate contacts. RX TX Fast Screen relay K1 Coaxial relays RF drive (optional TX inhibit) Grid bias switching (optional) Slow TX RX Fast Slow
When the PTT line is grounded, the current is about 140mA. When the PTT line is un-grounded, the open-circuit voltage is regulated at +12V.
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7.1.2 Coax relay control

You have two options: Energized on transmit the usual way. Energized on receive less commonly used, but has the advantage of failing safe and protecting your preamplifier when the system is not in use. To use one of these options, you must wire the connections to the two relays K2 and K3 as shown below.
COAX RELAYS ENERGIZED ON TX
(TRACK SIDE)
NC NO 1
COAX RELAYS ENERGIZED ON RX
G2-CONTROL BOARD
NC
NO
RL IN
RL IN
1N4001
1N4001
7.1.3 TX inhibit
A common problem with TX/RX sequencing is that the transceiver starts to generate RF drive before the PA is ready for it. The Tetrode Boards include a TX Inhibit feature that holds the transceivers EXT ALC INPUT line fully negative, preventing RF drive until the correct time in the changeover sequence. You can use this feature if your transceiver has an external ALC INPUT connection, and if the transceivers ALC recovery is fast enough to allow an acceptably quick 2 changeover. The TX Inhibit feature can only be used if you are also using ALC see Sections 7.5 and 9.5. Also, you cannot use both TX Inhibit and the G1 switching feature (Section 7.4) because they use the same changeover contacts on K2 and K3.
G2-CONTROL BOARD (TRACK SIDE)
NC NO 1
K2 - FAST
TO 'INH IN' TERMINAL ON REC-G1-ALC BOARD
K3- SLOW
4
RL IN
The Yaesu FT-990 and FT-1000 series have an alternative way to inhibit the transmitter until the amplifier is ready. The transmitter will only operate when pin 8 of the BAND DATA socket is grounded. To use this feature, wire the N.O contacts of K2 and K3 in series, and use them to switch pin 8 to chassis ground.
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7.2 Coax Relay Voltage

The operating voltage for the external coaxial relays is connected to RL IN on the G2-CONTROL board. If your relays work quickly and reliably with 12V DC, link +12V OUT on the REC-G1-ALC board directly to RL IN on the G2-CONTROL board. The maximum total current from the +12V HV ENABLE and +12V OUT tags is 1.5A, limited by the 7812 voltage regulator IC which also provides short-circuit protection. For 24V coax relays, link RL-UNREG on the REC-G1-ALC board to RL IN on the G2-CONTROL board. The unregulated voltage is 2425V, which should be enough to operate relays up to 24V DC. For other relay operating voltages, you must organize your own power supply. CAUTION MAXIMUM VOLTAGE 50V AC/DC.
7.3 HV Supply Control

The +12V HV ENABLE tag on the G2-CONTROL board is the safety interlock to your HV (B+) supply. This tag provides +12V DC to a mains power relay in the HV supply. The control voltage is available after the warm-up timer has cycled. If the trip circuit operates for any reason, the HV control voltage is removed in less than 5 milliseconds. HV control is an important safety feature. We strongly recommend that you use it! To use the +12V HV ENABLE feature you must install a 12V DC-operated relay to interrupt the mains supply to the HV transformer. Make sure that the relay is capable of handling and breaking the maximum overload current of the transformer with a large safety margin. The maximum total current available from the +12V HV ENABLE and +12V OUT tags is 1.5A. The current is limited by the 7812 voltage regulator IC which also provides short-circuit protection.
7.4 G1 Switching
The Tetrode Boards offer you the option to switch the control grid to a more negative voltage on receive. However, for most tetrodes, switching the screen grid to cathode using K1 is enough to ensure zero anode current in the RX condition. If you know that you will not require G1 switching, make a wire link on the REC-G1-ALC board in place of R107, and ignore the rest of this section. If you do require G1 switching, R107 (4.7k 2W) is supplied with the kit. Also connect the G1 SWITCH tag on the REC-G1-ALC board to K2 and K3 on the G2-CONTROL board as shown below, and connect the switched line to the CATHODE tag.
G2-CONTROL BOARD (TRACK SIDE)
NC
NO
G1 SWITCH G1 SWITCH CATHODE
RL IN
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If you are using G1 switching, you may also need to alter R107 from the value provided in the kit (4.7k 2W), but do not exceed the tube manufacturers maximum grid-cathode voltage in the RX condition. Note that you cannot use both G1 switching and the TX Inhibit feature (Section 7.1.3) because they use the same changeover contacts on K2 and K3.
7.5 Automatic Level Control (ALC)

The Tetrode Boards provide an automatic level control (ALC) output to feed back to your transceiver. ALC is recommended to prevent overdriving your linear amplifier. ALC is derived by sensing the control-grid current. The ALC circuit on the Tetrode Boards is normally configured for class-AB1 operation. That should mean zero grid current under all conditions of drive! In reality, ALC control will begin at a few hundred micro-amps of control-grid current. To use ALC, simply connect the ALC OUT tag on the REC-G1-ALC board to the EXTERNAL ALC input of your transceiver. The ALC OUT tag provides an industry-standard negative voltage, adjustable to suit your transceiver. Even if you choose not to use ALC, the Tetrode Boards will still be monitoring your control-grid current to protect the tube. The circuit will disable the PA and light the ALARM LED if you run more than a few milliamps of grid current reduce the RF drive level and press the RESET button to continue.
7.6 Additional Fault Monitoring

The AUX TRIP IN tag on the G2-CONTROL board can be used to prevent PA operation if this tag is grounded. For example you could use a blower airflow switch (open-circuit when air is flowing).
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8. Building the Kit

The standard Tetrode Boards kit contains extra resistors that you can select according to the screen grid voltage and current required. Sections 4 and 5 explained how to select these values for specific tubes. (At the end of assembly, you will therefore have a few resistors left over.) If you are providing your own components, use the component list at the rear of this manual (check the Tetrode Boards website for any updates) and follow these instructions as applicable.
8.1 Mounting the Boards

Use the bare boards as templates to mark the chassis fixing holes (hole centers 4.5in x 3.5in). Fix the two boards to the chassis on 0.5-in (12mm) pillars. Take care with insulation around the isolated mounting holes high-voltage tracks pass nearby. The REC-G1-ALC board generates significant heat, so it must be mounted above the chassis to allow the heat to rise freely. If you intend to stack the two boards, the REC-G1-ALC board must be mounted on top to dissipate heat. Use 1.5-in (3540mm) pillars. To give access to RV1 and RV2 on the G2CONTROL board for setting-up, drill out the two holes on the REC-G1-ALC board marked RV1 and RV2. CAUTION Do not drill the holes in the REC-G1-ALC board any larger than 0.25 in (6mm) diameter. To adjust RV1 and RV2, use a slim INSULATED trimming tool, to avoid shock hazards or short-circuits between the two boards.
8.2 Assembling the Boards

1. Insert the connector tags into the boards first. Lay the board on a flat sheet of expanded polystyrene, component-side up. To insert a connector tag, hold it with long-nosed pliers and tap it gently into place with a very small hammer. When all the tags have been inserted, solder them to the PC pads underneath the board. 2. Wire the above-board links using insulated solid wire. The G2-CONTROL board has two links (LK1 and LK2) above the board. For screen supply voltages up to 400V, also wire the link LK3 in line with R8. For higher voltages, use a second resistor in this position (see Section 4.2). The REC-G1-ALC board has two wire links (LK1 and LK2). 3. If necessary, install suitable meter shunt resistors: R17 on the G2-CONTROL board; and R108 on the REC-G1-ALC board. 4. Identify the components in the kit see below.
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COMPONENT MARKINGS Check the markings on each component BEFORE you solder it in place... make that a DOUBLE-check! Facts of modern life Components are getting smaller. Markings are often microscopic and often dont agree exactly with the full part number. There are now two different resistor color codes. The whole world is changing over to solders that contain no lead. Sorry, thats just the way things are... we hope the following notes will help. Resistors Some resistors are marked with the familiar three-band value code, e.g. 10k is brown-blackorange... BUT... Many resistors in the kit are marked with the newer four-band value code: 1st digit, 2nd digit, 3rd digit (always black), number of zeroes. In this coding, a 10k resistor is brown-blackblack-RED so take care! If in doubt, measure the resistors with a multimeter. Trimpots These have a two-digit marking: 1st digit is value, 2nd is number of zeroes: 500 52 1k 13 10k 14 Ceramic capacitors The 10nF capacitors are marked 103 (read the code as 1, 0 and 3 more zeroes, i.e. 10,000pF). The 0.1F (100nF) capacitors are marked 104. The 4.7nF (4700pF) capacitors are marked 472 or 4n7.7 Diodes Check the small glass diodes carefully using a magnifier. All the 1N4148 diodes will usually be banded together. Some of the zener diodes have the voltage in the part number the BZX79C12 diodes are 12V zeners, and the BZX79C15 diodes are 15V. Transistors and ICs Install all the small transistors and the TO-220 devices according to the outlines printed on the board. Q2 is mounted separately on its own large heatsink, following the G-D-S connections printed on the board. (Note the rectangular outline printed on the board is for an optional 3-pole connector.) Take extra care to install all of the DIL sockets with the index notch at the correct end. Lead-free parts In future, all parts will be supplied with lead-free plating the boards are now silver-plated! For reliable soldering, we strongly recommend you continue to use regular tin/lead solder. (In Europe, this is still legal for home constructors.) Heatsinks You must provide the large off-board heatsink for Q2, as stated in Section 2.2. You must also provide nuts and screws to fix the TO-220 transistor tabs to all of the heatsinks. For Q2 there is a plastic bush to insulate the bolt from the transistor tab, and also a special insulating, heat-conducting washer do not use heatsink compound with this washer. For the three small heatsinks on the boards, use heatsink compound with a nut and bolt. No insulation is required.
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5. Assemble the components to the two boards. Observe polarity of diodes, IC sockets and ICs. Use a fine-tip soldering iron watch out for missed pads and solder bridges. 6. Wire the two high-voltage links LK4 and LK5 under K1 on the G2-CONTROL board (view below is from under-side of board). Use Teflon insulated wire or sleeving.
7. For on-board TX/RX wiring options, follow the instructions in Section 7 and wire the necessary links in the area beneath K2 and K3 on the G2-CONTROL board. 8. When you have finished all wiring, remove flux residues, solder balls etc. from the under-side of both finished boards, using denatured alcohol or isopropyl alcohol and an old toothbrush. Rinse well and allow to dry. 9. Check both boards very carefully for missed connections, dry joints or solder bridges. Use a magnifier!
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9. Initial Power-up
CAUTION Do not connect the Tetrode Boards to the amplifier yet. Do not insert tubes into the amplifier until you reach Section 10 Power-up Your Amplifier. If you find any problems, look in Section 9.2 for help.
9.1 Procedure
Follow these instructions carefully. Check-off each step as you go. 1. Remove any socketed ICs. 2. Disconnect the following tags at the REC-G1-ALC board: G2-UNREG, +12V OUT, CCW and RL-UNREG (if used). 3. Apply mains power to the transformer and check that the following DC voltages appear on the REC-G1-ALC board: G2-UNREG to CATHODE: +450V (approx, depends on transformer voltage) CCW to CATHODE: 150V (approx, depends on transformer voltage) RL-UNREG to chassis +25V (approx, depends on transformer voltage) +12V OUT to chassis: +12.0V Pin 4 of U102 (LM324) socket to chassis: +12.0V Pin 11 of U102 (LM324) socket to chassis: 12.0V (approx). CAUTION If there are any problems here, fix them before you go any further. 4. Switch off and disconnect from the mains. 5. Replace the +12V OUT connector and the RL-UNREG connector (if used). Connect the coax relays to pin 4 near K2 and K3. Connect the LED and RESET switch (the PTT test below will not work without the LED connected). Apply power to the mains transformer. If you have configured the G2-CONTROL board to have the coax relays energized on RX (Section 7.1.2) they should change over when you apply power. Ground the PTT line: all relays should change over, with a sequenced ker-lick from K2 and K3. Un-ground the PTT line: all relays should change back, again with a sequenced ker-lick from K2 and K3. Switch off and disconnect from the mains. Then replace all the other connectors on the RECG1-ALC board. 6. Remove the tube(s) and the HV connector from the PA, and connect the Tetrode Boards to the PA.
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CAUTION Before this step, you must have installed the screen-grid components in the PA, as described in Section 3.4. In particular, you MUST have installed the screen-cathode bleeder resistor Rs! 7. Adjust R14 to the value that you calculated in Section 4.2.4. Set all trimmer potentiometers and RV102 to mid-range. Insert U2 (748) on the G2-CONTROL board (observe polarity). Do not insert the opto-couplers U3 and U103 yet. 8. Apply mains power to the transformer(s) and check that the correct voltages appear at all terminals of the tube socket(s) in the RX condition: Nominal heater voltage (check again later, with the tubes inserted) G2 at same potential as the tube cathode and the CATHODE tag (because in the RX condition G2-REG OUT is connected to CATHODE by K1) Approximately correct negative G1 voltage in RX condition (depending on your choice for G1 switching see Section 7.4). The ALARM LED should light dimly, but not brightly. 9. Ground the PTT line to switch to the TX condition, and check the G2 voltage again: G2 voltage should now be present, and should be approximately the correct value with respect to the tube cathode and the CATHODE tag. Check that RV1 can vary this voltage around the required value. In case of problems, see Section 9.2.1. Move the positive test probe to the G2 METER + tag (or the meter itself). The voltage should be exactly the same as at the G2 tag on the tube socket. Un-ground the PTT line and check that the voltage does not change significantly in the RX condition. This checks the keep-alive function that reduces power consumption in the RX condition. 10. Ground the PTT line and check the G1 voltage in the TX condition: Check for approximately correct negative G1 voltage in the TX condition. Check that RV102 can vary this voltage over a range of about 5V. 11. Switch off and disconnect from the mains.
9.2 Problems?
The most likely source of all problems is wiring errors either between boards or on the boards themselves.
9.2.1 Screen supply troubleshooting

Problem Zero voltage at screen grid Possible Causes and Solutions Not in TX mode, i.e. PTT not grounded. (In RX mode, zero screen voltage is correct !) Unregulated supply not reaching G2-UNREG IN tag check wiring continuity. K1 not switching, or under-board links to K1 missing. Check wiring continuity from G2-UNREG IN through to G2 METER + , G2 METER and K1, and on to G2-REG OUT .
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Problem Output voltage high (unregulated RV1 has little or no effect)
Possible Causes and Solutions Q2 installed backwards with gate and source connections interchanged check polarity (Q2 often survives this error). No shunt path through R14, Q2 and Q1 to CATHODE rail check wiring continuity. Q2 gate failure handle Q2 with care and observe anti-static precautions! Current leakage in D6 is preventing the MOSFET Q2 from turning on. (If D6 is a 4.7V zener, as supplied with earlier kits, change this component to a 12V zener see the Components List.) Voltage on cathode of D7 (band) should be +82V with respect to CATHODE rail. Voltage on collector (tab) of Q1 should be +30V with respect to CATHODE rail. If Q1 collector voltage is +30V, then the reference voltage at pin 2 of U2 should be +23V with respect to CATHODE rail. When the circuit is regulating correctly, the voltages at pin 2 and pin 3 of U2 should both be almost exactly 23V.
Output voltage low (unregulated RV1 has little or no effect)
Output from U2 not reaching Q2 gate. If the voltage is correctly regulated for a few seconds but then drops out of control, the standing current is probably too high for a single MOSFET (e-mail for details of modification).
9.2.2 Control grid supply troubleshooting

All voltages in this section are measured with respect to the CATHODE tag on the REC-G1-ALC board, and are negative. Problem Zero output voltage Output voltage high (unregulated RV102 has little or no effect) Possible Causes and Solutions Unregulated supply not reaching RV102. If you are not using G1 switching, check that R107 has been replaced by a permanent wire link. No path through Q101 to G1 SWITCH and CATHODE rail check continuity. When G1 SWITCH is linked to CATHODE, voltage on collector (tab) of Q101 should be 0; voltage on emitter of Q101 (= RV102 CW tag) should be -33V. If you are using G1 switching (Section 5.4), and the PTT is not grounded, a high negative G1 voltage on RX may be correct ! Output voltage low (unregulated RV102 has little or no effect) Check Q101, D114 and associated components for short-circuits.
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9.2.3 ALARM LED Lights at switch-on

This can happen occasionally, due to switching surges. False alarms are more likely in wiring layouts that have long ground connections. Simply press the RESET button and continue as normal. If problems persist, see Section 10.4 for possible solutions.
9.2.4 TX/RX sequencing

To investigate problems with TX/RX sequencing, you can slow down the make/break operation of K3 by connecting a higher-value capacitor in parallel with C25. If you have successfully arrived here, everything is basically working. You are ready for the next stage of adjustments, in preparation for power-up and RF testing.
9.3 Screen Supply Adjustments

Now is the time to set the screen standing current, voltage and trip current to the design values that you selected in Section 4.2.
9.3.1 Screen standing current

1. Switch off and disconnect from the mains. 2. Connect a well-insulated current meter in series with R14, apply mains power to the screen transformer and adjust R14 for the correct standing current as calculated in Section 4.2.2. WARNING ELECTRIC SHOCK HAZARD ON R14! Before making any adjustment to R14, always switch off, disconnect from the mains and short-circuit the screen supply.
CAUTION To avoid damage to the exposed windings of R14 (if you are using the recommended Ohmite resistor), ALWAYS slacken the screw clip until it rattles and will move freely. NEVER attempt to slide the clip while the circuit is live!
9.3.2 Screen voltage

If the screen supply has passed all the tests described earlier in this section, you should be able to adjust RV1 on the G2-CONTROL board to the exact G2-REG OUT voltage required (measured with respect to CATHODE remember to ground PTT).
9.3.3 Screen meter

The exact screen voltage will also affect the current passing through the screen-cathode bleeder resistor Rs (Section 3.4) and this in turn will affect the reading on the screen current meter. The bleed current through Rs will make the meter read approximately 10mA up-scale from zero. Use the meters mechanical adjusting screw to place the needle exactly on the 10mA scale mark. This indicates zero screen current (the extra 10mA is going through the bleeder resistor). In effect, a typical 050mA meter is now reading screen current from 10mA to +40mA. Optionally, you can re-scale the meter to look something like this (drawn using AutoSketch).
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9.4 Screen-current Trip

This section explains how to set the screen-current trip to the value specified from Section 4.1. First, fill out this worksheet to calculate the resistance value RL that will be needed to load the screen supply up to the trip current level: Calculation steps A B C D E F Required screen voltage (A from Section 4.2.3 worksheet) Required current trip level for a single tube (A from Section 4.2.2 worksheet) Multiply B by number of tubes RL = A x 1000 / C W RL = A x C / 1000 Select appropriate resistors to make up RL Your tube(s) Example: 2 x 4XC800/GU-74B 350V 40mA 40 x 2 = 80mA 350 x 1000 / 80 = 4375 350 x 80 / 1000 = 28.0W 3.3k 25W in series with 1.0k 10W; or Ohmite D50K5K*
* The value of RL only needs to be as accurate as you wish to set the trip current a few percent is accurate enough.
Setup Instructions 1. Switch off and disconnect from the mains. Disconnect the Tetrode Boards from the amplifier. 2. Turn RV2 on the G2-CONTROL board fully clockwise. 3. Insert the opto-coupler U3 (observe polarity). 4. Apply power, and ground PTT. The ALARM LED should light dimly as usual it should not light brightly. When PTT is grounded, confirm that the screen current meter comes up to the new zero mark (see above). Switch off and disconnect from the mains. 5. Connect the load resistor RL between the G2-REG OUT tag and the CATHODE tag on the G2-CONTROL board. Apply power, and ground PTT. The screen current meter should now read the correct trip current level. Confirm that the regulated DC voltage does not change when this load is applied. If you have a suitable oscilloscope, also check that this voltage remains clean and constant under maximum load. If you see negative spikes at 100/120Hz, these are caused by AC ripple on the unregulated input. You may be able to adjust R12 slightly to remove the spikes; but if this is not possible, the transformer AC voltage is too low you will need to review Section 4.2.3. Tetrode Boards: AN-1 Issue 1.21, May 2006 30
6. With the load resistance applied, rotate RV2 very slowly counter-clockwise until the ALARM LED lights brightly and the relays drop out. If you overshoot, release the PTT, turn RV2 back a little and press the RESET button. The LED should go dim again (it is normal that the LED does not go out completely). 7. Switch off and disconnect from the mains. Remove the temporary load resistor and restore all connections to normal. The screen current trip will now protect the amplifier during your further tests.
9.5 Control-grid Protection and ALC

Many modern tetrodes are intended for class-AB1 operation, which should involve no control-grid current at any time. The control grids of such tubes often have a very small power dissipation and require protection against excessive grid current. The Tetrode Boards will protect the control grid of tube against excessive grid current. The circuit will disable the PA and light the ALARM LED if you drive the tube into more than a few milliamps of grid current. (If this happens, reduce the RF drive level, and press the RESET button to continue operating.) Although class-AB1 amplifiers should operate with zero grid current at all times, tube manufacturers state that small amounts of grid current are acceptable for peak signal sensing purposes. The Tetrode Boards provide an automatic level control (ALC) output that is derived by sensing a few hundred microamps of peak control-grid current. (Some ceramic tetrodes also display negative control-grid current at medium levels of RF drive. This appears to be normal for those tubes. At higher levels of drive, the grid current will turn around and come upward through zero.) Setup Instructions 1. Insert the LM324 op-amp U102 and the opto-coupler U103 (observe polarity). Turn RV103 fully counter-clockwise. 2. Disconnect both of the 105V AC tags from the REC-G1-ALC board. Temporarily connect the G1 OUT tag to chassis ground (see hookup diagram below). 3. Disconnect the wire going to RV102 slider from the RV102 SLIDER tag on the REC-G1-ALC board. 4. If you are using the TX Inhibit feature (Section 7.1.3), disconnect the lead to the INH IN tag on the REC-G1-ALC board. 5. Apply power. With no grid current flowing, the voltages at the ALC OUT tag and the G1 TRIP OUT tag should both be zero. 6. Remove power. Temporarily connect the RV102 SLIDER tag via a 22k 0.5W resistor to the +12V OUT tag. (Do not disconnect the 12V feed from +12V OUT to the G2-CONTROL board it will be needed for step 9.)
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DISCONNECT
105V AC
REC-G1-ALC BOARD
RV102 SLIDER G1 TRIP OUT G1 METER + G1 METER -
M2 RV102 G1 BIAS TEMPORARY GROUND + G1 CURRENT DISCONNECT 22K
7. Apply power. The grid current meter should read 0.5mA. This current also flows through the grid opto-isolator U103 and activates the protection and ALC circuits. 8. Confirm that RV103 is fully counter-clockwise. Then confirm that, at some point within RV101s total range of travel, the voltage at the ALC OUT tag will change quickly between 0V and almost 12V. Trouble-shooting for step 8: Problem: the ALC OUT tag is permanently at 11 to 12V, and RV101 has no significant effect. Solution: short-circuit R122 (under the board) and repeat step 8. You should now be able to vary the voltage correctly. Problem: the ALC OUT tag is permanently close to 0V, and RV101 has no significant effect. Solutions: first check that you have the correct opto-isolator in U103 (the MCT5211, not the 4N36). If that is not the problem, change R122 to 1.0k and repeat step 8. You should now be able to vary the voltage correctly. 9. Switch off power, and turn RV101 fully clockwise. Replace the 22k test resistor with 3.3k. Apply power, and observe that the grid current meter now reads about 3mA. Turn RV101 slowly counter-clockwise until the ALARM LED lights. Turn RV101 a little clockwise, and press the RESET button to cancel the current trip. Now turn RV101 very slowly counterclockwise again, to find the exact trip point if in doubt, repeat this step until you are sure. 10. Switch off and disconnect from the mains. Remove all temporary hookups and return all connections to normal. The above adjustments will ensure that full ALC feedback will be developed at peak grid currents of only a few hundred microamps, and the amplifier will trip at 3mA to protect the tube(s). See Section 10.3 for final ALC setup instructions.
9.6 Warm-up Timer

1. If you are using an instant-on tetrode with a directly heated filament, you do not need the warm-up timer at all. You can skip this section, and you can also leave out C15, D11, R19, R20 and U5 from the G2-CONTROL board. 2. Switch off and disconnect from the mains, and insert U5 (LM555CN) in the G2-CONTROL board (observe polarity). 3. Switch on the power the ALARM LED will light brightly, and you will find that the PTT has no effect. 4. After about 3 minutes the ALARM LED will go from bright to dim (the LED will not go completely dark this is normal). Now +12V appears at the +12V HV ENABLE tag and you can use the PTT.
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+12V OUT G2_CTRL BOARD
G1 OUT
10. Power-up Your Amplifier

10.1 Final Checks
1. Switch off and disconnect from the mains. Insert the tube(s) in the amplifier. Connect the heater and G1 supplies but DO NOT connect the HV or G2 supplies. 2. Switch on the power and check the heater voltage, right at the tube pins.
Hint: stretch transparent plastic film wrap over the bottom of the PA chassis, so that you can reach all the socket terminals with a sharp-pointed voltmeter probe while still applying cooling air to the tube(s).
3. Check that approximately the correct G1 voltage is actually reaching the tube pins, in both RX and TX conditions. 4. Switch off and disconnect from the mains. Disconnect the heater supply and connect the G2 supply. Apply power and check that the correct G2 voltage is actually reaching the tube pins in the RX and TX conditions. 5. Switch off and disconnect from the mains. Connect the heater and HV supplies. Apply power and wait for the warm-up period to complete. If you have used the +12V HV ENABLE option (which is strongly recommended see Section 7.3) the HV will not be enabled until the end of the warm-up period. 6. When the warm-up period completes, the ALARM LED will go dim and HV will be applied. The tube anode current should still be zero until you key the PTT. 7. Ground the PTT line but do not apply RF drive. Adjust the control grid bias using RV102 to obtain the correct zero-signal anode current.
Congratulations the Tetrode Boards are completely checked out and ready for use!
10.2 RF Testing
RF testing of power amplifiers is outside the scope of this manual... but whichever way you do it, the Tetrode Boards will protect the tube(s). You should disable ALC feedback until you have finished testing the amplifier and established correct RF drive levels. To disable ALC, turn RV103 fully clockwise.
10.3 Final ALC Adjustment

ALC adjustment should be the very last step in commissioning the amplifier. Section 9.5 configured the ALC circuit for class-AB1 operation. That should mean zero grid current under all conditions of drive! In reality, full ALC control will be available at a few hundred microamps of control-grid current. You may just see the G1 meter move, but nothing more. ALC is intended to deal with transient modulation peaks only. If the ALC meter in your transceiver is flickering all the time you are speaking, reduce the RF drive to the amplifier until the meter only flickers on occasional speech peaks. With correct adjustment of tuning and loading, this should ensure a clean signal. There are two alternative ALC adjustment procedures, depending whether or not you are using the TX Inhibit feature (Section 7.1.3).
33
If you ARE using TX Inhibit 1. Disconnect the PTT line from the transceiver to the G2-CONTROL board. Ground the PTT tag at the G2-CONTROL board, so that the amplifier comes up to the TX condition, independently of the transceivers PTT. 2. Key the PTT on the transceiver and apply full SSB modulation. If RV103 on the REC-G1-ALC board is turned fully clockwise, you should see full RF output from the amplifier. 3. Turn RV103 counter-clockwise until the RF output from the amplifier is reduced to a very low level under all conditions of drive. Do not turn RV103 beyond this point. This sets the correct ALC level for TX Inhibit operation, and hopefully should provide good ALC control under normal modulation conditions too. However, not all transceivers are suitable for both normal ALC operation and TX Inhibit. If you are NOT using TX Inhibit Adjust RV103 on the REC-G1-ALC board for smooth ALC operation with your transceiver. The ALC meter on your transceiver should only flicker on occasional speech peaks. If it moves all the time you are speaking, reduce the RF drive to the amplifier. If you choose not to use ALC The Tetrode Boards will still be monitoring your control-grid current to protect your tube(s). If you drive the tube into more than a few milliamps of grid current, the trip circuit will disable the PA and light the ALARM LED. Press the RESET button and reduce the RF drive level.
10.4 False Alarms

You should not experience false alarms and trip-outs when you press the PTT. If you do, it may be due to voltage spikes on the control lines, or a spike of full RF power when your transmitter is first keyed... or there may be a genuine intermittent problem such as sparking in the tube(s). Trouble-shooting Apply the following tests in the sequence shown: 1. Remove the tubes and test again by repeatedly keying the PTT. Re-check the screen current trip setting that was described in Section 9.4. 2. Test again with tubes that are known to be problem-free. 3. Try shorter and thicker wires for the CHASSIS_GROUND straps on the two boards. Route the CHASSIS_GROUND connections from both boards to a single point on the chassis. 4. Remove the G1_TRIP_IN connection to the G2-CONTROL board. If the false trips no longer happen, there may be a spike on this line caused by inadequate grounding. Alternatively, your transceiver may be producing a spike of full RF output when the key is first pressed. If you cannot improve the grounding any more (step 2) then change R126 to 10K and insert a 10K resistor on the G2-CONTROL board in place of LK2. 5. If steps 3 or 4 do not work perhaps because the problem is in your transceiver increase C14 to 0.471.0F. This has the disadvantage of increasing the reaction time of the trip sensing (but the main delay is still in the HV control relay). 6. If you are using DC-grounded screen, with the cathode and B-minus line floating below ground, you may see a screen-current trip on TX/RX switching. This is because the switching makes the B-minus line change potential, and thus charges and discharges the RF bypass capacitors at the cathode. These pulses of charge/discharge current are sensed as screen current and may cause a false trip. The solutions are to check that the bypass capacitors are not larger than needed for RF performance, and to equalize the total capacitances from anode to chassis and from cathode to chassis. It may also help to increase C14 to 0.47 1.0F. Tetrode Boards: AN-1 Issue 1.21, May 2006 34
10.5 Thats All !

You should not need to make any of the above adjustments again, except perhaps to readjust RV103 (ALC output level) if you change transceivers. The Tetrode Boards will continue to provide protection and stable operating voltages for your amplifier under all operating and fault conditions. Normal operation Normally, the trip circuit will never operate, and the ALARM LED will stay dim. When the screen-current trip operates, the ALARM LED lights and the PA is placed in Standby mode with the screen voltage removed. HV will also be removed if you have used the +12V HV ENABLE option, which is strongly recommended see Section 5.3. When the trip has operated, the tube heaters are still powered, so you only have to press the RESET button to return to normal operation. Before you press the PTT, wait a few moments for the HV to come up. If there is still a fault, the trip will operate again as soon as you press the PTT.
35
11. Updates and Product Support

Updates and further Application Notes will be provided on the web: http://www.ifwtech.co.uk/g3sek/boards For advice on details not covered by these notes, you can e-mail G3SEK direct: boards@ifwtech.co.uk If you purchased the Tetrode Boards from Toms Tubes in the USA, please e-mail boards@ifwtech.co.uk to be included on the list for any future e-mail updates.
36
Interconnections
330V AC
SEE NOTES CHASSIS GROUND INH IN
G2-UNREG OUT CATHODE 105V AC
ALC OUT 18-0-18V AC G1 TRIP OUT +12V OUT
REC-G1-ALC BOARD
RV101 SLIDER RL-UNREG G1 METER + G1 METER RV101 CCW G1 SWITCH
RV101 CW
Labels for terminals on the boards are shorter versions of the ones you see here.
12V COAX RELAY OPTIONS 24V
SEE NOTES M2 RV102 G1 BIAS + G1 CURRENT
ALARM SEE NOTES
RESET
TO HV SUPPLY
SEE NOTES
G1 OUT
ALC PTT
TRANSCEIVER
+12V HV ENABLE
1 2 3 4
AUX TRIP IN
+12V IN
CHASSIS
PTT
G1 TRIP IN
J1
RL IN
TX/RX OPTIONS SEE NOTES G1
G2-CONTROL BOARD
G2-REG OUT G2 METER + G2-UNREG IN G2 CATHODE G2 METER R14 R14
TO TUBE(S) GROUND CATHODE / G1 / G2, AS REQUIRED

SEE NOTES
M1 + G2 CURRENT GATE TO Q2 - DRAIN SOURCE
R12 CATHODE
R12
37
G2-CONTROL Schematic Sheet 1

G2-UNREG IN
TETRODE BOARDS G2-CONTROL BOARD: SCREEN REGULATOR

Issue 3C 040416 (c) IFWtech Ltd
R14 - SEE TEXT R16 1k5 2 U3A 4N36 (U3B on sheet 2) 1 R15 82R 1W typ R13 10K 2W typ K1A RX BR1
4 2
1k 50W typ
D8 1N5337B
(4.7V 5W)
R17 Meter Shunt + Ig2 METER, 50mA
C10 10n 1kV VDR1 V320LA40B C11 470n
R10 150k 1W typ R11 82k
R12 - SEE TEXT
50-100W typ
D9 D10 1N4001
- Ig2
K1B G2-REG OUT D7 BZT03C82 (82V 3W) G D6 BZX79C12 (12V 0.5W) D Q2 STP5NB100 typ G DS S +30V rail R5 2k7 R4 39k C4 100n
6 8 7
C8 4n7 1kV R8 470k 1W
LK3
RX VDR2 V320LA40B
U1 LM317L
2
VO ADJ
VI
C2 10u 35V
C9 100n 1kV
D1 C3 100n C1 10u BZX79C15 (15V 0.5W) D2
D4 1N4148 U2 748
3 2 5 1 4
CATHODE (COMMON NEGATIVE) RV1 10k
R7 22k C6 33p D5 1N4148 C7 100n R9 27k typ
R1 270R
Q1 TIP122 R3 470R D3 1N4148 C5 4n7
R2 4k7
+23V reference
R6 22k
WARNING
EUROPEAN COMPONENT CODES 4k7 = 4.7k = 4700 ohms etc 4n7 = 4.7nF = 4700 pF etc. Q1 REQUIRES A SMALL HEATSINK Q2 REQUIRES A LARGE HEATSINK R12 AND R14 HAVE HIGH HEAT DISSIPATION Values marked "Typ" depend on screen voltage and current required see text and Components List THE SCREEN VOLTAGE INPUT AND OUTPUT ARE UNGROUNDED! USER MUST PROVIDE GROUNDING AS REQUIRED.
38
G2-CONTROL Schematic Sheet 2

TETRODE BOARDS G2-CONTROL BOARD: CONTROL CIRCUIT
Issue 3C 020317 (C) G3SEK ALARM LED J1 U4
3
USER-CONFIGURABLE RELAY SEQUENCING

SEE APPLICATION NOTES FOR WIRING OPTIONS K2A +12V REG IN K2B "FAST"
RESET SW1
78L05 VI GND
1 1 2 3 4
VO
C13 100n
R24 10k R21 470R 1W
R26 10k
C16 100n
K3A "SLOW"
K3B Q4 2N4403 Q6 IRF9520
U3B 4N36
C12 10u
RL-IN : SUPPLY VOLTAGE INPUT FOR EXTERNAL COAX RELAYS 4 R18 220R Q3 2N5061 R29 10k RV2 500R C14 100n LK2 G1 TRIP IN K1 12V K2 12V
2
D11 1N4148
R20 100k
8 7
U5 VCC DSC THR CNT
LM 555CN GND TR OUT RST

1 2 3 4
R27 10k R22 10k Q5 MPS2222A
D12 1N4001
C15 100u
6 5
+12V HV ENABLE (TO HV PSU) R28 82R 1W D13 1N4001 K3 6V C17 2200uF 16V
1 2
R23 10k
R25 10k
R19 1M
LK1 AUX TRIP IN

1 1
D15 1N4001
D14 1N4001 EUROPEAN COMPONENT CODES 4k7 = 4.7k = 4700 ohms etc 4n7 = 4.7nF = 4700 pF etc.
D16 1N4001
D17 1N4001 PTT (GROUND)
39
TO COAX RELAYS ETC
REC-G1-ALC Schematic
TETRODE BOARDS REC-G1-ALC BOARD
Board Rev 3D 000831 (C) G3SEK BR101 2W04 18-0-18V AC D101-108 1N4007 330V AC G2-UNREG C105 4700u 35V R109 4K7 2W
1
RL UNREG (+24V) D119 1N4001 +12V OUT U101 IN 7812 GND OUT
3
LK2 +12V U102
D120 1N4001
C106 100n
C109 100n
R101 100K 2W
C101 100u 385V
C107 100u 35V
D118 BZX 79C12
C108 100n 35V -12V
R110 470R 1W R102 100K 2W C102 100u 385V CATHODE INH IN R107 4K7 2W (or link) C103 220u 200V G1 SWITCH C111 100n C112 33p R111 10K
13 14 12
R113 100K
U102C LM 324
11
D121 1N4148
R114
100R
ALC OUT
D122 1N4148 C114 33p
RV103 10K
R104 100K 2W Q101 TIP122
R112 10K D114 1N5364B (33V) 1N5370B (56V) R115 10K
C113 100n
U102A LM324
3 1 2
D110-113 1N4007
R103 1K5 2W
D123 1N4148
LK1 R119 2K7 R120 1M 0
R116 10K C104 100n 100V R106 10K 470R 1W U103 MCT5211
1
10 8
+12V
105V AC R105 3k3 2W
R117 470K
R118 470K C115 100n
C116 1u0 C117 33p
U102D LM 324
R128 22K
D117 1N4001
A B A B 5 K C K C 4 E E R122 470R
R121
10K
C119 33p R124 10K
U102B LM 324
5 7
R126
100K
D124 1N4148 G1 CURRENT TRIP (TO Q3)
R108 RV102 (REAR PANEL) 500R 1W EUROPEAN COMPONENT CODES 4k7 = 4.7k = 4700 ohms etc 4n7 = 4.7nF = 4700 pF etc.
M eter Shunt
+ G1 M ETER 0-10mA _
C110 100n R123 22K C118 100n
RV101 1K G1 OUT D115 D116 1N4001
R125 470K
R127 33K
C121 100n
C120 100n
40
G2-CONTROL Board Layout

Actual size is 5in x 4in
41
REC-G1-ALC Board Layout

Actual size is 5in x 4in
If you are stacking the two boards, drill 0.25in (6mm) max. See warning note!
42
The Tetrode Boards

Components List
SUPPLIERS There are many sources for most of these components. The Farnell # columns shows order codes from Farnell Electronics (http://www.farnellinone.co.uk). Farnell have associate companies in many countries, including Farnell Chicago in the USA (1 800 718 1977 note that US order codes may differ). In the USA, Mouser Electronics (http://www.mouser.com) is probably the best single source; Digi-Key (http://www.digi-key.com) is also a good source for most parts. Resistors and capacitors may be subject to minimum order quantities. Small quantities can often be bought more cheaply from other dealers, e.g. Maplin in the UK. Note that you must also supply some off-board parts see this list and also Section 2.2.
TYPICAL VALUES Some component values depend on the output voltages and currents required. These values are marked typ in the list below and in the schematics see the cross-references for further details.
Boards: G2-CONTROL issue 3B, REC-G1-ALC issue 3D Manual: Issue 1.21, May 2006 43
The Tetrode Boards

Components List
Capacitors
Total 5 1 1 1 16 C# C6, C112, C114, C117, C119 C5 C8 C10 Value 33pF 4n7 (4700pF) 4n7 (4700pF) 10n (0.01uF) Volts 100 63 1000 1000 63/50 Comments
Ceramic, 0.1" radial leads Ceramic, 0.1" radial leads HV ceramic, Murata HV ceramic, Murata Multilayer ceramic, 0.2" radial leads
Farnell #
113-8847 113-8879 952-7249 952-7222 750-992
C3, C4, C7, C13, 100n (0.1uF) C14, C16, C106, C108, C109, C110, C111, C113, C115, C118, C120, C121 C104 C9 C11 C116 C1, C2, C12 C15 C107 C101, C102 C103 C17 C105 100n (0.1uF) 100n (0.1uF) 470n (0.47uF) 1.0uF 10uF 100uF 100uF 100uF 220uF 2200uF 4700uF
1 1 1 1 3 1 1 2 1 1 1
100 1000 100 50 35 16 50 385 200 16 35
Polyester, BC (formerly Philips) 368 Polyester, BC/Philips 375 1.1" radial leads Polyester, BC/Philips 368 0.6" radial leads Electrolytic, 0.1" radial Electrolytic, 0.1" radial leads Electrolytic, 0.1" radial leads Electrolytic, 0.2" radial Electrolytic, Panasonic TSUP Electrolytic, Panasonic TSUP Electrolytic, 0.2" radial leads Electrolytic, Panasonic TSUP
304-013 659-733 304-050 945-1358 945-1242 945-1080 945-1412 652-295 383-6927 945-1137 652-088
The Tetrode Boards

Components List
Resistors
R in resistor values means , e.g. 15R = 15, 0R33 = 0.33, 3K3 = 3.3k, 1M0 = 1.0M etc. 1W, 2W and 3W resistors are metal film power types, e.g. BC/Philips PR02 and PR03. Total 1 1 1 1 1 3 2 1 R15 R28 R114 R18 R1 R3, R106, R122 R21, R110 R12 R# Value ("R"= ) 47R typ 82R 100R 220R 270R 470R 470R 1K typ W 1 1 0.25 0.25 0.25 0.25 1 50
Optimum value will vary see Section 4.2.5. 1K0 50W metal-clad supplied in kit, but may not be optimum for all applications.
Comments
See Section 4.3.2 for alternative values
Farnell #
947-4625 337-729 543-147 543-226 934-1633 934-1943 337-810 Calculate the correct value before ordering.
R14
1K
50
Wire-wound adjustable resistor see Section 4.2.4.
Mouser: 588D50K1K0 Digi-Key: D50K1K0-ND or AVT50-1.0K-ND
1 1 2 1 1 2 13
R16 R103 R5, R119 R105 R2 R107, R109
1K5 1K5 2K7 3K3 4K7 4K7
0.25 2 0.25 2 0.25 2 0.25
543-421 550-190 543-482 550-218 934-1951 550-220 934-1110
R22, R23, R24, 10K R25, R26, R27, R29, R111, R112, R115, R116, R121, R124 R13 10K
If the RX/Standby voltage across R13 is more than about 150V (unusual), use two identical 10K 3W resistors in series.
327-8335
R6, R7, R123, 22K R128
0.25
543-706
The Tetrode Boards

Components List
Total 1 1 1 1 3 3 1 3 1 2 0 0 R9 R127 R4 R11 R20, R113, R126 R101, R102, R104 R10 R117, R118, R125 R8 R19, R120 R17 R108 R# Value ("R"= ) 27K typ 33K 39K 82K 100K 100K 150K typ 470K 470K 1M0 Meter shunt Meter shunt W 0.25 0.25 0.25 0.25 0.25 2 1 0.25 0.75 0.25
Not provided in kit Not provided in kit See Section 4.3.1 for alternative values
Comments
See Section 4.3.1 for alternative values.
Farnell #
934-1650 934-1757 934-1862 543-846 934-1129 550-309 338-102 544-024 337-493 544-103
RV # 2 1 1 1 RV1, RV103 RV2 RV101 RV102
Value 10K 500R 1K 500R 1W
Comments
Bourns 3306P series Bourns 3306P series Bourns 3306P series Allen-Bradley W1 series, rear panel mounted
Farnell #
108-239 108-235 108-236 351-246
The Tetrode Boards

Components List
Semiconductors etc
Total 2 2 8 Part # BR1, BR101 D1, D2 D3, D4, D5, D11, D121, D122, D123, D124 D6, D118 D7 D8 D9, D10, D12, D13, D14, D15, D16, D17, D115, D116, D117, D119, D120 D101-108, D110-113 (D109 not used) Type AM152 (2W02) BZX79C15 1N4148 A / PIV / W
2A 200V 15V 0.4W Comments
Farnell #
938-1449 369-512 984-3680
2 1 1 13
BZX79C12 BZT03C82 1N5337B 1N4001
12V 0.4W 82V 3W 4.7V 5W Or any highernumbered 1N400x 1A 1000V 33V 5W 47V 5W See Section 4.3.3
369-494 939-8490 955-7946 956-4993
12 2 2 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1
1N4007
956-5051 955-8217 955-8250 117-5020 117-5019 980-4021
D114 (kit contains two 1N5364B alternatives) 1N5368B K1, 2 K3 Q1, Q101 Q2 Q3 Q4 Q5 Q6 U1 U2 U3 U103 U4 U5 U101 U102 8A 2PCO 8A 2PCO TIP122
12VDC relay, Schrack or Potter & Brumfield type RTE24012 6V DC relay, Schrack or Potter & Brumfield type RTE24006 100V NPN Darlington
IRF840, STP5NB100 etc Depends on screen voltage and current see notes on page 48.
2N5061 2N4403 MPS2222A IRF9530N LM317LZ UA748CN 4N36 MCT5211 LM78L05ACZ LM555CN MC7812CT LM324N
1V 350A gate 40V PNP, hFE 100 min 40V NPN, hFE 100 min 100V 6A, Rds(ON) 0.6 E-B-C pinout E-B-C pinout P-MOSFET, G-D-S pinout
363-121 920-7473 955-6842 864-8603 948-8545 302-4660 102-1094 326-616 948-9444 948-8243 966-6109 975-5926
Any LM317 in TO-92 package Any 748 equivalent (but must be a 748) Current transfer ratio 100% @ 10mA Current transfer ratio 110% @ 1mA Any 78L05 in TO-92 package Any CMOS 555 (but must be CMOS) Any 7812 (12V 1A, TO-220 pkg) Any LM324 in DIL package
The Tetrode Boards

Components List
Total 4 Part # VDR1, 2 Type A / PIV / W
alternatives Install the 2 extra VDRs at the tube sockets. For a 1-tube amp, connect in parallel Comments
Farnell #
241-465
V320LA40B typ See Section 4.3.1 for
Other parts
Total 2 2 1 1 For Q2 Part # Type 6 DIL socket 8 DIL socket 14 DIL socket TO-220 mounting kit (dry silicone insulating washer and plastic bush) Vertical mounting with lugs 2.8 x 0.8mm 2.8 x 0.8mm
User provides nut & bolt User provides nuts and bolts 25 for each board 25 for each board
Comments
Farnell #
428-5610 428-5566 428-5578 522-636
3 60+ 60+
TO-220 heatsinks Connector blades PCB mounting Blade sockets
170-070 342-3815 209-314
Options for Q2
There are several options for Q2, depending on the screen voltage and current required. Voltages up to about 400V, screen currents up to about 100mA: IRF840 is best value. Higher voltages and/or higher currents: STP4NB100, STP5NB100 (TO-220 package); or STW8NB100, IRFPF40, IRFPG30, IRFPG40 (TO247/TO3P package). The kit is now supplied with the STP5NB100 (Farnell 323-9342) which is good for most applications. When screen voltages and currents are high, the FET requires a specially good heatsink an area of chassis cooled directly by the PA blower is ideal, and even a small heatsink fan will help a lot. If the total standing current (Section 4.2.2) is greater than about 100mA, you may require two MOSFETs connected in parallel with equalizing resistors as shown below. The transistors must be mounted at least 40mm (1.5in) apart on the heatsink.
D
47
STP5N B100 x2 47 4.7 1W 4.7 1W
NEMOS
The Tetrode Boards
The Tetrode Boards

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THE TETRODE BOARDS

For one or two tetrodes, including: 4CX250350400 (all types), 4CX800/

'Universal' DC grounding use with grounded cathode, grounded screen or

Tetrode Boards: AN-1 Issue 1.21, May 2006

1998-2006 IFWtech Limited

DANGER - AC mains voltage and high DC voltages!

Tetrode Boards: AN-1 Issue 1.21, May 2006

Tetrode Boards: AN-1 Issue 1.21, May 2006

2.1 What You Get

Tetrode Boards: AN-1 Issue 1.21, May 2006

2.2 What Youll Need

2.3 Choosing Configuration Options

Tetrode Boards: AN-1 Issue 1.21, May 2006

3. Tetrode Grounding Connections

3.1 Grid Driven, DC-grounded Cathode

Tetrode Boards: AN-1 Issue 1.21, May 2006

3.2 Cathode Driven, DC-grounded Screen Grid

V1 G2 V2 Rs R1 SEE TEXT Ca C1 VDR VDR1 V2

3.3 Cathode Driven, DC-grounded Control Grid

IF V2 IS USED, REPEAT RFC1, R2, VDR1, C1 RFC1 RFC TEXT SEE

G2 Cs C1 R2 100R 1W Rd 100 1W Rs R1 SEE TEXT VDR VDR1

3.4 Screen-grid Components

Tetrode Boards: AN-1 Issue 1.21, May 2006

4. Screen-grid Supply Configuration

AC voltage current capability and/or winding resistances.

4.1 Examples of Tubes

Tetrode Boards: AN-1 Issue 1.21, May 2006

Suggested current trip level (mA)

4CX1600U / GS-23B GU-73B GU-78B GU-84B YL1050/1052/1056

Tetrode Boards: AN-1 Issue 1.21, May 2006

4.2 Off-board Component Calculations

Unregulated input voltage

Regulated screen voltage

4.2.1 Screen bleeder resistor, Rs

If in doubt, use the next recommended lower value of resistance here.

Tetrode Boards: AN-1 Issue 1.21, May 2006

4.2.2 Calculate the Trip Current and the Standing Current

40 x 1.1 = 44mA 44 x 2 = 88mA 88 rounds up to 90mA

4.2.3 Calculate the transformer AC voltage requirement

Tetrode Boards: AN-1 Issue 1.21, May 2006

4.2.4 Calculate R14

Tetrode Boards: AN-1 Issue 1.21, May 2006

4.2.5 Calculate R12

2000 (110 + 20) x 2000 / 6 10 = 33.8W

Tetrode Boards: AN-1 Issue 1.21, May 2006

4.3 On-board Component Changes

4.3.1 Screen voltage

4.3.2 Screen current sensing

4.3.3 Control-grid voltage

4.4 Further Information

Tetrode Boards: AN-1 Issue 1.21, May 2006

5. Control-grid and Relay Supply Configuration

5.1 Control-grid Supply

5.2 Relay Supply

Tetrode Boards: AN-1 Issue 1.21, May 2006

6. Basic Inter-board Connections

Tetrode Boards: AN-1 Issue 1.21, May 2006

Tetrode Boards: AN-1 Issue 1.21, May 2006

7. Power and Control Options

7.1 TX/RX Changeover Sequencing

Tetrode Boards: AN-1 Issue 1.21, May 2006

7.1.2 Coax relay control

COAX RELAYS ENERGIZED ON RX