Re: [Elecraft] PA Transistors Maintenance in K2

2017-10-29 Thread Eric J
Single best tip I've learned all year from this reflector. And there 
were many good ones.

Eric KE6US


On 10/29/2017 4:24 AM, Drew AF2Z wrote:
> Also, you can search the pdf schematics- very convenient when tracing 
> through circuits spanning multiple sheets.
>
> 73,
> Drew
> AF2Z

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Re: [Elecraft] PA Transistors Maintenance in K2

2017-10-29 Thread Ron D'Eau Claire
When writing and validating the kit assembly procedures, I restrict myself
only to the basic hand tools recommended by the design engineers. The
objective is to avoid customers having to go out and buy additional tools
that are not really needed. If I find that I cannot do a particular step
with those tools I bring it up to Wayne and the other engineers who decide
on an alternative. Sometimes that is to require a new tool. For example, we
went through that over adding the requirement for a temperature-controlled,
ESD-safe soldering iron some years back. The K2 and other early kits had no
such requirement but as more sensitive components were used, Wayne specified
that we add it to the tools requirement.

On the other hand, there are times we have specifically said NOT to use a
special tool. A while back we had a lot of damaged parts because builders
were using electric screwdrivers that had no torque control or which had the
torque set too high, so Wayne had me say NOT to use them, preferring hand
pressure instead.

Actually we do provide torque spec's in one case; the mounting nut for the
transformer in the KPA500. That nut must work against a Belleville washer
that acts as a spring. The objective is to apply the right pressure to the
washer (55 inch pounds) without permanently deforming it. But, even in that
case, the engineers came up with a workable alternative to avoid builders
having to go out and buy a torque wrench. 

73, Ron AC7AC


-Original Message-
From: elecraft-boun...@mailman.qth.net
[mailto:elecraft-boun...@mailman.qth.net] On Behalf Of David Woolley
Sent: Sunday, October 29, 2017 6:04 AM
To: elecraft@mailman.qth.net
Subject: Re: [Elecraft] PA Transistors Maintenance in K2

As far as I can tell, no torque settings are given for any of the fasteners,
wouldn't it be an idea to provide those, for people who do have suitable
tools.  Generally there are just warnings not to over-tighten.

On 28/10/17 20:24, Mel Farrer wrote:
>   If the people at Elecraft have done their job and mounted the transistor
properly with the correct torque on the mounting hardware procedure, no
additional maintainance is required.

--
David Woolley
K2 06123

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Re: [Elecraft] PA Transistors Maintenance in K2

2017-10-29 Thread Clay Autery
It is possible that an explicit torque has never been calculated.  It is 
not a particularly hard thing to do however.


I do not have a K2, so I can't do it, but here's the idea:

1) Fastener size/type, material, thread spec: (e.g. 4-40 x ___ pan head, 
phillips, zinc coated, non-rated steel
2) What does fastener anchor in?  (e.g. aluminum heat sink, what alloy 
aluminum, thickness of threaded area.
3) Thread spec... not JUST the #4, 40 tpi, but the rating for thread 
engagement.
4) Check the specs for the RF transistor package, et al.  Docs 
may/should have a max torque spec for the package maybe... package 
material, etc.

5) # of fasteners... usually 1 maybe 2.

There are tables that specify general torque specs for fasteners, 
threads in various materials, etc The idea is to take the lowest max 
value from the list.  This becomes the MAX NTE.
Then, use some analysis and judgement in what forces are to be imparted 
to the joint  static tension, sheer, axial, radial, vibration, et al...
Then in this instance consider the qualities of the mating surfaces  
are the flat?  What is the run out?  Are they smooth? To what grit spec 
are they smooth?  There's a difference between flat and smooth.
What is the interface material being used?  Thermal pad? Insulating?  
Non-insulating? Initial thickness? Read the spec sheet for the thermal 
pad/compound.


I suspect here that the RF package has an insulating thermal pad between 
it and the heatsink...  It was probably spec'd to keep the RF package 
within its operating envelope under 90% of expected operating 
conditions... knowing Elecraft, probably even a higher spec, and maybe a 
little extra to cover the "cheater".


Thermal pads and MANY top quality thermal compounds REQUIRE a curing 
period.  If the package is held with a tension spring/fastener, there is 
usually no requirement/need to re-torque.


IF it is JUST a screw and maybe a locknut, you NEED TO RETORQUE after a 
given number of thermal cycles  The thermal interface material flows 
under heat and cools when not in use.  Eventually it reaches an equilibrium.
You torque the fastener JUST enough to hold the junction static at this 
point.  I'm a freak, I would use a thermally conducting thread 
locking/anti-seize compound (I made one).
I NEVER torque unlubricated fasteners ESPECIALLY steel to aluminum 
interfaces.


The final torque for this application is likely in the relatively low 
inch-pound range just guessing.  I have 2 inch-pound wrenches... 
0-15, and 0-70.  Most people don't


Key... do NOT over-torque.  Consider the lever length and force applied...

73,
Clay, KY5G


On 10/29/2017 8:03 AM, David Woolley wrote:
As far as I can tell, no torque settings are given for any of the 
fasteners, wouldn't it be an idea to provide those, for people who do 
have suitable tools.  Generally there are just warnings not to 
over-tighten.


On 28/10/17 20:24, Mel Farrer wrote:
  If the people at Elecraft have done their job and mounted the 
transistor properly with the correct torque on the mounting hardware 
procedure, no additional maintainance is required.


--
David Woolley
K2 06123

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Re: [Elecraft] PA Transistors Maintenance in K2

2017-10-29 Thread David Woolley
As far as I can tell, no torque settings are given for any of the 
fasteners, wouldn't it be an idea to provide those, for people who do 
have suitable tools.  Generally there are just warnings not to over-tighten.


On 28/10/17 20:24, Mel Farrer wrote:

  If the people at Elecraft have done their job and mounted the transistor 
properly with the correct torque on the mounting hardware procedure, no 
additional maintainance is required.


--
David Woolley
K2 06123

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Re: [Elecraft] PA Transistors Maintenance in K2

2017-10-29 Thread Drew AF2Z
Also, you can search the pdf schematics- very convenient when tracing 
through circuits spanning multiple sheets.


73,
Drew
AF2Z


On 10/28/17 15:08, Cameron Francey wrote:

A nice tip which I use when looking for anything in any sort of .pdf manual, 
Elecraft included as I have accumulated quite a number of them over time is to 
use the search feature on the .pdf reader.  Ctrl+f on WIndows and cmd+f on Mac 
and type what I'm looking for.  The index and contents tables are good, but 
obviously can't have everything in them, so I use the find feature a lot.


Hope this helps.


Regards, Cameron - AF7DK/GM7LQR



From: elecraft-boun...@mailman.qth.net  on behalf 
of Dauer, Edward 
Sent: Friday, October 27, 2017 8:15 PM
To: elecraft@mailman.qth.net
Subject: [Elecraft] PA Transistors Maintenance in K2

I vaguely remember reading somewhere that after some number of hours of 
operation – maybe 50 – the hardware holding Q7 and Q8 onto the heat sink should 
be tightened, I presume to maintain good heat conduction from the tabs to the 
sink.  But I can’t find that instruction in the manual now.  Anyone know where 
I might have gotten that notion, or did I just make it up?

Thanks,

Ted, KN1CBR


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Re: [Elecraft] PA Transistors Maintenance in K2

2017-10-28 Thread Bill Frantz
The .pdf reader search function is an excellent way to find 
where the off-sheet connections go when reading the Elecraft schematics.


73 Bill AE6JV

On 10/28/17 at 12:08 PM, cameronfranceyut...@hotmail.com 
(Cameron Francey) wrote:


A nice tip which I use when looking for anything in any sort of 
.pdf manual, Elecraft included as I have accumulated quite a 
number of them over time is to use the search feature on the 
.pdf reader.  Ctrl+f on WIndows and cmd+f on Mac and type what 
I'm looking for.  The index and contents tables are good, but 
obviously can't have everything in them, so I use the find 
feature a lot.

-
Bill Frantz| When it comes to the world | Periwinkle
(408)356-8506  | around us, is there any choice | 16345 
Englewood Ave
www.pwpconsult.com | but to explore? - Lisa Randall | Los Gatos, 
CA 95032


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Re: [Elecraft] PA Transistors Maintenance in K2

2017-10-28 Thread Don Wilhelm

Ed,

I was speaking of the KPA100 amp for the K2.  I don't think the KXPA100 
needs any maintenance.


73,
Don W3FPR

On 10/28/2017 7:52 PM, Edward R Cole wrote:

Don,

I ran my KXPA100 mobile for 5,000 miles to-Seattle and back to AK this 
spring.  Is there any advise for maint for extended mobile use?

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Re: [Elecraft] PA Transistors Maintenance in K2

2017-10-28 Thread Edward R Cole

Don,

I ran my KXPA100 mobile for 5,000 miles to-Seattle and back to AK 
this spring.  Is there any advise for maint for extended mobile use?


73, Ed - KL7UW.
making 9,600 mile R/T summer of 2018.

From: Don Wilhelm 
To: "Dauer, Edward" ,"elecraft@mailman.qth.net"
    
Subject: Re: [Elecraft] PA Transistors Maintenance in K2
Message-ID: 
Content-Type: text/plain; charset=utf-8; format=flowed

Ted,

Not Q7 and Q8 in the base K2, but for the KPA100, yes tightening the
screws for Q1 and Q2 should be done after 5 to 10 hours of operation at
greater then 50 watts.

73,
Don W3FPR


73, Ed - KL7UW
  http://www.kl7uw.com
Dubus-NA Business mail:
  dubus...@gmail.com 


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Re: [Elecraft] PA Transistors Maintenance in K2

2017-10-28 Thread Ron D'Eau Claire
The K2 is a kit built by the customer, not Elecraft. 

With respect, my experience is different from Mel's. In many years working 
electronics field and shop service industry have found that re-tightening 
hardware subjected to thermal stress is commonly required by manufacturers. 
Manufacturers routinely do that after a "burn in" period of testing before the 
unit leaves the factory. Elecraft customers are instructed to do it on some 
gear after a period of use. 

The rarity of failures in spite of many thousands of rigs in service suggests 
that Elecraft's recommendations are good ones. 

BTW, when Elecraft has found that a better than metal-to-metal thermal 
conduction is needed, they use thermal pads instead of thermal compounds. The 
pads are entirely adequate and avoid customers handling messy compounds. 

In commercial work, when a manufacturer specifies using a thermal compound, I 
use GC Type 44. It is a non-silicon based compound and so does not 'migrate' 
from where it was placed. My small tube has plenty left and it predates the 
computer "age" -  bought it sometime in the 1970's. Like the old Wildroot Cream 
Oil for hair they mean it when they say a "little dab will do ya" yet it 
remains flexible and never hardens. 

73 Ron AC7AC 

-Original Message-
From: elecraft-boun...@mailman.qth.net 
[mailto:elecraft-boun...@mailman.qth.net] On Behalf Of Mel Farrer via Elecraft
Sent: Saturday, October 28, 2017 12:24 PM
To: Cameron Francey; Dauer, Edward; elecraft@mailman.qth.net
Subject: Re: [Elecraft] PA Transistors Maintenance in K2

Ted,
 If the people at Elecraft have done their job and mounted the transistor 
properly with the correct torque on the mounting hardware procedure, no 
additional maintainance is required. I have been in the industry for a LONG 
time .  Three things to remember in the mounting of any RF or high power 
device.  Flat surfaces, minimual mating gu, and required torque. Lack of any of 
these will kill a device if not correct.  I have never required retorqueing 
parts, with one exception.   In 000 copper wire terminals, the copper does 
relax and needs to be retorqued to achieve a gas tight seal connection, but 
that is in industrial application.  Small RF devices only need the initial 
torque to be correct.

Mel, K6KBE


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Re: [Elecraft] PA Transistors Maintenance in K2

2017-10-28 Thread Ross Primrose

K2s are not factory assembled.

73, Ross N4RP

On 10/28/2017 03:24 PM, Mel Farrer via Elecraft wrote:

Ted,
  If the people at Elecraft have done their job and mounted the transistor 
properly with the correct torque on the mounting hardware procedure, no 
additional maintainance is required. I have been in the industry for a LONG 
time .  Three things to remember in the mounting of any RF or high power 
device.  Flat surfaces, minimual mating gu, and required torque. Lack of any of 
these will kill a device if not correct.  I have never required retorqueing 
parts, with one exception.   In 000 copper wire terminals, the copper does 
relax and needs to be retorqued to achieve a gas tight seal connection, but 
that is in industrial application.  Small RF devices only need the initial 
torque to be correct.

Mel, K6KBE

   From: Cameron Francey 
  To: "Dauer, Edward" ; "elecraft@mailman.qth.net" 

  Sent: Saturday, October 28, 2017 12:10 PM
  Subject: Re: [Elecraft] PA Transistors Maintenance in K2

A nice tip which I use when looking for anything in any sort of .pdf manual, Elecraft included as I have accumulated quite a number of them over time is to use the search feature on the .pdf reader.  Ctrl+f on WIndows and cmd+f on Mac and type what I'm looking for.  The index and contents tables are good, but obviously can't have everything in them, so I use the find feature a lot.



Hope this helps.


Regards, Cameron - AF7DK/GM7LQR



From: elecraft-boun...@mailman.qth.net  on behalf 
of Dauer, Edward 
Sent: Friday, October 27, 2017 8:15 PM
To: elecraft@mailman.qth.net
Subject: [Elecraft] PA Transistors Maintenance in K2

I vaguely remember reading somewhere that after some number of hours of 
operation – maybe 50 – the hardware holding Q7 and Q8 onto the heat sink should 
be tightened, I presume to maintain good heat conduction from the tabs to the 
sink.  But I can’t find that instruction in the manual now.  Anyone know where 
I might have gotten that notion, or did I just make it up?

Thanks,

Ted, KN1CBR


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transmitter power necessary to carry out the desired communications.”

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Re: [Elecraft] PA Transistors Maintenance in K2

2017-10-28 Thread Don Wilhelm

Mel,

That is NOT true for the KPA100 power transistors - and it is not 
because of initial torquing.  The thermal pads take both time and heat 
to fully conform to the heatsink and any irregularities in the 
transistor surface.


BTW, with the KPA100, Elecraft has "done their job" when the parts are 
put into the box.  This is not sold as an assembled item - the builder 
must assemble it.


I tighten those screws on every KPA100 that I service.  I am amazed at 
the number I find loose.


73,
Don W3FPR

On 10/28/2017 3:24 PM, Mel Farrer via Elecraft wrote:

Ted,
  If the people at Elecraft have done their job and mounted the transistor 
properly with the correct torque on the mounting hardware procedure, no 
additional maintainance is required. I have been in the industry for a LONG 
time .  Three things to remember in the mounting of any RF or high power 
device.  Flat surfaces, minimual mating gu, and required torque. Lack of any of 
these will kill a device if not correct.  I have never required retorqueing 
parts, with one exception.   In 000 copper wire terminals, the copper does 
relax and needs to be retorqued to achieve a gas tight seal connection, but 
that is in industrial application.  Small RF devices only need the initial 
torque to be correct.

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Re: [Elecraft] PA Transistors Maintenance in K2

2017-10-28 Thread Mel Farrer via Elecraft
Ted,
 If the people at Elecraft have done their job and mounted the transistor 
properly with the correct torque on the mounting hardware procedure, no 
additional maintainance is required. I have been in the industry for a LONG 
time .  Three things to remember in the mounting of any RF or high power 
device.  Flat surfaces, minimual mating gu, and required torque. Lack of any of 
these will kill a device if not correct.  I have never required retorqueing 
parts, with one exception.   In 000 copper wire terminals, the copper does 
relax and needs to be retorqued to achieve a gas tight seal connection, but 
that is in industrial application.  Small RF devices only need the initial 
torque to be correct.

Mel, K6KBE

  From: Cameron Francey 
 To: "Dauer, Edward" ; "elecraft@mailman.qth.net" 
 
 Sent: Saturday, October 28, 2017 12:10 PM
 Subject: Re: [Elecraft] PA Transistors Maintenance in K2
   
A nice tip which I use when looking for anything in any sort of .pdf manual, 
Elecraft included as I have accumulated quite a number of them over time is to 
use the search feature on the .pdf reader.  Ctrl+f on WIndows and cmd+f on Mac 
and type what I'm looking for.  The index and contents tables are good, but 
obviously can't have everything in them, so I use the find feature a lot.


Hope this helps.


Regards, Cameron - AF7DK/GM7LQR



From: elecraft-boun...@mailman.qth.net  on 
behalf of Dauer, Edward 
Sent: Friday, October 27, 2017 8:15 PM
To: elecraft@mailman.qth.net
Subject: [Elecraft] PA Transistors Maintenance in K2

I vaguely remember reading somewhere that after some number of hours of 
operation – maybe 50 – the hardware holding Q7 and Q8 onto the heat sink should 
be tightened, I presume to maintain good heat conduction from the tabs to the 
sink.  But I can’t find that instruction in the manual now.  Anyone know where 
I might have gotten that notion, or did I just make it up?

Thanks,

Ted, KN1CBR


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Re: [Elecraft] PA Transistors Maintenance in K2

2017-10-28 Thread Cameron Francey
A nice tip which I use when looking for anything in any sort of .pdf manual, 
Elecraft included as I have accumulated quite a number of them over time is to 
use the search feature on the .pdf reader.  Ctrl+f on WIndows and cmd+f on Mac 
and type what I'm looking for.  The index and contents tables are good, but 
obviously can't have everything in them, so I use the find feature a lot.


Hope this helps.


Regards, Cameron - AF7DK/GM7LQR



From: elecraft-boun...@mailman.qth.net  on 
behalf of Dauer, Edward 
Sent: Friday, October 27, 2017 8:15 PM
To: elecraft@mailman.qth.net
Subject: [Elecraft] PA Transistors Maintenance in K2

I vaguely remember reading somewhere that after some number of hours of 
operation – maybe 50 – the hardware holding Q7 and Q8 onto the heat sink should 
be tightened, I presume to maintain good heat conduction from the tabs to the 
sink.  But I can’t find that instruction in the manual now.  Anyone know where 
I might have gotten that notion, or did I just make it up?

Thanks,

Ted, KN1CBR


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Re: [Elecraft] PA Transistors Maintenance in K2

2017-10-27 Thread Don Wilhelm

Ted,

Not Q7 and Q8 in the base K2, but for the KPA100, yes tightening the 
screws for Q1 and Q2 should be done after 5 to 10 hours of operation at 
greater then 50 watts.


73,
Don W3FPR

On 10/27/2017 11:15 PM, Dauer, Edward wrote:

I vaguely remember reading somewhere that after some number of hours of 
operation – maybe 50 – the hardware holding Q7 and Q8 onto the heat sink should 
be tightened, I presume to maintain good heat conduction from the tabs to the 
sink.  But I can’t find that instruction in the manual now.  Anyone know where 
I might have gotten that notion, or did I just make it up?

__
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Re: [Elecraft] PA Transistors Maintenance in K2

2017-10-27 Thread Victor Rosenthal 4X6GP

On page 51 of the Rev 2 KPA100 manual, I found the following:

--
IMPORTANT: The hardware holding the RF power
transistors in place will loosen slightly during initial use.
After 5-10 hours of normal operation at 50 watts or more,
remove the KPA100 assembly and its shield, then re-tighten
the mounting hardware for Q1/Q2 approximately 1/8 turn.
---

I didn't look to see if this was in other versions of the manual; this 
was the first place I looked.



73,
Victor, 4X6GP
Rehovot, Israel
Formerly K2VCO
http://www.qsl.net/k2vco/
On 28 Oct 2017 06:15, Dauer, Edward wrote:

I vaguely remember reading somewhere that after some number of hours of 
operation – maybe 50 – the hardware holding Q7 and Q8 onto the heat sink should 
be tightened, I presume to maintain good heat conduction from the tabs to the 
sink.  But I can’t find that instruction in the manual now.  Anyone know where 
I might have gotten that notion, or did I just make it up?

Thanks,

Ted, KN1CBR

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