"Sloppy engineering?" I think it may be a "feature creep" issue. As I recall
the Tyco/AMP connectors were first used with the Tritons. While I don't have
the info for the 540 handy, the Omni-A specs 400mA receive, 18A maximum
transmit and thus several amps less than the Orions. Added features in new
rigs over the years eventually became the straw that broke the camel's back.
73, Al
On Sat November 5 2016 11:36:44 am Ben Antanaitis - WB2RHM wrote:
> FYI-
>
> From a 2009 posting to another group:
> >>>>>>>While I love the performance of my Orion............
>
> The thing that disturbs me the most about the DC
> connector problem, (and before I looked into it,
> I had replaced the 'stock' parts 4 times), is
> that for years Ten Tec advertised "100% Key Down
> operation" when the optional fan unit was
> purchased and attached to the heat sink on the
> rear of the 565 and they supplied a DC power
> cable (and a replacement connector and pins).
> Well, if you read the specs for the 565 you will see:
> "The ORION transceiver requires a source of
> well-filtered and regulated DC voltage. The
> supply voltage can range from +12.8 to
> +15.0 Vdc but +13.8 Vdc is the optimum
> value. The voltage source must be capable
> of supplying 22 amperes continuous duty.
> We recommend using the included DC
> power cable (P/N 86095). We have also
> included spare connector pins (P/N 41020)
> and a spare 2 pin power connector shell
> (P/N 35165) (Tyco/AMP Mate-and-Lock) for building your own cable.
> The power supply plug will attach in only
> one direction to the polarized two-pin DC
> connector on ORION's rear panel. Use no
> less than #14 gauge (#12 recommended)
> stranded wires for three-foot long <-- note 3 foot cable
> connections to accommodate the required
> current demand during transmit. Use
> heavier gauge wire for longer power supply
> leads."
> BUT, if you read the Tyco/AMP Mate-and-Lock specs
> for the socket, plug, and pins...... (Tyco
> documents 108-1031 and 114-1010 and 108?1053).
> You will see a 15 amps max current capacity for
> normal product use on the socket and the plug,
> and 20 amps as the product absolute limit for the
> 221 degrees temperature for the plug housing.
> Note that that 20 amps max is only 90% of the Ten
> Tec specified Power Supply minimum constant DC
> current requirement. No safety factor margin here.
> Is this sloppy engineering, bad engineering, or cost of part engineering?
> Now, for example, if you are a high duty cycle
> mode operator, and I am a RTTY contester and RTTY
> is almost 100% duty cycle under contest
> conditions.... the pins overheat and then the
> housing overheats and that leads to total
> connector failure over time.......... smelling, smoking, burning, oh my!
> I have been told that the connector, pins, and
> socket are specified correctly...... I just don't think so!
> I have removed them all and run #14 wire directly
> from Power pole connectors to the PC board.
> Haven't had a problem since. <<<<<<<<
>
> 2016, still running same 30AMP Power Poles and
> #14 gauge wire with no problems on the power
> source side. (Had to do the A9 total replacement, but that is another
> topic) 73,
> Ben WB2RHM
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> TenTec@contesting.com
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