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Re: [Amps] Starting up a NEW Henry amp

To: Carl Braun <Carl.Braun@cattron.com>, "amps@contesting.com" <amps@contesting.com>
Subject: Re: [Amps] Starting up a NEW Henry amp
From: gudguyham--- via Amps <amps@contesting.com>
Reply-to: "gudguyham@aol.com" <gudguyham@aol.com>
Date: Tue, 5 Dec 2023 10:50:14 +0000 (UTC)
List-post: <mailto:amps@contesting.com>
If all else fails the inputs are adjustable.  What tube are these units running?


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On Monday, December 4, 2023, 8:22 PM, Carl Braun <Carl.Braun@cattron.com> wrote:

...new updates on the Henry 3K Ultra amps as of 12/3/2023

The Henry 3K Ultra head SN 65-171 and its mate RF console 65-171 are working 
well now.  I re-tapped the HV transformer and the Filament transformer to get 
the voltages down in the range that Eimac and Henry call for on the 3CX1200D7 
tubes. Im seeing approx. 4800V SSB/3900V CW after having tapped the HV 
transformer for 250VAC in.  The filament voltage is down to 6.3v on the money 
after jumping two taps on that transformer.

I was also able to install a new Guardian T/R relay and that solved the signal 
degradation issue I'd seen as well.

Lastly, a new 25K ohm resistor for the 28v AC MAINS light was replaced and a 
new number 85 bulb was installed...and there was light!

A few 80w dits at 4800V SSB setting gets 2200w+ out

The RF console 65-104 is ready to undergo surgery when I get back into town 
from a business trip.  I found several resistors in the PS section of the amp 
that were bad.  Two (50 ohm and 75 ohm) were related to the step start circuit 
and one 20K 100W resistor related to the HV resistor string.

I can send over the Henry drawings showing the components that failed if anyone 
has interest.

One last issue I would like some comments on...I am seeing high SWR on my 
transceiver when I transmit 1KW + with these Henry amps.  The display on the 
transceiver will commonly hit 3:1 when driving either Henry amp.  When driving 
my Alpha 77 amp I see 1.02:1 SWR on my transceiver at 1.5KW.  My antennas are 
flat with 200W in.

By enabling the tuner in the rig I can knock down most of the SWR when running 
the Henry's but I don't have to do that with my other amp. One difference...  I 
do have a longer coax run (25') from the Henry's back to the PM II watt meter . 
The Alpha has a three ft (3') jumper from the amp to the watt meter. I'm going 
to shorten the coax from the Henry RF consoles to the coupler to 8' or so to 
see if that lessens any of the RF coming back to the rig. I do have a W2FMI 
line isolator in the line going to the amps with no visible changes. More parts 
are coming like RFI kits for the amp and transceiver, a 1:1 unun for the output 
of the amp and one for the base of the antenna.
Any other Suggestions?

Thanks

Carl W9LF


From: Carl Braun
Sent: Friday, November 17, 2023 11:01 AM
To: amps@contesting.com
Subject: RE: Starting up a NEW Henry amp

I have some updates on the Henry amp(s) I picked up and thought some of you may 
find the results interesting.  Maybe some of you can help with some of the 
issues that remain.

I picked up Henry 3K Ultra head SN 65-171 and its mate, the SN 65-171 RF deck.  
Along with those two pieces came an additional RF deck; Henry SN 65-104 that 
was still in the Henry crate.  I brought all three of these components back in 
my 2005 Honda pilot. Left Wisconsin on Sunday morning at 6 am then on to 
Prescott AZ and back home on weds at 3pm. Once home, I had two other guys help 
me up the steps with the 250# consoles to my ham shack where I would dig into 
the amps.

I did a visual inspection of the head and both RF decks.  The -171 RF deck had 
a damaged doorknob cap but looked ok other than that. Replaced 50pf doorknob.  
Afterward,  I plugged the -171 head into the -171 RF console, put on my safety 
glasses and headphones in case there were any loud surprises. Fire extinguisher 
on standby.  I flipped the mains switch on the console and pushed the POWER 
button on...the amp jumped to life and a flurry of ceramic chunks started 
flying everywhere. Hmmmm.  I took the RF deck out of the console and found 
ceramic debris everywhere.  I found the culprit...it was toroid across the tube 
that was loose due to its damaged ceramic standoff insulator.  RF Parts came 
through on that and I was able to install the new ceramic standoff and resolder 
the toroid. All servo motors and tuning working well.

The only issues I have with this -171 RF console are:

  *  HV and Filament voltages are high.  Eimac says 5500V max at 6.3 on the 
filament.  Henry implies voltage on the plate at 3800 CW/4800V SSB or so and 
the filament voltage at 6.3.  Mine are at 5500V and 7.0V respectively. With 
243VAC coming into the shack I will be re-tapping the plate transformer to 
5000V and filament closer to 6.3v.
  *  When repaired, I put this amp on the air and noted a severe problem with 
the degradation of the incoming signal when the amp was ON.  With the amp 
idling, I can copy a strong, clear station and within seconds the signal begins 
to get scratchy and eventually gets so bad the signal is unreadable.  
Eventually the band signals disappear on the scope.  A simple tap of a CW key 
brings everything back into clear reception for another 8-10 seconds before the 
signal degrades again.  This is happening on all bands.  Checked and cleaned 
input/output connections. Reseated tube as well as removed and inspected bird 
element connections.  Same problem.  It could be the crappy little guardian 
input relay Henry used to switch in the incoming RF? I have to pull the RF deck 
again and flip it over to see if I can pull and re-seat that relay. Suggestions?

After that exercise, I pulled the -104 RF console out of the crate and plugged 
it into the -171 control head.  I flipped on the wobbly AC mains switch and 
nothing... After some quick inspecting I found the mains circuit breaker 
broken.  It appears it was smashed when it was placed into the crate.  I found 
a replacement Heinmann 40A breaker and installed that.  Then I threw the switch 
and the amp came to life.  This amp had not seen voltage since 1994...that was 
the date on the shipping crate sent from Henry to General Dynamics in SoCal.  I 
saw 6.3 on the filament and 3800 CW/4900V SSB on the multimeter so I left the 
amp on to cook and walked away for 24 hours.  Returning to the shack all seemed 
well and I applied some RF to the amp.  Working like a champ.  70 watts in gets 
1800 into the dummy load.

So, as it sits now I am in need of some advice as to why I see the signal 
degradation with the first RF console.  I plan on yanking the RF deck this 
weekend to flip it over to see if I can see anything obvious.

I also need to know a source for the small push in bulbs Henry used for their 
indicator lights.  No cross reference in my Ultra or 3KA manuals

Thanks in advance for any help you can provide.

More soon

Carl W9LF

From: Carl Braun
Sent: Saturday, October 21, 2023 3:49 PM
To: amps@contesting.com<mailto:amps@contesting.com>
Subject: Starting up a NEW Henry amp

I'm headed out tomorrow am on my way to save a Henry 3K Ultra amplifier. I'm in 
Wisconsin and the amp(s) is in Arizona. My buddy has gotten out of ham radio 
years ago and still has this Henry 3K Ultra. He also has a second RF console 
that came with it that has never been out of the crate. All of the hardware was 
originally sold to General Dynamics in southern California. The crates console 
still has the paper tag on it that shows delivery from Henry to Gen Dynamics.

My plan is to get the amp and extra console back home and get them back on the 
air. I don't see myself doing anything other than plugging them into 240vac, 
turn them on individually and letting the tube go thru a gettering process for 
a day or so. These are 3cx1200D7 tubes with a controller that displays plate 
and filament voltage so I can quickly see if anything is awry.

Any other suggestions from the group on starting these amps up?

Carl W9LF

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