Flex Genius XL power supply failure

  • 1
  • Problem
  • Updated 2 months ago
On power up  self test shows power supply failure. All other tests passed.  I just received the amp today. Any ideas other than contact Flex 
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Trader Dave

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Posted 2 months ago

  • 1
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Chris Tate - N6WM, Elmer

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Open a help desk ticket.
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Watts - K4QJZ

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I have had the same issue before. There may be a simple fix. If your comfortable opening up your amp (Hex head screws on the sides) you can probably solve this quickly.
With the cover removed you will find the main power supply on the right side as you face the front of the Amp..
There has been an issue with excessive handeling in shipment where the power supply has slipped towards the front of the Amp. Try pushing it towards the rear of the Amp as it has most likely slipped out of the rear connector thus leaving it unpowered.
In some cases you may have to loosen the bracket on the top of the power supply to be able to slide it to the rear. It only had to move 1⁄8 -1⁄4 “ to be disconnected.
That solved my issue and has not been a problem since.
It’s a great Amp, hope that solves it!
Watts
K4QJZ
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bahillen

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Nice to hear from someone who finally received a PGXL

73
Bill
W9JJB
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Burch - K4QXX

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Yes, glad to hear amps are again shipping.  Hopefully I'll get mine soon.
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AC9S

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I much prefer the way Alpha shipped their amps - with the transformer in a separate package.  Note I just sent my "standby" KPA500 back for some factory work and they recommended taking the transformer out prior to shipping.  Lots of mass!


Keith - AC9S
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David Decoons wo2x, Elmer

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The power supply in the PG XL is a switching supply and does not have the weight of the old Alpha/Peter Dahl transformers.

Dave wo2x

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Dan Quigley, N7HQ

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Yes, Watts is correct and his directions for a fix are also correct. 

This is a too-common shipping fail for the PGXL.  However, for most hams, it is usually an easy field fix.  The standard caveat of making sure you disconnect the amplifier from AC power also applies.  If for any reason you find stripped screws or cannot loosen and slide the power supply back into its socket, the amp will need to be returned. 

The brackets that hold the power supply in place have been redesigned and we are awaiting a shipment to send out to all PGXL owners. 

Best,
Dan
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mikeatthebeach .

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I want FedEx for shipping and will
Pay extra for that shipping carrier
and Not accept UPS for shipping My PGXL

The new thicker bracket was to prevent
This disaster is a must if the PGXL since
The PGXL is so fragile for shipping

PGXL Power Supply dislodges and damages
Unit during shipping

Hopes FRS inspects each unit
Before shipping out any more
PGXL’s !!!!!!!!!

Unacceptable for a $7K Amplifier for FRS to do
otherwise

My SPE 2K Amp was double boxed and the
Packing that FRS is not acceptable
in lieu of the mechanical bracket
Design flaw in the PGXL

73 Mike
(Edited)
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Bill -VA3WTB

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The Flex amps are very well packed as well as all their products. Every now and again we here of a damaged PGXL from very a high impact. Under normal handling this damage would never occure.
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HCampbell WB4IVF

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Maybe Flex needs to add an UPS driver to the alpha team for shock impact testing. 

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Sergey Abrikosov

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Maybe manufacturing quality control need to add a steps to secure parts inside of Amp for shipment. Parts or connectors should not move during shipment or movement
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Dan Quigley, N7HQ

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When PGXLs arrive they are typically palatized. The current inbound acceptance process for each unit is: 

1) Inspected for any physical damage.
2) Bench-tested to ensure each meets acceptance specifications. 
3) Repackaged for shipment to customers.

These tests are in addition to those performed at the factory

Best,
Dan
(Edited)
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HCampbell WB4IVF

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Looks like 4O3A/Flex redesigned the bracket that failed and will also send them to all buyers per Dan’s first post.  Haven’t seen any postings of shipping-related damage issues other than the bracket.






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Trader Dave

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The 4 screws on the side of the power supply were not tight
This caused the power supply to slip out of place. I fixed the problem by pushing the power supply back in place and tightening the screws. Flex should address this problem by adding another screw and bracket at the front of the power supply to prevent slippage. There may be other solutions.
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Trader Dave

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Thanks to K4QZE for identifying the problem. I loosened the screws on the side of the power supply and pushed the supply  more than 1/4 inch towards the back. That fixed the problem. Thanks to all replies. 

Dave WA6DKN . 
(Edited)
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Watts - K4QJZ

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Glad to hear it worked, now the fun begins. Unfortunately there is not much anyone can do to control how something is really handled. The amps are doubled boxed and isolated with soft foam all the way around to absorb most shocks.
Enjoy your weekend,
Watts
K4QJZ
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Trader Dave

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Thank you