> I've suggested possible RFI issues somehow causing the issue, but this
> is just a guess. I'm just as perplexed as he is.
I am going to offer a solution based on an audio model as it seems to cover both your conditions. But, first, let me reframe the conditions and results to make sure I am understanding it correctly.
Condition A: When he modulates rF into an rF amplifier at a low level, all is well.
Condition B: When he modulates rF into an rF amplifier at full output, he either blows the fuse (solid-state amp), or fries the output tubes (tube amp):
If that is a correct understanding here is a potential diagnosis - and suggestion:
Under Condition A, the secondary amplifier is not modulating anywhere near 500 watts. And so is not under any stress. Just as I have a 250wpc stereo amp at home being fed from a pre-amp with roughly 2 volt maximum output, but running, typically, at about 0.02 watts. Peak-to-average in this case is 20 dB. The power-amp may run the very rare 200-watt peak, but most of the time it is running at far less.
Under Condition B, the system is modulating at the "FULL" 500 watts. Were my power-amp to modulate at its maximum outlet, even briefly (more than a few seconds), it would be pulling very nearly 30 amps at the wallplate - i.e.: Blowing fuses. My 75wpc tube amp would handle it somewhat better, but were it to be expected to do it for over those few seconds, it would red-plate the tubes in short order. Given its class, what it draws at full output and quiescent is not substantially different - lots of waste in tube designs, all those filaments, so it would red-plate before blowing a fuse - they exist to protect the transformers.
So, I think your friend has a fundamental misunderstanding (if my contentions and interpretations are correct) on how amplifiers work. They have a rating - which is what they can deliver cleanly for some period of time at a certain input level. But they are not (usually) designed to operate at full peak modulation, all the time.
Peter Wieck
Melrose Park, PA