How it Works
ELECRAFT
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XV222
Assembly Manual
57 pgs1.78 Mb0
User Manual
97 pgs3.31 Mb0

ELECRAFT XV50, XV144, XV222 User Manual

Elecraft XV Series Transverters
Models XV50, XV144, XV222
Rev B, November 7, 2003
Table of Contents
Schematic and Parts Layout Diagrams……………………………………………….……………………………...……………..Appendix A
Troubleshooting...................................……………………………………………….……………………....……...………….....Appendix B
— — 1
Introduction
The Elecraft XV Series high-performance transverters may be used with any transceiver or transmitter/receiver pair that covers 28 MHz. Separate transverters are offered for the following bands:
• Model XV50: 50 to 52 MHz.
• Model XV144: 144 to 146 MHz.
• Model XV222: 222 to 224 MHz
I.F. connections to the transceiver can be either single-port (single RF cable) or dual port (separate receive and transmit cables).
The transverters include an adjustable input level control that will provide full output from I.F. power levels from as low as 0.01 watts up to 8 watts continuous. Full protection against accidental high-power transmit of up to 100 watts into the I.F. port is also included.
The receiver features a very low noise figure with a PHEMT RF stage for weak-signal work. Relays are used for transmit/receive switching to avoid receive performance degradation by diode switches in the signal path.
The transmitter is conservatively rated at 20 watts output PEP SSB, CW or data modes. The RF output is displayed on the front panel with a 10­segment LED bargraph. The LED display may be switched between dot or bar modes and has two brightness levels when used with an Elecraft K2 transceiver.
The transverters are housed in attractive, low-profile enclosures that may be stacked for multi-band operation. An illuminated band label identifies the transverter in use. Several transverters may be connected to the transceiver in most cases. Internal relays select only the transverter for the band in use, avoiding the need to switch I.F. cables.
Using an Elecraft K2 as the I.F. Transceiver
While the transverters will work with nearly any HF transceiver, using them with our Elecraft K2 (or K2/100) offers additional benefits. The high-performance K2 provides:
• Low noise, single-conversion, wide dynamic range receiver
• Four adjustable I.F. crystal filter bandwidths per mode
• Automatic transverter band switching with individual menu-
selected output power levels for up to three transverters.
• Direct display of the transverter operating frequency to 10 Hz,
including per-band adjustable offsets of +/- 9.99 kHz
• Four RIT ranges from +/- 0.6 to +/- 4.8 kHz
We recommend that K2’s with serial numbers 3445 and below be equipped with Elecraft-approved modifications that reduce spurious responses and enhance frequency stability. See page 68 for details.
Figure 1. Three Transverters May Be Controlled by an Elecraft K2.
— — 2
Transverter Kits
The XV Transverters are intermediate-to-advanced kits, yet you'll be surprised at how uncomplicated they are to build. All of the radio frequency (RF) circuits are on one printed circuit board (PCB). A second smaller PCB holds the microcontroller and front-panel LEDs. High­quality, double-sided PCBs are used, with plated-through holes for optimal RF performance. Point-to-point wiring is minimal. All components to be installed have wire leads; the few surface-mount devices required are pre-installed on the circuit board.
This kit uses just one torodial inductor, which is easy to wind. However, if you prefer not to wind this inductor yourself, you can order one pre­wound with the leads tinned and ready to install from an Elecraft-qualified source. Ordering information is on our web site at
www.elecraft.com.
Customer Service and Support
Whether you build the kit or buy a factory-built transverter, you’ll find a wealth of information on our web site at
www.elecraft.com. Among the
materials there you’ll find the latest application notes, photographs, any updates to this manual, and information on new products. We also have a popular e-mail forum, for which you can sign up from the web site. It's a great way to interact with other Elecraft owners, exchange ideas and find answers to many questions.
You can also get assistance by telephone or by sending an e-mail to
support@elecraft.com. E-mail is preferable because it gives us a written
record of your question. Telephone assistance is available from 9 A.M. to 5 P.M. Pacific time, Monday through Friday (except US Holidays) at 831­662-8345.
Repair Service
Contact Elecraft before returning your equipment to obtain the current information on repair fees.
To ship the unit, first seal it in a plastic bag to protect the finish. Use a sturdy packing carton with at least 3-in (8 cm) of foam or shredded paper on all sides. Seal the package with reinforced tape. (Neither Elecraft or the carrier will accept liability for damage due to improper packaging.) Ship the equipment to:
Elecraft P.O. Box 69 Aptos, CA 95001-0069
Elecraft 1-Year Limited Warranty
If building a kit, complete the assembly, carefully following all instructions in the manual, before requesting warranty service.
What is covered: During the first year after the date of first consumer purchase, Elecraft will replace defective parts free of charge (post-paid). We will also correct any malfunction caused by defective parts and materials. You must send the unit at your expense to Elecraft. We will pay return shipping.
What is not covered: This warranty does not cover correction of assembly errors or misalignment; repair of damage caused by misuse, negligence or builder modifications; or any performance malfunctions involving non-Elecraft accessory equipment. The use of acid-core solder or any corrosive or conductive flux or solvent will void this warranty in its entirety. Also not covered is any reimbursement for loss of use, inconvenience, customer assembly or alignment time, or cost of unauthorized service.
Limitation of incidental or consequential damages: This warranty does not extend to non-Elecraft equipment or components used in conjunction with our products. Any such repair or replacement is the responsibility of the customer. Elecraft will not be liable for any special, indirect, incidental or consequential damages, including but not limited to any loss of businesses or profits.
— — 3
Specifications
Numeric values are typical; your results will be somewhat different. Also, specifications may be affected by the options or accessories chosen. See www.elecraft.com for details about options and accessories currently available. Specifications are subject to change without notice.
General
Size Cabinet: 1.3” H x 7.8” W x 8.3” D (3.3 x 19.8 x 21 cm)
Overall: 1.5 H x 7.8 W x 9.5 D incl. feet and connectors. (3.8 x 19.8 x 21 cm)
Weight: 2.5 lbs (1.1 kg) Supply Voltage: 13.8 VDC Current Drain:
Receive: 250 mA (typical) Transmit
1
: 4 A (typical)
Frequency Ranges: XV50: 50 – 52 MHz XV144: 144 – 146 MHz XV222: 222 – 224 MHz
T/R Switching Time: 3 ms (typical)
T/R Key Input: Ground for transmit: must pull 5 volt
logic level to within 0.5 volts of ground at < 1 ma.
I.F. Overload Protection: Survives 100 watts RF input at the I.F.
Port without damage with transverter un-keyed (in receive mode).
1
Current varies with supply voltage, load impedance and power output. We
recommend a minimum 5 A supply.
Amplifier Key Output: Ground on transmit: 200 VDC at 1 A
maximum.
Connectors:
K2 Interface: DB9 Keying Line Input: RCA Keying Line Output: RCA I.F. In/Out: BNC Aux (Rx-Only Ant): BNC Antenna: SO-239 (UHF) on XVR 50 Type N on XVR 144 & XVR 222
Transmitter
Power Output: 20 watts into 50 ohms Minimum Supply
Voltage Recommended: 12 VDC
Operating Modes: CW, SSB, AM, FM, PSK I.F. Input Frequency Range: 28 – 30 MHz I.F. Input Power Range: 0.01 mW (-20 dBm) to
8 watts (+ 39 dBm)
Harmonic Content: < - 60 dBc at 20 watts output.
Receiver
Noise Figure: < 1 dB Conversion Gain: 25 dB (typical) Image Rejection: > 60 dB 3rd-Order Intercept: +20 dBm (typical)
— — 4
Preparing for Assembly
Overview of the Kit
The Elecraft XV transverters use modular construction, both physically and electrically. This concept extends to the chassis (Figure 2). Any chassis element can be removed to provide access for troubleshooting.
Figure 2. XV Transverter Modular Cabinet Parts.
There are two printed circuit boards (PCBs) in the transverter: the front panel board, which sits vertically behind the front panel, and the large RF board.
The boards are interconnected using board-to-board connectors which eliminates the need for a wiring harness. Gold-plated contacts are used on these connectors for reliability.
Tools Required
You will need the following tools to build this kit:
• Fine-tip temperature-controlled soldering station with 700 or
800°F tip (370-430°C). Do not use a high-wattage iron or gun with small components since this can damage pads, traces, or the parts themselves.
• IC-grade, small-diameter (.031”) solder (Kester #44 or
equivalent).
• Desoldering tools and supplies are invaluable if you make any
modifications or need to do any repairs. Narrow solder wick or a good vacuum desoldering tool such as the Soldapullt® model DS017LS are recommended. See Soldering, Desoldering and Plated-Through Holes, on page 9 for more information.
i
DO NOT use acid-core solder, water-soluble flux solder, additional flux or solvents of any kind. Use of any of these will void your warranty.
• Screwdrivers: a small, #2 Phillips and a small flat-blade for slotted
screws.
• Needle-nose pliers.
• Small-point diagonal cutters, preferably flush-cutting.
• Digital Multimeter (DMM) for voltage checks and confirming
resistor values. A DMM with capacitance measurement capability is desirable, but not required.
• Noise generator (Elecraft N-Gen or equivalent
2
) or signal
generator with output in the RF frequency range of the transverter.
• RF power meter capable of measuring RF power levels up to 25
watts at the RF frequency used by the transverter.
• 50-ohm dummy load capable of handling 25 watts, minimum.
Refer to www.elecraft.com for tool sources and solder recommendations.
2
Check www.elecraft.com for availability.
BACK PANEL
LEFT SIDE PANEL
TOP COVER
FRONT PANEL
BOTTOM COVER
(RIGHT SIDE PANEL NOT SHOWN)
.
— — 5
Preventing Electro-Static Discharge Damage
Your XV transverter uses integrated circuits and transistors that can be damaged by electrostatic-static discharge (ESD). Problems caused by ESD often can be difficult to troubleshoot because components may be degraded but still operating at first rather than fail completely.
To avoid such problems, simply touch an unpainted, grounded metal surface before handling any such components and occasionally as you build, especially after moving about.
For maximum protection, we recommend you take the following anti­static precautions (listed in order of importance):
1. Leave ESD-sensitive parts in their anti-static packaging until you
install them. The packaging may be a special container or conductive foam (Figure 3). Parts which are especially ESD­sensitive are identified in the parts list.
2. Ground yourself briefly before touching any sensitive parts or
wear a conductive wrist strap with a series 1 megohm resistor.
DO NOT ground yourself directly as this poses a serious shock hazard.
3. Make sure your soldering iron has a grounded tip.
4. Use an anti-static mat on your work bench.
Figure 3. A common anti-static packaging is conductive foam which
keeps all of the terminals of a device at the same potential.
Unpacking and Inventory
We strongly recommend that you do an inventory of the parts before beginning to assemble the kit. Even if you don’t count all the parts, an inventory is helpful to familiarize yourself with them. A complete parts list is included in the next section.
Identifying Parts
The parts list contains illustrations of the parts to help you identify them. Identifying marks on the individual parts are shown in the text in parenthesis. For example, “Transistor Q4 (PN2222)…” indicates a transistor, Q4, which may be located in the parts list that has the characters shown in parenthesis printed on it. Sometimes these letters are not obvious. They may be printed in light gray on a black body, for example. Also, there may be other marks on the device in addition to the letters listed.
Identifying Resistors
Resistors are identified by their power capacity and their resistance value. The power rating in watts determines the physical size of a resistor. The most common resistors are 1/4 watt. Higher wattage resistors are proportionately larger. The resistance value and wattage of each resistor is shown in the Parts Lists and in the individual steps of the assembly procedures. The silk screened outlines on the circuit boards indicate the relative physical size of the resistors as well.
Most resistors use a color code. The color bands are listed in the text along with the values of each resistor. For example, “R4, 100k (brn-blk-yel)…” indicates a 100k ohm resistor and the colors to look for are brown, black and yellow, starting with the band nearest the end of the resistor.
Some resistors use numbers instead of color bands. For example, an 820 ohm resistor might be stamped with the digits 821 instead of having gray, red and brown color bands. Some larger resistors have their value in ohms stamped on the body using numbers. For, example the 820 ohm resistor would be stamped with 820 instead of 821 as described above. Normally, when the value is shown in ohms it will be followed with the word “ohms” or the Greek letter omega: Ω
— — 6
Reading Resistor Color Codes
It is very helpful if you learn to read the color codes. A color-code chart showing how to read the four-color bands on resistors with a 5% or 10% tolerance is shown in Figure 4. 1% resistors are similar except that they use a fifth band to provide a way of showing another significant digit. For example, a 1,500 ohm (1.5 k-ohm) 5% resistor has the color bands brown, green and red signifying one, five and two zeros. A 1,500 ohm (1.5 k­ohm) 1% tolerance resistor has the color bands brown, green, black and brown signifying one, five, zero, and one zero.
The optional band shown in Figure 4 indicates other performance specifications for the resistor. When used, it is separated from the other color bands by a wider space.
i
If in doubt of a resistor’s value, use a DMM. It may be difficult to see
the colors on some resistors, particularly 1% tolerance resistors with a dark blue body. Do NOT be concerned with minor deviations of your DMM reading from the expected value. Typical errors in most DMMs and the tolerances of the resistors normally produce readings that are slightly different from the value indicated by the color bands.
Identifying Molded Inductors
Small molded inductors have color bands that use the same numeric values as resistors but they start near the center of the inductor and work toward the end. These colors are listed in the text after the value of the inductor, for example: 27µH (red-vio-blk). The red stripe would be near the center of the inductor and the black strip would be closer to the end. On very small chokes, the first color will be only slightly farther from one end than the last color. There may be a variety of other stripes on inductors as well, indicating their tolerance, conformance to certain specifications and other data.
FIRST DIGIT
TOLERANCE:
OPTIONAL
SECOND DIGIT
MULTIPLIER
Black Brown Red Orange Yellow Green Blue Violet Gray White Silver Gold
0 1 2 3 4 5 6 7 8 9
-
-
X 1 X 10 X 100 X 10K X 10K X 100K X 1M
-
-
­X 0.01 X 0.1
COLOR
DIGIT
MULTIPLIER
GOLD = 5% SILVER = 10%
Figure 4. Resistor Color Code.
— — 7
Identifying Capacitors
Capacitors are identified by their value and the spacing of their leads. Small-value fixed capacitors usually are marked with one, two or three
digits and no decimal point. The significant digits are shown in parenthesis in the text. For example: “C2, .01 (103)”.
If one or two digits are used, that is always the value in picofarads (pF). If there are three digits, the third digit is the multiplier. For example, a capacitor marked “151” would be 150 pF (15 multiplied by 10
1
). Similarly, “330” is 33 pF and “102” is 1000 pF (or .001 µF). You may think of the multiplier value as the number of zeros you need to add on to the end of the value.
Note: In rare cases, a capacitor manufacturer may use “0” as a decimal placeholder. For example, “820” might mean 820 pF rather than
82 pF. Such exceptions are usually covered in the parts lists. If possible, measure the values of all capacitor below .001 µF. Most DMMs include capacitance measurement capability.
Fixed capacitors with values of 1000 pF or higher generally use a decimal point in the value, such as .001 or .002. This is the value in microfarads (µF). Capacitors also may have a suffix after the value, such as “.001J”.
The lead spacing is noted in the Parts Lists for most capacitors. If two different types of capacitors have the same value, the lead spacing will indicate which one to use. When the lead spacing is important, both the value and the lead spacing is shown in the assembly procedure. For example, “LS 0.1” means that the Lead Spacing is 0.1 in.
Hard-to-Identify Capacitor Values
2.2 pF: These are “disc ceramic” capacitors with round, pillow-shaped
bodies about 1/8” (3 mm) in diameter and a black mark on the top. The capacitor should be labeled “2.2” but the marking sometimes requires a magnifying glass to see clearly.
150 pF: These capacitors are marked “151” on one side, but the other side may be marked #21ASD. The “#21” may look like “821”.
— — 8
Assembly Process
There are seven steps in the transverter assembly process:
1. Front Panel board assembly.
2. RF Board Assembly, Part I, parts common to all models.
3. RF Board Assembly, Part II, band-specific parts.
4. RF Board Assembly, Part III, installing the RF Power
Module.
5. Final Assembly.
6. Interconnect cabling.
7. Test and alignment.
Follow the assembly process in the order given. Each part builds on what has been completed before it. For example, the Front Panel assembly procedure contains details about installing certain parts that are not repeated when similar parts are installed later.
Forming Component Leads
Sometimes the space provided for a component on the PC board is larger than the distance between the leads on the part itself. In such cases, you’ll need to carefully bend the leads out and then down to fit the given space. Always use long-nose pliers to accomplish this task, and bend the leads – don’t tug on them. This is especially important with capacitor leads, which are fragile.
Step-By-Step Procedures
Perform the assembly steps in each procedure in the order given, and do not skip any steps. Otherwise you may find that you’ve installed one component that hinders the installation of another. When groups
of components are installed, they are listed in a logical order as you work around the circuit board to reduce the time needed to find where each part goes.
Each step in the assembly procedures has a check box.
Some steps have more than one task. For example, you may be installing a number of components listed. When a step has a number of tasks, each task is indented with space for a check mark:
Check off each task as you complete it.
— — 9
Soldering, Desoldering and Plated-Through Holes
CAUTION: Solder contains lead, and its residue can be toxic. Always wash your hands after handling solder.
The printed circuit boards have circuitry on both sides (“double-sided”). Boards of this type require plated-through holes to complete the electrical connections between the two sides.
When you solder components on these boards the solder fills the plated holes making excellent contact. This means that you do not need to leave a large “fillet” or build-up of solder on top of the pads themselves. A small amount of solder will do for all connections.
Unfortunately, removing components from double-sided PC boards can be difficult. To remove a multi-pin component you’ll need to get all of the solder out of every hole to free the leads. You will need to use solder wick or a vacuum desoldering tool (see Techniques below).
The best strategy for avoiding de-soldering is to place all components properly the first time. Double-check values, component placement and orientation. Take care to avoid ESD damage to components.
Techniques
• Don’t pull a lead or pin out of a hole unless the solder has been
removed completely, or you are applying heat. Otherwise you can literally pull the plating out of the plated-through hole.
• Limit soldering iron contact to a few seconds at a time.
• Use small-size solder wick, about 0.1” (2.5 mm) wide. Use wick
on both the top and bottom solder pads when possible. This helps get all of the solder out of the hole.
• Buy and learn to use a large hand-operated vacuum desoldering
tool such as the Soldapullt® model DS017LS. Small solder suckers are not effective.
• When removing ICs and connectors, clip all of the pins at the
body first, then remove each pin one at a time, working slowly. You may damage pads and traces by trying to remove a component intact, possibly leaving a PC board very difficult to repair.
• Invest in a PC board vise with a heavy base if possible. This
makes removing parts easier because it frees up both hands.
• If in doubt about a particular repair, ask for advice from Elecraft
or someone with PCB repair experience. Our e-mail reflector is an excellent source of help.
— — 10
Parts Inventory
You should do a complete inventory. Contact Elecraft if you find anything missing.
i
Leave painted panels wrapped until they are needed during assembly. This will protect the finish.
Cabinet and RF circuit board components used in all transverters.
Picture Ref. Designator(s) QTY Description Part #
1
Printed Circuit Board, XV, 50,144,222
i
Handle with care – ESD Sensitive. This board is supplied with
several surface mount components pre-installed. Some of these components
are static-sensitive and are vulnerable until the other parts are installed on
the board. There is a temporary jumper across the solder pads for L1 on the
board to prevent static damage to Q3. Do not remove this jumper until
instructed to do so.
E100169
1 Front Panel E100153 1 Rear Panel E100154
2 Side Panel E100140 1 Top Cover E100146
See Figure 2.
1 Bottom Cover E100155 1 Heat Spreader E100156
8 2D Connector E100078
2 Right Angle Bracket E700073
40 Pan Head Black Machine Screw, 3/16 inch. 4-40. E700015 5 Pan Head Zinc Machine Screw, 5/16 inch, 4-40 E700077
2 Pan Head Black Machine Screw, 1/2 inch, 4-40 E700030
— — 11
Picture Ref. Designator(s) QTY Description Part #
10 Machine Screw Nut, 4--40 E700011 14 Split Lock washer, #4 (Includes two spares) E700004
8 Internal Tooth Lock washer, #4 E700010 2 Flat Washer, #4 E700044
1 Ground Lug E700062
2 M-F Standoff for DB9 Connector E700078
4
Rubber Foot, Self Adhesive
i
A Bail kit is available as an optional accessory if desired. The Bail will hold the front of the transverter up at a convenient viewing angle. See www.elecraft.com for details
E980067
2 RCA Jack E620057 3 BNC Connector assy. with nut and lock washer, PC Mount E620020
3 Nut for BNC Connector E700059 3 Lock washer for BNC Connector E700058
1 DB9 Female Connector, PC Mount E620058
1 DB9 Male Cable Connector E620049
1
DB9 Back Shell (Shell components are normally packaged together in a transparent bag).
E620050
4 Anderson Crimp Terminal E620062
— — 12
Picture Ref. Designator(s) QTY Description Part #
1 Anderson Roll Pin E700071 2 Anderson Power Pole, Shell, Red E620059
2 Anderson Power Pole, Shell, Black E620060 P1 1 Header Connector, 12 Pin , Right Angle E620065
JP5,JP6, JP9 3 Header Connector, 2 Pin E620054
JP1,JP2,JP3,JP4, JP5, JP6, JP9
3
7 Header Connector, 3 Pin E620007
9 Header Shorting Block, 2 Pin E620055
S2 1 DPDT Power switch E640006
SW1 1 4 Pole DIP switch E640014
1 Key Cap, Black E980023
F1 1 Resettable Fuse, 5A PolySwitch (Thin, about 3/8” [9.5mm] square.) E980065
K1, K2, K4, K5, K6, K7, K8, K9
8
Relay, Small
(G6E-134P)
E640011
K3 1 Relay, SPDT, 12 A, 12 VDC, Large (KLT1C12DC12). E640012
D3 1 Diode, Zener, 6.8 volt, 1N5235B E560011
D5 1 Diode, SB530 E560003 D10, D11 2 Diode, LED, Red E570007
3
JP9 comprises a three pin and a two pin header connector.
— — 13
Picture Ref. Designator(s) QTY Description Part #
Z1 1 Frequency Mixer, ADEX-10H E600050 U1 1 MMIC Amplifier, ERA-6 E600051
Pre-mounted on the PCB
U5 1 MMIC Amplifier, MAR-3 E600073 U2 1 Voltage Regulator, 9 volt, LM78L09 E600054
Q6 1 Transistor, NPN, PN2222A E580001 U4 1 Voltage Regulator, 5 volt, LM7805 E600024
Q5 1
Transistor, MOSFET, 2N7000
i
Handle with care – ESD Sensitive. Do not remove it from its ESD-protective packaging until you are instructed to install it.
E580002
Q4 1
Transistor, HEXFET, IRL620
E580018
Pre-mounted on the PCB
Q3 1 Transistor, PHEMT, ATF 34143 E580020
Q2 1 Transistor, NPN , BFR96 E580021
R21 1 Resistor, metal oxide, 1 watt, 5%, 820 ohm (821) E500094 R20, R26, R27 3 Resistor, metal oxide, 3 watt, 5%,160 ohm (160) E500095
R10 1 Trimmer Potentiometer, PC mount, 100K (104) E520001
R13, R22 2 Trimmer Potentiometer, PC mount, 100 ohm (101) E520008 D1, D2, D4, D13, D6,
D12, D9, D14, D15, D16
10 Diode, 1N4148 E560002
D7, D8 2 Diode, 1N5711 E560004
— — 14
Picture Ref. Designator(s) QTY Description Part #
R25 1 Resistor , 1/4 watt, 5%, 56 ohm (grn-blu-blk) E500096 R14 1 Resistor , 1/4 watt, 5%, 4.7 ohm (yel-vio-gld) E500062 R1, R7, R9, R33 4 Resistor , 1/4 watt, 5% , 10K ohm (brn-blk-org) E500015 R11 1 Resistor, 1/4 watt, 5%, 1K ohm (brn-blk-red) E500013 R18 1 Resistor, 1/4 watt, 5%, 620 ohm (blu-red-brn) E500097 R4, R5 2 Resistor, 1/4 watt, 5%, 5.6K ohm (grn-blu-red) E500007 R23, R34 2 Resistor, 1/4 watt, 5%, 100K ohm (brn-blk-yel) E500006 R40 1 Resistor, 1/4 watt, 5%, 22k ohm (red-red-org) E500090 R31 1 Resistor , Metal Film, 1/4 watt, 1%, 15.0K ohm (brn-grn-blk-red) E500112 R32 1 Resistor, Metal Film, 1/4 watt, 1%, 3.92K ohm (org-wht-red-brn) E500110 R30 1 Resistor, Metal Film, 1/4 watt, 1%, 7.50K ohm (vio-grn-blk-brn) E500111 R35 1 Resistor, Metal Film, 1/4 watt, 1%, 5.11K ohm (grn-brn-brn-brn) E500109 R16, R8 2 Resistor , 1 watt , 5%,120 ohm (brn-red-brn) E500105 R12, R19 2 Resistor, 1 watt, 5%, 180 ohm (brn-gry-brn) E500113 R15 1 Resistor 56 ohm SMD, 1206 size E500099 Pre-mounted on the
PCB
R17 1 Resistor, .02 ohm SMD, 2512 size E500100 C2,C57 2 Ceramic Capacitor, 100 pF (101) E530117 C35 1 Ceramic Capacitor, 10 pF (100) E530118 C55,C56 2 Ceramic Capacitor, 270 pF (271) E530050 C52,C54 2 Ceramic Capacitor , 150 pF (151) E530049 C53 1 Ceramic Capacitor, 18 pF (180) or (18), LS 0.2 E530088 C3, C17, C15, C7, C39 5
Ceramic Capacitor, .001
µF (102), LS 0.1
E530129
C8, C9, C10, C27, C16, C19, C23, C20, C34, C38, C37, C36, C63, C22, C40, C6, C61, C62, C64, C67, C71
21
Ceramic Capacitor, .01µF (103), LS 0.1
E530130
C65, C68, C29 3
Ceramic Capacitor, .047 µF (473), LS 0.1
E530131
Capacitors shown
are typical. Different
styles may be
supplied.
C30 1
Ceramic Capacitor, .22 µF (224), LS 0.1
E530132 C18 1 Ceramic Capacitor, 2.2 pF (2.2), LS 0.1 E530047 C70 1 Ceramic SMD Capacitor, 27 pF E530121
C72 1 Ceramic SMD Capacitor, 4.7 pF E530125
Pre-mounted on the PCB
C25, C21, C24, C41, C32 C66, C31, C4, C84, C85
10
Ceramic SMD Capacitor, .047 µF, 50 V
E530120
— — 15
Picture Ref. Designator(s) QTY Description Part #
C26, C60 2
Electrolytic Capacitor, 22 µF, 25 volt
E530012
L9 1
Molded Inductor, .47 µH (yel-vio-silver)
E690020
L8 1
Molded Inductor, 15 µH (brn-grn-blk)
E690012
L15,L16,L17 3 Variable Inductor, .243-.297 µH, shielded, grey plastic insert. E690025
L7 2 Ferrite Bead E980029
T1 1 Toroid Core, FT37-43 E680003
12 in.
(30 cm)
Solid Insulated Wire, #24 E760005
12 in.
(30 cm)
Red magnet wire, , #26 E760002
12 in.
(30 cm)
Green magnet wire, #26 E760004
3 in.
(7.5 cm)
Bare copper wire, , #14 E760023
5 ft.
(1.5 m)
Red/Black 2-conductor wire, #12 stranded (for DC power wiring) E760017
3 ft.
(91 cm)
4-conductor shielded cable (serial I/O cable) E760009
1 Heat sink gasket, large E100170 1 Heat sink gasket, small E100171 1 5” Hex Tuning Tool E980068
— — 16
Front panel circuit board components.
Picture Ref. Designator(s) QTY Description Part #
1 Printed Circuit Board E100168 2 Screw, Fillister Head, 1/8 inch, 2-56 E700023
U1 1
Microcontroller PIC16F872, Programmed (packaged in foam)
i
Handle with care – ESD Sensitive. Do not remove it from its
conductive foam until you are instructed to install it.
E610014
1 IC Socket, 28 pin (packaged in foam) E620011
J1 1 Header Socket, 12 Pin E620008 D1, D2 2 Rectangular LED, Red E570007
D3 1 Rectangular LED, Yellow E570009 D4, D5, D6, D7, D8,
D9, D10,
7 Rectangular LED, Green E570008
R6, R7, R8, R9, R10, R11, R12, R13,R14, R15, R16, R21, R22, R23
14 Resistor, Metal Film, 1/4 watt 120 ohm (brn-red-brn) E500022
R1 1 Resistor, Metal Film 1/4 watt, 5%, 220 ohm (red-red-brn) E500002 R2 1 Resistor, Metal Film 1/4 watt, 5%, 470 ohm (yel-vio-brn) E500003 R3 1 Resistor, Metal Film 1/4 watt, 5%, 10K ohm (brn-blk-orn) E500015 R4, R17 2 Resistor, Metal Film 1/4 watt, 5%, 100K ohm (brn-blk-yel) E500006 R25 1 Resistor, Metal Film 1/4 watt, 5%, 270K ohm (red-vio-yel) E500101 R18, R19, R20,R24 4 Resistor, Metal Film 1/4 watt, 5%, 2.2K ohm (red-red-red) E500104 R5 1 Resistor, Metal Film 1/4 watt, 5%, 1 megohm (brn-blk-grn) E500024 C4 1
Capacitor, Monolithic, .001 µF, (102), LS 0.1
E530129
C2, C3 2
Capacitor, Monolithic, .01 µF, (103), LS 0.1
E530130
C1 1
Capacitor, Monolithic, .047 µF (473), LS 0.1
E530131
D11 1 LED Light Bar, Yellow (packaged in foam) E570011
— — 17
Picture Ref. Designator(s) QTY Description Part #
Q1,Q2,Q3,Q4,Q5,Q6 6 Transistor, NPN, PN2222 E580001
Z1 1 Ceramic Resonator, 4 MHz E660001
JP1 1 Header Connector, 2 pin E620054
1 Header Shorting block, 2 pin E620055
— — 18
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The remainder of the parts in your kit depend upon the band of operation. Check only the list that corresponds to your transverter.
XV50: The following parts are included only in the XV50 transverter.
Picture Ref. Designator(s) QTY Description Part #
1 Front Panel Label, XV50 E980059
Pre-mounted on the PCB
U6 1
SGA7489, Sirenza Gain Block Amplifier (Three-lead device with tab. Two leads and tab are soldered to the board. Center lead is not connected)
E600055 U3 1 Voltage Regulator, 9-volt, LM78L09 E600054
Q1 1 Transistor, NPN, MPS918 E580022
U7 1 RF Power Module, M57735 E600056
J1 1 SO-239 Chassis Mount Connector E620064
R24 1 Resistor, Metal Oxide, 2 watt, 5%, 56 ohm (56J) E500102 Z4 1 Resistor, 1/4 watt, 5%, 56 ohm (grn-blu-blk) E500096 R6 1 Resistor, 1/4 watt, 5%, 330 ohm (org-org-brn) E500103 C69 1 Ceramic Capacitor, LS 0.1, 10 pF (100) E530118 C14, C58, C59 3 Ceramic Capacitor, LS 0.1, 390 pF (391) E530051
C12 1 Ceramic Capacitor LS 0.1, 100 pF (101) E530117 C42,C43 2 Ceramic Capacitor, SMD, 50 V, 82 pF E530133
C44 1 Ceramic Capacitor, SMD, 50 V, 150 pF E530134 C5,C49,C50 3 Ceramic Capacitor, SMD, 50 V, 2.2 pF E530123 C48,C51 2 Ceramic Capacitor, SMD, 50 V, 10 pF E530135 C28 1 Ceramic Capacitor, SMD, 50 V, 15 pF E520127 C45,C47 2 Ceramic Capacitor, SMD, 50 V, 22 pF E530136
Pre-Mounted on the PCB.
C46 1 Ceramic Capacitor, SMD, 50 V, 27 pF E530121 C1, C33 2 Ceramic Trimmer Cap, 5-30 pF E540001
— — 19
Picture Ref. Designator(s) QTY Description Part #
Z3 1
Molded Inductor, .15 µH (brn-grn-silver)
E690022
L2, L3 2
Molded Inductor, .22 µH (red-red-silver)
E690028
L10,L11 2
Variable Inductor,
.198-.240 µH, Blue
E690032
L1 1
Variable Inductor,
.333-.407 µH, Grey
E690033
L12,L13,L14 3 Variable Inductor, .243-.297 µH, Shielded, Grey Plastic Insert. E690025
L3 2 Ferrite Bead E980029
Y1 1 Crystal, 22 MHz Fundamental (22.00) E660004
— — 20
XV144: The following parts are included only in the XV144 transverter.
Picture Ref. Designator(s) QTY Description Part #
1 Front Panel Label, XV144 E980060
Pre-mounted on the PCB
U6 1
Amplifier, MMIC, ERA-5 (Four-lead device with no tab. All four leads soldered to board)
E600052 U3 1 Voltage Regulator, 5-volt, LM78L05 E600029
Q1 1 Transistor, NPN, MPS918 E580022
U7 1 RF Power Module, RA30H1317M E600058
R39 1 Pot, PC mount, 1K ohm (102) E520010 Z4, R29 2 Resistor, 1/4 watt, 56 ohm (grn-blu-blk) E500096
R24 1 Resistor, 1 watt, 120 ohm (brn-red-brn) E500105 R28 1 Resistor, 1/4 watt, 1K ohm (brn-blk-red) E500013 R6 1 Resistor, 1/4 watt, 470 ohm (yel-vio-brn) E500003 C14 1 Ceramic Capacitor, 0.1 LS, 33 pF (330) E530116 C12 1 Ceramic Capacitor, 0.1 LS, 10 pF (100) E530118
C13 1
Ceramic Capacitor, 0.1 LS, .047
µF (473)
E530131 C42,C43 2 Ceramic Capacitor, SMD, 50 V , 27 pF E530121
C44 1 Ceramic Capacitor, SMD, 50 V , 47 pF E530122 C5 1 Ceramic Capacitor, SMD, 50 V, 2.2 pF E530123 C48,C51, C28 3 Ceramic Capacitor, SMD, 50 V, 4.7 pF E530125 C45,C47 2 Ceramic Capacitor, SMD, 50 V, 12 pF E530126 C46 1 Ceramic Capacitor, SMD, 50 V, 15 pF E530127
Pre-mounted on the PCB
C49,C50 2 Ceramic Capacitor, SMD, 50 V, 1 pF E530128 C1 1 Ceramic Trimmer Capacitor, 4-15 pF (Has a blue dot for identification) E540003
— — 21
Picture Ref. Designator(s) QTY Description Part #
L2, Z3 2
Molded Inductor, .1 µH (brn-blk-silver)
E690021
L4 1
Molded Inductor, .15 µH (brn-grn-silver)
E690022
L10,L11 2 Variable Inductor,
.085-0.1µH, Orange E690023
L1 1
Variable Inductor,
.108-.132 µH, Orange
E690024
L12,L13,L14 3
Variable Inductor,
.059-070 µH, Red Plastic Insert.
E690027
Y1 1 Crystal, 116 MHz, 5th Overtone Series Resonant (116.000) E660016
J1 1 Type “N” Chassis Mount Female Connector E620069
Teflon Tubing E980075
— — 22
XV222: The following parts are included only in the XV222 transverter.
Picture Ref. Designator(s) QTY Description Part #
1 Front Panel Label, XV222 E980061
Pre-Mounted on the PCB
U6 1
SGA7489, Sirenza Gain Block Amplifier (Three-lead device with tab. Two leads and tab are soldered to the board. Center lead is not connected)
E600055 U3 1 Voltage Regulator, 5-volt, LM78L05 E600029 Q1 1 Transistor, NPN, MPS918 E580022
U7 1 RF Power Module, RA30H2125M or RA30H2127M E600057
R28 1 Resistor, 1/4 watt, 5%, 1K ohm (brn-blk-red) E500013 R6 1 Resistor, 1/4 watt, 5%, 220 ohm (red-red-brn) E500002 R24 1 Resistor, 2 watt, 5%, 56 ohm (grn-blu-blk) E500102 R29, Z4 2 Resistor, 1/4 watt, 5%, 56 ohm (grn-blu-blk) E500096 C14 1 Ceramic Capacitor, LS 0.1, 22 pF (220) E530139 C12 1 Ceramic Capacitor, LS 0.1, 10 pF (100) E530118
C13 1
Ceramic Capacitor LS 0.1, .047 µF (473)
E530131
R39 1 Trimmer Potentiometer, PC mount, 1K ohm (102) E520010 C42, C43, C44, C44A,
C45, C47
6 Ceramic Capacitor, SMD, 50 V, 10 pF E530135
C5, 1 Ceramic Capacitor, SMD, 50 V, 2.2 pF E530123 C48,C51 2 Ceramic Capacitor, SMD, 50 V, 3.3 pF E530124 C46 1 Ceramic Capacitor, SMD, 50 V 12 pF E530126 C49, C50, C45A, C46A, C47A
5 Ceramic Capacitor, SMD, 50 V, 1 pF E530128
Pre-mounted on the
PCB
C28 1 Ceramic Capacitor, SMD, 50 V, 4.7 pF E530125 C1 1 Ceramic Trimmer Capacitor, 4-15 pF (Has a blue dot for identification) E540003
L2, Z3 2
Molded Inductor, .1 µH (brn-blk-silver)
E690021
— — 23
Picture Ref. Designator(s) QTY Description Part #
L10, L11, L4A, L19 4
Variable Inductor,
.064-.080 µH, Red
E690029
L1 1
Variable Inductor,
.041-.044 µH, Brown
E690034
L12, L13, L14 3
Variable Inductor, Shielded,
.038-.040 µH, Brown Plastic Insert
E690031
Y1 1 Crystal, 194 MHz 7th Overtone Series Resonant (194.000) E660017
J1 1 Type “N” Chassis Mount Female Connector E620069
1 in Teflon Tubing E980075
— — 24
Front Panel Board Assembly
Place the front panel board on top of the heat spreader with the silk screened side down as shown in Figure 5. Temporarily attach the board to the heat spreader with a single 3/16” (4.8 mm) pan-head screw.
FRONT-PANEL PCB SILK-SCREENED SIDE DOWN
Figure 5. Preparing Front Panel to Install Light Bar.
Prepare the leads of the yellow light bar for mounting on the board by bending them as shown in Figure 6. Press the leads against a smooth, hard surface and roll the roll the light bar until they are at about a 45 degree angle to the side of the light bar.
1
23
.
Figure 6. Preparing Light Bar Leads.
Position the light bar in the cutout of the board as shown in Figure 7. Adjust the leads as necessary so they line up with the six solder pads at the edge of the cutout. The leads will NOT pass through the solder pads. The tips of the leads will rest just inside the top of each solder pad.
Figure 7. Installing Light Bar.
Solder the six terminals to the circuit board pads.
Remove the front panel board from the heat spreader.
— — 25
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The front panel board has parts on BOTH sides of the board. Follow the instructions carefully. If parts are placed on the wrong side of the board, it will not mate with the RF board properly or it will not fit inside the enclosure when construction is finished. Parts that go on the back (not silk screened) side of the board are identified by asterisks on the silk screening.
Place the 28 pin IC socket in the holes provided on the front panel board at the end opposite the light bar you just installed. The socket goes on the BACK of the board (the side opposite the silk screened outline). Orient the socket so the notch in the end is facing away from the end of the board, as shown on the outline.
While holding the IC socket against the board, wet the tip of your soldering iron with a very small amount of solder and then touch it a pin and solder pad at one end of the socket to tack-solder it in place.
Tack-solder a second pin at the opposite end of the socket.
Check the IC socket carefully to ensure:
The socket is on the side of the board that is NOT silk-screened. The notched end of the socket is on the end farthest from the end of the board (as shown on the silk-screened outline). The socket is against the board at both ends. If necessary, heat the tack-soldered joints and adjust the socket so it is flush.
Solder all 28 pins of the IC socket and trim the leads. Be sure to solder properly the two pins you tack-soldered above.
i
If your solder joints are not clean and shiny, your iron may
not be hot enough, or you may be using the wrong type of solder. These "cold" solder joints will likely result in poor performance, reliability problems, or component failure. You may wish to consult our web site for additional soldering instructions and tool recommendations.
Locate the silk screened outline for Q5 near the yellow light bar. Install a PN2222 transistor on the BACK side of the board (the side that is not silk screened). The transistor’s leads should protrude through the board on the silk screened side.
Note: The wide, flat side of the transistor must line up with the flat side of the silk screened outline on the board (See Figure 9). The part number may be on either side of the transistor.
O
R
FLATTENED
BACK
ROUNDED
BACK
PCB OUTLINE
Figure 8. Transistor Orientation Guide.
Position the transistor on the board as shown in Figure 9 and bend the leads to hold it in place. Solder and trim the leads as short as possible.
A
PPROX.
3/16” (3 mm
)
SPACE
SOLDER & TRIM LEADS
Figure 9. Installing Transistors.
— — 26
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In the steps that follow, you'll be installing groups of components. When working from a long list, install all of the items on one line before moving on to the next. Arrows (⇒) appear in the list to remind you of this order. Components may be soldered one at a time or in groups. Leads can be trimmed either before or after soldering. After trimming, leads should be 1/16" (1.5 mm) or less in length.
Install six additional PN2222 transistors on the BACK side of the board (the side that is NOT silk screened) just as you did Q1. Align the flat side of each transistor with the outline shown on the silk screening.
__ Q6
⇒
__ Q1 __ Q7
__ Q2
⇒
__ Q3 __ Q4
Install capacitor C1, .047 µF (473) on the BACK side of the board (the side that is NOT silk screened). Position the capacitor as shown in Figure 10 .
INSERT LEADS UP TO THE PLASTIC COATING
473
BE SURE NUMBERS SHOWN IN PARENTHESIS IN TEXT APPEAR ON BODY. THERE MAY BE ADDITIONAL MARKINGS AS WELL.
SOLDER & TRIM LEADS
Figure 10. Installing Capacitors.
Install capacitor C4, .001 µF (102) on the BACK side of the board
(the side that is NOT silk screened).
Install ceramic resonator Z1 (4.0 MG) on the BACK side of the board (the side that is NOT silk screened). This part may be inserted in either direction. Like the capacitors, insert the resonator as far as the plastic coating on the leads will allow.
Install JP1, a two-pin header connector on the BACK side of the board (the side that is NOT silk screened) as shown in Figure 11 . Temporarily place a shorting block on the pins to provide a finger rest while soldering. Do not hold the solder iron on the pins more than 1
or 2 seconds. Excessive heat will melt the plastic part of the header.
SILK SCREENED SID
E
SHORT PINS GO THROUGH BOARD
Figure 11. Installing Header Connectors.
Check to ensure that:
_ All of the above parts were installed in the BACK of the
BOARD (the side with NO silk-screening).
_ All parts are soldered. _ All leads are trimmed to 1/16” (1.5 mm) or less.
— — 27
i
The remaining parts will be installed on the FRONT of the
circuit board Follow the LED installation instructions carefully to preserve the
appearance of your transverter’s front panel. When finished, the LEDs should be perpendicular to the board and in a straight line (See Figure 12).
Figure 12. Power LEDs Installed on Front Panel Board.
Sort the rectangular LEDs into groups according to color.
Note that one lead of each LED is longer than the other. This is the anode lead. It must be inserted in the right hand hole for each LED as shown on the front panel board. The right hand holes have square PCB pads to help identify them. The LEDs will not illuminate if the leads are reversed.
Insert the leads of a green LED through the holes provided for D10
on the silk screened side of the front panel board. Be sure the long lead is in the right-hand hole (with the square pad). Do not solder yet.
Hold the LED with the back of the plastic housing flat against the board (not tilted). Bend the leads outward on the bottom side to hold it in place.
Solder one lead of the LED, keeping soldering time to 1 to 2 sec.
If the LED is tilted or is not flat against the board, re-heat the lead while pressing the LED down.
Once the LED is correctly positioned, solder the other lead, again keeping soldering time to 1 or 2 seconds. Then trim both leads.
Install a green LED at D9. Make sure the long lead is to the right as shown on the board. Before soldering, adjust the LED's position as with D10.
Install green LEDs at D8, D7, D6, D5, and D4. Make sure the long lead is to the right for these and all remaining LEDs.
Install a yellow LED at D3.
Install red LEDs at D2 and D1.
— — 28
Sort all of the resistors by value. If the color bands are difficult to read, use a DMM (digital multimeter) to verify their values. Tape them to a piece of paper with the values labeled.
Install the resistors below on the front (silk screened) side of the board. Align each resistor to rest against the board inside the silk screened outline (See Figure 13). Start with R1 near the light bar end of the board.
__R1, 220 ohm (red-red-brn)
⇒
__R16, 120 ohm (brn-red-brn)
__R22, 120 ohm (brn-red-brn)
__R21, 120 ohm (brn-red-brn)
__R24, 2.2k (red-red-red)
__R2, 470 ohm (yel-vio-brn)
__R25, 270k (red-vio-yel)
__R23, 120 ohm (brn-red-brn)
__R14, 120 ohm (brn-red-brn)
__R15, 120 ohm (brn-red-brn)
__R13, 120 ohm (brn-red-brn)
__R5, 1 meg (brn-blk-grn)
__R3, 10k (brn-blk-org)
__R18, 2.2k (red-red-red)
__R20, 2.2k (red-red-red)
__R4, 100k (brn-blk-yel)
__R17, 100k (brn-blk-yel)
__R19, 2.2k (red-red-red)
__R12, 120 ohm (brn-red-brn)
__R11, 120 ohm (brn-red-brn)
__R10, 120 ohm (brn-red-brn)
__R9, 120 ohm (brn-red-brn)
__R8, 120 ohm (brn-red-brn)
__R7, 120 ohm (brn-red-brn)
__R6, 120 ohm (brn-red-brn)
BODY OF PART AGAINST THE BOAR
D
ENSURE MARKINGS AGREE WITH INSTRUCTIONS IN TEXT
SOLDER & TRIM LEADS
Figure 13. Installing Resistors.
Install the two capacitors listed below on the front (silk screened)
side of the board, near the outline of the 28-pin IC socket. Check each
capacitor's labeling carefully (shown in parentheses).
__C2, .01µF (103) __C3, .01 µF (103)
Inspect the board carefully for the following:
All connections soldered. No solder bridges between pads (use a magnifier as needed). All leads clipped to no more than 1/16” (2 mm) long.
Uninstalled Components
Verify that all component locations on the front panel board are
filled, except the following:
U4 (controller 16F872) should not be installed in its socket yet. J1 at the bottom center of the board. This will be installed in the next
section.
You’ve finished the Front Panel Board Assembly Procedure. Go to the RF Board Assembly – Part I on the next page to continue.
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