Galaxy mosfet-update-3600xx User Manual

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How to update the Galaxy Radios

Trrii

for using IRF520 MOSFET’s.

s..

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Draft Ver 2.0

SECTION 1

1.0 INTRODUCTION:

1.1 TOOLS NEEDED:

1.2 BEFORE YOU START NOTES:

2.0 MODELS COVERED:

3.0 WHERE TO GET THE PARTS NEEDED:

4.0 PARTS LIST:

SECTION 2

4.0 OVERVIEW OF STEPS FOR A SINGLE FINAL MODELS:

5.0 OVERVIEW OF STEPS FOR A DUAL FINAL MODEL:

SECTION 3

6.0 SINGLE FINAL CHASSIS PICTURES BEFORE CONVERSION COMPONENT SIDE VIEW:

6.1 SINGLE FINAL CHASSIS SCHEMATIC AND PCB LAYOUT BEFORE CONVERSION:

6.2 SINGLE FINAL CHASSIS SCHEMATIC AND PCB LAYOUT SCHEMATIC AFTER CONVERSION:

SECTION 4

7.0 DUAL FINAL CHASSIS PICTURES BEFORE CONVERSION COMPONENT SIDE VIEW:

7.1 DUAL FINAL CHASSIS PICTURES BEFORE CONVERSION COPPER SIDE VIEW:

7.2 DUAL FINAL CHASSIS SCHEMATIC AND PCB LAYOUT BEFORE CONVERSION:

7.3 DUAL FINAL CHASSIS SCHEMATIC AND PCB LAYOUT SCHEMATIC AFTER CONVERSION:

7.4 DUAL FINAL MOSFET PICTURES AFTER CONVERSION:

SECTION 5

8.0 ADJUSTMENT:

SECTION 6

9.0 TRANSISTOR DATASHEET:

9.1 FINAL NOTES:

NOTE: There may be more information in this package than you need depending on your experience. When you click the print icon you can select print all the pages, range of pages or any current page you have displayed.

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Galaxy DX Radios for using IRF520 MOSFET’s SECTION 1

1.0 INTRODUCTION:

Soon all Mitsubishi 2SC1969, 2SC2166 and 2SC2312 transistors will disappear or become too expensive to buy. This is how to correctly update the Galaxy Radios for using IRF520 MOSFET’s. This project is not for novices or anyone who does not have the proper equipment for aligning RF circuitry, or anyone faint at heart. Leave the installation and alignment to a proven technician.

NOTE:

Update sheet is written on the assumption that you know the basics. Exercise a great deal of care with this mod! Due to the placement, size, and close proximity of the surrounding traces. If done wrong you could destroy the PCB.

If you have even the slightest doubts or the proper equipment, it would be wise to have someone else you trust perform the mod for you.

SO TAKE YOUR TIME AND DOUBLE CHECK YOUR WORK!!!!

1.1 TOOLS NEEDED

You will need a Soldering Iron, and solder. Long nose pliers. Cutting pliers (What you are looking for are "flush cutting" pliers rather than the traditional "dikes" or "diagonal cutting pliers.) Digital Multimeter. Magnifier for examining circuit board traces and solder connections. Preferably some experience soldering and de-soldering components.

1.2 BEFORE YOU START NOTES:

If you properly replace the 2SC2166 driver and 2SC1969 final or both finals in SSB chassis with three IRF520 mosfets, you will gain slightly more power when done correctly. The radio will also have less than 10% distortion at full-modulated power. Pushing the mosfets harder will naturally give higher wattage but this comes with problems like harmonics, distortion and high temp plus they will become very unstable.

So be weary of those that post numbers of 50 watts per mosfet when in reality the safe numbers are closer to 20-25 watts each. Mosfets are not as forgiving as bipolar’s so failure rates for mosfet radios will be very high when tweakers and peakers start casting their magic spells on them.

One other thing to be weary of are the folks out there that’s going to jump on the kit bandwagon. Ask questions about their kit of components.

For Example:

1. Does the kit come with all of the components needed?

2. If doing a single to dual final update. Does the kit come with the Heatsink, and transistor mounting hardware?

3. Do they offer any support if you have problems?

Be REAL careful with the bunch on ebay.

Preparing the Radio for the Mod.

1. Fully check out the radio and be sure everything works before starting this mod!

2. Carefully remove the top and bottom radio covers. When removing the bottom cover, disconnect the speaker connector from the main board.

3. Put the Radio back to stock i.e. a. If AMC has been defeated, return AMC back to operation. b. Remove any of the so-called swing Mods.

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Galaxy DX Radios for using IRF520 MOSFET’s SECTION 1

2.0 MODELS COVERED:

Radios with the following Main Chassis (Single and Dual final)

EPT360011B, EPT360012B, EPT360014B, EPT360014C. DX33HML, DX44V, DX55V, DX66V, DX73V, DX77HML, DX88HL, DX99V, Galaxy Plus, DX11B

3.0 WHERE TO GET THE PARTS NEEDED:

All Galaxy DX Radio parts and IRF520’s, purchased directly from the following distributors

RF PARTS CO.

435 S. Pacific St. San Marcos CA 92069 TEL: (800) 737-2787 strictly orders only! (760) 744-0700 all other questions FAX: (760) 744-1943

Web Site: http://www.rfparts.com/

MAYCOM COMMUNICATIONS PRODUCTS

1134 W. JOHN BEERS ROAD STEVENSVILLE (DERBY), MICHIGAN 49127 1-269-429-8522 1-269-429-8541 Fax: 1-269-429-2137

Web Site: http://maycomcomm.com/

All Galaxy DX Radio parts and IRF520’s Wholesale Only Distributors

J T I Distributors

PO Box 300 Welcome NC 27374-0300 Toll Free: 1-800-626-3059 strictly orders only! Local: 336-731-8177 Fax: 336-731-2805

Web Site: http://www.jtronix.com/

Mouser has the IRF520’s also

MOUSER ELECTRONICS

1000 N. Main St. Mansfield TX 76063 TEL: (800) 346-6873, (817) 483-4422 (800) 992-9943 to get a catalog only FAX: (817) 483-0931

Web Site: http://www.mouser.com/

NOTE: The IRF520’s are not expensive do your research and check prices.

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Galaxy DX Radios for using IRF520 MOSFET’s SECTION 1

4.0 PARTS LIST:

Single Final Models

IRF520 MOSFET TR43, TR44, TR56

1N4148 D88, D89, D112

220K 1/4 Watt L47-R218

1K 1/4 Watt L50-R271, L35-R216

680pF /UL C175

820pF /SL C171, C209

100KB (Galaxy Part # RE10400020) VR10, VR11, VR20

470K 1/4 Watt D90

82K 1/4 Watt R219

100K 1/4 Watt R215, R270

47K 1 Watt R217, R272

390pF /UJ C167

150pF /CH Solder side of TR44 S-D

Wire for jumpers J77, J98

Heatsink (Galaxy Part # MM7878041B)

SCREW M2x0.4Px12 (Galaxy Part # JS052012MN) TR56

Insulating Ring (Galaxy Part # XZZZ90003Z) TR56

Insulating Plate 10x14x1.55mm (Galaxy Part # XZZZ90358Z) TR56

Dual Final Models

IRF520 MOSFET TR43, TR44, TR56

1N4148 D88, D89, D112

220K 1/4 Watt L47-R218

1K 1/4 Watt L50-R271, L35-R216

680pF /UL C175

820pF /SL C171, C209

100KB (Galaxy Part # RE10400020) VR10, VR11, VR20

470K 1/4 Watt D90

82K 1/4 Watt R219

100K 1/4 Watt R215, R270

47K 1 Watt R217, R272

390pF /UJ C167

150pF /CH Solder side of TR44 S-D

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Galaxy DX Radios for using IRF520 MOSFET’s SECTION 2

4.0 OVERVIEW OF STEPS FOR A SINGLE FINAL MODEL:

Single Final Models

1. Change TR44 to IRF520 MOSFET

2. Change TR43 to IRF520 MOSFET

3. Add TR56 IRF520 MOSFET (Install ceramic plate and thermal paste)

4. Remove L47 and install a 220K 1/4 Watt in L47-R218

5. Install a 1K 1/4 Watt in L50-R271

6. Remove L35 and install a 1K 1/4 Watt in L35-R216

7. Add D89 1N4148 (Install reversed, see attached schematic and PCB layout)

8. Add D112 to 1N4148 (Install reversed, see attached schematic and PCB layout)

9. Add D88 to 1N4148 (Install reversed, see attached schematic and PCB layout)

10. Change C175 to 680pF /UL

11. Add C209 820pF /SL

12. Remove C171-J98 and install a 820pF /SL in C171

13. Add VR11 100KB

14. Change VR10 to 100KB

15. Change VR20 to 100KB

16. Add D90 470K 1/4 Watt

17. Add R219 82K 1/4 Watt

18. Change L37 from 7 turn to 4 turns

19. Add R270 100K 1/4 Watt

20. Add R215 100k 1/4 Watt

21. Add R217 47K 1 Watt

22. Add R272 47K 1 Watt

23. Change C167 to 390pF /UJ

24. Remove C508 (not used on all models, located on solder side of PCB across TR56)

25. Add 150pF /CH to solder side of TR44 S-D

26. Add jumper J98

27. Add jumper J77

28. Add rear Heatsink (Galaxy Part # MM7878041B).

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Galaxy DX Radios for using IRF520 MOSFET’s SECTION 2

5.0 OVERVIEW OF STEPS FOR A DUAL FINAL MODEL:

1. Remove rear heatsink

2. Change TR44 to IRF520 MOSFET

3. Change TR43 to IRF520 MOSFET

4. Change TR56 to IRF520 MOSFET

5. Change L47-R218 to 220K 1/4 Watt

6. Change L50-R271 to 1K 1/4 Watt

7. Change L35-R216 to 1K 1/4 Watt

8. Change D89 to 1N4148 (Install reversed, see attached schematic and PCB layout)

9. Change D112 to 1N4148 (Install reversed, see attached schematic and PCB layout)

10. Change D88 to 1N4148 (Install reversed, see attached schematic and PCB layout)

11. Change C175 to 680pF /UL

12. Change C209 to 820pF /SL

13. Change C171 to 820pF /SL

14. Change VR11 to 100KB

15. Change VR10 to 100KB

16. Change VR20 to 100KB

17. Change D90 to 470K 1/4 Watt

18. Change R219 to 82K 1/4 Watt

19. Change R270 to 100K 1/4 Watt

20. Change R215 to 100k 1/4 Watt

21. Change R217 to 47K 1 Watt

22. Change R272 to 47K 1 Watt

23. Change C167 to 390pF /UJ

24. Remove C508 (not used on all models, located on solder side of PCB across TR56)

25. Remove C210

26. Remove C173

27. Remove C168

28. Remove C170

29. Remove C208

30. Add 150pF /CH to solder side of TR44 S-D

31. Re-install rear heatsink

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Galaxy DX Radios for using IRF520 MOSFET’s SECTION 3

6.0 SINGLE FINAL CHASSIS PICTURES BEFORE CONVERSION COMPONENT SIDE VIEW:

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Galaxy DX Radios for using IRF520 MOSFET’s SECTION 3

6.1 SINGLE FINAL CHASSIS SCHEMATIC AND PCB LAYOUT BEFORE CONVERSION:

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Galaxy DX Radios for using IRF520 MOSFET’s SECTION 3

6.2 SINGLE FINAL CHASSIS SCHEMATIC AND PCB LAYOUT AFTER CONVERSION:

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