Vectronics VEC-1220K User Manual

IMPORTANT WARRANTY INFORMATION! PLEASE READ

Return Policy on Kits When Not Purchased Directly From Vectronics: Before continuing any further with your VEC kit check with your Dealer about their return policy. If your Dealer allows returns, your kit must be returned before you begin construction.

Return Policy on Kits When Purchased Directly From Vectronics: Your VEC kit may be returned to the factory in its pre-assembled condition only. The reason for this stipulation is, once you begin i nsta lli ng a nd sol deri ng pa rt s, you essenti al ly tak e over the rol e of the devic e's manufacturer . From this point on, neither Vect ronics nor its dea lers can reas onably be held accountab le for the qua lity or the outcome of your work. Because of this, Vectronics cannot accept return of any kit-in-progress or completed work as a warranty item for any reason whatsoever. If you are a new or inexperienced kit b uilder, we urge you to read the manual carefully a nd determine whether or not you're r eady to tak e on the job. If you wish to c hange your mind and return your ki t, you may--b ut you must do i t before you begin c ons tr uc ti on, a nd within ten (10) working days of the time it arrives.

Vectronics Warrants: Your kit contains each item specified in the parts list. Missing Parts: If you determine, during your pre-construction inventory, that any part is

missing, please contact Vectronics and we'll send the missing item to you free of charge. However, before you contact Vect ronic s, please look carefully to c onf ir m you haven't misr ea d the marking on one of the other items provided with the kit. Also, make certain an alternative part hasn't been substituted for the item you're missing. If a specific part is no longer available, or if Engineering has determined that an alternative component is more suitable, Vectronics reserves the right to make substitutions at any time. In most cases, these changes will be clearly noted in an addendum to the manual.

Defective Parts: Today's electronic parts are physically and electrically resilient, and defective components a re r a re. However, if you disc over a n it em duri ng your pr e- c onst r uct i on inventory that's obviously broken or unserviceable, we'll replace it. Just return the part to Vectronics at the address below accompanied with an explanation. Upon receipt, we'll test it. If it's defec tive and appear s unused, we'll ship you a new one right away at no charge.

Missing or Defective Parts After You Begin Assembly: Parts and materials lost or damaged after construction begins are not covered under the terms of this warranty. However, most parts supplied with VEC kits are relatively inexpensive and Vectronics can replace them for a reasonable charge. Simply contact the factory with a complete description. We'll process your order quickly and get you back on trac k.

Factory Repair After You Begin Assembly: Kits-in progress and completed kits are specifically excluded from coverage by the Vectronics warranty. However, as a service to

customers, tec hnicia ns ar e availa ble t o evaluate a nd repai r malf unctioni ng kits for a minimum service fee of $18.00 (½ hour rate) plus $7.00 shipping and handling (prices subject to change). To qualify for repair service, your kit must be fully completed, unmodified, and the printed circuit board assembled using rosin-core solder. In the event your repair will require more than an hour to fi x (or $36.00, subject to change), our technicians will contact you in advance by telephone b efore p erforming t he work. Def ective unit s should b e shipp ed prep aid to:

Vectronics 1007 HWY 25 South Starkville, MS 39759

When shipping, pack your kit well and include the minimum payment plus shipping and handling charges ($25.00 total). No work can be performed without pre-payment. Also, provide a valid UPS return address a nd a day time phone number where you may be reac hed.

VEC-1220K/1230K/1240K/1280K Owner's Manual

INTRODUCTION

This kit provides a great introduction to QRP operation, one of the hottest and fastest growing activities in amateur radio. With these little rigs, you'll discover what thousands of QR P enthusiasts alread y know--the magic of communicating world-wide using less energy than it takes to illuminate a pen-light bulb!

Your VEC QRP-CW Transmitter Kit is simple to build, yet it gives you many sophisticated features to make QRP operating both easy and fun. For example, a built-in diode antenna switch handles T/R transfer in milliseconds for full QSK operation in between CW characters. In fact, if your receiver has a good AGC, you can simply plug into the T/R jack and copy both sides of the conversation simultaneously, without receiver muting. In addition to full QSK, you get shaped keying--just like on the most expensive commercial transceivers.

For drift-free frequency stability, the transmitter is crystal-controlled. However, that doesn't mean you're "stuck" in one spot. The wide-range VXO circuit uses a high-Q variab le-c ap a ci to r fo r maximum frequenc y shift. Also , a se co nd o pt io nal crystal frequency may be added and selected with the push of a switch. Best of all, there's no need to order crystals to get started--each kit already includes one cut for the internationally recognized QRP calling-frequency on that band.

Finally, when your kit is assembled and it's time to fire up, you won't need to fiddle with tricky tuning--or to substitute output transistors for best results. You'll get a solid 1-watt plus signal that's filtered through a high-Q toroid lowpass filter to ensure compliance with FCC rules. In short, your kit provides everything you need to get on the air fast!

TOOLS AND SUPPLIES

Construction Area:

area where you can easily organize and handle small parts without losing them. An inexpensive sheet of white poster board makes an excellent construction surface, while providing protection for the underlying table or desk. Welldiffused overhead lighting is a plus, and a supplemental high-intensity desk lamp will prove especially helpful for close-up work. Safety is an important consideration. Be sure to use a suitable high-temperature stand for your soldering iron, and keep the work area free of combustible clutter.

Universal Kit-building Tools:

additional items to complete, virtually all construction projects require a work area outfitted with the following tools and supplies:

Soldering Iron

Kit construction requires a clean, smooth, and well-lighted

Although your particular kit may require

VEC-1220K/1230K/1240K/1280K Owner's Manual

High-temperature Iron Holder with Cleaning Sponge

Rosin-core Solder (thin wire-size preferred)

Needle Nose Pliers or Surgical Hemostats

Diagonal Cutters or "Nippy Cutters"

Solder Sucker, Vacuum Pump, or Desoldering Braid

Bright Desk Lamp

Magnifying Glass

Special Tools for This Kit:

RF power meter or VSWR bridge

50-ohm dummy load or 1-watt 47 ohm carbon-film resistor

Telegraph key with a 3.5 mm "mini" phone plug.

LED (any color)

BEFORE YOU START BUILDING

Experience shows there are four common mistakes builders make. Avoid these, and your kit will probably work on the first try! Here's what they are:

1. Installing the Wrong Part:

and a 10K resistor may look almost the same, but they may act very differently in an electronic circuit! Same for capacitors--a device marked 102 (or .001 uF) may have very different operating characteristics from one marked 103 (or .01uF).

2. Installing Parts Backwards:

capacitors to make sure the positive (+) lead goes in the (+) hole on the circuit board. Transistors have a flat side or emitter tab to help you identify the correct mounting position. ICs have a notch or dot at one end indicating the correct direction of insertion. Diodes have a banded end indicating correct polarity. Always double-check--especially before applying power to the circuit!

3. Faulty Solder Connections:

bridges. Cold solder joints happen when you don't fully heat the connection-or when metallic corrosion and oxide contaminate a component lead or pad. Solder bridges form when a trail of excess solder shorts pads or tracks together (see Soldering Tips below).

It always pays to double-check each step. A 1K

Always check the polarity of electrolytic

Inspect for cold-solder joints and solder

VEC-1220K/1230K/1240K/1280K Owner's Manual

4. Omitting or Misreading a Part:

Always double-check to make sure you completed each step in an assembly sequence.

Soldering Tips:

Cleanliness and good heat distribution are the two secrets of professional soldering. Before you install and solder each part, inspect leads or pins for oxidation. If the metal surface is dull, sand with fine emery paper until shiny. Also, clean the oxidation and excess solder from the soldering iron tip to ensure maximum heat transfer. Allow the tip of your iron to contact both the lead and pad for about one second (count "one-thousand-one") before feeding solder to the connection. Surfaces must become hot enough for solder to flow smoothly. Feed solder to the opposite side of the lead from your iron tip--solder will wick around the lead toward the tip, wetting all exposed surfaces. Apply solder sparingly, and do not touch solder directly to the hot iron tip to promote rapid melting.

Desoldering Tips:

If you make a mistake and need to remove a part, follow these instructions carefully! First, grasp the component with a pair of hemostats or needle-nose pliers. Heat the pad beneath the lead you intend to extract, and pull gently. The lead should come out. Repeat for the other lead. Solder may fill in behind the lead as you extract it--especially if you are working on a double-sided board with plate-through ho les. Should this happen, try heating the p ad again and inserting a common pin into the hole. Solder won't stick to the pin's chromium plating. When the pad cools, remove the pin and insert the correct component. For ICs or multi-pin parts, use desoldering braid to remove excess solder before attempting to extract the part. Alternatively, a low-cost vacuum-bulb or springloaded solder sucker may be used. Parts damaged or severely overheated during extraction should be replaced rather than reinstalled.

This is easier to do than you might think!

Work Habits:

Kit construction requires the ability to follow detailed instructions and, in many cases, to perform new and unfamiliar tasks. To avoid making needless mistakes, work for short periods when you're fresh and alert. Recreational construction projects are more informative and more fun when you take your time. Enjoy!

Sorting and Reading Resistors:

The electrical value of resistors is indicated by a color code (shown below). You don't have to memorize this code to work with resistors, but you do need to understand how it works:

VEC-1220K/1230K/1240K/1280K Owner's Manual

Resistor Color Code

Black = 0 (tens) 1st Digit 2nd Digit Multiplier

Tolerence

(gold or silver)

When you look at a resistor, check its multiplier code first. Any resistor with a black multiplier band falls between 10 and 99 ohms in value. Brown designates a value between 100 and 999 ohms. Red indicates a value from 1000 to 9999 ohms, which is also expressed as 1.0K to 9.9K. An orange multiplier band designates 10K to 99K, etc. To sort and inventory resistors, first separate them into groups by multiplier band (make a pile of 10s, 100s, Ks, 10Ks, etc.). Next, sort each group by specific value (1K, 2.2K, 4.7K, etc.). This procedure makes the inventory easier, and also makes locating specific parts more convenient later on during construction. Some builders find it especially helpful to arrange resistors in ascending order along a strip of double-sided tape.

Some VEC kits may contain molded chokes which appear, at first glance, similar to resistors in both shape and band marking. However, a closer look will enable you to differentiate between the two--chokes are generally larger in diameter and fatter at the ends than resistors. When doing your inventory, separate out any chokes and consult the parts list for specific color-code information.

Reading Capacitors:

Brown = 1 (hundreds)

Red = 2 (K)

Orange = 3 (10K)

Yellow = 4 (100K)

Green = 5 (1Meg)

Blue = 6 Violet = 7 Gray = 8 White = 9 Silver = 10% Gold = 5%

Unlike resistors, capacitors no longer use a color code for value identification. Instead, the value, or a 3-number code, is printed on the body.

Value Code

10 pF = 100 100 pF = 101 1000 pF = 102

.001 uF = 102*

.01 uF = 103 .1 uF = 104

As with resistors, it's helpful to sort capacitors by type, and then to arrange them in ascending order of value. Small-value capacitors are characterized in pF (or pico-Farads), while larger values are labeled in uF (or micro-Farads). The transition from pF to uF occurs at 1000 pF (or .001 uF)*. Today, most

Multilayer

(270 pF)

271

Ceramic Discs

(.001 uF) (.1 uF)

102

104

Electrolytic

1 uF

1uF

35V

VEC-1220K/1230K/1240K/1280K Owner's Manual

monolithic and disc-ceramic capacitors are marked with a three-number code. The first two digits indicate a numerical value, while the last digit indicates a multiplier (same as resistors).

Electrolytic capacitors are always marked in uF. Electrolytics are polarized devices and must be oriented correctly during installation. If you become confused by markings on the case, remember the uncut negative lead is slightly shorter than the positive lead.

Diodes:

Diodes are also polarized devices that must be installed correctly. Always look for the banded or cathode end when installing, and follow instructions carefully.

Transistors:

If transistors are installed incorrectly, damage may result when power is applied. Transistors in metal cases have a small tab near the emitter lead to identify correct positioning. Semiconductors housed in small plastic cases (TO-92) have an easily-identified flat side to identify mounting orientation. Many specialized diodes and low-current voltage regulators also use this type packaging. Larger plastic transistors and voltage regulators use a case backed with a prominent metal tab to dissipate heat (T-220). Here orientation is indicated by the positioning of the cooling tab.

Cathode

(shorter Lead)

Diode

Metal Can Device Plastic Device Tab-cooled Device

Emitter

LED

Metal Tab

Flat Side

Integrated Circuits:

Proper IC positioning is indicated by a dot or square marking located on one end of the device. A corresponding mark will be silk-screened on the PC board and printed on the kit's parts-placement diagram. To identify specific IC pin numbers for testing purposes, see the diagram below. Pin numbers always start at the keyed end of the case and progress counter-clockwise around the device, as shown:

VEC-1220K/1230K/1240K/1280K Owner's Manual

8 7 6 5

Installation

Key

1 2 3 4

Pin Numbers

Installation

Key

PARTS LIST

The parts list for your kit is presented in two parts. First, you'll identify and inventory the generic parts--those items common to all VEC QPR transmitter kits regardless of band. Then, you'll inventory the parts specifically for your particular VEC QPR transmitter, which contains frequency-critical parts that determine the specific band of operation.

If any parts are missing or damaged, refer to the manual's warranty section for replacement instructions. If you can't positively identify an unfamiliar item on the basis of the information given, set it aside until all other items are checked off. You may then be able to identify it by process of elimination. Finally, your kit will go together more smoothly if parts are organized by type and arranged by value ahead of time. Use this inventory as an opportunity to sort and arrange parts so you can identify and find them quickly.

First, locate and identify the generic parts bags. These items are common to all four models of the VEC QRP-CW Transmitter Kit:

Generic Parts Resistors:

! ! ! ! ! !

Capacitors:

(fourth gold color band indicates 5% tolerance)

Qty Part Description Designation

2 100 ohm (brown-black-brown) R4,R7 1 270 ohm (red-violet-brown) R8 3 470 ohm (yellow-violet-brown) R5,R9,R11 1 1K (brown-black-red) R10 3 10K (brown-black-orange) R1,R2,R3 1 47K (yellow-violet-orange) R6

Qty Part Description Designation

VEC-1220K/1230K/1240K/1280K Owner's Manual

10 .1 uF disc ceramic (103 or 103Z) C1,C3,C9,C10,C11

C12,C15,C17,C18,C21

1 470 uF electrolytic C4

1 .1 uF disc ceramic (104 or 104Z) C2

1 multi-section variable capacitor C5

Chokes, Coils:

Qty Part Description Designation

2 100 uH (brown, black, brown, silver) RFC4, RFC5

1 T37-2 toroid form (round, red) L1

Semiconductors:

Qty Part Description Designation

1 2N3906 transistor Q1

1 2N3904 transistor Q2

1 PN2222 transistor Q3

1 2N3053 transistor Q4

2 1N4007 diode D1,D2

1 1N4148 diode D3

Jacks, Switches:

Qty Part Description Designation

1 3.5mm key jack J1

1 2.1mm coaxial power jack J2

2 RCA type phone jack J3,J4

2 DPDT push-button switch SW1,SW2

Miscellaneous Ite ms:

Qty Part Description

1 clip-on transistor heat sink

1 printed circuit board

1 instruction manual

1 length, double-sided tape

1 1/2" tuni ng shaft extension

(molded chokes are larger than resistors)

Now, to complete the inventory, select the correct list below for the specific model of your kit--and check off those items:

VEC-1220K (20-Meter QRP-CW Transmitter Kit) Capacitors:

Qty Part Description Designation

VEC-1220K/1230K/1240K/1280K Owner's Manual

1 22 pF multilayer (22 or 220) C6

1 47 pF multilayer (47 or 470) C8

1 68 pF multilayer (68 or 680) C16

3 220 pF multilayer (221) C7,C19,C20

1 330 pF multilayer (331) C14

1 470 pF multilayer (471) C13

Inductors/Chokes:

Qty Part Description Designation

3 1.8 uH (brown, gray, gold, silver) RFC1,RFC2,RFC3

1 12" length of #22 enameled wire for L1

Crystal:

VEC-1230K (30-Meter QRP-CW Transmitter Kit) Capacitors:

! ! ! ! ! ! !

Inductors/Chokes:

! !

Qty Part Description Designation

1 14.060 MHz crystal Y1

Qty Part Description Designation

1 33 pF multilayer C6 1 47 pF multilayer C8 1 100 pF multilayer C16 1 220 pF multilayer C7 2 330 pF multilayer C19,C20 1 470 pF multilayer C13 1 680 pF multilayer C14

Qty Part Description Designation

3 2.2 uH (red, red, gold, silver) RFC1,RFC2,RFC3 1 12" length of #22 enameled wire L1

Crystal:

VEC-1240K (40-Meter QRP-CW Transmitter Kit) Capacitors:

! !

Qty Part Description Designation

1 10.108 MHz crystal Y1

Qty Part Description Designation

1 47 pF multilayer C6 2 100 pF multilayer C8,C16

VEC-1220K/1230K/1240K/1280K Owner's Manual

1 220 pF multilayer C7

3 470 pF multilayer C13,C19,C20

1 1000 pF multilayer C14

Inductors/Chokes:

Qty Part Description Designation

3 4.7 uH (yellow, violet, gold, silver) RFC1,RFC2,RFC3

1 12" length of #24 enameled wire L1

Crystal:

VEC-1280 (80-Meter QRP-CW Transmitter Kit) Capacitors:

! ! ! ! !

Inductors/Chokes:

Qty Part Description Designation

1 7.040 MHz crystal Y1

Qty Part Description Designation

1 68 pF multilayer C6 1 100 pF multilayer C8,C16 2 470 pF multilayer C13,C16 2 820 pF multilayer C19,C20 2 1000 pF multilayer C7,C14

Qty Part Description Designation

3 10 uH (brown, black, black, silver) RFC1,RFC2,RFC3

1 12" length of #24 enameled wire for L1

Crystal:

Once again, if any parts are missing, consult the warranty page on the inside cover for specific replacement instructions. If your parts inventory is complete, you're ready to star t buil ding. Re member, o nce c onstr uctio n begins, you may no longer return your kit.

Many builders find it helpful to make a Xerox copy of the parts placement diagram and the schematic diagram. These may then be posted in your work

Qty Part Description Designation

1 3.579 MHz crystal Y1

+ 24 hidden pages