HF PackerAmp V4 Construction Manual Download Page 5 | Manualshive

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Section One - Introduction

Welcome all builders to the homebrew Hfpacker-Amp

V4 R6 Project. This project parts and your efforts will
eventually provide you with a compact 5 watt input to 30-35
watt output linear amplifier for use with QRP SSB/CW
transmitters on the amateur bands 160 through 10 meters and
which can be powered from a 12 volt DC supply. In this
section, you are introduced to the building of the HF Packer
Amp. The design is a good balance between output power,
physical size and battery power consumption. The completed
amplifier will reward the builder with a clean, more powerful
output signal for a QRP rig when radio conditions become
marginal.

This project is not a beginner's project and requires a

medium skill level to complete it successfully. You can take
advantage of some fabricated options available to you.

•

Fabricated Coil Set

•

Fabricated Cable Set

•

Fabricate and install Amp circuit board

Inductors

Builders require soldering, hand tool, basic electronics

and component identification skills. This project manual is not
included with the kit in order to keep kit costs to a minimum. All
builders will receive the construction manual in a pdf format.
You can also download from the hfprojects site:

http://groups.yahoo.com/group/hfprojects/

Membership is free.

The manual is produced in landscape format to allow more
readable text per screen. This manual provides all you will

need to successfully complete the amplifier project, however,
some additional PDF files are provided at the above website
for those interested in seeing more pictures of the project at
various stages of construction.

The genesis of the basic amp circuit is fully described

in the 2001 ARRL Handbook and in reprint articles from the
ARRL. If you are an ARRL member, you can view the amplifier
articles on-line. Full amplifier circuit design credit is given to
Mike Kossor, WA2EBY. The amplifier module is mounted to
the inside bottom of the chassis box and its MOSFETs are
attached to a heat sink. The power supply unit is an integral
part of the amplifier module while the filter board is mounted
above the amplifier module.

Circuit Details

The amplifier module is a push-pull design, biased for

Class AB linear operation and uses low-cost power MOSFETs
in its output stage. Maximum efficiency is at 10 MHz and
develops over 50 watts output. QRP transmitter RF input is
first sensed, which trips a relay, feeding RF through an RF
attenuator pad. The signal is then applied to the primary of T3
via an input impedance-matching network consisting of L2. T3
is a 1:1 balun that splits the RF signal into two outputs 180
degrees out of phase. One of these signals is applied by C3 to
Q1's gate. The other signal is routed via C7 to Q2's gate. The
drains of Q1 and Q2 are connected to the primary of output

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Summary of Contents for PackerAmp V4

Page 1: ... unchanged but there are significant additions warranting the Rev 6 designation for the project Changes are 1 The Low Pass Filter Module LPF is revised to include an interface cable for the LED module HFPA FILTER 12 R1 2 A new LED Module LEDM 100 R0 including an interconnecting cable between the LED and the LPF 3 The chassis revised to include the holes for the LED module 4 The front panel silk sc...

Page 2: ...rd 16 Section 3 Low Pass Filter Module Assembly 17 Organize for Assembly 17 Install Relays and Diodes 17 Capacitor Assembly 17 Core Winding Table 18 Core Winding Technique 18 Core Installation 19 Switch Assembly 19 Connector Assembly 19 In Circuit Tuning Adjustments 20 20 Selector Switch Stop Pins Installation 20 20 Amplifier Cable Connections Error Bookmark not defined Section 4 Case and Chassis ...

Page 3: ...Test 37 RF Signal Testing 38 DC Current Test and Bias Adjustment 38 Voltage Test 38 LPF RF Testing 39 LT1270ACT Alert Notice 39 RF Power Testing 40 PTT Connections FLEX 1500 and FT817 41 Section SIX Specifications and Operation 42 Specifications 42 Operation 42 Do s and Don ts for Successful Operation 43 Maintenance Issues 43 CW SSB Auto Selection 43 Section 7 Theory of Operation and Troubleshooti...

Page 4: ...OSFET AMP HFPA 10 Schematic 48 Pi resistive Network 48 L2 and T3 48 T2 49 T1 49 BIAS 49 BIAS Adjustment 49 Heat Sinking the MOSFETs 49 HFPA FILTER MODULE 12 50 J1 Filter Input 50 J2 Filter Output 50 MANUAL CHANGES 50 ...

Page 5: ...produced in landscape format to allow more readable text per screen This manual provides all you will need to successfully complete the amplifier project however some additional PDF files are provided at the above website for those interested in seeing more pictures of the project at various stages of construction The genesis of the basic amp circuit is fully described in the 2001 ARRL Handbook an...

Page 6: ...3W to the gates of the MOSFETs The attenuation matches the popular FT817 power setting of 5W The maximum of 0 63W is below the distortion level of the MOSFETs This is important for distortion free SSB operation The bias current is 100mA per MOSFET while transmitting The switch mode power supply circuits boost the nominal 12 VDC input to 29 VDC at 3 4 amperes during voice peaks The power supply is ...

Page 7: ...This will familiarize you with the circuitry building requirements and components After reading this document and prior to assembly you should do an inventory of parts Appendix A C In the unlikely event that you appear to have missing parts duplicates or wrong parts please first double check for the parts in all bags recheck the inventory and if this fails please contact the project organizers Thi...

Page 8: ...ring iron electronics grade solder iron stand and sponge De soldering braid and or desoldering pump or bulb fine needle nose pliers small fine wire cutters wire stripper small screwdrivers including jewelers screwdrivers small file multi meter LCR meter used to measure inductance and capacitance Crimp tools for Molex pins and Power Pole Terminals Included Speciality Tools 1 16 and 7 64 Hex Head to...

Page 9: ...ut has poor thermal characteristics of 3 5 C Watt When used in intermittent SSB and CW service forced air cooling is not required Tuning time with full power should be limited to less than 30 seconds with 1 2 minutes between cycles to prevent overheating Operating at 29VDC does not press the MOSFET to their limits The Sil Pad TO220 mounting kit has excellent thermal performance and provides a grea...

Page 10: ... body to fit the component outline on the board Make sure cathode bar on the part matches the cathode symbol on the silk screen outline Install Install six 1K 1 8W resistors BRN BLK RED R14 R20 R15 R10 R21 and R12 Install Insert two 4 7K 1 8W resistors YEL VIO RED R17 R19 Install Insert two 27 ohm w resistors RED VIO BLK R1 R2 Install Insert three 10K 1 8w resistor BRN BLK ORN R5 R6 and R4 Install...

Page 11: ...otentiometers VR1 and VR2 on the board The lead under the adjustment screw is inserted in the square pad in the circuit outline Do not bend the leads Solder one pin reheat and align part perpendicular and flat on the board Solder all pins Install Turn the 25 turn potentiometers CCW at least 20 turns You will not hear a click and there is no mechanical stop Install the 14 pin DIP socket for U2 Alig...

Page 12: ...t board Install Insert a LT1270A Switching Regulator U4 is mounted horizontal into the 5 holes on the circuit board outline for U4 First bend the legs straight Bend to match pattern while keeping the mounting hole centered You will later screw this component down to a stud projecting from the heat sink below LT1270ACT Lead Insertion Detail Install 4N33 6 pin IC at U3 Make sure the round depression...

Page 13: ...es insert the two parallel wires Bend the wires into a U shape Holding the two wires together in one hand with the cores at the bottom of the U Shape grasp the wires in the rear and insert the wires on front right side through the core four additional times Pull each wrap snug keeping the wires parallel without crossovers After completion of the loops on the right side pass the remaining wires thr...

Page 14: ...t the bottom of the U Shape grasp the wire in the rear and insert the wires on the front right side through the core four additional times Pull each wrap snug Avoid crossover of the leads After completion of the loops on the right side pass the remaining wires through the core on the front left side 5 times Pull each wrap snug You will now have 10 turns passing through the core Separate and scrape...

Page 15: ...tion L2 require 4 inches of the 24AWG remaining wire Use a 3 16 inch drill bit as a winding form and wrap 4 complete turns of the wire tightly around the drill bit Trim the excess lead length to inch and tin the leads Insert L2 into the L2 position on the circuit board Install Use the end of a ball point pen to push into the end of the air coils slightly to reform the wires should they become defo...

Page 16: ...s tight Push the white wires through a final time through the adjacent tubes You now have the yellow wire leads on one end and the white wire leads on the other You are done winding the core Trim about 3 8 inch length off each lead Strip each wire about 3 8 inch and lightly tin the tip You are now ready to install the transformer into the board The yellow primary input and white secondary output I...

Page 17: ...HE LPF BOARD Install Relays and Diodes Install the six diodes on the circuit board observing that the stripe on the diode matches the board silkscreen for the part Be careful that your tools do not damage the circuit board The diodes require that the leads are bent very close to the body of the diode Before installing scrape the leads near the body to remove any oxidation on the leads Install Inst...

Page 18: ...e between a start time 7pm and a end time 5pm example Evenly adjust the wire spacing to match the clock setting Core Winding Technique The starting position Divide the wire in half letting the core hang down The wire passing through the core counts as one turn L3 Example Wind one side Start with the wire in the back and wrap 10 turns on the right side Use a pair of needle nose pliers to aid in pul...

Page 19: ...Switch Assembly Insert the switch on the top side of the assembly Make sure the leads are flush with the board Install Connector Assembly Insert J1 and J2 Make sure the parts are flush and vertical Solder one pin to start reheat while making final alignment Solder the remaining pins Make sure the friction tab is in the position shown below The J1 tab is to the right and the J2 tab is down in the d...

Page 20: ...and outputs grounded Consolidated Filter Response Where Y axis dB X axis F MHz The Plot was acquired using a miniVNA sweeping 1 100 MHz Data was captured to an Excel spread sheet and graphed Selector Switch Stop Pins Installation The switch includes a little package that has two stop pins and a sticker Your goal is to install the pins in the correct holes without losing the stop pins Turn the shaf...

Page 21: ... and the Low Pass Filter Module Note that the LED long lead is at the top The LEDs mount on the side of the board without silk screen information It is best to use the front panel as a temporary jig to hold the LEDs in position while soldering one pin on each LED By using the front panel as a jig the board will fit properly when installed ...

Page 22: ... two circuit boards to be connected and plug together Rotate Low Pass Filter Module into position and attach to the front panel Minimize the flat cable by pinching the folds together as shown right Fit a length of double side tape to the circuit board as shown and trim excess Expose the tape and insert the LED module in the case ...

Page 23: ... coax sleeve Adjust to mid position Shrink inch length of black shrink over cores Strip inch of the coax sleeve on each end Comb out the shield and tightly twist into a pig tail Trim to 3 8 inch Prepare two 1 3 8 inch lengths of black TEF 24AWG wire by stripping 1 8 inch from each end Tin one end The shields on both ends are connected to 1 4 inch TEF 24 black hookup wire Heat sink the shield when ...

Page 24: ...a fixed position while tightening Position the Cores near the BNC connector The cable is routed along one edge under the circuit board under the wire clamps to relieve cable congestion in the box RF Input Cable Clamp the cable at the threads of the BNC with the 4 inch plastic Ty wrap See RF IN RF OUT and PTT Wires picture RF Output Cable ...

Page 25: ... attach to a red 4 ring terminal Follow up by soldering the connection Attach connector to rear panel using two 4 40 x inch screws one split lock washer and two 4 40 nuts Attach a 12 inch length of 24AWG Teflon coated hookup wire white to the PTT connector on the rear panel This wire is routed along with the output cable and terminated into the 3 pin connector J4 The cable is routed along one edge...

Page 26: ...nk tubing View the picture on the next page for the finished cable appearance Low Pass Filter Output Cable Fabrication The top cable is the finished Low Pass Filter Input Cable Fabricate the Output cable in a similar manner Cut the length of the RG174 cable to 5 0 inches Prepare the ends with the crimp pins Cut a 5 inch length 24 AWG Red and Black Teflon coated wire and attach crimp terminals to b...

Page 27: ...Baskett Make sure your connectors match the LPF and AMP circuit board connectors On Bypass Switch and LED Wiring Attach two 5 inch lengths of hook up wire to the small rocker switch Shrink with inch red shrink tubing The switch can be damaged with too much heat ...

Page 28: ...ation Locate the bottom notched keeper used to retain the Power Pole Housing in the panel Locate the Red and Black Power Pole pieces The Power Pole housing can be joined in various ways There is one standard that is used on the HF PACKER AMP Looking at the front of the red black housing mate the two pieces side to side with the red on the left and the contacts in the lower position The top keeper ...

Page 29: ...e wire is firmly seated in the PP housing Plug the Blue Flag Terminal on the Power Switch outside terminal Crimp both ends of another 4 inch length 14AWG RED Teflon coated wire to a Blue Flag Terminal Plug the Blue Flag Terminal on the remaining Power Switch terminal The other end of this 4 inch RED wire will plug on the circuit board at H1 during circuit board and case assembly Crimp one end of a...

Page 30: ...e washers and the MOSFET back side for maximum thermal connection Practically any available thermal compound will work My personal choice is Artic Silver Only a tiny dab is required The washers are considerably thicker 0 08 inch which puts the MOSFETs closer to the bottom of the circuit board An extra washer will be required on the male female spacer that screws into the heat sink so that the U4 c...

Page 31: ... wires Arrange the other cables to not interfere with board mounting Attach the circuit board from the top of the case using four black 4 40 x 3 16 inch screws MOSFET Alignment over Heat Sink Holes Micro adjust as necessary by moving the body of a MOSFET so that the hole in the MOSFET matches the threaded mounting hole in the heat sink Do not over tighten the nylon screws You could shear off the h...

Page 32: ...With no cables attached you should read a very high resistance LT1270A U4 Attachment to the heat sink A 4 40 male female threaded spacer 5 16 inch length should be installed on the heat sink by this time The LT1270A U4 part is attached to the spacer by passing a 4 40 x inch screw through the tab of the part and screwing into the spacer No insulator is required or desired ...

Page 33: ...to inch Tin the braid and attach a black hookup wire to the braid Cover with heat shrink tubing The wires are positioned as shown Attach a 2 pin connector on one end of each cable Note in the picture that the openings for the terminal tabs are up in the picture Attach the coax center wire to the pin indicated in the picture Fabricate a five inch 2 wire cable from the red black wires supplied Attac...

Page 34: ...100 PI Module when installed Remove L2 from the circuit board if installed It will not be used We will attach the PI networks to these holes Attach the two 3 inch cables at L2 and grounds as shown in pictures above and to the right Note that the coax center goes into the hole on the left in the L2 position The shield wire connects to the hole directly above it This cable will connect to J1 on the ...

Page 35: ...male Jack Screw just added The PI 100 Module will extend towards the rear over the PSU and rest on top of the rubber bumper Cable Connections on the Model PI 100 Module Plug in the two RF Cables to J1 and J2 Attach the Power Cable to J4 The two RF cables at J1 and J2 route with very short connections from the Amp Set the Jumper at the 3 pin header J3 on the PI 100 Module Install the provided jumpe...

Page 36: ... 36 100 PI Theory of Operation A 2dB resistive pi network is installed on the AMP module Add additional attenuation using the PINET 100 PI module Choices are 2dB 6dB and 9dB corresponding to 1W 2 5W and 5W Max RF Input scales ...

Page 37: ...ad in series to the SO239 RF Output connector Test Mode Setup Connect XCVR to the BNC RF Input Connector Set LPF for 160M Set the XCVR for 160M Set the XCVR Power Setting for Low Power about 1W Key XCVR The 1W of power should be displayed on Watt meter and SWR should 1 0 1 Record _____ W Basic Current Test I recommend a special cable that allows you to easily measure current Power Poles are on eac...

Page 38: ...expires Measure from case ground to the right side of R18 Key the XCVR The voltage switches from 0 0VDC to about 29 5VDC H4 no longer has function CW SSB selection is now automatic See description in section six Tap the key on XCVR Note the time that the LED is ON and that the fan runs Tap the key on XCVR Note a longer LED ON time and fan runs Rig a toggle switch and RCA plug to test the PTT funct...

Page 39: ...s a signal source 1 The RF In cable normally at J3 on the amp board is rerouted to plug instead into the LPF input connector J1 You will have to physically free this cable up to re route to the LPF input 2 Attach transceiver to BNC connector on the case Set the transceiver RF out to about 1W 3 Attach a watt meter and dummy load to the SO239 connector 4 Jumper the PTT input to cause the LED to ligh...

Page 40: ...in 1 at R14 converter off when at ground Be very careful RF Power Testing Attach 12VDC power source capable of supplying 10A continuous current The 12VDC source should be fused at 20A Monitor Current Connect XCVR set for 160M and 5W setting Set Band Switch for 160M In BYPASS mode adjust the power out to 5W ______ In ONLINE mode and key down for a few seconds observe the power output and DC current...

Page 41: ...ex 1500 to key the Packer Amp Do not connect the ground connection as the Amp and Radio are already referenced to the same ground Using an additional ground connection has been reported to cause distortion FT817 Connect the center wire from the PTT jack to pin 1 of the ACC jack on the FT817 PTT Do not connect the ground as the Amp and Radio are already referenced to the same ground Using an additi...

Page 42: ...nse and sequencing of T R relay and Intelligent Power Switch and fan control Amplifier IRF510 MOSFET Push Pull Class AB1 Linear Amplifier Bias set to 100mA per transistor Easy pot adjustment A test Jumper activates the PSU for adjustment Fan option not required for intermittent SSB operation For high duty cycle CW or digital modes either reduce drive or include a user supplied fan Internal fan jac...

Page 43: ...solder Clean up flux The most important issue is to save the board circuit connections by carefully removing the old pins Follow the installation procedure outlined in Section Four Re install MOSFETs using the non metallic 6 32 x 5 16 cap head screws CW SSB Auto Selection The amp has auto switching between CW and SSB hang time delay CW hang time is 0 15 seconds while the SSB hang time is 0 50 seco...

Page 44: ...t power source and only be down 1 or 2 S units from a 100W rig Many can testify how effective this is Power Input The 12V is input through the 30A contacts of the Power Pole connectors There is a right way and a wrong way of putting the little plastic pieces together to insure your connectors are polarized correctly The industry has a certain way of joining the pieces together to be compatible wit...

Page 45: ...divider which sends a small sample of the output voltage back to the U4 chip pin 2 FB or feedback pin The sampled voltage on pin 2 is internally compared to an internal voltage reference of 1 244V The U4 chip will adjusting the switching duty cycle of the output on pin 4 to make the voltage on pin 2 equal to 1 244V the internal reference So now the output voltage is set by the ratio of R13 and R18...

Page 46: ...urrent into the short circuit until the U4 blows up How can you know if you have a short circuit The front panel LED will not light You might hear a squeal from the amp and U5 will get hot Don t worry it is doing its job What is the most likely thing to cause a short circuit The MOSFETs We will get more into MOSFET failure in the AMP descriptions to follow At this point you should sufficiently kno...

Page 47: ...gger TX There is an additional way to achieve TX It is by the Push To Talk input sensed on pin 3 of J4 This would be an external contact closure to ground 12V common or case ground The contact closure is normally supplied by the transceiver or SDR software defined radio A current flows through an opto isolation circuit in the 4N33 device U3 The output of U3 on pin 5 becomes an input to the control...

Page 48: ...e extreme left side This is the transmit output from the transceiver at this point The signal reaches this point if TX is activated The impedance of the transceiver is 50 ohms and the transceiver is happiest when it sees a 50 ohm impedance load Pi resistive Network That is where R3 R7 and R8 comes into play This combination of resistors is actually a pi resistive network that has two functions Fir...

Page 49: ...f bias was chosen to eliminate low level cross over distortion that would exist otherwise It is not necessary to increase or decrease the bias from the nominal 100mA specification Once you have removed the distortion it is pointless to increase the bias further To do so only increases self heating of the MOSFET You cannot adjust the power level of the AMP by adjusting the bias If you want to chang...

Page 50: ...ay input selection provides a high degree of isolation and improved filter overall performance All of the HF bands are selected with 6 choices from the front panel switch It is very important that the filter choice equal the band of operation For instance operating on 15M with the filter set to 80M is a recipe for MOSFET failure There is no interlocking or cross checking provided except by the ale...

Page 51: ... each 2 Stacked T50 43 10T 22 15 each PINET INSTALL NOTES Attach cables for PINET 100 PI Module at L2 and Grounds remove L2 Replace R3 R7 R8 with 2dB values Set bias current each MOSFET to 100mA HFPAV4R5 0 MOSFET AMP HFPAV4R5 B 1 3 Friday April 19 2013 Title Size Document Number Rev Date Sheet of Q2D Q1D SW_VOLTS RF_IN VCC VCC T3 1 3 2 4 T2 1 3 2 4 L3 C3 1uF Q2 IRF510 2 1 3 T1 1 3 2 4 VR1 10K 1 3 ...

Page 52: ...ment Number Rev Date Sheet of RF_IN TX SW_VOLTS TX IPS PSU 12V 12V 12V 12V VCC 12V VCC 12V 12V VCC VCC VCC VCC Q6 2N5089 R21 1K R22 1 2K R11 1M U3 4N33 1 6 2 5 4 R10 1K Q3 2N5089 R12 1K K2 3 2 4 6 7 5 1 8 K3 3 2 4 6 7 5 1 8 C13 001 C12 01 D2 1N4007 C11 01 U1 78L05 1 3 2 VIN GND VOUT C10 01 J2 1 2 3 4 J6 1 2 C23 1 R4 10K R5 10K J3 1 2 D3 1N4148 J5 1 2 3 4 R6 10K R18 3K U2 PIC16F688 5 2 3 4 14 6 7 8...

Page 53: ...5089 D1 1N4148 R23 10K U7 AUIR3320S J7 2 pin conn R9 2 7K HFPAV4R5 0 PSU HFPAV4R5 B 3 3 Wednesday May 15 2013 Title Size Document Number Rev Date Sheet of VSW2 IPS SW_VOLTS PSU VCC 12V H1 1 2 SW1 SW SPST 1 2 D5 RL251 CB1 C21 330uF L4 50 uH R14 1K Q4 2N5089 U5 IPS511S 1 2 3 4 5 GROUND IN VCC DG OUT C17 1uF D4 MBR1060G 3 1 U4 LT1270A 1 2 3 4 5 VC FB GND VSW VIN R20 1K C15 100uF Q5 2N5089 R19 4 7K R1...

Page 54: ...A3020 F_HIGH F_LOW F_LOW B6040 F4 F5 A1210 B1715 A1715 B1210 B160 B80 B6040 B1210 B3020 B1715 F0 F1 F2 F3 F4 F5 F_HIGH F_LOW F_HIGH F_LOW F_HIGH F_LOW F_LOW F_HIGH F_HIGH F3 F4 F5 F2 F1 F0 12V 12V 12V 12V 12V 12V 12V 12V JR1 TE 1 338068 8 8 PIN 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 C23 100pF L10 470nH C22 220pF K6 3 2 4 6 7 5 1 8 C25 39pF D5 1N4007 C21 150pF L11 430nH C26 82pF C19 12pF C20 39pF D6 1N400...

Page 55: ...ECTS 3 12 14 12 10M 17 15M 30 20M 60 40M 80 75M 160M This is the LED Module Model LEDM100 R0 The dimensions are 1 525 x 0 475 inch with LED spacing 0 268 inch JR1 is a little flat cable connector where a flat cable snaps in ...

Page 56: ... Model LEDM100 R0 0 LED Display Module HFPA V4R5 A 1 1 Tuesday March 11 2014 Title Size Document Number Rev Date Sheet of D1 AND123G D2 AND123G D3 AND123G D4 AND123G D5 AND123G D6 AND123G JR1 TE 1 338068 8 8 PIN 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 R1 1K ...

Page 57: ...C3 C4 C6 C7 C8 C9 C22 C23 CAP CER 1UF 50V 10 X7R 1206 581 SR201C104KAR 3 1 C5 CAP dip mica 47PF DM15 4 3 C10 C11 C12 Cap 01uF SR151C103K AVX 100V 10 581 SR151C103K AVX 100V 10 Mouser 581 SR151C103K Allied stk 507 0210 1C10X7R103K050B Vishay 581 SR151C103K 5 1 C13 Cap 1000pF 100volts 10 X7R C315C102K1R5CA 80 C315C102K1R5CA 6 1 C15 Cap 100 uF 50V LOW ESR 140 ESRL50V100 140 RXJ101M1HBK1016P 7 2 C21 C...

Page 58: ...G 11 1 D5 Diode 2 5A 100 PRV DO41 RL251 B Rectron Mouser 583 RL251 B 583 RL251 12 2 H1 H2 KeyStone Electronics 25 PCB TAB 032TPBR Keystone 534 1287 534 1287 ST 13 1 J4 Connector 3P Molex 70543 0002 Vertical header 538 70543 0002 14 2 J2 J5 Connector 4P Molex 70543 0003 Vertical header 538 70543 0003 15 3 J1 J3 J6 Connector 2P 70543 0001 Vertical header 538 70543 0001 16 2 H3 H4 Header 100 K K Conn...

Page 59: ... DALE VISHAY 70 IH 5 50 20 2 Q1 Q2 MOSFET TO 220AB N Ch Power Fairchild IRF510 512 IRF510 21 4 Q3 Q4 Q5 Q6 2N5089 Small Signal Transistors NPN Gen Pur SS Central Semiconductor 2N5089 610 2N5089 Mouser 610 2N5089 22 2 R1 R2 Resistor 27 ohm 1 2W 293 27 293 27 23 1 R3 Resistor 62 ohm 2W 282 62 RC 24 2 R7 R8 Resistor 100 ohm 2W 282 100 RC 25 6 R10 R12 R14 R15 R20 R21 Resistor 1K 5 1 8W Carbon Film XIC...

Page 60: ... 7K RC 30 1 R18 Resistor 3K 1 4W 291 3 0K RC 31 3 T2 T3 Core Grey 0 5 OD FT50 43 32 1 T1 Balun Core Binocular BN 43 3312 33 1 U5 Intelligent Power Switch IR IPS511S 34 1 U1 5V Regulator Fairchild 512 LM78L05ACZ Mouser 512 LM78L05ACZX 512 LM78L05ACZ 35 1 U2 IC Microchip PIC16F688 E P Microchip Microcontrollers MCU 7KB 256 RAM 12 I O 579 PIC16F688 E P 36 1 U3 Optocouplers DIP 6 PHOTO DARL 4N33 Allie...

Page 61: ...re Housings Molex 4P 538 50 57 9404 43 1 mating parts Headers Wire Housings SHUNT OPEN TOP 2P 538 15 38 1024 44 20 mating parts spares Socket 24 22 Molex Header and Wire Housing 538 16 02 0103 45 1 Inductors 12T Wire 24AWG 5FT 0 022 OD 566 8052 46 1 Inductors 7T Wire 22 AWG 3FT 0 026 OD 566 8051 46 1 inductors Wire 20 TEF 7 inch 602 5856 100 05 47 1 inductors Wire 20 TEF 10 inch 602 5856 100 05 48...

Page 62: ...DIX A www hfprojects com vstamps comcast net 281 467 9424 50 2 Spacer Hex 187x 75 ALUM 4 40 tap 534 2029 51 6 Screw 4 40 x 3 16 inch 52 4 Spacer Hex 187x 25 ALUM 4 40 tap 534 1891 53 1 D3 Diode Signal 1N4148 ...

Page 63: ...2 23 2021 4 1 J3 Vertical PC Header 100 K K 3 CKT Molex 538 22 03 2031 538 22 03 2031 5 2 K1 K2 RELAY DPDT Relay 12VDC Non latching Single coil P2 Tyco Electronics Axicom V23079A1003B301 Mouser 6 2 R1 R2 Resistor 220 ohm 1W 281 220 RC 4dB 7 1 R3 Resistor 24 ohm 1W 281 24 RC 4dB 8 1 R6 Resistor 43 ohm 3W 283 43 RC 7dB 9 2 R4 R5 Resistor 130 ohm 3W 283 130 RC 7dB 10 1 Amp 2dB PI Resistor 12 ohm 1W 2...

Page 64: ... 14 6 J1 J2 J4 Terminals crimp 538 08 50 0114 15 1 J4 Wire Black 5 inch 16 1 J4 Wire Red 5 inch 17 4 J1 J2 Wire Black 1 4 inch for pig tails 18 4 J1 J2 Black Shrink Tubing 1 2 inch length 19 1 Bumper peal stick 517 SJ 5303CL 20 2 Screw 4 40 x 3 16 inch 21 1 Circuit Board PINET 100 PI R1 22 1 J3 Jumper 2 pin 538 15 38 1024 ...

Page 65: ...APPENDIX A www hfprojects com vstamps comcast net 281 467 9424 ...

Page 66: ...0V 110J 9 3 C13 C21 C27 Cap 150pF 500V 150 10 3 C16 C17 C22 Cap 220pF 500V 220 11 1 C11 Cap 330pF 500V 330 12 1 C9 Cap 390pF 500V 390 13 1 C10 Cap 680pF 500V 680 14 2 C6 C4 Cap 1000pF 500V 1000 15 2 C3 C1 Cap 1500pF 500V 152xxx 16 1 C5 Cap 1800pF 500V 182xxx 17 1 C2 Cap 2700pF 500V 272xxx 18 6 D1 D2 D3 D4 D5 D6 Diode 1N4007 19 1 J1 Connector CON2 538 70543 0001 20 1 J2 Connector CON4 538 70543 000...

Page 67: ...e 22 AWG 38 inch Belden 8051 28 1 PCB Circuit Board 29 1 mating parts Headers Wire Housings HSG 2P WITH LKG RAMP 538 50 57 9402 30 1 mating parts Headers Wire Housings HSG 4P WITH LKG RAMP 538 50 57 9404 31 6 mating parts Headers Wire Housings CRIMP TERM 22 30 TIN 538 16 02 0103 32 1 Connector JR1 TE Conectivity 7 215079 8 A99471CT ND Note xx don t care www hfprojects com vstamps comcast net 281 4...

Page 68: ...20 Screw Set S001Z80N 2 1 Heat Sink Alpha NovaTech FS6020PF FS6030PF 3 1 Fan 60x25mm 12V 4500RPM 24CFM 35DB Ball Bearing Orion OD6025HB OD6025 12HB 4 1 Finger Guard 60mm Plastic Orion Fans G60 P 5 4 4 40 Hex Nuts 6 4 Screw 4 40 x 5 16 7 4 Split lock Washer 4 8 1 Grommet Rubber 187 534 730 Finished Case Item Quantity Reference Description Part Number 3 1 Case fabricated painted and screened ...

Page 69: ...option ordered Heat Sink AAVID black rectangular finned 2 1 TyWrap 4 inch 644 PLT1M M69 3 1 Mating Connector Power Pole 30A Red Black PP30 50 4 1 Switch Power Rocker 611 DA102J12S215HQF 676 0031 5 1 Knob BLK AL KNRLD IND LN PKG50B1 8 6 4 Foot F2 ENCLOSURE BLACK FEET 537 F2 7 3 Q1 Q2 Nylon Socket Cap Head Screw 6 32 x 5 16 Black 1 spare McMaster Carr 95868A295 ...

Page 70: ... TO220 DK 4171G ND 10 4 Screw 4 40 x 3 16 MSPPK0403 11 6 Screw 4 40 x 1 4 Pan Phil Black Oxide PANPMS0404 10D4 12 8 Screw 4 40 x 5 16 13 4 4 40 Hex Nuts 14 8 Split lock Washer 4 15 0 16 1 Powerpole Mounting Clamp Pair for 2 or 4 PP15 30 45 Powerpoles 1462G1 17 1 1 16 Hex Key Long 116HK L pointe products com 18 1 7 64 Hex Key Long 764HK L pointe products com ...

Page 71: ...f ordered uses cable components in fabrication Item Quantity Reference Description Part Number 1 1 RF In Cable 2 1 RF Out Cable 3 1 DC Power Cable 4 1 Front Panel Cable 5 1 LPF RF In Cable 6 1 LPF RF Out Cable Cable Components List supplied if fabricated cable set not ordered Item Quantity Reference Description Part Number 1 8 inch RF Cable finishing Shrink Tubing 1 4 inch x inch lengths as FIT221...

Page 72: ...C 530 CP 1094 AST 4 1 RF Out Cable Connector SO239 25 7350 5 1 Front Panel Switch Cable Switch TX On Bypass PRK22J5BBBNN Switch Rocker ULTRA Miniature ON OFF NO LEGEND Cherry 908 0065 6 2 Front panel switch cable Hookup wire Gray 24 5 inch length 7 1 DC Cable Power Pole Set 30A Red Black PP30 50 8 1 DC Power In Wire Red 14AWG Teflon red 4 inch Wire TF 14 9 1 DC Power In Wire Red 14AWG Teflon red 4...

Page 73: ...ack 24 Teflon 17 inch Cut to 1 4 inch lengths for pig tails 13 1 LPF Control cable Hookup wire Black 24 Teflon 5 inch 14 1 LPF Control Cable Hookup wire Red 24 Teflon 5 inch 15 1 PTT Wire RF Output Cable Hookup wire White 24 15 inch length 16 17 1 PTT component RF Out Cable Switchcraft Phono RCA Connectors REAR MOUNT JACK 502 3501FRX 18 1 RF Out Cable RG174 11 inch 19 1 RF In Cable RG174 11 inch 2...

Page 74: ...LPF RF In Cable RG174 5 0 inch 22 1 LED Front panel switch cable LED Panel Mount Indicators HI EFF RED DIFFUSED 5in WIRE LEADS 645 558 0101 007F 23 8 RF In RF Out Cable Core 23 43 4 per cable with shrink tube covers 24 1 RF Out Cable Terminals RING 22 18 AWG 4 517 2204A ...

Page 75: ...cts com vstamps comcast net 281 467 9424 Appendix D LPF Coil Set L1 L2 L3 L4 L5 L6 5 08uH 2 51uH 1 37uH 1 17uH L7 L8 L10 L9 L11 L12 580nH 470nH 430nH 360nH L13 Use the ZOOM feature to see greater detail 280nH ...

Page 76: ......

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