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QRP PROJECT Blue Cool Radio Manual Download Page 33

Rev:Nobember 20.  2006

33

1

2

3

4

5

6

7

8

9

10 11 12 13 14 15 16

LCD-Display  2x16

+5V

+5V

19 18 16

35

12

25 26 27 29

24

36

37

Drehgeber

39

38

Keyer

zu T10 (Sendertastung)

20

2

8

Speed

+5V

Eingabetaster

41

+5V

Kontrast

T16

34

13

14

15

4MHz

zu P4

Mithörton

Mithörton-

Filter

7

zu Rel.2

zu Rel.3

Rel.2-3 gem.

Ausgangsfilter

21

22

23

von T6 (AGC-Spannung)

Uvor

Urück

von SWR-Messkopf

4

5

6

3

+12V (Batterieüberwachung)

CPU

PIC16F877PLCC

Steuerteil "blue cool radio"

DL4JAL

Stand: 1.12.2005

FSYNC

SCLK

SDATA

11

10

9

zu DDS-Unit

R52

R53

R55

R56

R57

R58

R59

R60

R61

R62

P7

P8

C76

C77

C78

C79

C80

C81

C82

C83

C84

C85

C86

T17

DG1

D15

Q5

DSP1

L10- 33mH

Bu1

IC4

1nF

1n

1n

100R

100R

1nF

10nF

10k

3k3

6k8

10nF

10nF

22k

1k

4k7

2k7

BS170

1N4148

1k

100nF

100nF

BS170

2M2

5k

Keramik Resonator

1,5uF

1,5uF

R63

R63 bei grünem Display NICHT bestücken.

+12V

R54

220R

Summary of Contents for Blue Cool Radio

Page 1: ...1 The blue cool Radio BCR QRPproject Motzener Straße 36 38 12277 Berlin http www QRPproject de Telefon 49 30 85 96 13 23 e mail support QRPproject de Manual written by FIservice Peter Zenker DL2FI email dl2fi qrpproject de ...

Page 2: ...ich may destroy it The choosen regulator IC 7808 needs 9 5 V to work properly a NiMH pack with ten AA cells never should be used below 9 5 V The seperate 5V Regulator generates the supply for the central PIC Processor which controlls the BCR Start at the upper left corner at coordinates A 2 Find IC 6 an 78L05 Integrated Circuit in a TO92 housing It s flat side must be positioned as shown in the dr...

Page 3: ...e before you solder it However it shoud lay flat on the PCB to enable the heat to flow away IC5 7808 TO220 F 5 S2 Toggle Switch 2xUmupright Typ MS500 G 5 Si1 Fuse Holder G H 5 Bu4 DCBU 2 1 PR DC Jack 2 1mm H 4 5 Si1 Put a fuse into the holder Now recheck all your work to find eventually solder failures Use an Ohmmeter to check the resistance between the switch and ground it must be in the range of...

Page 4: ...MD 0805 Bottom Bu1 3 5mmStereo Jack A 1 2 The following trimmer potentiometer must be placed at the bottom side of the PCB P7 5K PIHER PT6 A B 1 Now solder the socket for the PIC and the socket for the display Carefully think what you are doing before you solder them especially the big PIC socket is the hell to desolder if it is wrong Look at the PIC socket PLCC socket One of its 4 corners shows a...

Page 5: ...rews and spacers to a safe place Now the C Mos Transistors Remember they are extremly ESD sensitive Use ESD tools or decharge yourself by touching a metal ground plate Drawing first picture section 2 T16 BS170 C D 2 T17 BS170 C D 1 There ar e only a few parts left L10 33mH radial Choke C 2 3 P8 10K Potentiometer SMC 10 V B C 3 DG1 Shaft encoder ALPS A B 3 To complete the controller section you now...

Page 6: ...and unsoldered Pins If this is ok apply 12 Volt and start testing of section 2 After power on adjust Contrast Pot P7 on solder side of the PCB to make the signs in the display readable If so swith power off an on again The display should show it s initial sequence for a short time Blue cool Radio and the Firmware revision e g 1 14 After the initial frequency it should show VFO A and B both at 7030...

Page 7: ...n 12 memory store Write top Memoryr Choose the Memory like in Menue 12 Store the actual VFO and Band information by pressing the Shaft encoder Any content in the memory will be overwritten 13 tune Switches the transmitter to TUNE During TUNE power and SWR are displayed 14 split 1k DDS switches VFO A to receive only and VFO B to transmit only TX VFO starts exactly 1 kHz above the RX frequency The S...

Page 8: ...o Antenna Antenna jack open or Dummyload installed S0 Hex value is shown Press shaft encoder menue will jump to point 2 2 Apply 50uV ato the Antenna jack measured Hexvalue is shown Press Shaftencoder and leave th eMenbu by SAVE The Pic will calculate the S Meter curve now and store it into memory 4 pitch Frequency of the sidetone can be choosen by the CW speed poty Last stored value shown in the d...

Page 9: ...C 3 Install fullowing diode also upright There is a convention to place the cathode banded side to th eupper end The body is placed inside the printed circle in the placement plan D11 1N4148 B C 2 3 R27 100K upright B 3 C37 1uF rad B 2 3 X C38 4 7nF SMD 0805 bottom of PCB X C39 4 7nF SMD 0805 bottom of PCB R23 270R upright A B 3 4 Bu2 3 5mm Stereo Jack A 2 3 P3 10K Potentiometer SMC 10 V B C 4 P4 ...

Page 10: ...D10 has to do 2 jobs 1 it is used as AM Detector if BCR is used in AM with BFO switched off and 2 it generates the AGC Voltage directle from the IF without an extra amplifier The AGC curve can be adjusted by P5 D10 generates a negative voltage which is proportional to to the IF Voltage The neagtiv voltage reduces the base current of T6 in conjunction with the fieldstrength of the received signal s...

Page 11: ...rld Radio Amateurs are telling sad stories how difficult it is to make such coils i will describe the how to make coils a little bit broader to show you that there is nothing secret nor complicated In american kits torroids are preferred In Germany for long times only cylindrical and shielded cylindrical coils have been used Both types have advantages and disadvantages and that s the reason that i...

Page 12: ...onsists of 2 turns Start at PIN 3 again with 3 turns around the pin very next to the body go up throuh the gap and wind clockwise 2 times around the body You will end at Pin 4 Go down through the notch 3 times around PIN 4 and cut the wire you dont need for this coil 1 2 cm behind the pin This coil is ready except it has to be soldered now The easiest way to do is to hold it with the PINs upside i...

Page 13: ...bottom of PCB T7 BF981 Attention ESD rules A 4 The Quartz must be soldered a little above the PCB to prevent it against getting shortened by solder at its bottom Easiest way to to is to use a cut of from a resistor temporary between the PCB and the quartz Dont forget the to remove the cutof after soldering the quartz Q4 4 915MHz HC49U A 4 5 Next to the Quarz you will see a little rectangular solde...

Page 14: ... your BCR and remove the link wire Go ahead with section 5 Group 5 DDS Signal preparation Mixer IF buffer and Ladder Filter C48 1000pF 102 E 3 C47 10nF 103 E 3 R33 1M upright E 2 3 R36 100R upright E 3 R34 47k upright E 3 R35 1K upright E 3 C49 100nF 104 E 3 Attention place the notch of the socket to the right side as shown in the picture DIL 14 socket D E 3 Dont install the IC now this will be do...

Page 15: ...the mixer is on board only stage missing to be ready to receive signals is the Frontend with Preselector and Low Pass filter However you can test the complete IF part now The link we used in the section before this time is not needed because the Mixer does a direct connection between IF and DDS Generator As you know the BCR RX and TX frequency are generated in a different way in TX mode the DDS VF...

Page 16: ...de of greater capacity until it has exact the same frequency as the sidetone If it is adjusted correctly both tones will be heard as 1 tone with a little jamming on it Leave the menue by choosing save at the right side of the display Grroup 6 LPF RX Frontend Preselector In this section you will complete the receiver After finishing you will be able to use it as an RF Receiver Attention If you plan...

Page 17: ...the ring wind the next turns counterclockwise The picture shows such a torroid with 8 turns OK lets start Wind L6 on a yellow Torroid Count inside the ring wind 13 turns 0 4mm laquered wire All turns should be tautly tight on the ring if all 13 turns are made spread them over 2 3 of the ring The enamel wire supplied with the kit can be heat stripped A good method to do this is to place a small amo...

Page 18: ... 50 Ohm coax abt 4 7 cm long Remove about 1cm of the insulation at both ends Solder one side to a BNC jack and the other end to the points shown in the drawing As usual check your work to find shorts or missing solder points I understand that you are hot to hear the first signals now but DO THE CHECK FIRST Use a Magnifier and bright light Done the check OK Connect your headphones and the power sup...

Page 19: ...inner conductor of the BNC jack as a very short antenna and couple the signal to this antenna It must not be loud it must just be audible Adjust L1 and L2 using a nonconductive tool to maximum of AGC Voltage Redo adjustment several times using the smallest possible signal During adjustment do NOT change the Preselector Pot All ok Its on your own what you will do next listening into the bands or bu...

Page 20: ...T37 43 ferrite for the Choke Again take care to meet the geometrical requirements remember to count the turns inside the ring Dr7 Amidon FT37 43 10turns 0 5mm laquered wire F 3 Prepare Dr7 by using the blob method as you did it in the LPF section C54 47nF 473 G 4 C56 47nF 473 G 4 Now a new thing a transformer wound on a double hole core a so called PigNose Because this is new and bacause I know th...

Page 21: ...y Now the secondary The secondary is made by 1 turn 0 5mm wire Start just at the opposite end of the pignose Upper right to upper left and back lower left to lower right Thats it Tin the 4 ends the same way you did it with the Torroids Place the ready made pignose to the PCB The primary thin wire goes to solder point 1 and 2 the secondary thick wire goes to solder point 3 and 4 Tr1 BN43 2402 Doubl...

Page 22: ...til the transistor is lying really flat on the board Now screw it to the bord If this has been done solder the legs from the bottom side T15 2SC1969 Silicone insulator F G 3 4 Last thing to install the output transformer Again it is a pignose only a little bigger than the other one This time it is an step up transformer Both windings are made from 0 5mm enameled wire Because it is not possible to ...

Page 23: ...ubles Find out this points for all bands and mark the points on the enclosure later on as maximum usable power per Band You may build your BCR into the enclosure now There are 8 long spacers in the kit Be aware that this actually are 2 diffent types The 4 longer ones must be screwed to the upper side of the PCB part side the 4 shorter belong to the buttom side of the PCB Install the BNC jack into ...

Page 24: ...Rev November 20 2006 24 ...

Page 25: ... 14 15 6 19 20 1 2 3 SDATA SCLK FSYN C9 C10 C8 C7 R4 R5 R6 R3 R2 R1 C1 C2 C3 C4 C5 C6 C11 C12 C14 C13 C15 C16 L1 L2 MCLK DDS Unit blue cool radio DL4JAL DK1HE Stand 1 12 2005 100n 100n 10uF 10uF 100nF 100nF 100nF 10nF 10nF 100nF 39p 5p6 5p6 68p 49p 10nF 150R 10R 10R 6k8 220R 220R 1 8uH 1 0uH ...

Page 26: ...21 22 23 von T6 AGC Spannung Uvor Urück von SWR Messkopf 4 5 6 3 12V Batterieüberwachung CPU PIC16F877PLCC Steuerteil blue cool radio DL4JAL Stand 1 12 2005 FSYNC SCLK SDATA 11 10 9 zu DDS Unit R52 R53 R55 R56 R57 R58 R59 R60 R61 R62 P7 P8 C76 C77 C78 C79 C80 C81 C82 C83 C84 C85 C86 T17 DG1 D15 Q5 DSP1 L10 33mH Bu1 IC4 1nF 1n 1n 100R 100R 1nF 10nF 10k 3k3 6k8 10nF 10nF 22k 1k 4k7 2k7 BS170 1N4148 ...

Page 27: ...Rev Nobember 20 2006 27 DDS Unit ...

Page 28: ...Rev November 20 2006 28 BCR Mainboard Part side complete ...

Page 29: ...Rev Nobember 20 2006 29 BCR mainboard Solderside SMT Parts ...

Page 30: ...Rev November 20 2006 30 ...

Page 31: ...ember 20 2006 31 Akku 12V intern Bu4 12V extern Ladebuchse Si1 C87 D16 S2 IC5 IC6 C88 C89 C90 C91 12V 8V 5V Stromversorgung blue cool radio DK1HE Stand 6 01 2005 Ein Aus 100nF 1N5402 1uF 1uF 7808 78LO5 1uF 1uF ...

Page 32: ...Rev November 20 2006 32 ...

Page 33: ...21 22 23 von T6 AGC Spannung Uvor Urück von SWR Messkopf 4 5 6 3 12V Batterieüberwachung CPU PIC16F877PLCC Steuerteil blue cool radio DL4JAL Stand 1 12 2005 FSYNC SCLK SDATA 11 10 9 zu DDS Unit R52 R53 R55 R56 R57 R58 R59 R60 R61 R62 P7 P8 C76 C77 C78 C79 C80 C81 C82 C83 C84 C85 C86 T17 DG1 D15 Q5 DSP1 L10 33mH Bu1 IC4 1nF 1n 1n 100R 100R 1nF 10nF 10k 3k3 6k8 10nF 10nF 22k 1k 4k7 2k7 BS170 1N4148 ...

Page 34: ...Rev November 20 2006 34 ...

Page 35: ...rton Lautst Hörer 8V 8V S Mithörton T8 D11 IC3 P3 P4 R23 von CPU 8V CW AM R26 R27 R28 R29 C36 C37 C38 C39 C40 C41 C42 C43 C44 Bu2 S1 3 2 4 7 5 1 6 100uF 47nF 10uF 4n7 10nF 10k LM386N 1 100uF 4n7 BS170 100k 1uF 120R 1N4148 10k 220nF 270R 4R7 10k Baugruppe NF Teil ...

Page 36: ...Rev November 20 2006 36 ...

Page 37: ...8V CW AM C19 C20 C21 C22 C23 C24 C25 C26 C27 C28 C29 C30 C31 C32 C33 C34 C35 L4 L5 1 2 3 4 1 2 3 4 Dr3 100uH Dr4 33uH Dr5 100uH S1 0 47uF 50k 10pF 47n 10uF 47n 100uF 1N4148 100k 150R 1k 10k 47n 82p 2 5 60pF BF981 4 915 5k6 270R 47nF 47nF 150p 18Wdg 6Wdg 6 8nF 470k 270R BC550 BF199 BF199 47nF 47nF 8k2 12k 47nF entfällt 150p 3k3 12k 33pF 47nF 47nF 2Wdg 18Wdg 3k9 270R 1k 150pF 47nF 47nF 2k2 BF244A Ba...

Page 38: ...Rev November 20 2006 38 ...

Page 39: ...uH 14 7 2 3 9 10 1 4 8 11 12 6 13 5 74HC4066 47nF 56k 56k 47nF 10k BB112 BB112 150p BF244B 47nF 150pF 1k 82R 6k8 18Wdg 4Wdg 1 INV5 1 INV6 1 INV7 1 INV8 DDS Board Taktaufbereitung IC1 IC1 74HC04 5V T11 5V FSYNC SCLK SDATA von CPU R33 R34 R35 R36 C47 C48 C49 1 2 3 4 5 6 9 8 7 14 13 11 IC1 74HC04 IC1 74HC04 IC1 74HC04 1M 1000pF 1k 47k BF199 10nF 100nF Taktaufbereitung Mischer ZF Buffer und Quarzfilte...

Page 40: ...Rev November 20 2006 40 ...

Page 41: ...4148 68k 68k 47n 1k 47n 47n 47n 74HC4066 IC1 74HC04 IC1 74HC04 150p BF244B 47nF 150pF 1k 82R 18Wdg 4Wdg BB112 BB112 BF244B 10k 2Wdg 11Wdg 11Wdg TX Ausgangsfilter Uvor Urück SWR Messkopf Ant zum RX Preselektor D12 D13 Tr3 Rel 2 Rel 3 R46 R47 R48 R49 R50 R51 C61 C62 C64 C65 C66 C67 C68 C69 C70 C71 C72 C73 C74 C75 L6 13Wdg 0 4 L7 17Wdg 0 4 L8 10Wdg 0 5 L9 11Wdg 0 5 3 4 1 2 von CPU von CPU von CPU Bu3...

Page 42: ...Rev November 20 2006 42 ...

Page 43: ... 2 3 4 Dr7 10Wdg FT37 43 Dr8 47uH Dr9 47uH 250R 10nF 56k 330R 10k 27R 3k9 180R 15R 47nF 47nF 47nF 47nF 47nF 1N4148 4 Wdg 1 Wdg 47R 1uF 100nF 47nF 680R 47nF BF199 2N3866 BF199 10nF TX Taststufe 8V von Rel 1 T9 T10 von CPU Schwellwert Schalter TX Weichtastung R30 R31 R32 C45 BC546B 3k3 10k 100k BS250 DDS Board 5V FSYNC SCLK SDATA von CPU Senderbaugruppe R64 C93 10R 1 5nF C94 820p SMD ...

Page 44: ...Rev November 20 2006 44 ...

Page 45: ...Rev Nobember 20 2006 45 RX Preselektor T15 2SC1969 zum RX Preselektor C61 von CPU 2 Wdg 47nF Tr2 1 2 3 4 4 Wdg Sende Endstufe Zum Tiefpassfilter ...

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