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Assembly & Instruction Manual

Bayou Jumper

40 Meter CW Transceiver

For revB (Blue Panel) kits shipped after 1 Jan 2021

David Cripe

NM0S

Jim Giammanco

N5IB

Four State QRP Group

ACØBQ photo

Содержание Bayou Jumper 40 Meter CW Transceiver

Страница 1: ...ssembly Instruction Manual Bayou Jumper 40 Meter CW Transceiver For revB Blue Panel kits shipped after 1 Jan 2021 Copyright 2017 2020 David Cripe NM0S Jim Giammanco N5IB Four State QRP Group ACØBQ photo ...

Страница 2: ...eritage His presentation on the project was one of the most popular presentations at OzarkCon 2016 The Four State QRP Group is proud to be able to present the Bayou Jumper to the QRP community The transceiver is comprised of two separate circuits a crystal controlled transmitter and a regenerative receiver The transmitter uses 4SQRP s super simple super robust NS 40 transmitter circuit with tradem...

Страница 3: ...lpitts oscillator The power amplifier Q4 is tuned to operate in the Class E mode generating 5 watts from 13 6 volts at better than 85 efficiency Closing the key contact grounds the source circuits of Q4 and Q5 permitting oscillation to commence If the transmit receive switch is in the receive position closing the key permits the Master Oscillator to oscillate without the PA operating enabling spot...

Страница 4: ... This IC an NJM2113 is a low noise headphone driver amplifier Its balanced output feeds the tip and ring contacts of the Headphone jack J4 The shell contact is left floating placing the two headphone elements in series This amplifier is also capable of driving an external 8 ohm speaker A 6 volt regulator IC U2 provides steady bias voltage to the low level RF and audio circuitry of the receiver eli...

Страница 5: ...nife 11 blade best Diagonal cutters flush cutting type preferred Needle nose pliers Fine file or emery board Phillips screwdriver Allen wrench 1 5mm for the pointer knob s set screw Hand drill with 1 8 bit Non metallic alignment tool Fine jeweler s screwdrivers Electrical tape Clear fingernail polish Wood glue Clamps or spring clothespins Magnifier Digital volt ohm meter Calibrated general coverag...

Страница 6: ... screws in the parts kit for mounting the circuit board assembly If driven directly into the corner blocks there is a risk the blocks will split so it is necessary to drill pilot holes for the mounting screws Use a 1 8 bit in a hand drill or drill press if available drill down approximately 1 2 Solder Filling Selected Vias Vias are small plated through holes that electrically join the top and bott...

Страница 7: ...he main PC board flat right side up on a hard work surface and insert the mounting tabs and pins of R8 50 k marked 503 through the PCB mounting holes so that the tips of the two tabs rest flush against the work surface without extending past the bottom of the board This ensures that the shaft of the pot sits as high as possible Notice that when the two mounting tabs are flush with the bottom of th...

Страница 8: ... firmly seated against the PCB and should auto align You may wish to read the section in Appendix A concerning shortening the shaft of the rotary switch It s only for appearance sake to allow the knob to nestle down close to the panel If you decide to do this optional step it is most easily accomplished before the switch is soldered to the board optional The shaft of the rotary switch is too long ...

Страница 9: ...ning pins of the BNC jack and rotary switch The leads of resistors and axial leaded inductors should be bent in a gentle radius about 0 1 from the body of the part so that the component body is not stressed or broken If you have a bending jig use it selecting 0 4 spacing for all W resistors and diodes 0 5 for L4 and 0 6 for L2 The bodies of these components should rest flush against the board surf...

Страница 10: ...30 k Orange orange yellow W 5 axial R5 33 k Orange orange orange W 5 axial R11 470 k Yellow violet yellow W 5 axial R9 470 k Yellow violet yellow W 5 axial R14 470 k Yellow violet yellow W 5 axial R18 470 k Yellow violet yellow W 5 axial Special note for builders who intend to install a NA1MH Soup er Up er accessory board that is described in Appendix J That accessory is not currently available bu...

Страница 11: ...bove the board so that it is clear of those solder filled vias Ref Value Description D1 1N5819 Schottky Diode rectifier D2 1N5819 Schottky Diode varactor D3 1N5819 Schottky Diode varactor Q1 2N3904 TO 92 NPN BJT rf amp Q3 2N3904 TO 92 NPN BJT af amp Q5 2N7000 Static sensitive part TO 92 N Channel Enhancement Mode MOSFET oscillator Q4 IRF510 Static sensitive part TO 220 N Channel Enhancement Mode P...

Страница 12: ...F 103 Ceramic Disk red body 0 1 lead spacing C17 0 01 µF 103 Ceramic Disk red body 0 1 lead spacing C24 0 033 µF 333 Dipped Monolithic Ceramic tan body 0 1 lead spacing C5 0 1 µF 104 Dipped Monolithic Ceramic tan body 0 1 lead spacing C7 0 1 µF 104 Dipped Monolithic Ceramic tan body 0 1 lead spacing C19 0 1 µF 104 Dipped Monolithic Ceramic tan body 0 1 lead spacing C25 0 1 µF 104 Dipped Monolithic...

Страница 13: ...r capacitors and the toroid s windings to be accomplished without having to remove the front panel The silkscreen outline is duplicated on the bottom to assist you Actual performance of the receiver is not impacted whichever you choose Do not be concerned that it appears the windings of a bottom mounted toroid would be in the opposite directions It is only the relative direction of the windings th...

Страница 14: ...e counted as the number of times the wire passes through the center of the toroid It is essential that the turns are pulled snugly around the toroid so that there is no slack between the wire and core When complete cut the wire ends to about 1 2 Next wind the tickler Wind 4 turns 4 pictured of 24 AWG magnet wire for the tickler winding Cut the wire ends to about 1 2 Finally wind the input link Win...

Страница 15: ...ingle square post header pins are to be installed At J7 7 and J7 9 as shown insert the short end of a pin down through the top of the board and solder at the bottom A bit of masking tape may help to keep the pin in position At V reg Rx Vcc and TP 1 insert the long end through the board from the top and solder on the bottom as shown at right This is done because these are just test points not conne...

Страница 16: ...liers or a crimping tool gently squeeze the crimp area marked on the photo until the pins are a snug fit into the holes in the board for the crystal socket Make certain each pin is vertical before soldering and adjust as necessary to correct any misalignment Front Panel Components Assemble the built in key Locate the key leaf spring This is a rectangular piece of 1 32 plated PCB with three holes I...

Страница 17: ...f the board as shown in the photo to minimize the chance of an accidental short circuit A matching power plug is supplied Wire up that 12 V power plug with your choice of wire type and length so that 12 V can be applied to the circuit A fused or current limited supply is recommended at least for initial testing Mount the two 1 8 stereo jacks to the front panel by inserting them through the bottom ...

Страница 18: ...m them as in the upper Solder both resistors to their pads as shown at right Note that two leads of the bi color LED D4 will be soldered onto the same pads as the right hand ends of the resistors Install the bi color LED D4 also on the underside of the front panel again Pittsburg style The LED has three leads The longest lead is the common cathode negative The next longest is the RED anode positiv...

Страница 19: ...it between the front panel and the main board when they are plugged into the header pins To make room remove the little plastic spacer on each of the pins J7 7 and J7 9 Just grasp the plastic spacer with your long nose pliers and pull straight up The plastic part will slide off The photos show how Here s how the bi color LED indicator works When the transceiver is in Tx mode 12 V is supplied to pi...

Страница 20: ...rom the headphone and key jacks snug and solder them into place on the circuit board Solder the two wires from the power jack as well Inspect the power jack lugs and wire leads to be sure there are no accidental short circuits If the crystal pins are not centered under the front panel holes re heat the solder and reposition them Push two plastic insulating sleeves into the crystal socket holes in ...

Страница 21: ...of the crystal adapters is pretty straightforward Trim the leads of the HC 49 crystals and bend them so the body of the crystal sits flat on the board Solder them down to the two round pads Cut two lengths of 10 bus wire about 5 8 long and solder down to the two rectangular pads Check the spacing against the crystal socket on the PCB Using a fine file or emery board taper the ends of the 10 wires ...

Страница 22: ... an unpowered speaker to the PHONES jack The audio output amplifier IC chip will be damaged by improper connections Plug headphones or unpowered computer speakers into the PHONES jack of the Bayou Jumper The isolated stereo jack is wired to place the left and right earpieces in series Turn the Bayou Jumper power switch to the RECEIVE position Turn the ATTEN and REGEN controls to their fully clockw...

Страница 23: ...gh its range You should hear two heterodynes and the receiver will be tuned to 7 030 at the midpoint between the two This point should occur at approximately the 3 position on the tuning knob If no signals are heard the regenerative detector may not be oscillating Jump ahead to the Regeneration Setup section to adjust the regeneration range If the frequency of the Bayou Jumper regenerative oscilla...

Страница 24: ...s completely removing the toroid though with care you could re wind 20 turns while the core is still attached by the other two windings Adding more capacitance will have the additional effect of slightly reducing the width of the tuning range while adding inductance extra turn has the opposite effect The tuning range in either case should still be more than adequate to cover the portions of the ba...

Страница 25: ...n control R10 about 30 of its clockwise travel Set the main tuning to the low frequency end of the tuning range Try to adjust C21 so that oscillation just begins as evidenced by an increase in hiss in the audio then back off C21 until the detector just barely drops out of oscillation At this point the regeneration control R10 should be able to being the detector smoothly into and out of oscillatio...

Страница 26: ...ponents were installed in their correct locations In particular be sure that C20 and C4 have not been interchanged which would make to tuning range too high in the band C20 should be 120 pF and C4 should be 100 pF A check of voltages at strategic locations on the board while under power can serve to isolate problems to a particular circuit The table on the next page lists nominal voltages for the ...

Страница 27: ...sed on a 12 0 V power supply Component ID Pin Expected V Measured V Q1 E 5 4 B 6 C 6 Q2 G 0 D 1 5 to 3 5 V for revA and earlier between 0 5 and 0 6 V for revB S 6 Q3 E 0 B 0 65 C between 2 4 Q4 G xxx D 12 S xxx Q5 G 3 D 12 S xxx Q6 G 12 D 0 S 0 S MPF102 G D B 2N3904 C E G 2N7000 D S GND 78L06 IN OUT IRF510 ...

Страница 28: ...umper revB Assembly Manual page 27 of 46 U1 1 square pad 0 2 5 7 3 5 7 4 5 7 5 5 7 6 12 7 0 8 5 7 U2 1 OUT nearest C2 6 2 GND middle 0 3 IN nearest C25 12 R8 WIPER PIN 2 to 6 as R8 is varied R10 WIPER PIN 0 to 6 as R10 is varied ...

Страница 29: ...r two loud regions of heterodyne whistle noise with a dead zone in the middle caused by the oscillator RF overloading the regenerative detector You won t be able to zero beat exactly but you can come close knowing the transmitter frequency is in the middle of the two noise regions See Appendix G for an alternate method of spotting the crystal Returning the REGEN ATTEN and VOLUME controls to their ...

Страница 30: ...revised 3 Feb 2021 Bayou Jumper revB Assembly Manual page 29 of 46 ...

Страница 31: ...revised 3 Feb 2021 Bayou Jumper revB Assembly Manual page 30 of 46 ...

Страница 32: ...revised 3 Feb 2021 Bayou Jumper revB Assembly Manual page 31 of 46 ...

Страница 33: ...revised 3 Feb 2021 Bayou Jumper revB Assembly Manual page 32 of 46 Top copper pattern and silkscreen viewed from top side Bottom copper pattern and silkscreen viewed from bottom side ...

Страница 34: ...revised 3 Feb 2021 Bayou Jumper revB Assembly Manual page 33 of 46 Front panel top and bottom views ...

Страница 35: ...b 2021 Bayou Jumper revB Assembly Manual page 34 of 46 Photos by WØEB Top Populated PCB before toroid installation note builder supplied socket for U1 Bottom Populated PCB bottom view with toroid mounted on bottom ...

Страница 36: ...ractor diodes Regeneration control also employs a Schottky varactor as the throttle capacitor Use of potentiometers controlling only the DC bias on the varactors for tuning and regeneration means the controls are not hot with RF so hand effect detuning is minimized RF attenuator control which is useful when employed with full scale antennas Robust headphone audio and will drive a small speaker wit...

Страница 37: ...104 1 C10 1 µF electrolytic 0 1 LS 1 µF Note polarity 4 C3 C6 C9 C13 4 7 µF electrolytic 0 1 LS 4 7 µF Note polarity 1 C12 47 µF electrolytic 0 1 LS 47 µF Note polarity DIODES 3 D1 D2 D3 1N5819 Schottky diode 1N5819 Note polarity 1 D4 Red Green bi color LED 5 mm common cathode water clear lens Note polarity installed under front panel CONNECTORS 1 J1 BNC jack antenna 1 J2 2 1x5 5 mm coaxial power ...

Страница 38: ...lied socket 1 U2 78L06 voltage regulator TO 92 78L06 CRYSTALS 1 X1 7030 kHz quartz crystal HC 49 7030 1 X2 7122 kHz quartz crystal HC 49 7122 2 Crystal Adapter PC board Cajun Crystals OTHER HARDWARE 1 Front panel PC board Rev B blue solder mask 1 Main PC board Rev B green solder mask 2 Nylon screw insulator bushing Use with J5 J6 1 2 1x5 5mm coaxial power plug Mates with J2 1 chicken head pointer ...

Страница 39: ...der pins 1 conductor 1 DIP socket 8 pin Socket for U1 Optional parts Not supplied with kit for modifications See manual appendices R5a TBD could be potentiometer C33 TBD approx 560 pF Filter switch SPST miniature toggle For Soup er Up er Fine Tuning 1K potentiometer Bourns series PV09 25 mm shaft center detent Bourns PTV09A 4225F B102 For Soup er Up er Same physical size type as R1 C20a 10 pF NP0 ...

Страница 40: ...t is even possible to use diagonal cutters but don t try to make one clean cut through the shaft best to nibble away until the desired length is attained NA1MH s photo at right shows such a shortened shaft B Key Stiffness The spring lever of the built in key is made of thin double sided PCB stock If the touch feels too light a replacement lever can be fashioned from thicker 1 16 stock Alternativel...

Страница 41: ... be in the 7100 to 7125 kHz region it could be spread out over nearly the full travel of the main tuning control But the range could be easily restored to cover the lower part of the band A potentiometer at R5a does act rather like a fine tuning control but its effect is greatest at the low end of the range diminishing to no effect at all at the top end F PCB footprints for optional additional com...

Страница 42: ...mplify this process the BNC antenna connector has been relocated close to one of the PC board mounting standoffs Installing the standoff topped with with a 3 16 6 32 screw on top of the front panel replacing one of the 3 8 6 32 screws allows an FT 243 sized crystal to be easily connected momentarily between the center pin of the BNC jack and the grounded standoff There is an MP3 recording posted o...

Страница 43: ...ode D3 TP1 connects to the Q2 end of the tickler winding for scope or counter J7 1 J7 3 these pads connect to the terminals of the optional potentiometer J7 5 J7 7 connects to the 12 V supply during both Tx and Rx operation J7 9 connects to the 12 V supply during Rx operation only J7 11 connects to the input resistor of the audio amplifier IC U1 J7 13 connects to the internal key line J7 15 connec...

Страница 44: ...is required Provisions for mounting a fine tuning potentiometer and filter IN OUT switch have already been made on the revA circuit board see Appendix F and the underside of the front panel is marked to locate the holes to be drilled to accommodate the extra controls K Using a keyer During transmit key down intervals the keying current of the Bayou Jumper is about 750 mA which will exceed the capa...

Страница 45: ...in to circuit ground will produce a short circuit which will irretrievably damage the chip If you want to use an external amplifier or external narrow band audio filter such as a NEscaf or HI PER MITE you must use a DC blocking capacitor in series with both the tip and ring connections Check the schematic of your external device A blocking capacitor may already be in place in the signal lead so yo...

Страница 46: ...w 12 4 volt supply Key up normal headphone volume 24 mA Key down spotting mode 71 mA Transmit mode idling current 12 4 V supply Key up 17 mA Transmit power measurements All voltages measured at the power jack key down 7120 1 kHz 7122 crystal Vsupply at power jack RF output Peak peak volts RF output watts Supply current mA PA efficiency 11 0 35 2 3 1 360 78 12 0 38 4 3 7 395 78 13 0 41 6 4 3 425 78...

Страница 47: ...revised 3 Feb 2021 Bayou Jumper revB Assembly Manual page 46 of 46 Builder s Notes ...

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