KD1JV Designs Mountain Topper Manuel utilisateur
The Mountain Topper
A very small, very efficient, two band rig
By
KD1J Designs
http://kd1jv.qrpradio.com
Specifications:
Dual band, 20 M and 40 M typical, 30 M and 80 M possible.
Receiver:
MDS: ~0.2 u
Small signal band width ~ 500 Hz
Audio output limited to ~ 800 mv p-p
Headphone output, 16 ohms min recommended.
Minimum current (no signal) ~35 ma
Transmitter:
2.5 watts @ 9 volt supply typical
Spurs -50 dBc or better
1
Table of Contents
Assembly:..........................................................2
Check out and Calibration:.............................12
Reference Oscillator Frequency
Calibration:............................................12
Local Oscillator frequency trim and BFO
ad ustment:.............................................13
Receiver input peaking:.........................13
Transmitter test and output (low pass)
filter ad ustment:....................................13
Mounting into an enclosure. ...........................16
Basic operation:...............................................17
Turning the rig on and off:.........................17
Volume control: .........................................17
Band selection:...........................................17
Control switches:........................................17
Frequency tuning: ......................................18
Tuning limits: ........................................18
SPLIT MODES:.........................................18
MENU:.......................................................18
Quick selections: .......................................18
DFE Mode: ...........................................19
Tune Mode: ...........................................19
Battery Voltage:.....................................19
MENU switch only selected functions:......19
Frequency readout: ....................................19
S: Selecting Keyer code speed...............19
M: Keyer Memory entry: .....................20
Checking and storing the message:.......20
Sending messages: ................................20
D: Digital Mode.....................................21
P: Program user preferences..................21
Straight key mode:.....................................21
Operating voltages: ...................................21
HIGH SWR CAUTION: ......................21
Digital modes:............................................24
Entering into digital mode operation:.........24
Running Pocketdigi:...................................24
Calibration:.................................................24
Assembly:
●Your work area should be reasonably clean and uncluttered. Good lighting is a must.
●Empty the packets containing the parts into small paper bowls. This will ensure that they do not get lost. Some
people like to do the assembly over a cookie sheet, as the lip around the edge helps to keep parts from going far.
The metal sheet also provides some measure of static control, especially if you ground it. A white sheet under
your work area could help in finding a part which might get away from you.
●A very thin (0.015”) solder is supplied for soldering the surface mounted parts. ery little solder is need for each
connection. Ideally, you want a little convex fillet at the end of chip resistors and capacitors. Try not to end up will
a ball of solder at the end of the part.
●Do not use liquid solder flux. It simply makes a mess and is difficult to clean off the board and get out from under
parts. If not completely removed from the board, it can cause problems.
●Before placing a part, lightly tin one pad for where it will go. You can speed assembly by tining one pad at all the
locations for which a particular value of part will go. There is no need for a low wattage soldering iron. It is best to
have a hot tip which will let you get the job done quickly. You will need a small tip on the iron, 1/32” to 1/16”
chisel or round is best.
●Most of the surface mount parts come in part carriers. To remove the part(s), hold the carrier close to the work
surface and carefully peel back the clear plastic covering the part. This can be done with the tip of a sharp hobby
knife such as a #11 Xacto blade or pointy tipped tweezers. Once you remove the clear plastic strip, dump the
part out of the carrier and onto your work surface.
●If you use tweezers to handle the parts, be very careful you don't grab onto them too tightly. These little parts
have a way of flying out from between the tips of the tweezers, never to be seen again. Apparently, they go into
the twilight zone, along with all the pens, small parts and hardware which falls off the bench. They must go
someplace since its never anywhere I can ever find them again!
●An alternative to using tweezers to handle the parts is to use a tooth pick or chop stick with the end rubbed into
a little bees wax. The bees wax makes the end sticky so the part will stick to it. For the smaller IC's I grab them
length wise with the tweezers.
●Tack the end of a part in its place by applying heat to the end of the part over the tined circuit board pad, while
applying a little pressure to make sure it lays flat to the board. Be sure to heat both the pad and the end of the
part. Generally, you will not have to add any additional solder to this connection. Then solder the other end of the
part. If you don't do this right away and go onto tacking down some more parts, there is a good chance you will
forget to go back and solder all the parts which require it.
●It is nearly impossible not to make solder shorts between pins on the DDS chip, due to the close pin spacing.
Remove any shorts with solder wick.
Using solder paste:
Using solder paste is the ideal way to build the board. Small amounts of solder paste in an application syringe can be
bought for about $5.00 from Cash Olson over the internet. Also needed is a warming plate to preheat the board to about
200 degrees and a low power heat gun. An “Embossing” heat gun is commonly used (found at craft stores), though a hair
dryer on low setting might work. A soft air flow is required as to not to blow parts off the board.
A very small dab of solder paste is put on the pads and then the part placed over the pads. The parts will slide
around very easily, so one must be careful not to nudge them. The phono jacks and LED display should be hand soldered,
along with all the through hole parts. Start with the back side of the board with the most parts first.
Once all the parts have been placed, put the board on the warming plate and heat to about 200 degrees. Then
slowly heat the top of the board with the hot air gun. When the solder paste reaches its melting point, you will see it
liquefy and the parts snap into alignment to the pad. This is when the solder paste turns from a dull gray to shinny. Be on
the look out for “tomb stoning” which is when a chip cap or resistor will stand up on one end. Once all the solder has
reflowed, remove the power to the heating plate and let it cool down.
A video showing how to hand solder SMT parts and how to use solder paste can be found on the CD and is
viewable with Windows media player. The file is in the folder labeled “ ideo”
Using the parts placement guides:
The parts placement guides on the following pages are color coded to show the location of the various parts. Parts which
are not yet to be installed or already have been installed are colored the same as the background color. The guides are
scaled so that the writing on them is easy to see on a computer monitor and come out crisper after the conversion to pdf.
Unfortunately, if you print all these pages out, it will use up a bunch of your ink jet ink.
2
Some parts do not have values marked on them or are very hard to read. Capacitors are not marked so these have been
color coded with a marker on the part carrier. This color matches the color shown on the location guides.
SOT-23 parts have numbers printed on them, but are very hard to read. Therefore, these parts are also color coded, but
with a color sticker, as they come in plastic carriers. Again, the color on the carrier matches the color shown on the
placement guide diagram.
Resistors have their value printed on them, though it might take a magnifying glass to read the numbers. Therefore,
individual values are not color coded.
arious photos:
Using a straight edge to hold the TSSOP IC's in alignment with
the pads for soldering.
Semiconductor package types.
Finished board:
3
SOT-223
TSSOP-28
Diode
SOT-23-6
SOT-23
SO-8
SOT-23-5
Component location diagrams
There wasn't enough space between components on the circuit board to put component designations next to most of the
chip resistors and caps. Use the diagrams below to locate a part with its designation number. Note: Slide switches can be
mounted on either the top or bottom of the board.
Top Side:
Bottom Side:
4
Jumper
between R14
and R13
added on final
assembly
Parts list:
5
QTY Value Color code
or value #
Location(s)
1 51 510 R20
3 270 271 R10, R1 , R18
9 470 471 R2, R31 to R38
2 2.2 K 222 R2 , R27
1 3. K 3 2 R15
8 10 K 103 R1, 7, 9, 13, 22, 23, 24 [BSR]
1 15 K 153 R21
7 22 K 223 R17, 28, 30, 41, 42, 43 [BSR]
2 47 K 473 R44 [BSR]
3 100K 104 R25, R39, R40
1 220 K 224 R19
2 330K 334 R5, R12
1 1MEG 105 R14
1 2. 7K 2 71 1% R
1 14.0K 1402 1% R29
1 113K 1133 1% R11
1 2 7K 2 73 1% R8
5 30 p GREEN SMT TRIMMER CAPS
2 3.3 p YEL/green C25, C2
5 22 p ORANGE C18, C30, C32, C 5, C 8
2 47 p BROWN C24, C or C 8 - 30M BAND
1 8 p BLACK C or C 8 – 40m BAND
9 100 p VIOLET C4, 5, , 8, 9, 11, 21, 22, 38
3 470 p BLUE/red C7,C19 ,C44
2 1000p YELLOW C31, C49
17 0.01 u BLUE C2,12,15,1 ,17,28,29,35,40,41,
48,54,55, 1, 2, 3, 4
1 0.022u YEL/blue C58
14 0.1 u RED C10,13,14,23,27,33,34,39,42,43
,45,50,53, 7
1 1 u YEL/red C3
1 0.1 u 104 TH C 0 TH = THROUGH HOLE
2 150 p 151 TH C4 , C5
3 330 p 331 TH C47, C51, C57
1 80 p 81 TH C52
3 4.7 u ELECTRO C1, C20, C37
1 33 u ELECTRO C3
1 100 u ELECTRO C59
2 3.9 uH BLUE L3, L SMT 120
3 10 uH ORANGE L1, L2, L9 SMT 120
2 18 uH 40M BRN/GRY/BLK/GLD
2 12 uH 30M BRN/RED/BLK/GLD
2 8.2 uH 20M GRY/RED/GLD/GLD
QTY Part number Color code or
value #
location/description
2 SA 12A U1, U3 MIXER
1 LM4808M U2 AUDIO AMP
1 TC1014-3.3VCT713 BROWN
A5xx (last
two
characters
are date code
U4 3.3V REG
1 LM38 M U5 AUDIO AMP
1 AD9834BRUZ U DDS
1 MCP1703-5002E/DB MCP1703 U7 5V REG
1 74AC02M AC02 U8 QUAD OR
1SN74LVC1G3157DBV CC5R U9 ANG SWITCH
1 MSP430F2132IPW U10 MPU
1 ASV-40-EJ-T ASV 40.0 U11,40 MHz CLK
1 MMBF54 1 GRN [G1U] Q1 P-CHN J-FET
1 MMBT3904 BLUE [1AM] Q2 NPN
2 2N7002 RED [702] Q3, Q4 MOSFET
2 NDT2955 2955 Q5, Q P-CH
3 BS170 Q7,8,9 MOSFET
1 BAV99 YEL [A7] D1
2 BZT52C5V1-F [W8] D2, D3 5.1V zener
1 BZX85C47 GLASS D4 47V zener
1 0.2” 7 SEG LED DISPLAY
1 32.7 8 kHz CYLINER CRYSTAL
5 4.5912 MHz HC-49/US XTAL, MATCHED
3 DPDT SLIDE SWITCHES
4 X 4.3mm TACT SWITCH 12-
TL1105EF100Q
1 1.7mm X 4mm DC JACK 1 3-4018-EX
1 1.7mm X 4mm DC PLUG 171-3219-EX
2 3.5mm STEREO JACKS
4 0.187” # 2 SWAG THREADED SPACER
4 #2-32 1/4” SCREW
1 Red display filter film 1/2” x 1/2”
4 T-30-2 RED IRON TOROID
1 FT37-43 BLACK FERRITE TORIOD
1 48” #28 MAGNET WIRE
1 12” HOOK UP WIRE
1 48” 0.015” SOLDER
1 CIRCUIT BOARD
2 220 p [221] TH FOR 30M OPTION
1 5 0 p [5 1] TH FOR 30 M OPTION
Semiconductor placement
●Finding Pin 1. Some of the ICs used in this kit have a dot or indentation at
the Pin 1 corner of the chip. For others, the Pin 1 locations isn't as obvious.
The manufactures logo is sometimes used (as is the case for U1 and U3) or
sometimes there is a line along the Pin 1 end of the chip. In all cases, there is
a beveled or rounded edge along the side of the Pin 1 (left) side of the IC
package. When the chip is viewed so the package is orientated vertically, Pin 1
is always in the upper left corner.
●Before placing an IC or transistor, tin one of the corner pads and then tack
that lead of the part down first. Before soldering any other pins, make sure all the leads are lined up on the pads.
This is especially important for U6 and U10, where these isn't much room for error. Then solder the lead on the
opposite corner from the tacked lead to make sure the body doesn't move when you solder the rest of the leads.
●You will have to carefully check the number on the 8 pins IC's to tell them apart. Using a magnifying glass and
tilting the part slightly to the light will aid in reading the a part number. The rest of the IC's are each in unique
packages, so are easier to determine their locations.
●U4 and U9 are very similar. The way to tell them apart is the fact U4 has 5 leads and U9 has 6. To help tell them
apart, U4 has been color coded Brown. U9 has a faint dot which marks the pin 1 end, also the lettering “CC5R”
will be upside down when installed correctly.
●There are several different SOT-23 devices, the packages they are in are each color coded to match the layout
diagram.
●U11 is the rectangular box with the silver top. Be sure to get solder to flow into the little “U” shaped cups near
each corner of the part. A number of builders have had trouble with this and not made solder connection to the
pads under the part. A fine tipped iron is required here. Also, be careful of using too much solder and making a
short to the metal top of the package.
●D3 has very faint line on one end to indicate the cathode end. Look carefully for this line and face it towards the
line printed on the board.
●There maybe more numbers or letters on the semiconductor packages then indicated on the layout diagram.
These are date or lot codes and can vary depending on when the parts are purchased. Therefore these are not
used for part identification on the layout diagrams.
●CAUTION! There are three parts in SOT-223 packages, one of which is the 5 regulator, which goes on the top
side of the board. Do not mix up with the 2955 MOSFETS, Q5 and Q6. The regulator is loose in the semiconductor
parts bag, while the two MOSFETS are together in a parts carrier.
●HINT: Taping a straight edge, such as a thin metal ruler, across the board and lined up with the bottom outline of
U6 or U10 (as the case maybe) will aid in keeping the part aligned with the pads. First do U6, then U10. After
soldering the leads, clean up any solder shorts with the supplied solder wick. Be sure to only pull the wick parallel
to the leads, not against the gain! (see picture, page 3)
6
LOCATION PART # PACKAGE
U AD9834 TSSOP-20
U10 F2132 TSSOP-28
Q1 Green/G1U SOT-23
Q2 Blue/ 1AM SOT-23
Q4 Red/702 SOT-23
D1 Yellow /A7 SOT-23
U1/U3 SA 12A SO-8
U2 LM4808 S0-8
U5 38 S0-8
U8 74AC02 SO-14
D3 -- W8 2 leads
U4 Brown/A5xx SOT23-5
U9 ---- CC5R SOT-23-
U11 40.00 silver
Q5 2955 SOT-223
Remember, Q5 is in parts carrier, not loose
Resistors : Bottom
●Since part designation numbers for most parts are not printed on the board, you will need to use the diagram to locate where the
part goes. Pay careful attention to where the part is located to be sure it doesn't go where a cap will go later.
●Resistor locations are highlighted in yellow. The number shown inside the outline is the same as marked on body
of part. Note that several resistors have four numbers printed on them, these a 1% values. Resistors with three digits are 5%.
●Three inductors will also be installed with the resistors. These are packaged with the resistors, but are larger and have no numbers
printed on them. There are two values used, so they are color coded. The two left over “orange” inductors will be used on the other
side.
●There will be a number of resistors left over which go on the top side of the board. Put these aside in a safe place until needed.
●The “approximate location ” in the table will help locate the position of the resistor values on the board. upper/middle/lower is Y
coordinates area while left/center/right is X coordinates.
●Resistors R3 (BS1) and R4 (BS2) values depend on the band to be used see band value table below.
7
Value # places Approximate location
471 1 upper/center
271 3 upper/center
222 2 lower/center
3 2 1 upper/center
103 5 upper/left
153 1 middle/left
223 5 middle/left
lower/left
lower/center
104 2 lower/center
224 1 middle/left
334 2 upper/left
105 1 upper/left
NOTE The next two values
look alike – only the
last digit is different.
2 71 1 upper/left
2 73 1 upper/left
1133 1 upper/left
R3-
BS1
10K
1 upper/right
(20 M value)
R4-
BS2
47K
1 upper/right
(40 M value)
Orange 1 upper/right inductor.
Blue 2 middle/right inductor.
Band value table:
40M 47 K
30M 22 K
20M 10 K
BS1 (R3) should be highest frequency
band, typically 20 M
Capacitors : Bottom
Capacitors part carriers are color coded as the part its self has no markings to identify its value directly. Install all the
capacitors of a given value before starting to install another value. This will prevent mixing up values. Several values are
indicated by two colors, a main solid color and a second color stripe.
Several values are used on the top side of the board. Snip these from the strips and put them in a safe place for the time
being. light blue/red stripe – 1, Brown – 1, Orange – 1, Red – 3, Blue – 2.
●It is easy to confuse the orange caps (22 pfd) with the Red (0.1 ufd) caps on the layout digram, so we will pace
the orange ones first.
●Part number start in upper left and run left to right, top to bottom in a
zig-zag fashion.
8
Location color # places
C18, 30,
32, 8
Orange 4
C25, 2 Yellow/green stripe 2
C4, 5, , 8,
9, 11, 21,
22, 38
Violet 9
C24 Brown 1
C58 (below
Q5)
Yellow/blue stripe 1
C3 (below
Q1)
Yellow/red stripe 1
C31, 49 Yellow 2
C7, C19 Light blue/red stripe 2
C2, 12, 15,
1 , 28, 29,
35, 40, 41,
54, 55, 1,
2, 3, 4
Blue 15
C10, 13,
14, 23, 27,
34, 39, 42,
45, 50, 53
Red 11
Capacitor / Resistors : TOP
Semiconductors Top:
Trimmer caps:
CT1 notched end
faces U1
9
Value/color location #places
Orange* C 5 1 (20M- 22p)
Black* C 1 (40M- 8p)
Red C33, 43, 7 3
Blue C17, 48 2
Blue/red C44 1
510 R20 1
471 R31 to R38 8
103 R23, R24 2
223 R41 1
473 R44 1
104 R39 1
1402 R29 1
Orange L1, L9 2
*Note: C 5 and C values for 40/20 band
combo. Values or locations will change if
other band combinations are desired.
Value location
Red (702) Q3
---- tiny! W8 D2 Polarity!
MCP1703 U7 Don't confuse
with Q !
2955 Q
7 seg
display
LED
Display
Make sure
decimal point is
in lower right
hand corner.
Once soldered
in place, the
display is
nearly
impossible to
remove.
●Four trimmer capacitors labeled BNDB
and BNDA now need to be installed
before the through hole parts are
mounted to the top side of the board.
●CT1 is on the bottom side. Install this one
now.
●Note the cut corners on one end of the
trimmer. This end aligns with the
corresponding cut corners on the outline.
If you get it backwards, the adjustment
screw will be “hot”.
●There isn't much of a solder tab to solder
to, so you best have a real fine tip on your
iron, although the edge of a small chisel
tip could work.
Through hole parts:
(use your normal solder {.02 or /.032} for most of these parts)
●L14 – 8 turns on black T37-43 core. Wind now, but put aside and
install later.
10
●X1 – X5 tack solder case of X1,2, 3 and 4
to the pad along the top edge of the board.
A little blob of solder in between X1-X2 and
X3-X4 will do. Roughing up the edge of the
can with a small file can make the solder
stick to it easier.
●Insert and solder the four (4) threaded
spacers into the corner holes and solder.
Insert from top side and solder on bottom.
●X - tack solder top of crystal to solder pad.
●Slide switches – these can go on either
side of the board, but the top side is
preferable.
●S1-4 TACT switches. These can only go in
one way, so don't force them. The leads
which go along the top and bottom are
spaced a little farther apart.
●Through hole caps. Values shown in layout
locations are for 40 and 20 meter bands. If
another band combination is desired,
change values as needed. See table below
for value.
20M 40M 30M
C 0 104 [0.1u] C 0 104 [0.1u] C 0 104 [0.1u]
C4 , 5 151 [150 p] C47, C57 331 [330 p] C47, C57 221 [220p]
C51 331 [330 p] C52 81 [ 80 p] C52 5 1 [5 0p]
C 5 22p [Orange] C 8 p [Black] C 47p [Brown]
(C 5/C already installed, values shown for reference if other band combination used)
●C1, C20, C37 – 4.7 uFd electrolytic –
observe polarity, LONG LEAD PLUS.
●C3 – 33 uFd electrolytic
●C59 – 100 uFd electrolytic – lay this part
over SMT components below Q5. See
photo below.
●D4 – large glass diode – 47V zener.
●Q7, Q8, Q9 - BS-170 TO-92
●L4/8 L7/5 mount vertically.
● L10 to L13 See table below for inductor
values.
Location 20M 40M 30M
L5, L7 8.2 uH GRY/RED/GLD/GLD ------------------------------------------
-
-----------------------------------------
L4, L8 -------------------------------- 18 uH BRN/GRY/BLK/GLD 12 uH BRN/RED/BLK/GLD
L10 T30-2 RED 11 turns 8” -------------------------------------- ----------------------------------
L11 T30-2 RED 15 turns 10” -------------------------------------- ------------------------------------
L12 ----------------------------------- T30-2 RED 1 turns 10” T30-2 RED 13 turns 9”
L13 ----------------------------------- T30-2 RED 19 turns 11” T30-2 RED 14 turns 10”
C 59 mounting
Autres manuels pour Mountain Topper
1
Table des matières
Autres manuels KD1JV Designs Émetteur-récepteur
