QRPKits DC40A Manuel utilisateur
2/14/2007 Page - 1
The DCxxA Family of Transceivers
High Performance Direct Conversion Transceivers for 40, 30 and 20 eters
DC30A Transceiver
Evolution of the popular DC40 to the DCxxA series on 40, 30 and 20 eters
A KD1JV “ elt Solder” Design
Distributed by Hendricks QRP Kits
www.qrpkits.com
Join Yahoo’s DC40 Kits group for support from other buil ers an information about operation an mo ifications.
Be sure to inclu e your call an real name with your request
.
http://groups.yahoo.com/group/ c40kits/
2/14/2007 Page - 2
The DCxxA
A Direct Conversion, Fixed-Frequency Transceiver for 40, 30 and 20 eters
The DCxx is a mo erately complex rig, which yiel s excellent performance, yet is small enough to fit into
an Altoi s tin. The receiver features nearly complete immunity to AM SWBC interference an can be run on an AC
supply with little hum pickup or AM BC interference common to most DC receiver esigns. One stage of au io
ban pass filtering gives the receiver some selectivity. The transmitter puts out a respectable 750 mW of power,
with a 12V supply an over 1 Watt with 13.8 volts. The transmitter frequency is automatically shifte up about 600
Hz to provi e the proper T/R offset. The rig also inclu es a simple keyer chip.
Assembly:
Review the entire manual and inventory the parts for each group before proceeding.
Assembly of the boar will be one in several groups. You may fin it convenient to separate the parts for
each of the groups as shown in the parts lists for each group.
You can “smoke test” most of these groups when finishe , or move on to the next group an test
everything at once. If a group fails to pass the smoke test, see the trouble shooting section locate after the
assembly instructions.
If you plan on installing the boar into an Altoi s tin, trim off the corner of the boar next to the pa le jack
before you install the jack. You may also want to mark where the mounting holes an where the phone jacks will
be in the tin before installing any parts.
The parts location iagram for the whole boar is shown below. Component values are marke in re .
Experience buil ers shoul be able to buil up most of the boar using just this iagram.
Steve an Doug wish to thank Chuck Carpenter, W5USJ, for manual e iting an revisions. Also our thanks to Jay Bromley,
W5JAY, Tony Fishpool, G4WIF an Davi Yarnes, W7AQK, for kit testing an manual proof rea ing.
2/14/2007 Page - 3
Parts list
RESISTOR VALUE TYPE Caps Value Type
R1 1 meg 5% 1/4w CF C1 .012 uF FILM
R2 360 K 1.00%
C2 330 p Mono or Disk
R3 1 meg C3 .1 uF Mono
R4 1 K C4 .1 uF Mono
R5 1 K C5 .012 uF FILM
R6 10 OHMS C6 Skippe Not use
R7 1 K C7 Ban specific See page 5 Mono or Disk C0G
R8 1 MEG C8 40 p YEL TRIMMER
R9 100 K C9 22 uF / 16V ALUM
R10 1.5 K C10 .001 uF Mono or isk
R11 36 K 1.00%
C11 .1 uF Mono
R12 22 K C12 .1 uF Mono
R13 Skippe Not use C13 100 uF/16V ALUM
R14 Skippe Not use C14 Skippe Not use
R15 100 OHMS C15 330 p Mono or Disk
R16 100 K C16 Skippe Not use
R17 15 K C17 .001 uF Mono or Disk
R18 10 ohms C18 .001 uF Mono or Disk
R19 15 K C19 .001 uF Mono or Disk
R20 Skippe Not use C20 .1 uF Mono
R21 Skippe Not use C21 100 p Mono or Disk C0G
R22 470 ohms C22 100 uF/16V ALUM
R23 10 K C23 Ban specific See page 5 Mono
R24 100 OHMS C24 .1 uF Mono
R25 51 OHMS C25 .1 uF Mono
R26 10 ohms C26 .1 uF Mono
R27 470 ohms C27 . 1 uF Mono
R28 100 K C28 Ban specific See page 5 Mono or Disk C0G
R29 Skippe Not use C29 Ban specific See page 5 Mono or Disk C0G
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R30 10K C30 Ban specific See page 5 Mono or Disk C0G
T1 Ban Specific See page 5 C31 Ban specific See page 5 Mono or Disk C0G
T2 See page 13 C32 100 p Mono or Disk C0G
T3 See page 11 C33 Ban specific See page 5 Mono or Disk
L2/3 Ban Specific See page 5 C34 40p YEL TRIMMER
C35 4.7uF/16V ALUM
C36 .001 u Mono or Disk
C37 .1 u Mono
C38 .001 u Mono or Disk
C39 .001 u Mono or Disk
C40 .01 u Mono
C41 Ban specific See page 5 Mono or Disk C0G
Semiconductors
X1 crystal U1 NJM4556AD High current opamp
SWITCH 6mm TACT 14mm shaft U2 74HC4053 Analog multiplex
U3 ATTINY11 MPU
U4 LM78L05 5V Regulator
JACKS PC mount stereo Hea phone,
Pa le
PC Boar Q1 PN2222A NPN
Re an Green Magnet wire Q3 2N3904 NPN
2, 8-pin IC sockets Q2/4/5/6/7/8/9 2N7000 Tfet
16-pin IC socket Q10 2N3819 j-fet
D1/2/10 1N4148
D9 1N5817
2/14/2007 Page - 5
Band specific values
Location 40M 30M 20M Type
C31 47p 47p 22p C0G Mono or Disk
C33 100p 47p 22p C0G Mono or Disk
C7 47p 33p Not use
C0G Mono or Disk
C28 330p 220p 150p C0G Mono
C29 680p 560p 330p C0G Mono
C30 330p 220p 150p C0G Mono
C23 68p 68p 33p C0G Mono
C41 Not use 68p 100p C0G Mono or Disk
Toroid Winding Charts
40 eters Wire Core Turns Wire Length
L1 (Not Used)
L2 #28 Re T37-2 (re ) 21T 16”
L3 #28 Re T37-2 (re ) 16T 12”
T1 #28 Re /Green T37-2 (re ) 35T Pri/5T Sec. 24” Re , 6” Grn.
T2 #28 Re /Green FT37-43 6T Bifilar 10” Re , 10” Grn
T3 #28 Re /Green BN2402-43 5T Pri/1T Sec 5” Re , 2” Grn
30 eters Wire Core Turns Wire Length
L1 (Not Used)
L2 #28 Re T37-2 (re ) 15 11”
L3 #28 Re T37-2 (re ) 13 10”
T1 #28 Re /Green T37-2 (re ) 35T Pri/5T Sec. 24” Re , 6” Grn.
T2 #28 Re /Green FT37-43 6T Bifilar 10” Re , 10” Grn
T3 #28 Re /Green BN2402-43 5T Pri/1T Sec 5” Re , 2” Grn
20 eters Wire Core Turns Wire Length
L1 (Not Used)
L2 #28 Re T37-6 (yellow) 17 13”
L3 #28 Re T37-6 (yellow) 13 11”
T1 #28 Re /Green T37-2 (re ) 25T Pri/5T Sec. 29” Re , 6” Grn.
T2 #28 Re /Green FT37-43 6T Bifilar 10” Re , 10” Grn
T3 #28 Re /Green BN2402-43 5T Pri/1T Sec 5” Re , 2” Grn
2/14/2007 Page - 6
.
Examples of Component Types
Note variations in shape, size an color of similar component types. Some component lea s will nee to be
reshape to fit the holes in the PCB.
2/14/2007 Page - 7
Tips and Info for First Time Builders
Installing parts:
You can insert several parts at a time onto the boar . Parts shoul be presse flush to the top of the boar . The
exception are the transistors which shoul stan off the boar by about 1/8” ue to their three legge nature. Once
you insert the part, kink one of the lea s over slightly to keep it from falling out of the boar when you flip the boar
over to sol er.
The .1 uF caps use in the kit have forme lea s, so these will not sit quite flush to the boar . Several of the isc
caps have lea spacing larger than the pa s on the boar . You can reform these lea s with your pliers so they will
sit flush to the boar .
Once you sol er a part in place, clip the lea nearly flush to the boar . Clip at the top of the little fillet of sol er
which forms aroun the lea .
Fin ing the right part.
A picture at the bottom of the parts list on the previous page can be use to help i entify some of the parts. The
parts not shown shoul be obvious or e uce by the process of elimination. The numbers i entifying the
monolithic caps (mostly yellow or blue in color) can be har to rea . The use of a magnifying glass can help you to
see them. In a ition to the part value of the capacitor, there are a number of other letters an numbers printe on
the part. Simply look for the three number group which matches the value your looking for, 331 for 330 pF, 104 for
.1 uF, 681for the 680 pF cap an so on.
IC pin 1.
The outline on the boar for the ICs has a “V” notch on one en . This in icates the pin 1 en of the IC. If a socket
is use , there is also a notch on one en of the socket. This en goes over the V notch outline on the boar .
Finally, pin 1 of the IC is marke with a roun imple or ot. This en of the IC will go towar s the notch on the
socket or “V” on the outline.
Sol ering
There are two important things which nee to be one to ensure the successful operation of a kit. One is getting
the right part into the proper place on the boar . The secon is goo sol ering. To ensure a goo connection, the
sol ering iron shoul touch both the component lea an the circuit boar pa it’s to be sol ere too. Heat the
connection for just a secon , then put the sol er to the iron/pa /lea junction. Allow just enough sol er to flow to fill
the hole an wick aroun the lea . Go easy on the sol er, you on't nee a whole lot. If you use a thin sol er like
0.02” instea of the more common 0.032” type, you have better control of the amount of sol er use . For parts
which connect to the groun plane, you may have to heat the connection a little longer.
Coils an Transformers
You may fin it convenient to win an prepare all of the coils an transformers before you start inserting parts.
That way you on’t nee to stop an possibly loose concentration to win an them for installation. See page 5 for
ban specific etails.
2/14/2007 Page - 8
Group 1: Power, Audio and Keyer stages.
NOTES:
Do not install the ICs into the sockets until after the initial smoke test. R11 an R2 are 1% resistors, so have four color ban s
for the value, instea of three for the 5% resistors. They also may have a blue bo y color, instea of tan. On C9, C13 an C22
the long lea is + an the negative lea si e is marke with a black strip on the cap bo y. Dio es D1 an D2 are installe “back
to back”, therefore, the black ban on the io e (catho e en ) shoul be facing in opposite irections from each other.
Part # value markings PART#
VALUE MARKINGS TYPE
R1 1 MEG BRN/BLK/GRN R30 10K BRN/BLK/ORN
R3 1 MEG BRN/BLK/GRN C4 .1 uF 104
Mono
R4 1 K BRN/BLK/RED C11 .1 uF 104
Mono
R5 1 K BRN/BLK/RED C12 .1 uF 104
Mono
R7 1 K BRN/BLK/RED C20 .1 uF 104
Mono
R10 1.5 K BRN/GRN/RED C25 .1 uF 104
Mono
R9 100 K BRN/BLK/YEL C10 .001 uF 102
Mono or Disk
R6 10 Ohm BRN/BLK/BLK C17 .001 uF 102
Mono or Disk
R11 36K, 1% ORG/BLU/BLK/RED C18 .001 uF 102
Mono or Disk
R2 360K, 1% ORG/BLU/BLK/ORG C19 .001 uF 102
Mono or Disk
R8 1MEG BRN/BLK/GRN C1 .012 uF 123
FILM (Brown)
R15 100 ohms BRN/BLK/BRN C5 .012 uF 123
FILM (Brown)
D9 1N5817 Schottky C2 330 p 331
Mono or Disk
D1/D2 1N4148 io e C15 330 p 331
Mono or Disk
U4 78L05. +5 regulator C21 100 p 101
Mono or Disk
U1/3 socket 8 pin C9 22u/16V 22/16 Alum RADIAL ALUM ELECTRO
pa le jack stereo C13 100u/16V 100/16 Alum RADIAL ALUM ELECTRO
phone jack stereo C22 100 u/16V 100/16 RADIAL ALUM ELECTRO
2/14/2007 Page - 9
Connection of jumper from U4-3(output) to U1-3 required for missing 5V buss PCB trace.
There was a mistake ma e when the boar was lai out an the connection shown below was misse . The kit
buil er nee s to sol er a jumper in place as shown. A soli insulate wire, 26 or 28 ga, shoul be use for the
connection. Sol er the jumper in place after U1 an U4 are sol ere .
Smoke Test:
Connect the positive lea of a 12V power source to the hole marke “+V”. Connect the negative lea to the hole marke “GND”.
You can tack these to the bottom of the boar , so they are easy to remove uring further assembly. Apply power to the boar .
Using a voltmeter, verify there is about 5 volts between pins 4 (groun ) an pin 8 (+V) on U3. If this tests goo , remove power
an insert U3, the ATTINY11 keyer chip an U1, the 4556 op amp. Insert a pair of hea phones into the phones jack an a
pa le or straight key into the pa le jack. Restore power to the boar . Using the pa le or straight key, you shoul hear the
si e tone in the hea phones. (You may fin it easier to use the final power lea s rather than tack in test lea s.)
2/14/2007 Page - 10
Group 2: Receiver front end:
NOTES:
C8: the flat si e of the trimmer goes towar s the line on the
outline.
U2: Install the 16-pin socket at the U2 position. Be sure the
notch is positione to match the notch shown on the boar .
Then install U2 into the socket orienting the ot an notch.
T1: Ban Specific Transformer, See Page 5
Using the re wire an a re T37-2 core, win the require number of turns for the ban you
are buil ing. Keep the turns snug an as close together as you can. This is the secon ary
win ing (SEC). Win 5 turns of the green magnet wire in the space between the start an
finish of the secon ary win ing. This is the primary or link win ing (LINK) You can overlap
these turns if there isn't enough room to make a single layer. Trim back the lea s to about
1/4” an tin. Tinning can be one with a HOT sol ering iron. It helps to have a blob of sol er
on the tip when you o this. Start at the wire en an move back towar the core. Insert the
two re wire lea s into the holes labele “SEC” on the iagram an the two green wires into the holes labele
“LINK”. The two holes on the left (closest to the e ge of the boar ), are both groun , so it oesn't matter if the SEC
an LINK wires on this en are crosse . Trim the T1 lea s after they are sol ere .
location
value markings
R26 10 ohms BRN/BLK/BLK
R12 22 K RED/RED/ORG
R28 100 K BRN/BLK/YEL
R27 470 ohms YEL/VIO/BRN
C3 .1 uF 104 Mono
C37 .1 uF 104 Mono
C26 .1 uF 104 Mono
C38 .001 uF 102 Mono or Disk
C39 .001 uF 102 Mono or Disk
C36 .001 uF 102 Mono or Disk
C7 Ban
specific
See page 5
C8 40p Yellow trimmer
Q10 2N3819 jfet
Q8 2N7000
U2 Socket 16-pin
Q7 2N7000
Q9 2N7000
U2 74HC4053
T3 See text
T1 Ban
Specific
See page 5
Ce manuel convient aux modèles suivants
2
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