DEM Part Number PCB, K and CK 23 cm Transverter PCB, Board Kit, and Complete Kit

Transcription

1 DEM Part Number PCB, K and CK 23 cm Transverter PCB, Bard Kit, and Cmplete Kit Frequency range: Nise Figure and Gain: Pwer Output: TXIF Drive level: DC Pwer requirements: DC Current drain: Specificatins 1296 MHz. = 144 MHz. <1.5 db NF, > 17 db Gain with >+5dBm IP3 Input 3 watts. Lwer levels with different cnfiguratins 1 mw t 10 Watts maximum dependant n IF cnfiguratin VDC nminal. 11 t 16.5 VDC peratinal. 500 ma t 2.5 Amps depending n utput pwer level. Operatinal Overview The DEM is a 23 cm t 144 MHz transmit and receive cnverter. It has a linear utput pwer f apprximately 3 watts and may be achieved with as little as 10 mw r a maximum f 10 W f IF drive with the crrect IF cnfiguratin. The highlight f this transverter is the receive sectin. The design uses a PHEMT that has a high-pass tuned input circuit biased fr High IP3 utput perfrmance. It is fllwed by tw 3 ple helical filters, a high utput IP3 MMIC gain stage, and a high level mixer with a IP3 utput f +30 dbm. This design prvides a sensitive lw nise receiver with superir ut f band signal rejectin that will tlerate IP3 input signals > +5 dbm! Other imprvements ver the previus versins f 1296 transverters are in the Lcal Oscillatr and TX sectin. The base scillatr f the lcal scillatr circuit is hused in a shielded enclsure n the circuit bard. This shield cupled with the higher frequency base scillatr peratin, (192 MHz), reduces the amunt f spurius utput while prviding greater temperature stability. The transmit sectin has imprved filtering t eliminate all ther spurius emissins. The DEM has a built in transmit / receive relay n the RF side with prvisins fr external switching fr adding a high pwer amplifier r preamplifier t yur 23 cm system. The 144 MHz IF levels and ptins are adjustable n bth transmit and receive with a dynamic range f apprx. 25 db. This is useful fr adjusting yur maximum utput pwer and setting the "S" meter level n yur IF receiver. The IF cnnectins are via BNC cnnectrs. Optins have been prvided fr a key line input PTT-H (+1 t 15 VDC) r PTT-L (a clsure t grund) and auxiliary cntacts n either transmit r receive with a cmmn line fr many applicatins. The cntrl, pwer, and auxiliary cnnectins are via RCA jacks. The 23 cm cnnectrs are Type 'N' r SMA if separate TX and RX prts are chsen. The is hused in ur standard 4.125" x 1.875" x 7.75" extruded aluminum enclsure that matches all f ur ther micrwave transverters. General Infrmatin The detailed technical design infrmatin is psted in the library sectin f the Dwn East Micrwave Web site. The paper stresses the receiver s immunity t ut f band signals and cvers the design stage by stage. The kits and PCB are supplied with a schematic and cmpnent placement diagram. The PCB is made f thick Fiberglass G10 material. It has plated 1 z. cpper with plated thrugh grund Vias and will nly require a general understanding f the circuit design accmpanied by gd cnstructin practices t prduce a great wrking transverter. The circuit bard alne may be assembled and used in many different cnfiguratins. It is perfect fr the experimenter in the 23 cm band and requires very little micrwave expertise. The PCB by itself desn t require external mechanical supprt but will require a special munting technique. Dwn East Micrwave will guaranty the perfrmance f ur circuit bard with yur cnfiguratin but will nt repair any transverters built frm the PCB unless /Kits/ CK.dc 1 Rev. B 9/20/2007

2 all cmpnents used are specified n the cmpnent list that accmpanies the PCB when purchased! Fr a higher prbability f success, and 100% supprt f Dwn East Micrwave Inc., we recmmend at the minimum, using the K. The K (kit versin) includes the PCB and all cmpnents required t prduce a lw transmit level 23 cm transverter. If higher utput pwer is required, yu may simply rder the hybrid pwer mdule that the circuit was designed fr but physical munting may be difficult due t cmpnents lcated n bth sides f the circuit bard. Fr this reasn, if yu wish a 3 Watt unit, we recmmend using the cmplete kit versin. The CK (cmplete kit) includes the bard kit and the hybrid pwer mdule alng with all the necessary hardware, cnnectrs and enclsure. Als included in the CK is a special munting plate that allws the munting f the assembled PCB and hybrid mdule int the enclsure prvided. The circuit bard munting plate is machined s that the helical filters, PCB, lcal scillatr shield, the hybrid pwer mdule, and all external DC and RF cnnectrs are munted tgether as a cmplete assembly befre installing in t the enclsure. This plate is the key t the maximum reliability f the transverter (heat transfer and spurius scillatins) and allws cmplete alignment befre final assembly int the enclsure. Circuit Descriptin A lcal scillatr f MHz is multiplied X 6, filtered, and amplified t the +17 dbm level then is injected int a high level mixer. In receive, the 23 cm signal enters thrugh either the RX prt r the cmmn antenna prt. It is amplified by a high level, tuned input PHEMT lw nise amplifier that has apprximately db f gain with <1.0 db nise figure. The input circuit is designed t attenuate all signals ut side f the desired 23 CM band. The amplified signal then passes thrugh a 3 ple helical filter that allws apprximately 30 MHz. f amplified bandwidth. This signal is then amplified by a high level MMIC befre being filtered by the next 3 ple helical filter that restricts the receivers peratin t a narrw segment f the 23 CM amateur band. This signal enters the high level mixer and exits the IF prt passing thrugh a VHF lw pass filter and ptinal IF gain stage with a variable attenuatr. Then depending n the cnfiguratin, it will pass thrugh the IF switch r nt befre becming available t the 28 MHz. receiver. On transmit, it is a reverse prcess. The 2 meter transceiver applies a signal f up t 10 watts f drive and it is then attenuated and filtered befre entering int the mixer. The 23 cm transmit signal then exits the mixer and is filtered by the 3 ple helical befre being passed thrugh the transmit gain stages. It is then amplified up t apprximately +15 dbm befre it is filtered again t narrw the pass band energy. At this pint the signal can be used as is r be amplified up t the 3 watt level befre either exiting the TX prt r the cmmn antenna prt. Other LO input, RF and IF frequency schemes may be used with the 1296 transverter such as ur ther 28 MHz IF versins r the 1268/9 transmit cnverters. Simply d the math. There are a few limiting factrs fr different frequencies f peratin. The IF will perate n any frequency between 28 and 188 MHz. With the crrect LO filters. The RF filters will cver the whle 23 cm band. The LO filters in this kit will nt tune t a 28 MHz IF range. All filters included in the kit may need t be re-tuned r replaced and the levels will need t be checked. Therefre, if attempting a large frequency change r using an dd IF frequency, is nt recmmended unless yu have a knwn signal surce and a spectrum analyzer t determine yur desired utcme f the transverter. Fr a mre detailed circuit descriptin abut any cmpnent r circuit in particular, r if yu have questins abut a desired scheme, we recmmend yu cntact Dwn East Micrwave befre prceeding with a mdificatin t the kit. /Kits/ CK.dc 2 Rev. B 9/20/2007

3 Assembly Tips It is recmmended t read the entire dcument befre yu begin t assemble the kit, but the fllwing few paragraphs is a cmpilatin f assembly techniques used and required t assemble this kit. These varius assemble techniques will be used fr mre than ne cmpnent and may determine the utcme f this kit. Review the examples shwn and becme familiar with the cmpnents described in the text. Sldering surface munted active cmpnents The dts r angle cut leads n the MMICs IC1-IC3, IC5-IC7 are as shwn n the cmpnent placement diagram and determine their crrect rientatin. IC10 is a 3 leaded package with a slder tab. Its rientatin is shwn n the cmpnent placement diagram. The MMIC s must be psitined crrectly prir t sldering. Remving a MMIC withut damage is difficult. The PHEMT Q3 has a wide lead fr ne f the surce leads. (See figure 1B) Leads n all active surface munted cmpnents shuld be smewhat flat against the munting surface, if they are nt, a small tl such as a small bladed screw driver can be used t flatten them befre attempting t slder (See Figure 2). After verifying that the leads are flat t the surface, yu will be ready t slder. 1. T begin t slder, pick ne pad n the circuit bard that yu wish t attach the active device t. Withut the cmpnent in place, heat ne side f the munting area and Tin the area by flwing a small amunt f slder n it. Allw it t cl. 2. Align the desired cmpnent n the circuit bard based n the placement diagram. While hlding the cmpnent in place, apply heat t the tinned pad and re-flw the existing slder until the cmpnent lead drps int the slder. Allw t cl and bserve the alignment f all f the leads. 3. If the alignment is acceptable, slder the remaining leads. Yu need enugh slder t cver the lead and munting surface f the entire lead length. (See Figure 2 shaded areas) If necessary, re-slder the riginal lead. Input Lead is angle cut S D 03 ATF34143 Figure 1A Leads flat t trace, 4 places Sme spring back is OK G Figure 1B Slder shwn in shaded areas Slder full length f lead, 4 places S PCB Trace Typical side view f fur leaded surface munted device, lead bending clse t bdy. Figure 2 /Kits/ CK.dc 3 Rev. B 9/20/2007

4 Sldering surface munted passive cmpnents such as chip resistrs and capacitrs: 1. Determine the cmpnent munting psitin based n the assembly diagram. 2. Withut the cmpnent, tin ne f the munting pads nt shared by anther cmpnent. (Flw a small amunt f slder n it) 3. After cling, place the cmpnent in the crrect psitin per the assembly diagram, it shuld nw have ne end ver the tinned area. 4. Hlding the cmpnent in place with tweezers r ther sldering aid, heat the tinned area and allw the slder t flw arund the cmpnent. Remve the heat. 5. Once slidified, remve hlding tl and heat and flw slder t the ther side f the cmpnent nly if it is nt shared by a secnd cmpnent. If s, slder the cmpnent that shares the pad first. Yu are dne! See examples in figure 3. Crrect Slder Fillet Incrrect Incrrect Cmpnent Placement Circuit bard Figure 3. Prper SMD Assembly. Sldering leaded cmpnents (resistrs, capacitrs, dides, and inductrs) : Depending n yur available tls, yu can slder yur transverter's leaded cmpnents frm either the tp r bttm f the PCB. It is suggested fr the hme assembler t use a methd that is cmfrtable. A simple hlding vise can be utilized t allw the cmpnents t be 'drpped in' frm the tp side and sldered n this side withut flipping ver the assembly. As an alternate methd, yu can insert ne cmpnent at a time in the crrect munting lcatin and gently push dwn t the circuit bard, while hlding the cmpnent, flip ver the circuit bard and bend the leads ver in ppsite directin t hld the cmpnent in place. Althugh this is the mst reliable methd, there are sme drawbacks if the cmpnent must be remved when the PCB is installed in the enclsure. Sme leaded cmpnents may need t be surfaced munted either n ne r mre leads. If this is the case, the leads need t be pre-frmed befre sldering. If yu see a leaded cmpnent n the cmpnent placement diagram withut a circle at the end f the lead such as R25 and C49, thse leads will need t be surfaced munted as shwn in the drawings belw. DO NOT install any leaded cmpnents in the grund via hles if it is shwn as a surface munt lead. The PCB munts t a pallet and if there is any slder r extended lead interference, the PCB will nt be flush with the pallet. Leads sldered t PCB surface This end sldered t PCB surface Circuit Bard Surface Circuit Bard Surface Figure 4. Sme inductrs are pre-frmed and sme will need t be frmed such as L1. It is suggested that the cils be frmed n the supplied wden dwel. Winding cils is nt an exact science and yu shuld nt be intimidated by it. Using the enamel wire supplied, extend abut ¼" in a perpendicular directin ff f the dwel and wind the wire arund it, cunting each revlutin as ne turn. When the ttal number f turns is cmpleted (see the cmpnent list) cut the wire an /Kits/ CK.dc 4 Rev. B 9/20/2007

5 additinal ¼" beynd the dwel. Frm the tw ¼" leads s they are pinting in the directin as shwn in Figure 5. 1/4" Slder Tinned Area Slder Tinned Area 1/4" End view f frmed cil Tp view f nrmally frmed cil, (4 turns shwn) Figure 5. Dress the turns tgether if they are ut f shape frm winding, remve the cil frm the dwel. The cil frming is cmplete! T ensure a psitive slder cnnectin, the ¼" leads shuld be slder tinned as fllws. With a slder irn, flw a pl f slder n the tip. Place the desired end f enamel wire in the pl f slder. It may take a few secnds depending n the irn temperature, but the red enamel will melt and be replaced with a slder tinning. Als tin L5. It is pre-wund. Rewrk f sldered cmpnents if needed The easiest methd t rewrk sldered cmpnents is t emply a de-sldering braid that is specifically designed fr this purpse. It can be purchased at mst electrnics cmpnent distributrs. Place the de-sldering braid n the lead that yu are remving and apply heat t it. Withut excessive pressure the slder will flw int the braid leaving the lead r cmpnent ready t be remved. Printed Circuit Assembly Ntes Yur kit is prvided with easy t read cmpnent placement diagram that details every cmpnents placement and the reference designatrs that crrespnd t the prvided cmpnent list (Bag 1 - Bag 4). Each side f the printed circuit bard (PCB) is als shwn t eliminate mirrr image assembly errrs. The tp and bttm side assembly peratin shuld always begin by aligning the PCB utline with the ut line f the cmpnent placement diagrams. The tp side f the circuit bard is the side with the printed lettering n it. Mst f the sldering will be dne n the tpside. Again, when sldering n the grund plane, be sure that slder des nt flw and pl n the bttm side f the PCB. Start the Assembly This is a basic assembly instructin dcument. Every filter has been installed and tested in the circuit bard. Adjustment shuld nt be required. As f nw, this kit is fr a average t experienced RF circuit builder. T align this kit, it will nly require a vlt meter, a 23 CM signal, and a pwer meter that will measure up t 5 watts maximum. If yu have access a frequency cunter, a signal generatr, and a mw pwer meter it wuld be a plus. Please nte that this dcument assumes the Cmplete Kit. If yu have purchased the K, nly use cnstructin details that pertain t the circuit bard. Inventry the parts list. Every part in this kit is imprtant and shuld be identified. Bag 1 cntains resistrs, Bag 2 cntains capacitrs, Bag 3 cntains the inductrs and Bag 4 cntains the semicnductrs and relays. The filters are listed n the cmpnents list but are installed. Take yur time t get familiar with the kit cntents and verify it is cmplete. There are extra chip cmpnents packed in the vials, s n need t cunt them. Just verify that the value is included. /Kits/ CK.dc 5 Rev. B 9/20/2007

6 The hardware shuld be srted and identified. There are sme extras. But remember, N substitutins r yu are n yur wn!! Review the schematic and the cmpnent placement diagram. Read thrugh all f the assembly steps Identify every cmpnent used. This will ensure that yu have the crrect tls and supplies required t cmplete the transverter. It is als time t make the last minute decisin n building the kit r nt. A full exchange twards an assembled versin will be prvided if yu d nt g past this step. We want yu t be n the band and perating nt struggling t assemble this because yu were nt aware f the effrt and techniques required takes t assemble this transverter! At this time yu may want t mark the cmpnent placement diagram with the assciated cmpnent values by the designatrs. Simply transpse the cmpnent list values t the cmpnent placement dcument. We d nt d this because the values will change ver time depending n availability, engineering changes, r bslesces. The cmpnent list is easier t update and maintain prviding all users the latest imprvements r changes t the design. Updates t the design will be maintained n the DEMI web site in the future. Nw! Start the assembly! 1. Install all bttm side cmpnents f the PCB. K1-K3, Q1, and Q2. D nt slder the cans f Q1 and Q2. All 5 filters are already installed and adjusted! 2. Install all active surface munt active cmpnents, Q3, IC1- IC3, IC5- IC7, and IC10 n the tpside f the circuit bard per the tpside cmpnent placement diagram. D nt install IC4, VR1-VR4, r D1-D9 3. Install all surface munt capacitrs and resistrs and L31 per the tpside cmpnent placement diagram. Review the assembly tips if necessary pertaining t multiple cmpnents sharing the same pad. Be sure f the placement f C57and C59. They are dependent f the cnfiguratin f the transverter yu require. Cmmn antenna prt (C57 and C59) r split transmit and receive (C57A and C59A). 4. Wind inductrs L1, L3, L9 and L10 as specified in the Bag 3 parts list. Then install all inductrs L1-L31. L5 r L5A placement is dependent n the placement f C59. The mlded chkes L2, and L30 shuld be surface munted. L12 is ptinal and shuld be installed if yu wish t activate the PTT circuit thrugh yur Transceiver s IF cable. 5. Nw install all left ver leaded cmpnents, pts, resistrs, capacitrs, dides, Q4 and regulatrs. D nt install IC4, IC9, Y1, SW1, PTC1, R22, C72, r the LED s. D a surface munt installatin f C49, VR3, VR4, R25, R24, R10, R18, D2, D3, D8, and D9. When sldering the leaded surface munt cmpnents, d nt allw slder t leak thrugh the grund plane f the PCB. It will pl up and interfere with the pallet assembly. If yu have a questin, place the PCB n the pallet t check. 6. Install the crystal as shwn in Figure 6. D nt install the PTC1. It will ccur later in the assembly instructin after testing. The tpside cmpnent placement shws the crystal standing up but lay it dwn ver L2 as shwn in this pictrial. Again, d nt install the PTC. 9Vlt Supply Slder Wire t Grund and Xtal CRYSTAL Xtal leads ~1/8 Space between PC Bard and Xtal Figure 6. Crystal and PTC-60 installatin detail. /Kits/ CK.dc 6 Rev. B 9/20/2007

7 7. Attach the PCB t the pallet. Use tw 4-40 x 3/16 screws by the antenna cnnectr and tw 4-40 x 1/4 screws with #4 flat washers by the scillatr sectin. If yu find slder interference between the PCB and the pallet, remve it by wicking r filing! 8. Attach the cnnectr panel t the pallet. Review the cnfiguratins belw. Yur panel has all f the hles in it. Yu may install all f the cnnectrs r just the cnnectrs yu desire. Trim the Tefln n the cnnectrs flush with the panel. Use the 3-48 screws fr the SMA cnnectrs r 4-40 screws fr the N cnnectr. The lnger 3/8 screws g thrugh the cnnectr and panel, then int the pallet. The shrt 3/16 screws hld the cnnectrs t the panel. Yu may use the screws t plug the hles if yu d nt use the cnnectr. After the cnnectrs are installed, verify that the panel is a flush munt with the pallet and then slder the pins. If yu need t re-psitin the PCB fr the panel t be flush, d s. 9. Use the bttm side cmpnent placement as a guide and wire the cnnectins with the supplied #24 Tefln wire. Install them all as shwn. The cnnectin frm the +13 VDC cnnectin and the RCA cnnectr is dne with the heavier green wire. Make the cnnectin frm the PTT cnnectr t the PCB. Install the grund lugs as shwn with the shrt 1/ screws and slder the 1000 ρf caps in place. 10. Find the bttm half f the enclsure (the ne with the hles in it) and line up the pallet with the munting hles. Insert any tw 4-40 x 7/16 screws and start them. Install 2 flat head screws in the rear panel. Be sure the wires are clear f the ribs and filters and tighten all screws. If the pallet wbbles, smething is being pinched!! Insert the switch int its psitin but d nt slder. Install the switch panel with 2 flat head screws then slder the expsed leads f the switch. Install the LED s. The shrt lead is grund. Nw remve the pallet frm the enclsure and trim all excess leads frm the bttm side f the PCB and slder the munting leads f the switch. 11. Attach the M67715 t the pallet. Use the thermal cmpund supplied, line up the pins with the PCB and use the 4-40 x 1/4 screws. Slder the 5 pins. Nw make a determinatin f what keying scheme yu will use, PTT-H (+ vltage) r PTT-L (Grund t transmit) and make the apprpriate jumper cnnectin frm the PTT cnnectin n the tp side f the PCB. 12. Using the matrix belw, make a determinatin f the required IF drive level and decide if yu want a cmmn r split IF. All IF drive levels may be achieved frm 1 mw t 10 watts by fllwing the supplied schematic, matrix, and simplified cmpnent layut. The 50 hm lad (R36) is munted n the frnt panel and is installed after the pallet is aligned with the frnt panel during final test. 13. Install the IF cax between the IF cnnectr (s) n the rear panel and their prper lcatins n the PCB. Refer t the custm pictrial fr the crrect cnfiguratins. /Kits/ CK.dc 7 Rev. B 9/20/2007

8 144 MHz. IF Cnfiguratins mw Drive 200 mw-2w Drive 1-10W Drive C72 Nt Installed Nt Installed 1ρF R36 Nt Installed 50Ω, 30W 50Ω, 30W R22 220Ω, 1/4W 220Ω, 1/4W Nt Installed IF Cnnectins, Cmmn r Split Start the Testing Prcedure 1. All f the initial testing f the transverter is dne with the pallet assembly nly. Befre yu start verify that all cmpnents are installed except fr the mixer, IC4 and the 50 hm lad. Cnnect a 13.8VDC supply capable f 3 amps t the +13.8VDC cnnectr. Flip the switch t the n psitin (Up) and verify that the LED lights. 2. Test the receive vltages f the transverter first. Use the RX matrix belw. /Kits/ CK.dc 8 Rev. B 9/20/2007

9 LOCATION RX VOLTAGE Matrix referenced t Grund Junctin f C47 and C VDC Output f VR1 (+9) +9.0 VDC ±0.2V Output f VR4 (C66) +5.0 VDC ±0.2V Junctin f IC1 and C7 Between 1.5 and 2.5. Depends if Oscillatr is running r nt Junctin f IC1 and C9 Between 3.5 and 2.5. Depends if Oscillatr is running r nt Junctin f IC2 and C VDC ±0.3V Junctin f IC2 and C VDC ±0.5V Junctin f IC3 and C VDC ±0.3V Junctin f IC3 and C VDC ±0.5V Junctin f IC5 and C VDC ± 0.3V Junctin f IC5 and C VDC ± 0.3V Junctin f IC10 and F5 0 VDC Junctin f IC10 and C VDC ± 0.3V Junctin f Q3 and R VDC ± 0.5V Junctin f Q2 and C6 8.5 VDC ±0.5V Junctin f Q1 and C3 9.0 VDC ±0.5V If any vltages are fund t be ut f tlerance, check fr assembly errrs, pens, shrts, r wiring mistakes n the bttm f the pallet. Sme vltages may exceed the tlerances listed. This is because MMIC s vary lt t lt. MMIC s will exhibit a current drain if wrking. They will either drp all f the vltage acrss the resistr if shrted r nt draw any current if inperative. If the test vltages are clse, assume the MMIC is wrking crrectly fr nw. 3. Be sure t read all f the RF testing prcedure. If yu have test equipment like a signal generatr, spectrum analyzer, and mw pwer meter, yu may decide nt t install the mixer t cmplete the testing. The test prcedure will cver bth methds f testing. If yu d nt have the mentined test equipment, install the mixer, (after verificatin f the RX vltages). If yu have an mw meter, cnnect a cax pigtail t the pen pad n C17. This will be the LO circuit s utput and the Mixer s LO input. This pigtail shuld have a SMA r BNC type cnnectr s it can be used fr measuring the pwer level and frequency. Start the scillatrs tune up by spreading the turns f L1 t 1 wire diameter. Prbe the junctin f R6 and C7 with a vltmeter. There shuld be minimum vltage f apprximately 0.4 VDC. Adjust C2 t peak the vltage. Yu may need t cmpress L1 if yu cannt find a peak. If yu have a pwer meter cnnected, verify that the utput is +17 dbm (+15 dbm minimum). Yu may want t slightly Tweak F1 and F2 fr maximum pwer. D nt adjust F1 r F2 after the mixer is installed! After the vltage is peaked, verify the frequency f peratin if yu have a frequency cunter. If yu installed the mixer, yu can prbe C17 with a frequency cunter. The frequency shuld be apprximately MHz. Yu may nt be able t adjust C2 t net the frequency. It is nt imprtant at this time and will be adjusted after the final assembly. Just be sure the vltage is peaked. 4. After the LO has been tested, remve the DC pwer frm the pallet and slder the cans f Q1 and Q2 t the grund plane. Next find and un-slder ne lead frm PTC1. Attach the PTC t the crystal as shwn in figure 6. Attach a wire frm the crystal case t grund. Keep the lead as shrt as pssible. The vltage lead is attached t the utput pad f VR1, labeled n the cmpnent placement as +9. Pwer up scillatr t verify peratin. If OK, attach the shield ver the scillatr with the tw 4-40 x 1/4 screws and tw #4 flat washers. Be sure nt t shrt the utput /Kits/ CK.dc 9 Rev. B 9/20/2007

10 f F1 t the case. Psitin the shield as shwn n the cmpnent placement diagram. If yu are unsure abut the shield shrting the F1 filter, yu may cut a small ntch in the shield by C The RX testing is as fllws. Install IC4 nw if nt previusly dne. Cnnect the IF prt f the transverter t a 144 MHz transceiver r spectrum analyzer and adjust R14 cunter clckwise. Inject a 1296 signal int the antenna r RX prt (-30 dbm r s) with a signal generatr r use a signal n the 23 CM band. Adjust C59 and C60 fr maximum signal strength n the spectrum analyzer r in the 144 MHz transceiver. Tune fr max gain. This will be very clse t best nise figure. When cmplete, cycle the transverter pwer n and ff t detect the gain in the receiver. A final adjustment will be made after the final assembly is cmplete s yu d nt need t make it perfect. Just verify that the receiver has gain. If yu have a analyzer, this wuld als be the time t Peak F5 and F3 but it shuldn t be necessary. 6. Transmit testing is next. Discnnect all cables frm the transverter and install the pallet int the bttm enclsure Start all 6 f the 4-40 x 7/16 screws. D nt tighten. Start the rear panel screws. Then install the frnt panel and gradually tighten all f the 10 screws tgether t ensure a gd fit. Tighten everything evenly t be sure that the pallet is resting n the ribs in the enclsure. Be sure nt t pinch any wires. Cnnect a 50 hm lad either n the TXRF prt r the antenna cnnectr. Then cnnect the DC vltage and pwer it n. T test the TX vltages, key the PTT line (PTT-H r L) and measure t verify against the TX vltage matrix. If any vltage is ut f tlerance, verify all surrunding cmpnents and recheck bttm side wiring. Remember, MMICs draw a specified amunt f current but may be a bit ut f tlerance LOCATION TX VOLTAGE Matrix referenced t Grund Output f VR3 (C55) +9.0 VDC ± 0.3V Junctin f IC6 and C VDC ± 0.5V Junctin f IC6 and C VDC ± 0.5V Junctin f IC7 and C VDC ± 0.5V Junctin f IC7 and C VDC ± 1.0V Junctin f R12 and D VDC ± 0.3V Junctin f D3 and L VDC ± 0.3V Junctin f D1 and K VDC (if K3 is nt installed, n need t test) Junctin f D7 and K VDC (if K1 is nt installed, n need t test) Junctin f L30 and C VDC ±0.3V 7. T RF test the transmit sectin, If yu need t use yur 2 meter transceiver, install the 50 hm lad if it is required fr yur cnfiguratin. Cnnect a pwer meter that can measure MHz t the TXRF r ANT cnnectr Cnnect yur IF drive surce t the BNC cnnectr (cmmn IF r TXIF). Check yur drive pwer level befre applying drive. Adjust R20 clckwise fr maximum attenuatin. Key the PTT line and apply TX drive either frm yur generatr r transceiver and adjust the R20 t btain a desired utput pwer. The utput pwer will depend n the IF drive level setting f R20. If yu cannt btain the crrect utput pwer by adjusting R20, check yur cnfiguratin and measure yur drive level. D nt assume that there is t much attenuatin in the IF sectin if the unit will nt make the utput pwer specificatin and change the attenuatin values. If the IF is cnfigured fr a lwer drive level, damage may ccur t the mixer if it is ver driven even fr a shrt perid f time. If yu have variable utput pwer n yur 2 meter transceiver r generatr, set it t the minimum and raise it until saturatin ccurs. This is when the utput pwer des nt increase when the drive level is increased. If this happens, suspect a /Kits/ CK.dc 10 Rev. B 9/20/2007

11 prblem in the TXRF sectin f the transverter. If the transverter des nt appear saturated, suspect a prblem in the IF sectin. Final Assembly Check all screws and cnnectrs fr tightness. Place the tp lid n the enclsure and allw the unit t perate in receive fr 1 hur with either a lad r an antenna cnnected. The unit will becme warm t the tuch. If yu have a 23 cm signal and the IF transceiver cnnected, yu may ntice sme frequency drift. After the first hur f peratin, the majrity f frequency drift is cmplete and the scillatr will be stable enugh fr netting the frequency if required. Remve the cver and adjust C2 t match the frequency f a knw signal r measure the LO frequency at C17. If the desired frequency cannt be btained befre the scillatr either shuts ff r becmes unstable, determine if it is t high in frequency r t lw. If it is t high, remve the LO shield and cmpress the L1 inductr and readjust C2. If the frequency is t lw, spread the cil slightly and re-adjust C2. If the frequency is still t lw a circuit mdificatin will be required. The circuit mdificatin is described belw but technical details are cvered in ur Design Nte #16 fund in the library sectin f DEMI web site ( The mdificatin is simple. After the shield is remved frm the base scillatr sectin, remve the crystal and L2. D nt remve the PTC frm the crystal!! Cut and remve the nw empty pad still cnnected t R5 and R4 between the placement f L2 and the R4, R5 cmbinatin. Install a 10 pf chip cap acrss the gap in the cut pad. See figure belw. The chip cap becmes a series cap between the L2 /crystal and the R4/R5 cnnectin. Then re-install L2 and the crystal and retest. Yu may need t spread r cmpress the L1 inductr fr best results. Net the frequency, install the shield and allw the unit t warm fr 10 minutes befre the final adjustment is made. /Kits/ CK.dc 11 Rev. B 9/20/2007

12 When cmplete yu may retest the RX and TX sectin and re-adjust the IF levels as desired. If cmplete, attach the lid and the 4 screws r yu may als wish t install sme r all f the user ptins. They are listed starting n the bttm f this page. Cmpletin This cmpletes the assembly and testing f the CK. Yu nw have enugh knwledge f hw this assembly wrks that implementing it int a cmplete wrking transverter system shuld nt be a technical prblem. The receive cnversin gain is limited fr a reasn. This receive sectin will nt verlad in a RF dense envirnment. If the transverter is t be used in a high perfrmance terrestrial r EME set up, a mast munt LNA that has better nise figure perfrmance will be desired. If s, additinal filtering may be required and the use f the IF amplifier may need t be mitted. Simply adding a LNA t the frnt f the transverter will imprve the nise figure but will degrade its dynamic range by the amunt f gain added. It is nt recmmended t add an LNA unless it is mast munted. If a higher pwer amplifier is added, als cnsider and additinal filter and islatr. DEM User Optins and perfrmance Imprvements: Add an external preamplifier fr nise figure imprvement. If a better nise figure is desired, simply placing a LNA with a mdest gain at the antenna will slve that prblem. Understand that the additin f gain in frnt f this stck transverter will degrade the IMD perfrmance, and reduce the dynamic range f the transverter by mre than the amunt f gain added. Yu may get a way with ding nthing mre than adjusting the RXIF gain cntrl if yu perate in a nn-hstile RF envirnment. If yur LNA is a ultra lw nise unit, it mst likely will nt have the IP3 perfrmance the transverter has. It will verlad befre any cmpnent in the transverter will. S, yur receive system nw becmes limited by it s external LNA s perfrmance. If yu increase the gain perfrmance f yur external LNA, (25-30 db) yu may cnsider bypassing the transverters LNA cmpletely because it s IP3 perfrmance is ttally cntrlled by the external LNA. T d s, remve L5, L31, C59, R31, and R30 frm the circuit. Then cnnect a shrt piece f cax between the RX antenna and C63. Be sure t keep it as shrt as pssible and slder the grunds. Anther ptin is t remve the IF amplifier. If yu need t reduce the gain by less than 10 db, remve IC5 and R18. Then yu may use a 100 pf disc capacitr and place it frm where the input and utput leads f IC5 was. Yu may then still adjust the RXIF cntrl t yur desire. Install / Remve RXIF gain stages: This was briefly discussed in the external preamplifier sectin. Fr whatever reasn, yu may require additinal gain r have t much IF gain. IC5 can be installed r remved at any time. Be sure f yur systems perfrmance when deciding t make a change. Yu are als nt limited t the supplied ERA 6 MMIC. Yu may chse a higher gain unit. The ERA 6 was chsen fr its IP3 utput perfrmance. Using this MMIC desn t degrade the transverters verall perfrmance. A high gain MMIC will nt nly reduce the IP3 by the difference in gain but will als degrade the system if a lwer IP3 utput device is used. In the future, this MMIC will change as sn as smething better becme available. If changing r remving the MMIC, be sure t add r remve the crrect chke and bias resistr fr the desired MMIC. The RXON signal is the same vltage that the transverter perates n s calculate the new bias resistr based n that vltage. /Kits/ CK.dc 12 Rev. B 9/20/2007

13 Additinal RX selectivity: If yu find yurself requiring mre selectivity frm lwer frequency ut f band prducts, a mdificatin can be perfrmed. The alignment is very critical and virtually cannt be dne withut test equipment. A minimum f a steady level, signal surce is required. In the factry, we wuld nt ever think abut ding this with ut a nise figure meter. The md ges like this. In bag 3 f yur kit yu will find a 2 turn red cil and a piece f buss wire. The cil is designated L6A. First, remve L6 frm the circuit. It is a single turn and blue. Install L6A and the same side as L6 but as clse t the gate lead f Q3 as pssible. D nt stretch the cil! Slder the ther end n the grund. Then cut f buss wire. This wire will frm a shunt inductr. Put a slight bend in the wire and attach it n the same side as L6A but as clse t the FET side f C59 as pssible. Tack slder the ther end t grund. Then push the wire clse t the bars as pssible withut tuching. Nw measure frm C59 and put a slder bead n the wire t grund. Yu may nw re-tune the frnt end fr maximum gain. Yu may d an n the air test t check fr additinal selectivity. It shuld perfrm better and if nt there is little hpe with ut and external bandpass filter! What is the nise figure? We have seen the best at 1.5 db and the wrst at 3.5 db by tuning fr maximum gain. In the factry we assemble all f the transverters with this md. They are all tested n a nise figure meter and we find at sme time we need t sacrifice sme gain t imprve the nise figure. Gd luck with this md! Auxiliary Switching cntacts: The auxiliary cntacts in K2 are labeled C (cmmn) NO (nrmally pen) and NC (nrmally clsed). The C cnnectin can be wired t grund r psitive vltage such as the surce VDC. The K2 cmmn cnnectin will then be tggled depending n what state the transverter is in. The cntacts are marked fr the receive mde. The NO r NC can be wired t the AUX cnnectr n the enclsure. Peak Perfrmance. S yu want the best pssible perfrmance pssible? Unless yu have a signal generatr, nise figure meter, spectrum analyzer, and a micrwave pwer meter, yu have given it yur best sht. If yu d have this equipment, then have at it. Every filter can be ptimized t yur perating frequency fr maximum selectivity and minimum insertin lss. All f the filters have been tuned int a 50 Ohm system. Once they are cnnected t the active cmpnents, they nw have sme mismatches. Please understand that these mismatches are nt crucial t the peratin f the transverter, but they can be minimized. D what yur engineering skills allw yu t d. Yu culd always find a db r tw and reduce the amunt f spurius emissins. Yu may als find ut that if yu reduce yur TX drive level, the spurius imprve. A lessn well learned in mixer saturatin. Have fun!! Frequency Stability If the frequency stability is the prblem, remve the shield and re-peak the vltage. When adjusting fr frequency, the scillatr is smetimes left n the edge f perating. When n this edge, the frequency will be unstable. After the vltage is peaked, replace the cver n the LO and allw it t warm. Check fr stability. If stable, fllw the frequency netting instructin (DN016) fund in the final assembly sectin f this dcument. If the vltage is peaked and yu still experience drifting (greater than 300 Hz. After a 10 minute warm up), recrd its tendencies and cnsult DEMI with the prblem. Stability is the functin f temperature and cmpnent tlerance. If yu are sure the LO sectin is assembled crrectly we can help. /Kits/ CK.dc 13 Rev. B 9/20/2007

14 Cnclusin We hpe yu had fun with this kit and that yu enjy many hurs f peratin with this transverter. The gal f this kit was t ecnmically prvide the radi amateur with the highest perfrmance available in a 23 cm transverter while maintaining a cmpact and prtable design. We wish yu years f fun and excitement wrking many cntacts bth lcal and DX! Gd luck n the band! DEM K and CK Cmpnent List BAG 1 CONTENT Resistr (R) values are in Ohms and are chips unless therwise specified. R1 470 R9 130 R20 1K POT R28 24 R2 1K R /2W leaded R /4W leaded R29 24 R3 1.5K R12 1K 1/4 leaded R /4W leaded R30 12 R4 100 R /4W leaded R23 1K R R5 51 R14 1K POT R /4W leaded R32 12 R6 100 R /4W leaded R /2W leaded R33 1K R7 100 R /2W leaded R26 1K 1/4W leaded R34 5.1K 1/4W leaded R8 130 R /4W leaded R /4W leaded R35 5.1K 1/4W leaded BAG 2 CONTENTS: Capacitrs (C) values are in ρf and are chips unless therwise specified. C1 0.01µF C C39 33 C VAR. C2 1-4 Pistn C21 18 C40 0.1µF C61 0.1µF 1008 C3 0.01µF C23 18 C41 33 C62 0.1µF 1008 C4 18 C C42 33 C63 33 C5 22 C µF C43 0.1µF C64 33 C6 0.01µF C C47 0.1µF C µf C7 0.01µF C27 18 C C µf Tant. C8 0.1µF C28 18 C µf Elect. C67 33 C9 33 C C50 0.1µF C68 0.1µF C µf Tant. C30 0.1µF C C µf C11 0.1µF C C C70 33 C12 33 C C µf Tant. C µf C13 33 C33 0.1µF OPT. C54 0.1µF C72 1 ρf leaded C14 0.1µF C C µf Tant. C73 0.1µF C15 0.1µF C C56 0.1µF 10 pf ptinal (1) C16 33 C C57, A 33 C17 33 C µF C58 100µF Elect. C18 33 C38 33 C59, A VAR. BAG 3 CONTENTS: All inductrs have the enamel wire size and turns specified. Identify the Mlded chkes by bdy clr and band clrs. All thers are as indicated. L1 3 Turns 1/8" ID #24 Wire (HW) L9 5 Turns, 1/8 ID #24 WIRE (HW) L µh (Small bdy, brwn-black) L10 5 Turns 1/8" ID #24 Wire (HW) L3 6 Turns 1/8" ID #24 Wire (HW) L12 1.0µH (brwn/black) L5, A 5 Turns 0.05 ID #28 Wire (pre wund) L µh(green bdy, range bands) L6 1T, BLUE Bdy (pre wund) L31 10 ηh (0603 chip inductr) L6A 2T, RED Bdy (pre wund) ptinal 1 # 18 buss wire L8 5 Turns #28 Wire (pre-wund) 1 - wden dwel /Kits/ CK.dc 14 Rev. B 9/20/2007

15 BAG 4 CONTENTS: Nte that all filters (F1-F5) are pre-installed in yur PCB. Q1 2N5179 D9 1N914 IC6 MAR3 Q2 2N5179 F C - Installed IC7 MAV11 Q3 ATF34143 F C - Installed IC10 AH31 Q4 KN2222 F C- Installed VR1 78S09 D1 1N4000 type F C - Installed VR3 78S09 D2 MPN3404 F C- Installed VR4 78M05 D3 MPN3404 IC1 ERA3 K1 G6Y-1 D4 HSMP 3814 IC2 ERA2 K2 G5V-2 D5 1N4000 type IC3 ERA5 K3 G6Y-1 D6 1N914 IC4 SYM-14H PTC1 PTC 60 Thermistr D7 1N4000 type IC5 ERA 50 Y1 Crystal MHz HC 18/U D8 1N914 HARDWARE (2) 1000ρF leaded R36 THC 50 Ω, 10 W Lad (1) Type ¾ "N" cnnectr SW1 Pwer Switch (2) SMA cnnectrs (1) Shield- Prepped (2) BNC Female UG1094/U Cnnectrs (3 ) #18 Tefln wire (3) RCA Jacks (Cntrl, Aux., Pwer) (3 ) #24 Tefln wire (4) 4-40 x 3/16 Screws (20 ) Cax (2) 4-40 x 3/8" Screws (1) 3/8 Hle Plug (4) 3-48 x 3/16 Screws (4) Adhesive Backed Rubber Feet (4) 3-48 x 3/8 Screws (1) Set f Labels (5) 4-40 x 1/4 Screws (1) 1/4 Plate (6) 4-40 x 7/16 Screws (1) Switch Panel (2) 4-40 Nuts (1) Cnnectr Panel (2) #4 flat washers (8) Flat Head (2) #4 lugs (1) Machined Enclsure (2) LED, RED (1) Thermal Cmpund (2) 4-40 x 1/8 Screws Miscellaneus Lse Parts if required in yu kit (1) RF Pwer Mdule IC9, M (2) Printed Circuit Bard with filters installed. (3) Enclsure, tw halves. /Kits/ CK.dc 15 Rev. B 9/20/2007

16

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