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Table of Contents Introduction... 3 Required Parts List... 4 Before You Start... 6 Assembly Instructions... 7 Step #1 - Spacer (SPACER1, SPACER2, SPACER3, SPACER4)... 7 Step #2 - Transformer (T1, T2)... 9 T1... 9 T2... 11 Step #3 - Fixed Resistor (R1, R2, R3, R4, R5, R6, R7, R8, R10, R11, R13)... 13 Step #4 - Variable Resistor (VR1)... 14 Step #5 Diode (D1, D2, D4, D5, D6, D7)... 16 Step #6 - Field Effect Transistor (Q2, Q3)... 18 Step #7 Bead & Air Inductor (L2, L3, L4)... 20 Step #8 - Electrolytic Capacitor (C1, C2, C5, C8, C9)... 22 Step #9 - Ceramic & Mica Capacitor (C3, C6, C7, C10, C11, C12, C13, C14, C15, C16, C17, C18, C21, C22, C23, C24, C25)... 23 Step #10 - Fuse Holder (F1)... 25 Step #11 - Relay (RLY1)... 27 Step #12 - Toroid RF Choke (L1)... 29 Step #13 - Voltage Regulator (U1)... 31 Step #14 - Field Effect Power Transistor (Q1)... 33 Step #15 Field Effect RF Power Transistor (Q4, Q5)... 35 Step #16 Coaxial Cable... 37 Step #17 - Switch, LED, and Power Wiring... 38 PCB Mounting to Heat Sink... 39 Bias Adjustment... 42 Amplifier Operation... 43 Connecting the Amplifier... 43 Transmitting... 43 Troubleshooting... 44 Specifications... 45 RF Performance... 46 Page 2 of 46
Introduction Congratulations on your purchase of the new SkyWave DX150 RF Amplifier PCB. This PCB is a result of the highest quality engineering to provide excellent performance and reliability. Listed below are some of the key features: +13.8VDC Operation All Mode (AM, FM, SSB) 10-Meter Amateur Band Coverage MOSFET (FQP13N10) Push-Pull Configuration Low Current Requirement Can Plug into Most Vehicle Cigarette Lighter Receptacles Class-AB Bias High Output Power / Low Harmonic Content Carrier Operated or Manual* Transmit / Receive Switching Continuous Reverse Voltage Protection without Damage to Amplifier or Fuse Thermal Shutdown Fuse Protected Selectable SSB Delay Power and Transmit Indicators Low Stand-By Power Consumption Teflon Insulated Wire Premium Quality FR-4 Grade Printed Circuit Board w/ Solder Mask & Silk Screen High Reliability Design We have developed a logical step-by-step procedure that we hope will make your assembling experience efficient & pleasurable * Contact Telstar Electronics for details on using this feature. Page 3 of 46
Required Parts List Quantity Description Reference 24 Cable, Coaxial, RG174A/U Type, 52-Ohm RF IN, RF OUT 7 Capacitor, 0.01uF, 100V, 20%, Z5U, Radial (LS=0.197") C7, C11, C13, C15, C17, C18, C24 3 Capacitor, 0.1uF, 50V, 10%, X7R, Radial (LS=0.197") C6, C10, C14 1 Capacitor, 1000pF, 500V, 10%, X7R, Radial (LS=0.197") C12 1 Capacitor, 100uF, 25V, 20%, 1K Hours, 105C, 5x11mm, Radial (LS=0.079 ) 3 Capacitor, 10uF, 25V, 20%, Radial (LS=0.079") C1, C2, C5 1 Capacitor, 1uF, 50V, 20%, Radial (LS=0.079") C8 3 Capacitor, Dipped Mica, 330pF, 1000V, 5%, Radial (LS=0.232") C16, C23, C25 2 Capacitor, Dipped Mica, 47pF, 500V, 5%, Radial (LS=0.232") C3, C22 1 Capacitor, Dipped Mica, 560pF, 500V, 5%, Radial (LS=0.344") C21 2 Diode, High Speed Signal, 1N914, DO-35, Axial D1, D2 1 Fuse, ATC, 15A F1 1 Holder, Fuse, ATC Type, TH F1 2 Inductor, RF Choke, 15uH, Wound Bead, Axial L2, L3 1 Inductor, Air, 12T, #18 Magnet, 0.312" Diameter, Close Wound L4 3 Insulator, Phase Change, TO-220 1 PCB, (3.8 x 5.4 ) N/A 1 Potentiometer, 1K, 0.1W, V-Adjust, TH VR1 1 Regulator, Voltage, 5V, 1A, TO-220 U1 1 Relay, DPDT, 5V, 8A, DIP RLY1 1 Resistor, 1.5K, 0.25W, 5%, Axial R2 1 Resistor, 100, 0.25W, 5%, Axial R5 2 Resistor, 100, Metal Oxide, 2W, 5%, Axial R7, R8 1 Resistor, 100K, 0.25W, 5%, Axial R3 2 Resistor, 10K, 0.25W, 5%, Axial R4, R6 1 Resistor, 3.3K, 0.25W, 5%, Axial R11 2 Resistor, 330, 0.25W, 5%, Axial R1, R13 1 Resistor, 47K, 0.25W, 5%, Axial R10 C9 INSUL1, INSUL2, INSUL3 (Q1, Q4, Q5) Page 4 of 46
Quantity Description Reference 4 Screw, Machine, Philips Pan Head, 4-40, 1/4", Stainless Steel TO-220 to Heat Sink. 4 Screw, Machine, Philips Pan Head, 4-40, 5/16", Stainless Steel PCB to Heat Sink. 4 Spacer, Round, 0.250"D, 0.125"ID, 0.100" Thick 1 Toroid, 0.825"OD, 0.520"ID, 0.250"W, #43 Material L1 1 Transformer, RF Input, #43 Material T1 1 Transformer, RF Output, #43 Material T2 2 Transistor, FET, N-Channel, Switching, 100V, 12.8A, 65W, TO-220 Q4, Q5 1 Transistor, FET, N-Channel, 2N7000, TO-92 Q3 1 Transistor, FET, P-Channel, TP0606, TO-92 Q2 1 Transistor, FET, P-Channel, SUP75P03-07, TO-220 Q1 SPACER1, SPACER2, SPACER3, SPACER4 4 TVS, Uni-Directional, DO-15 D4, D5, D6, D7 3 Washer, Shoulder, Black Plastic Insulating, TO-220 14 Wire, #16, Teflon, Red, Stranded L1 WASHER1, WASHER2, WASHER3 (Q1, Q4, Q5) 21 Wire, #20, Teflon, Orange, Stranded T1, T2 (T1=6", T2=12") 24 Wire, #22, Teflon, Blue, Stranded LED1, SW1 24 Wire, #22, Teflon, Green, Stranded LED1, SW1 24 Wire, #22, Teflon, Purple, Stranded LED2, SW2 24 Wire, #22, Teflon, Yellow, Stranded LED2, SW2 24 Wire, Zip Cord, #12, Red/Black 13.8V, GND Page 5 of 46
Before You Start This document assumes a basic understanding of electronics, soldering, and operation of hand tools. In addition to basic hand tools, the following items will be required for proper assembly. PCB Assembly: Soldering Iron Electronic Solder 7/64 Drill Bit (Alignment of SPACER1, SPACER2, SPACER3, SPACER4) 1/4 Drill Bit (Lead Forming of U1, Q1, Q4, Q5) Needle Nose Pliers Diagonal Cutting Pliers Wire Stripper PCB Assembly to Heat Sink: Heat Sink (See Page 39 for Requirements) Power Drill #4-40 Tap (Mounting Holes in Heat Sink) #42 Drill Bit (Mounting Holes in Heat Sink) Masking Tape Transfer Punch Bias Adjustment: 13.8VDC Power Supply (1 Ampere Minimum) Ammeter (Capable of Measuring 200mA) Several Jumper Wires w/ Alligator Clips Please take a few minutes before you begin assembling to review the entire assembly & adjustment procedure. A few things to remember during the assembly: Several components in this design are sensitive to static electricity. Precautions should be taken to avoid static buildup during assembly by using a grounded workstation mat and wrist band. References are made to the top and bottom side of the PCB. The top side contains the printed reference designators and component outlines. If at any time, you re unsure how to perform an assembly step or have a question, email us for assistance at telstar.electronics@comcast.net 35W-65W recommended. Temperature controlled soldering equipment is always preferred. Solder recommendation is Kester 331. This solder has a flux that can be washed off with warm tap-water. Page 6 of 46
Assembly Instructions Step #1 - Spacer (SPACER1, SPACER2, SPACER3, SPACER4) Locate the positions on the bottom of the PCB where the spacers will be attached. (Figure 1) With the aid of a 7/64 drill bit, position the drill bit shank through a spacer and through the hole on the PCB. The drill bit will aid in centering the spacer on the PCB hole during the soldering process. (Figure 2) IMPORTANT - MAKE CERTAIN THE SPACERS ARE FLAT AGAINST THE BOTTOM SIDE OF THE PCB BEFORE SOLDERING INTO POSITION. USE A MINIMAL AMOUNT OF SOLDER MAKING CERTAIN NOT TO OBSTRUCT THE INNER HOLE. Solder the spacers in position. SPACER SPACER SPACER SPACER Figure 1 The drill bit shank is the solid portion that doesn t contain the spiral cutting flutes. Page 7 of 46
Details of spacer installation. Figure 2 Page 8 of 46
Step #2 - Transformer (T1, T2) T1 IMPORTANT - TRANSFORMERS ARE POLARIZED AND MUST BE INSTALLED IN THE PROPER ORIENTATION. Position T1 on the PCB noting the proper transformer polarity. (Figure 3) Solder all three pads on T1 for proper attachment to PCB. Strip the insulation from one end of the 6 AWG#20 wire. Solder the stripped end to the START pad. (Figure 3) Wind the unsoldered end of the wire three complete turns through the tubes of the transformer in a loop type fashion. (Figure 4 and Figure 5) Cut and strip the wire, making it just long enough to reach to the FINISH pad. (Figure 3) Solder the wire to FINISH pad. (Figure 3) START T1 FINISH Figure 3 Page 9 of 46
Details of T1 installation. Figure 4 Figure 5 Page 10 of 46
T2 IMPORTANT - TRANSFORMERS ARE POLARIZED AND MUST BE INSTALLED IN THE PROPER ORIENTATION. Position T2 on the PCB noting the proper transformer polarity. (Figure 6) Solder all three pads on T2 for proper attachment to PCB. Strip the insulation from one end of the 12 AWG#20 wire. Solder the stripped end to the START pad. (Figure 6) Wind the unsoldered end of the wire three complete turns through the tubes of the transformer in a loop type fashion. (Figure 7 and Figure 8) Cut and strip the wire, making it just long enough to reach to the FINISH pad. (Figure 6) Solder the wire to FINISH pad. (Figure 6) START T2 FINISH Figure 6 Page 11 of 46
Details of T2 installation. Figure 7 Figure 8 Page 12 of 46
Step #3 - Fixed Resistor (R1, R2, R3, R4, R5, R6, R7, R8, R10, R11, R13) IMPORTANT - FIXED RESISTORS HAVE NO POLARITY AND CAN BE INSTALLED IN EITHER DIRECTION. MAKE CERTAIN THE RESISTORS ARE FULLY SEATED IN THE PCB BEFORE SOLDERING. Install resistors into the PCB at the proper designated positions. (Figure 9) Solder all resistors in position. Cut the excess lead length on the bottom of the PCB. Figure 9 Page 13 of 46
Step #4 - Variable Resistor (VR1) IMPORTANT - VARIABLE RESISTORS ARE POLARIZED AND MUST BE INSTALLED IN THE PROPER ORIENTATION. MAKE CERTAIN THE RESISTOR IS FULLY SEATED IN THE PCB BEFORE SOLDERING. Insert VR1 into PCB. (Figure 10 and Figure 11) Solder variable resistor in position. Cut the excess lead length on the bottom of the PCB. Figure 10 Page 14 of 46
Details of VR1 installation. Figure 11 Page 15 of 46
Step #5 Diode (D1, D2, D4, D5, D6, D7) IMPORTANT - DIODES ARE POLARIZED AND MUST BE INSTALLED IN THE PROPER ORIENTATION. THE WHITE BAND INDICATED ON THE PCB INDICATES THE CATHODE. THIS POLARITY BAND IS ALSO PRESENT ON THE DIODE ITSELF. MAKE CERTAIN THE DIODES ARE FULLY SEATED IN THE PCB BEFORE SOLDERING. Insert D1 and D2 into PCB at the proper locations. (Figure 12) Solder diodes in position. Cut the excess lead length on the bottom of the PCB. Figure 12 Page 16 of 46
IMPORTANT - DIODES ARE POLARIZED AND MUST BE INSTALLED IN THE PROPER ORIENTATION. THE WHITE BAND INDICATED ON THE PCB INDICATES THE CATHODE. THIS POLARITY BAND IS ALSO PRESENT ON THE DIODE ITSELF. MAKE CERTAIN THE DIODES ARE FULLY SEATED IN THE PCB BEFORE SOLDERING. Insert D4, D5, D6, and D7 into PCB at the proper locations. (Figure 13) Solder diodes in position. Cut the excess lead length on the bottom of the PCB. Figure 13 Page 17 of 46
Step #6 - Field Effect Transistor (Q2, Q3) IMPORTANT - TRANSISTORS ARE POLARIZED AND MUST BE INSTALLED IN THE PROPER ORIENTATION. USE THE OUTLINE ON THE PCB AS A GUIDE TO INSTALL THE TRANSISTORS WITH THE FLAT SIDE AS SHOWN. Insert Q2 and Q3 into the PCB at the proper location. (Figure 14 and Figure 15) Solder transistors in position. Cut the excess lead length on the bottom of the PCB. FLAT FLAT Figure 14 Page 18 of 46
Details of Q2 and Q3 installation. Figure 15 Page 19 of 46
Step #7 Bead & Air Inductor (L2, L3, L4) IMPORTANT - INDUCTORS HAVE NO POLARITY SO THEY CAN BE INSTALLED IN EITHER DIRECTION. MAKE CERTAIN L2 AND L3 ARE FULLY SEATED IN THE PCB BEFORE SOLDERING. Insert L2 and L3 into the PCB at the proper location. (Figure 16) Solder both inductors in position. Cut the excess lead length on the bottom of the PCB. Apply solder to the PCB pads of L4. Apply solder to the ends of L4. It may be necessary to rub the soldering iron on the ends while applying solder, to get the solder to flow. Solder L4 in position, holding it in place using a needle nose pliers. (Figure 17) Figure 16 Page 20 of 46
Details of L2, L3, and L4 installation. Figure 17 Page 21 of 46
Step #8 - Electrolytic Capacitor (C1, C2, C5, C8, C9) IMPORTANT - ELECTROLYTIC CAPACITORS ARE POLARIZED AND MUST BE INSTALLED IN THE PROPER ORIENTATION. THESE CAPACITORS HAVE MARKINGS INDICATING THE - (NEGATIVE) TERMINAL. THE PCB INDICATES CAPACITOR POLARITY BY DISPLAYING A + (POSITIVE) SYMBOL CLOSEST TO THE POSITIVE TERMINAL OF THE CAPACITOR. MAKE CERTAIN THE CAPACITORS ARE FULLY SEATED IN THE PCB BEFORE SOLDERING. Insert capacitors into the PCB at the proper designated positions. (Figure 18) Solder all capacitors in position. Cut the excess lead length on the bottom of the PCB. Figure 18 Page 22 of 46
Step #9 - Ceramic & Mica Capacitor (C3, C6, C7, C10, C11, C12, C13, C14, C15, C16, C17, C18, C21, C22, C23, C24, C25) IMPORTANT - CERAMIC AND SILVERED MICA CAPACITORS HAVE NO POLARITY AND CAN BE INSTALLED IN EITHER DIRECTION. Insert each capacitor into the proper location. (Figure 19 and Figure 20) Solder all capacitors in position. Cut the excess lead length on the bottom of the PCB. C25 C21 Figure 19 Page 23 of 46
Details of ceramic & mica capacitor installation. Figure 20 Page 24 of 46
Step #10 - Fuse Holder (F1) IMPORTANT - FUSE HOLDERS HAVE NO POLARITY AND CAN BE INSTALLED IN EITHER DIRECTION. MAKE CERTAIN THE FUSE HOLDER IS FULLY SEATED IN THE PCB BEFORE SOLDERING. Press the fuse holder into the top of the PCB. (Figure 21 and Figure 22) Solder the fuse holder into position. Cut the excess lead length on the bottom of the PCB. Figure 21 Page 25 of 46
Details of F1 fuse holder installation. Figure 22 Page 26 of 46
Step #11 - Relay (RLY1) IMPORTANT - RELAYS ARE POLARIZED AND MUST BE INSTALLED IN THE PROPER ORIENTATION. MAKE CERTAIN THE RELAY IS FULLY SEATED IN THE PCB BEFORE SOLDERING. Install the relay into the top of the PCB. (Figure 23 and Figure 24) Solder relay in position. Cut the excess lead length on the bottom of the PCB. Figure 23 Page 27 of 46
Details of RLY1 relay installation. Figure 24 Page 28 of 46
Step #12 - Toroid RF Choke (L1) IMPORTANT - INDUCTORS HAVE NO POLARITY AND CAN BE INSTALLED IN EITHER DIRECTION. THIS INDUCTOR WILL REQUIRE WINDING THE SUPPLIED 14 LENGTH OF AWG #16 RED WIRE ONTO THE TOROID FERRITE CORE. Wind ten complete turns through the supplied core. Cut and strip wire ends. Solder L1 to top of PCB. (Figure 25 and Figure 26) L1 Figure 25 Page 29 of 46
Details of L1 installation. Figure 26 Page 30 of 46
Step #13 - Voltage Regulator (U1) IMPORTANT - VOLTAGE REGULATORS ARE POLARIZED, AND MUST BE INSTALLED IN THE PROPER ORIENTATION. Take the transistors and form the leads around a 1/4" drill bit so the leads are bent at a 90-degree angle. (Figure 28) Insert regulator from the bottom of the PCB so the leads protrude upward through the holes. (Figure 27) Place the PCB on a flat surface with the regulator in position and solder from the top of the PCB. (Figure 29) Cut the excess lead length on the top of the PCB. Figure 27 Page 31 of 46
Details of lead forming. Figure 28 Details of U1 installation. Figure 29 Page 32 of 46
Step #14 - Field Effect Power Transistor (Q1) IMPORTANT - TRANSISTORS ARE POLARIZED AND MUST BE INSTALLED IN THE PROPER ORIENTATION. Take the transistor and form the leads around a 1/4" drill bit so the leads are bent at a 90-degree angle. (Figure 31) Insert transistor from the bottom of the PCB so the leads protrude upward through the holes. (Figure 30) Place the PCB on a flat surface with the transistors in position and solder from the top of the PCB. (Figure 32) Cut the excess lead length on the top of the PCB. Figure 30 Page 33 of 46
Details of lead forming. Figure 31 Details of Q1 installation. Figure 32 Page 34 of 46
Step #15 Field Effect RF Power Transistor (Q4, Q5) IMPORTANT - TRANSISTORS ARE POLARIZED AND MUST BE INSTALLED IN THE PROPER ORIENTATION. Take the transistors and form the leads around a 1/4" drill bit so the leads are bent at a 90-degree angle. (Figure 34) Insert transistors from the bottom of the PCB so the leads protrude upward through the holes. (Figure 33) Place the PCB on a flat surface with the transistors in position and solder from the top of the PCB. (Figure 35) Cut the excess lead length on the top of the PCB. Figure 33 Page 35 of 46
Details of lead forming. Figure 34 Details of Q4 and Q5 installation. Figure 35 Page 36 of 46
Step #16 Coaxial Cable IMPORTANT - COAXIAL CABLE IS POLARIZED AND MUST BE INSTALLED IN THE PROPER ORIENTATION. THE BRAIDED PORTION OF THE CABLE IS ALWAYS ATTACHED TO GROUND (GND). Solder the coaxial cables at the proper designated positions. (Figure 36) Figure 36 Page 37 of 46
Step #17 - Switch, LED, and Power Wiring The SkyWave DX150 has been designed to accommodate two switches ** and two LED indicators. These switches and indicators have the following functions: SW1 (ON/OFF) Amplifier Main Power LED1 Main Power LED Indicator SW2 (SSB DELAY) SSB Delay Enable LED2 Transmit LED Indicator Solder the AWG#22 wires at the proper designated positions. (Figure 37) Solder the AWG#12 power cord into position with the red wire to 13.8V and the black to GND. (Figure 37) Details of switch, LED, and power wiring. Figure 37 ** Switches should be SPST type capable of 100mA@25V minimum. LEDs can be any color/size and should be rated for an operating forward current of 20mA. The PCB has been marked with the + for orientation connection purposes. Page 38 of 46
PCB Mounting to Heat Sink IMPORTANT - NOW THAT THE AMPLIFIER PCB HAS BEEN FULLY ASSEMBLED, IT MUST BE MOUNTED TO AN ADEQUATE HEAT SINK BEFORE THE BIAS ADJUSTMENT CAN BE PERFORMED. A HEAT SINK WITH A MAXIMUM THERMAL RESISTANCE OF 1.5 DEGREE CENTIGRADE/WATT IS RECOMMENDED FOR CONVECTION. Place the completed PCB on the heat sink. Use masking tape or equivalent to hold the PCB still during the marking process. Using a transfer punch, carefully mark the center of the four PCB mounting holes that contain the spacers, the two RF transistor mounting holes, and the two mounting tab holes at the edge of the PCB. (Figure 38) Figure 38 There are several internet sites that sell extruded aluminum heat sinks designed for RF power amplifiers. Several are listed below. Telstar Electronics takes no responsibility for the content of the links and does not endorse any specific product or service. Communication Concepts www.communication-concepts.com Heatsink USA www.heatsinkusa.com A transfer punch is a punch of a specific outer diameter that is non-tapered and extends the entire length of the punch (except for the tip). It is used to tightly fit the tolerances of an existing hole and, when struck, precisely transfer the center of that hole to another surface. Page 39 of 46
Remove the tape and PCB from the heat sink. Use an automatic center punch to enhance the marked centers prior to drilling. Use a #42 (0.0935 ) drill bit to drill all marked centers. Use a #4-40 tap to thread all eight drilled holes. Position insulators (INSUL1, INSUL2, INSUL3) on the heat sink so that they will make proper contact with the metal tabs of Q1, Q4, Q5 and will align properly with the tapped mounting holes. (Figure 39) Hover the PCB over the mounting holes drilled in the heat sink. Lower the PCB straight down onto the sink to avoid sliding the insulators. Install loosely four 5/16 #4-40 machine screws in the four PCB mounting that have the metal spacers below the PCB. Figure 39 Install loosely one 1/4" long #4-40 machine screw in the metal tab of U1. Page 40 of 46
IMPORTANT - PLASTIC INSULATING WASHERS ARE NOT SYMMETRICAL, AND MUST BE ORIENTED AS SHOWN BELOW. (FIGURE 40) Install three plastic insulating washers (WASHER1, WASHER2, WASHER3) on three 1/4"long #4-40 machine screws and install the screws loosely for Q1, Q4, and Q5. (Figure 40) Figure 40 IMPORTANT - DON T OVER-TIGHTEN SCREWS THAT CONTAIN THE PLASTIC INSULATING WASHERS. Tighten all eight 4-40 screws (6 in/lbs.) starting with Q4 and Q5. Page 41 of 46
Bias Adjustment The SkyWave DX150 amplifier has been designed to operate with class-ab biasing. IMPORTANT TO KEEP OUTPUT HARMONICS AT SPECIFIED LEVELS, THE BIAS MUST BE ADJUSTED PRIOR TO THE AMPLIFIER BEING PUT INTO SERVICE. Solder the two wires from SW1 (ON/OFF) together. Solder the two wires from SW2 (SSB DELAY) together. Insert 15A fuse (F1). Place an ammeter across jumper (JMP1) terminals. Turn VR1 (BIAS) fully counter-clockwise. Connect the 13.8VDC power cord to a power supply. Connect RF IN (center conductor of coaxial cable) to 13.8VDC. Ground of coaxial cable remains disconnected. Turn power supply on and set output at 13.8VDC. Adjust VR1 (BIAS) slowly clockwise to obtain 200mA (+/-25mA) on the ammeter. Disconnect all connections to power supply and ammeter. IMPORTANT - THE TWO PADS ON THE JUMPER MUST BE SHORTED TOGETHER FOR THE AMPLIFIER TO OPERATE PROPERLY. Apply a liberal amount of solder to the jumper (JMP1) pads so a solder bridge is formed. Page 42 of 46
Amplifier Operation Connecting the Amplifier IMPORTANT - THE AMPLIFIER REQUIRES A DC POWER SOURCE CAPABLE OF 13.8V@15A TO ACHIEVE MAXIMUM POWER OUTPUT. IN THE FINAL APPLICATION, KEEP THE POWER CABLE AS SHORT AS POSSIBLE TO OPTIMIZE AMPLIFIER PERFORMANCE. Attach the power cable to a DC source. IMPORTANT - MAKE CERTAIN THAT THE ANTENNA/FEEDLINE SWR IS 1.5:1 OR LOWER. A HIGH SWR WILL CAUSE EXCESSIVE OUTPUT TRANSISTOR HEATING THAT COULD RESULT IN PREMATURE DEVICE FAILURE. Hook the amplifier RF IN via a 50-Ohm coaxial cable to the driving transmitter. Hook the amplifier RF OUT via a 50-Ohm coaxial cable to the transmitting antenna. Install a SPST switch to the wiring coming from SW1 (POWER). Install a SPST switch to the wiring coming from SW2 (SSB). Install an LED to the wiring coming from LED1 (POWER). Install an LED to the wiring coming from LED2 (XMIT). Transmitting Set SW1 (POWER) switch to the ON position. Set SW2 (SSB) switch to the ON position if transmitter is in SSB mode. The amplifier is now ready for operation. Page 43 of 46
Troubleshooting Problem Possible Cause Possible Solution Amplifier doesn t operate (Power switch ON but power indicator not lit) Power source not connected. Fuse missing or blown. Check F1. Faulty wiring from SW1 switch to circuit board. Check connection to power source. Check wiring from SW1 switch to circuit board. Amplifier doesn t operate (Power switch on and power indicator lit) Insufficient or no RF drive. Check transmitter and coaxial cable to input of amplifier. Relay engages on transmit but amplifier has no output power. J1 open. Check that J1 is shorted. Relay chatters during SSB operation. SW2 switch not in SSB position. Faulty wiring from SW2 switch to circuit board. Move SW2 switch to proper position. Check wiring from SW2 switch to circuit board. Relay chatters during AM/FM operation. Insufficient drive power. Increase drive power. Amplifier keeps blowing fuse. Plastic insulating washers (WASHER1, WASHER2, WASHER3) improperly installed. Insulators (INSUL1, INSUL2, INSUL3) improperly installed. Check plastic insulating washers on Q1, Q4, Q5. Check insulators on Q1, Q4, Q5. Page 44 of 46
Specifications Parameter Conditions/Notes Value Operating Modes - AM, FM, SSB Voltage Requirements Typical Maximum +13.8VDC +16VDC DC Current Maximum 12A RF Input Power RF Power Output Minimum Maximum @1dB Compression 500mW (AM, FM) 10W-RMS (AM, FM) 40W-PEP (SSB) 70W-RMS (AM/FM) 130W-PEP (SSB) 2nd Harmonic 25W CW@28MHz Typical -46dBc *** 3rd Harmonic 25W CW@28MHz Typical -30dBc Input / Output Impedance Typical 50-Ohms Input SWR Typical 1.2:1 Power Gain Typical @28MHz 8dB Bandwidth 26-30MHz 0.5dB Gain Flatness Class-AB Bias Current +25 C Heat Sink Temperature 200mA +/-25mA Fuse ATO - Automotive Type 15A SSB Relay Dropout Delay Typical 1.0 Second Stand-By Power Typical 75mW Reverse Voltage Protection No Damage to Amplifier or Fuse Continuous Thermal Shutdown Heat Sink Temperature ~120 C PCB Solder Mask & Silkscreen Premium FR4 Material *** Decibels below carrier. An antenna system with an SWR of 1.5:1 or less is critical for proper amplifier operation. Standing Wave Ratio. Page 45 of 46
OUTPUT (WATTS PEP) OUTPUT (WATTS RMS) RF Linear Amplifier PCB Assembly Manual RF Performance AM/FM Power Output @ 14.2V/28MHz 90 80 72 77 80 70 64 60 50 40 32 40 48 56 30 24 20 10 8 16 0 0 1 2 3 4 5 6 7 8 9 10 11 12 INPUT (WATTS RMS) SSB Power Output @ 14.2V/28MHz 175 150 135 145 150 125 105 120 100 90 75 60 75 50 30 45 25 15 0 0 5 10 15 20 25 30 35 INPUT (WATTS PEP) Page 46 of 46