SS-40_user_2011.pdf

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1、SS-40 Receiver Assembly Manual for Printed Circuit Board V1.0H (Manual V1.1A4) Copyright - 2011 Jim Kortge, K8IQY everything else goes on the top. Highlight them on the schematic when you are done soldering. Your PCB will look like that in the photos below. (Note: As can be seen in these photos, a p

2、air of standoffs assemblies have been used to elevate the back edge of the PCB during the building process.) J1-J4 Connectors TopJ1-J4 Connectors Bottom Step 2 - Power Supply Components Install these components in the order they are called out: D5-1N5817 diode, C41-0.1uF capacitor, C40- 22 uF capaci

3、tor (make sure that the polarity is correct), U4-78L08 8 volt regulator, C39-0.1 uF capacitor, and C38-22 uF capacitor (make sure that the polarity is correct). As each part is solder into the PCB, mark it off on the schematic with a highlighter. When all of them have been installed, your PCB will l

4、ook like the photos below. Power Supply Components - FrontPower Supply Components Rear Testing Apply 10-14 volts dc to power supply connector J2. Using a voltmeter, verify that there is approximately 9.5-13.5 volts at the right pad for resistor R9 and 8 volts at the rear pad for capacitor C47. Use o

5、ne of the two rear mounting holes for the voltmeter ground lead. (Note: the mating plug for J2 is a 5.5 mm barrel/2.5 mm pin.) Step 3 - Audio Amplifier Components Begin this build section by soldering in the 1 K volume control pot, VR1. Solder one lead, then make sure that the shaft is perpendicular

6、 to the surface of the PCB before soldering the remaining leads. Next, install an 8-pin IC socket at location U3. The notch in the socket should match the outline on the PCB. Solder one lead and verify that the orientation is correct before soldering the remaining leads. Sequentially solder in the f

7、ollowing parts: C36-220uF capacitor (make sure that the polarity is correct), C37-0.1uF capacitor, R24-10 Ohm resistor, R20-2.2 K Ohm resistor, C33-22 uF capacitor (make sure that the polarity is correct), C31-22 uF capacitor (make sure that the polarity is correct), and R19-10 Ohm resistor. As each

8、 part is solder into the PCB, mark it off on the schematic with a highlighter. When all of them have been installed, your PCB will look like the photos below. Audio Amplifier Components FrontAudio Amplifier Components Rear Testing Carefully bend the leads of the LM386 chip so that the pairs of leads

9、 are parallel to each other and perpendicular to the chip body. Install the chip into the U3 socket; please dont force it and break a lead. Plug a speaker or earphones into audio jack J3. Apply 10-14 volts to connector J2. Set volume control VR1 fully clockwise for maximum volume. Touch either pad f

10、or resistor R21 with your finger. A 60 Hz signal should be heard. Rotate VR1 counterclockwise to verify that the volume of the signal can be lowered. Step 4 Audio Mute Components Continue installing the audio mute components consisting of R21-22 K Ohm resistor, C35-0.1 uF capacitor, D6-1N5711 diode,

11、 R23-22 K Ohm resistor, C34-0.1 uF capacitor, C42-0.01 uF capacitor, C44-0.1 uF capacitor, R18-1 M Ohm resistor, Q4-J310 transistor (Note: J310 transistors are static sensitive, so touch the largest metal object near you before picking one up.), R22-1 M Ohm resistor, Q5-J310 transistor, and R25-1 M

12、Ohm resistor. As each part is solder into the PCB, mark it off on the schematic with a highlighter. When all of them have been installed, your PCB will look like the photos below. Audio Mute Components FrontAudio Mute Components Rear Testing No testing of this stage can be done now because there is

13、no dc bias on the J310 transistors. Well test this stage after completing the next step. Step 5 Product Detector Components Install an 8-pin socket at the U2 position. The notch in the socket should match the outline on the PCB. Solder one lead and verify that the orientation is correct before solde

14、ring the remaining leads. Install the following components C29-15 pF capacitor, TC4-10-70 pF trimmer capacitor (remove the bends in the leads before inserting it into the PCB and orient it so that the rounded end is grounded), L6-5.6 uH inductor, X5-9.21 MHz crystal (marked “LO”, use an insulator un

15、der the crystal and ground the crystal case to the pad provided), C28-120 pF capacitor, C32-120 pF capacitor, R17-39 Ohm resistor, and C30- 0.1 uF capacitor. As each part is solder into the PCB, mark it off on the schematic with a highlighter. When all of them have been installed, your PCB will look

16、 like the photos below. Product Detector Components FrontProduct Detector Components Rear Testing Carefully bend the leads of the SA612 chip so that the pairs of leads are parallel to each other and perpendicular to the chip body. Install the chip into the U2 socket; please dont force it and break a

17、 lead. Plug a speaker or earphones into audio jack J3. Apply 10-14 volts to connector J2. Set volume control VR1 fully clockwise for maximum volume. Product Detector Touch the right pad of L7 with a 3 foot test lead. A hissing signal should be audible. Audio Muting With the test lead still connected

18、 to the L7 pad, ground the cathode end (bar) of D6 with another test lead. The hissing signal being heard should now be muted. Step 6 Automatic Gain Control 1 Components Install the first set of automatic gain control components consisting of TR1-10 K Ohm resistive trimmer, D7-1N5711 diode, C45-10 u

19、F capacitor (make sure that the polarity is correct), Q6-PN2222A transistor, R26-1 K Ohm resistor, C46-22 uF capacitor (make sure that the polarity is correct), L7-1 mH inductor, and C43-0.01 uF capacitor. As each part is solder into the PCB, mark it off on the schematic with a highlighter. When all

20、 of them have been installed, your PCB will look like the photos below. Automatic Gain Control 1 Components Front Automatic Gain Control 1 Components Rear Testing No testing of this stage can be done now. Step 7 Crystal Filter Components Install these components in the order they are called out: C2-

21、150 pF capacitor, C6-270 pF capacitor, X4-9.21 MHz crystal, C10-270 pF capacitor, X3-9.21 MHz crystal, C9-270 pF capacitor, C8-150 pF capacitor, X2-9.21 MHz crystal, C7-270 pF capacitor, X1-9.21 MHz crystal, C1-150 pF capacitor, and C5-270 pF capacitor. Use an insulator under each crystal and ground

22、 the crystal cases to the pad provided, as shown in the photos. As each part is solder into the PCB, mark it off on the schematic with a highlighter. When all of them have been installed, your PCB will look like the photos below. Crystal Filter FrontCrystal Filter Rear Testing No testing of this sta

23、ge can be done now. Step 8 IF Amplifier (U1B) Install an 8-pin socket at the U1 position. The notch in the socket should match the outline on the PCB. Solder one lead and verify that the orientation is correct before soldering the remaining leads. Install the remaining components in this order: C21-

24、15 pF capacitor, C20-47 pF capacitor, R4-100 Ohm resistor, L5-4.7 uH inductor, R5-49.9 Ohm resistor, C17-0.1 uF capacitor, R10-1.2 K Ohm resistor, R12-62 Ohm resistor, C25-0.1 uF capacitor, R9-39 Ohm resistor, and C23-0.1 uF capacitor. As each part is solder into the PCB, mark it off on the schemati

25、c with a highlighter. When all of them have been installed, your PCB will look like the photos below. IF Amplifier_U1B Components FrontIF Amplifier_U1B Components Rear Testing A number of tests will be performed after the U1A components are installed. Step 9 Post Mixer Amplifier (U1A) Install the U1

26、A, Post Mixer Amplifier components in this order: R3-100 Ohm resistor, R8-1.2 K Ohm resistor, R11-62 Ohm resistor, C24-0.1 uF capacitor, R6-49.9 Ohm resistor, C16-0.1 uF capacitor, C26- 0.1 uF capacitor, R16-1 K Ohm resistor, R15-1 K Ohm resistor, C27-0.1 uF capacitor, and R14-39 Ohm resistor. As ea

27、ch part is solder into the PCB, mark it off on the schematic with a highlighter. When all of them have been installed, your PCB will look like the photos below. Post Mixer Amplifier_U1A-Components FrontPost Mixer Amplifier_U1A_Components - Rear Testing Carefully bend the leads of the LT1253 chip so

28、that the pairs of leads are parallel to each other and perpendicular to the chip body. Install the chip into the U1 socket; please dont force it and break a lead. Plug a speaker or earphones into audio jack J3. Apply 10-14 volts to connector J2. Set volume control VR1 fully counter clockwise for min

29、imum volume. Now advance the volume control clockwise. At about 90% rotation, white noise should be heard and increase in volume as the control is advanced. When at full rotation, connect a 3 foot test lead to the mixer end of capacitor C16. More noise should be heard and possibly some static. The r

30、eceiver is listening to 9.213 MHz, the nominal center frequency of the crystal filter. Rotate capacitive trimmer TC4 through 360 degrees. As that is done, a change in the audio tone of the noise should be noticed. Well use TC4 to set the receiver to have a 600-750 Hz audio tone when listening to a C

31、W signal centered in the pass band of the crystal filter. Step 10 VXO Components Install the following parts: D9-1N4148 diode, R30-15 K Ohm resistor, C51-0.1 uF capacitor, R32-100 K Ohm resistor, D8-MVAM109 tuning diode, L9-5.6 uH inductor, R33-22 K Ohm resistor, X6-16.257 MHz crystal, X7-16.257 MHz

32、 crystal, X8-16.257 MHz crystal (use an insulator under each crystal and ground the crystal cases to the pad provided), C50-47 pF capacitor, C52 is not used, R28-100 K Ohm resistor, C53-47 pF capacitor, C55-47 pF capacitor, Q7-PN2222A transistor, TR2-1 K Ohm resistive trimmer, and R38-470 Ohm resist

33、or. As each part is solder into the PCB, mark it off on the schematic with a highlighter. When all of these parts have been installed, your PCB will look like the photos below, including R30, which is missing. VXO Part 1 Components Front VXO Part 1 Components Rear Testing A number of tests can be pe

34、rformed on this section of the VXO depending on the test equipment at hand. Apply 10-14 volts to connector J2. Set TR2, the resistive trimmer to the center of its rotation. All measurements are taken at the lower pad of capacitor C54. Using an RF Probe with a DVM, a voltage of 0.8 to 1.0 volts shoul

35、d be seen. Using an oscilloscope, 2.5 volts p-p should be seen. If a counter is available, the VXO frequency can be measured. The VXO tunes 25 to 30 KHz, depending on the crystals and varies from receiver to receiver. On the unit in the photos, it tunes from 16.230 MHz to 16.258 MHz, which is quite

36、typical. When finished, this receiver should nominally tune from 7.017 MHz to 7.045 MHz. Continuing the VXO build, install these parts: C54-0.01 uF capacitor, R31-10 K Ohm resistor, R35- 15 K Ohm resistor, Q8-PN2222A transistor, and R37-1 K Ohm resistor. As each part is solder into the PCB, mark it

37、off on the schematic with a highlighter. When all of these parts have been installed, your PCB will look like the photos below. VXO Part 2 Components Front VXO Part 2 Components Rear Testing The same tests that were performed in the previous step can be repeated with the test point now being the rig

38、ht pad of C48. The results will be nominally the same, since this stage is a gain of 1 (well almost) buffer. Finishing the VXO build, install these parts: C48-0.1 uf capacitor, R34-2.2 K Ohm resistor, L10-1 mH inductor, D10-1N4148 diode, D11-1N4148 diode, C56-0.1 uF capacitor, C47-0.1 uF capacitor,

39、R27-820 Ohm resistor, Q9-PN2222A transistor, R36-39 Ohm resistor, T1-4T Pri/4T Sec transformer (use 6 inch lengths of #30 gauge wire for the windings see T1 details page), C49-47 pF capacitor, L8- 1.8 uH inductor, and finally R29-49.9 Ohm resistor. As each part is solder into the PCB, mark it off on

40、 the schematic with a highlighter. When all of these parts have been installed, your PCB will look like the photos below. VXO Part 3 Components FrontVXO Part 3 Components Rear Testing A number of tests can be performed on this section of the VXO depending on the test equipment at hand. At this stage

41、 of the build, it is the last time that the VXO levels output levels can be measured accurately. Once mixer MX1 is installed, loading of the VXO output precludes accurate measurements from being made. Apply 10-14 volts to connector J2. Set TR2, the resistive trimmer fully counterclockwise. Measuring

42、 at Mixer MX1-pad 6 and using an RF Probe with a DVM, a nominal level of 0.9 volts should be seen. As TR2 is rotated clockwise, the voltage should rise to a nominal level of 1.4 volts. Across the range of TR2, an oscilloscope will show 5 volts p-p at the low setting and 7 volt p-p at the high settin

43、g. On a spectrum analyzer, at the low setting, the power available is nominally 5.1 dBm and at the high setting, 8.2 dBm. At all settings of TR2, the 2nd harmonic of the 16.257 (nominal) LO drive from the VXO is 30 dB below the carrier level. Step 11 Mixer Component Notice that “component” is used a

44、s there is only one part to be installed in this step. However, it is probably the most difficult for most builders, especially those who are new. The key to soldering the MX1 Mixer is to use a tiny amount of liquid flux, if available, on each pad before setting the mixer on the PCB. If using liquid

45、 flux, let the part set for 15-20 minutes so that the flux “glues” the chip in place. The other key is to only solder one pin so that if the mixer moves position, that pin can be reheated and the chip pushed back into position. Also, use a small soldering tip for this part. Something on the order of

46、 1/16 inch +/- should work fine on a 25-40 watt soldering iron. Once one pin is soldered and the chip alignment is correct (make sure the dots align), solder the other 5 pins. Note: The mixer must be installed correctly for the SS-40 receiver to work. This step must be done right! After this part is

47、 soldered onto the PCB, mark it off on the schematic with a highlighter. When this step is done, your PCB will look like the photos below. Mixer MX1 Component FrontMixer MX1 Component Rear Testing Fun time! Plug a speaker or earphones into audio jack J3. Set volume control VR1 for minimum volume. Ap

48、ply 10-14 volts to connector J2. Attach an antenna to the right pad for capacitor C19. Advance the volume control until band noise is heard. Using the VXO VR2 tuning control, tune around to hopefully hear a CW signal on the lower end of 40 meters. Adjustment of TC4 may be required to set the CW tone

49、 you like when receiving. Since no front-end filtering is in place, signals that are much higher in frequency, i.e. those that are the mixing product of the VXO + IF, or nominally 25.458 MHz might also be heard. The receiver performance will improve significantly when the Front- End parts are installed, but for now, enjoy the sounds of a mostly working receiver! Step 12 Automatic Gain Control 2 Components Install the second set of automatic gain control components consisting of Q3-PN2222A transistor, R13- 330 Ohm resistor, Q2-PN2222A transistor