Small Wonder Labs PSK-20 Manual de usuario

Small Wonder Labs PSK-20 Transceiver Kit 8/31/04 1

PSK-20 Transceiver

Board Kit Instructions

Please take a few moments to look over the sections entitled "First Things First" and "Building Instructions"

before you dive in. These sections contain information which is key to your success with this kit

TABLE OF CONTENTS:

First Things First..................................... 2

Materials ................................................... 3

Component Identification……………….. 4

Parts List ................................................... 5

Operational Desription ..................................6

Schematics ................................................. 8

Pictorial Drawing................................... 10

Building instructions , general......... 11

Grouped assy. Instr……. 12

"Hooking Up" ................................ 20

Alignment ................................................ 21

Troubleshooting the "PSK-20 " ............... 22

"Frequently Asked Questions"………………24

Small Wonder Labs PSK-20 Transceiver Kit 8/31/04 2

THE FINE PRINT:

There are lots of small parts in this kit. With many of

us getting older, this may prove troublesome. I highly

recommend a magnifying glass or close-up glasses to

check all solder joints and component codes.

THE OTHER FINE PRINT:

If you encounter conflicts between various sections of

this document, contact me for a resolution. The

following order of precedence applies:

•

Schematic (most trustworthy)

•

Parts list

•

Pictorial

•

grouped assembly text

•

Everything else

TOOLS:

You'll need the following tools:

-Soldering iron- ~25W

- 60/40 solder, small diameter

-Diagonal cutters

-Needle-nose pliers

-Small slot screwdriver

-Wire-strippers (recommended)

-Tweezers (recommended)

TEST EQUIPMENT:

- Wattmeter (Radio Shack #21-534 / equiv.) ($30)

-Multimeter (recommended)

- Amateur transceiver (recommended)

PSK-20 Power Requirements

The PSK-20 is designed to operate with a minimum

supply voltage of approximately 10V. A power supply

capable of delivering a minimum of 1 Amp at 12-14

Volts DC is recommended. Maximum recommended

supply voltage is 15VDC.

A low-cost supply suggestion: Jameco's #228822, 15V

regulated 'wall-wart'. This supply requires a plug

adapter, their #229155CL. They're at 800-831-4242.

Note: the less expensive unregulated 'wall-warts' will

not provide adequately filtered DC- don't waste your

money! 'Filtered' is not sufficient- you need to see

the word "Regulated' on the description.

FIRST THINGS FIRST -

-Stuff worth knowing!

COLOR CODES:

Resistor color codes are given in the parts list.

Radio Shack's Color-Code Guide, #271-1210, or the

ARRL Handbook will help. If you're not sure, verify

the resistor values with a multimeter before installing.

For what it's worth, roughly 8% of the male

population is red/green color-blind. If you're one of

these, you should be verifying all resistors with a

multimeter before installing them.

The PSK-20 board is double-sided and all holes on

the board are plated-through. This means that you do

not need to solder on the top side of the board.

SOLDERING SKILLS

Hopefully this isn't your first experience with a

soldering iron. If it is, though, or this is your first

solid-state project, here are some tips to ensure your

success:

- Soldering Iron:

Use a small iron in the 25-watt class (such as a Radio

Shack #64-2070) and keep the tip clean. Use a

moistened sponge or paper towel to clean the tip

periodically as you work.

Apply only as much heat as is needed to get a good

joint. A small vise to hold the printed-circuit board

may make soldering easier.

Touch the soldering iron tip to the PC board trace and

the component lead simultaneously. Within a second

or two, apply solder and you'll see the solder flow onto

the junction. Withdraw the solder and then the

soldering iron.

Avoid the temptation to load solder onto the joint

until no more will fit! This is an invitation for trouble,

as solder bridges may form across the closer trace

separations. Here's what the correct and incorrect joint

treatments look like:

Small Wonder Labs PSK-20 Transceiver Kit 8/31/04 3

PLEASE READ THE SECTION BELOW BEFORE

REMOVING ANY PARTS FROM THE BOARD

Uh-oh! Sooner or later, you may need to remove a

part installed in the wrong location, or perhaps pull a

component for troubleshooting purposes.

Get yourself a roll of desoldering braid (Radio Shack

#64-2090B). Lay the end of the braid down on the

joint to be cleaned and press the soldering iron tip over

the braid. Within several seconds you'll see the braid

begin to wick up solder from the joint. Remove the

braid and reapply a new section as needed until the

joint is clean. It may be necessary to pull the

component out from the top side of the board while

heating the joint. Leave the iron tip on the board only

as long as necessary to do the job- the PC-board traces

will eventually delaminate (peel off) if overheated.

If that still doesn't do the job, it may be necessary to

cut the offending part off on the top side and pull the

remaining leads through with pliers. Contact me for

replacement parts if necessary.

If you need to remove a transistor, I'd highly

recommend sacrificing the part by snipping it off on

the top side of the board. The leads are best pulled out

singly to minimize the risk of lifting pads.

After removing a component from the board, the

through-hole will probably still be blocked with solder.

Use a dissecting needle or dental probe (explorer),

apply heat to the probe and the board trace

simultaneously until the tool pushes through. Lacking

either of these tools, a round wooden toothpick works

well also!

WINDING TOROIDS:

-Count as you go. Draw each turn snug against the

core to ensure a trim and tight winding

-Double-check the turns count when you're finished.

Use your fingernail or small screwdriver to "bump"

over each turn as you count- this is considerably easier

than counting by eye.

- Trim the excess wire off to about 1/4" and strip the

insulation off the ends with a wirestripping tool.

(Make sure the stripper is adjusted correctly for the

wire- it should cut the insulation cleanly but should not

nick the wire itself- try this out on a sample length of

toroid wire first.)

Counting the turns:

If the wire passes through the toroid center hole, it

counts as a turn. Here's an example:

REFERENCE DESIGNATORS:

Each component is uniquely identified with a

reference designator. Bypass capacitors are identified

as C101 and up. Reference designators are shown in

blue on the schematic pages.

OMPONENT IDENTIFICATION

•

Resistors and RF chokes

This manual describes the color coding for all resistors

and RF chokes. Only the first three bands are

described, the fourth band is a tolerance code, typically

gold (=5%) and is not listed. All resistors are 1/4W 5%

carbon film types, RF chokes are also an axial (leads

out of each end) component but are notably larger.

GOOD

SOLDER FILLET IS CONCAVE AND 'WETS'

SMOOTHLY TO COMPONENT LEAD

BAD

SOLDER FILLET IS CONVEX OR DOES NOT

ADHERE TO COMPONENT LEAD

This toroid is wound with 8 turns

Turns must be uniformly distributed around

the circumference of the toroid.

Small Wonder Labs PSK-20 Transceiver Kit 8/31/04 4

•

Capacitors:

These are disk capacitors (‘caps’):

Here's the general rule for disk cap nomenclature:

If 3 digits are printed on the capacitor, the first two are

significant figures and the third is a multiplier.

Examples:

'471' = 47 x 10

1 =

470 pF

'103' = 10 x 10

3 =

10,000 pF = .01 uF

Letter suffixes: J=5%, K=10%, M=20%.

Please: If you're not sure, please be sure to inspect

both sides of the caps before concluding we gave you

the wrong value!

These are monolithic caps:

These caps generally follow the same marking conventions

as for the disk caps.

The monolithic caps in this kit are provided in their

own poly bag. Capacitors are separated by value

within this bag and are ordered by capacitance value.

The capacitors in this assortment are identified by

shading on the parts list on the next page. Cut this bag

open when you're ready to proceed, and store the

groups of capacitors separately in marked envelopes or

small paper cups.

If these parts are supplied with a 0.1" (2.5mm) lead-

spacing for installation in a board hole-spacing of 0.2"

(5 mm), bend the wire leads gently to spread the

spacing . Avoid sharp bends right at the wire-lead exit

from the epoxy case; this may cause component

damage/failure.

These are electrolytic caps:

The black band on the left side of the cap bodies above

denotes the negative ( - ) side of the capacitor.

These are marked directly with the component value

and voltage rating. Note that you may find a higher-

than-specified voltage rating. It’s OK!

•

Extra information on components

There's often extraneous information marked on

components. Examining a sample IC, I find

"MC1458P1 KKJK 8949". You care only about the

'1458' or other markings I've specified If I've specified

a capacitor '104' and you find the correct number of

parts, but marked "104M', for instance, those are

them!

You'll find the following items with your PSK-20 kit:

1- bag of parts, miscellaneous

1- antistatic bag (contains semiconductors)

1- poly bag- SMT inductors, diodes

1- poly bag (resistors/disk capacitors)

1- poly bag (monolithic capacitors)

1- printed circuit board

- (this manual)

Small Wonder Labs PSK-20 Transceiver Kit 8/31/04 5

PARTS LIST

Quantity Reference Designator Value Description Markings or Ident.

1 C29 4.7 pF Disk cap 4.7

11 C1, C5-C9,C19-C23 27 pF Disk cap 27

1 C38 4-20 pF Trim cap Red, 2 leads

1 C42 6-30 pF Trim cap Green, 2 leads

3 C13, C39,C40 47 pF Disk cap 47

4 C3, C28,C30,C41 100 pF Monolithic cap 101J

2 C32,C37 150 pF Monolithic cap 151J

2 C43,C44 180 pF Monolithic cap 181J

2 C34,C36 330 pF Monolithic cap 331

4 C2,C27,C31,C35 470 pF Monolithic cap 471

20 C4,10,11,C24-26,C101-105,

C107-113,C118,C119

.01 uF Disk cap 103

6 C12,16,33,C114,115,117 .1 uF Monolithic cap 104

2 C15,C17 1 uF Electrolytic cap 1 uF

1 C14 10 uF Electrolytic cap 10 uF

1 C18 47 uF Electrolytic cap 47 uF

2 C106,C116 220 uF Electrolytic cap 220 uF

7 D1-D4,D7,D8,D10 1N4148A Diode Glass body, on tape

3 D5,D6,D9 1N5236B Diode, 7.5V Zener In marked bag-strip

1 D11 1N4001 Diode 1N4001

1 D12 1N5818 Diode 1N5818

1 HS1 - - Heat sink, small Black metal, w/ fins

1 HS2 - - Heat sink, medium Black metal, w/ fins

2 J1,J2 - - 3.5mm audio jack 3 leads, rectangular

1 J3 - - Power jack, 2.1/5.5 mm 3 leads, rectangular

1 J4 - - BNC, w/ lockwasher, nut (Antenna jack)

1 L1 4.7 uH RF choke Ylw-Viol-Gold

3 L2,L5,L6 1.5 uH Slug-tuned inductor, 10 mm

1 L3 3.3 uH SMT inductor In marked bag-strip

1 L7 1 uH SMT inductor In marked bag-strip

1 L8 T37-2 Toroid, 11 turns #24 Red 'doughnut'

2 L9, L10 T37-6 Toroid, 15 turns #24 Yellow 'doughnut'

1 P1 - - DC Power Plug, 2.1/5.5mm Plug, black body

2 Q1,Q3 2N3906 Transistor, TO-92 pkg. Small, plastic body

2 Q2,Q4 2N7000 Transistor, TO-92 pkg. Small, plastic body

4 Q5,Q6,Q8,Q9 2N4401 Transistor, TO-92 pkg. Small, plastic body

1 Q7 MPSH10 Transistor, TO-92 pkg. Small, plastic body

1 Q10 2SC1970 Transistor, TO-220 pkg. Large, metal tab

1 Q11 2SC1971 Transistor, TO-220 pkg. Large, metal tab

5 - - - - IC socket, 8-pin DIP 8 leads

3 R40-R42 1.5 ohm Resistor, 1/4w 5% Brown-grn-gld-gld

4 R9,R33,R35,R38 6.8 ohm " Blue-grey-gld-gld

3 R25, R26,R39 51 ohm " Grn-brn-blk-gld

2 R2,R32 100 ohm " Brn-Blk-brown-gold

2 R30,R34 220 ohm " Red-red-brown-gld

8 R1,R3,R4,R11,R22-R24,49 470 ohm " Ylw-viol-brown-gld

1 R27 680 ohm " Blue-gry-brown-gld

5 R6, R29,R37,R45,R48 1K " Brown-blk-red-gld

Small Wonder Labs PSK-20 Transceiver Kit 8/31/04 6

Parts list (cont'd)

Quantity Reference Designator Value Description Markings or Ident.

2 R12,R15 2.2K " Red-red-red-gld

1 R36 3.3K " Orange-org-red-gold

5 R5,R7,R18,R21,R28 4.7K " Ylw-viol-red-gld

4 R10,R14,R16,R20 10K " Brn-blk-orange-gld

5 R19,R31,R44,R47,R50 22K " Red-red-orange-gld

2 R43,R46 47K " Ylw-viol-orange-gld

1 R13 100K Brown-blk-ylw-gold

1 R8 510K " Grn-brn-yellow-gld

1 R17 1M " Brn-blk-green-gld

1 T1 FT50-43 Toroid, 4 turns -see text Grey 'doughnut'

3 U1,U2,U7 SA612AN Integrated circuit 8 leads, plastic

2 U3,U4 LM1458 Integrated circuit 8 leads, plastic

1 U5 TUF-1 Mixer, metal can package 4 leads, in-line

1 U6 78L08 Integrated ckt, TO-92 pkg. Small, plastic body

1 U8 MAR-3SM Surface-mnt IC, preinstalled Tiny- 4 leads

1 W1 - - 2' (0.7m) power wire 2-conductor

9 Y1-Y5,Y7-Y10 9.00 MHz Crystal, series-load

1 Y6 5.0688

MHz

Crystal, 20-pF load

1 - - - - Printed-circuit board 'SWL 3/02'

1 - - - - Mica washer

1 - - - - #4-40 x 1/4" nylon screw

1 - - - - #4-40 x 1/4"steel screw

2 - - - - #4-40 nut

1 - - - - 3' (1m) #24 magnet wire

2 - - 4" (10cm) solid wire Color varies

Theory of Operation:

This transceiver is a single PC-board design measuring

4.6" x 5.27" (12 x 13.4 cm). It is functionally a

crystal-controlled SSB transceiver with slightly wider-

than-normal IF passband characteristics. It covers the

range of 14.070 to 14.074 Mhz.

Receiver Operation:

The receiver RF input (schematic point 'D') is

applied through a series-tuned resonant circuit

(C1/L1). Diodes D1-D4 limit during key-down and

thereby restrict the signal levels presented to the

receiver front-end during transmit. The double-diode

configuration raises the network's intercept point with

respect to W7EL's original configuration to improve

IMD immunity. The combination of C2,C3 and L2

are a tuned circuit network which matches the input

impedance (1.5K ohms) of mixer U1.

U1 is fed with a 5.07 Mhz Local Oscillator (LO)

signal and converts the incoming 14.07 Mhz received

signal to the 9.00 MHz Intermediate Frequency (IF).

This mixer has approximately 12 dB of conversion

gain. The transistor (Q1) following the mixer is

configured as an amplifier with another ~12 dB of

gain.

Y1-Y4 and associated capacitors are the IF filter.

This filter has a 3-dB bandwidth of approximately 3.5

Khz and loss of roughly 2 dB. Its output is terminated

by the combination of R5 (2.2K) and U2's input

resistance

Product detector U2 receives the 9 Mhz IF filter

output and multiplies (mixes) it with a ~ 9 Mhz LO

signal (from schematic point 'E'. This results in an

audio output at pin 5 of that IC. C13 provides rolloff of

the audio to reduce high-frequency 'hiss'. Op-amp U3

and associated components provide audio

amplification. This stage has a gain of approximately

100 (40 dB).

Small Wonder Labs PSK-20 Transceiver Kit 8/31/04 7

Because the active soundcard inputs are always

active, even during transmit, the receiver must be

'muted' during transmit. Without this feature, the

receiver output will be mixed back through the

soundcard (in parallel with the desired DSP-based

transmitter drive) and cause transmitted signal

distortion. MOSFET Q2 provides this function by

shorting the receiver output to ground during transmit.

T-R Switching:

T-R switching is controlled by dual op-amp U4 and

associated components. The first section, U4-A, is

configured as a peak detector with a gain of

approximately 20 (26 dB). Incoming audio from the

computer sound card causes the voltage at capacitor

C16 to charge upwards in voltage. When the voltage is

high enough, the op-amp section U4-B switches its

output level from 'high' (~12V) to 'low' (~0-2V). This

threshold corresponds to a power output slightly

above 1W PEP [for a properly-adjusted PSK-20.]

The 'low' voltage at U4, pin 7 causes DC current to

flow out of the base of Q3 (via R18) and turns on Q3.

This circuit provide 'Vsw' used to bias a number of

transmitter stages.

'Vsw' is at 0V during receive and switches to V+

(~12V) on transmit. This also turns on (unmutes) TX

audio FET Q4. It also turns on RX muting FET Q2.

Transmitter operation:

Audio from the computer soundcard is applied to

the transmitter via J2. Q4 is switched on during

transmit and allows soundcard audio to reach the

amplifier stage (Q5 and associated components). Note

that when Q4 is off during 'receive', DC bias is

removed from Q5 and it is also non-conducting. The

combination of Q4 and Q5 provide relatively high

attenuation (>60 dB) of the soundcard audio during

receive. This is necessary since the transmitter's

double-sideband (DSB) generator -U5- is running

continuously- an audio signal applied to that stage's

input would be plainly audible through the receiver.

This situation would lead to soundcard

feedback/distortion on receive without the presence of

this muting function.

Single-sideband filtering is performed by a second

filter comprising Y7-Y10 and related capacitors. After

passing through the transmit IF filter comprising Y7-

Y10 and related components, the signal has been

reduced to a 9 MHz SSB signal. Its output drives 2nd

mixer U7. This mixer is also driven by a signal from

the 5.07 MHz LO, Colpitts oscillator Q9 and

associated components.

The output of this mixer consists primarily of both

the sum (14.07 MHz) and difference (3.93 Mhz)

frequencies applied to the mixer. Q7 is an emitter

follower used to buffer the high-impedance output of

the mixer. U8 is a Monolithic Microwave IC (MMIC)

and provides approximately 12 dB of gain.

Because the output of mixer U7 has energy on a

number of frequencies, bandpass filtering is required to

clean up its spectrum. L5, L6 and associated capacitors

form this filter, with input and output impedances of

50 ohms.

Q10 and associated components are the

transmitter's driver stage. This stage is feedback-

controlled by R36 for good linearity and operates

class-A (always conducting). The output of this stage

is L-network matched via L7 and C33 to the Power

Amplifier (PA) base. D11 biases the PA base to the

threshold of conduction, necessary for linear operation.

The PA stage (Q11) features a bifilar transformer (T1)

at its collector. This provides a 1:4 impedance match,

transforming the PA collector impedance at rated

power to 50 ohms. L8-L10 and C34-C37 are a 7-

element low pass filter used to remove harmonic

content from the PA output waveform. The design

complies with current FCC requirements for spurious

emissions. All harmonics were down at least 40 dB.

The largest spurious output is down 50 dB.

Small Wonder Labs PSK-20 Transceiver Kit 8/31/04 8

.01

.1 6

220

47 pF

510K

10 uF

470

2.2K

10K

.01

V+

6.8

4.7K

AF Out

.01 Vr

V+

Vsw

9.00 MHz

Y1 Y2 Y3 Y4

C5-C9: 27 pF

470

100

470

.01

V+

.01

100

470

4.7 uH

27 pF

D2 D3

R10 R11

C101

C102

C6 C7 C8

C103

C104

C10

C11

C12

C105

C106

R12

C13

C14

R50

22K

14 Mhz PSK31 Transceiver

D. Benson, K1SWL 1 27 2004

p.1 of 2

Vsw

V+ .01

10K

100K

10K

2N3 06

.01

4.7K

V+

1 uF

- +

U4-A

U4-B

C15

C16

R13

R17

R16

R15

R14

2.2K D7

C107

R18

22K

C108

1.5 uH

LM1458

4.7K

Small Wonder Labs PSK-20 Transceiver Kit 8/31/04 9

14 Mhz PSK31 Transceiver

D. Benson, K1SWL 1 27 2004

p.2 of 2

Y7 Y8 Y Y10

Y5 Y6

TP1

L5 L6 D11

V+

Vsw

ANT.

150

330 470 330

220 uF

150

1.5 (3 pl)

6.8

3.3K

1.5 uH

470

4.7

4-20 22K

47K

47 (2 pl)

3.3 uH

100

.01

78L08

5.068

.01

1 uF 10K

7K 470

47 uF

1 uH

(XMTR

AF In)

680

Y7-Y10: .000 Mhz

C1 -C23: 27 pF .01

.01

6.0V

.01

100

22K

220

.01

220

6.8 .01

.01

47K

MHz

.00

MHz

6-30

22K

MAR-3SM

V+

LINE OUT

Vsw

(8V)

470

100 100

180

(2 pl)

470

Vsw

C10

C17 R20

R21

R22

R23 R24

R25

C18 R26

R27

R2 R30

R31

R32

R33

R34

C110

C111 C112

C113

C20 C21 C22

C23

C24

C25

C26

D10

D12

Q10

Q11

'L4'

L8 L L10

C27

C28

C30

C31

C32

C33

C34 C35 C36 C37

C38

C40

C41

C42

C43

C44

R35

R36

R37

R38

R40-R42

R43

R44

R45

R46

R47

R48

C114

C115

C116

C117

C118

C11

Install

jumper

R28

4.7K

1.5 uH

Small Wonder Labs PSK-20 Transceiver Kit 8/31/04 10

470

D12

BNC

MICR. LINE

OUT

L10

D10

TP1

330

470

100

1.5

PWR.

J1 J2

100

C29

4.7

R12

R11

2.2K

470

C14

- +

10 uF

C33

6.8

C13

47 pF

510K - +

C106

220 uF

6.8

.01 C104

C12

.1 uF

4.7K

C15

C107

.01

10K

2.2K

MCL

TUF-1

Q2 R1410K

- +

C17

1 uF 1 uF

.01

C109

Q5 Q6 U5

4.7K

- +

47 uF

10K

470

680

C20

C21

27 27 27 27

Y8 Y9

Y4 27

.01

470

C111

C108

+ -

4.7 uH

220 uF

C116

C42 Y6

C118

.01

R18

D7 4.7K

R44

C39

C40

22K

100

47K

R43

R45

.01

100 220

R31

220

22K

.01

C112

Q11

180

C24

.01

R40

R41

R42

1N4001

R33

6.8

3.3K

R37

.01

C34

C35

C36

C37

470

330

150

.01

C101

470

100

C11

.01

C103

R16

R19

22K

2N7000

4401

R21

R20

R22

C18

R24

470

R25

R23

470

Y10

R26

R27

C19

C22

C23

C26

C28

R34

R29

.01

C25

C27

R32

.01

R30

.01

R28

C110

180

C43 C44

R17

R13

100K

C16

.1 uF

R15

2N7000

2N3906

R10

C10

C105

.01

10K

C41

C38

22K 47K

R47 R46

470

.01

C119

100

SA602

1458

.01

C32

150

R39

6.8

R48

R49

470

C117

C102

.01

C30 C31 D11

C115

R38

C113

R36

Q10

R35

C114

1N5818

5.068

3.3 uH

1 uH

1/28/04

4.7K

R50 22K

SA602

Otros manuales para PSK-20

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Small Wonder Labs

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