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Kit building instructions for: QROlle II Analogue boards A and B More information at: www.qrolle.se Version 2.6 – Nov 5, 2009 /SM0JZT / Tilman Page: 1(24)

QROlle II - Thulesiusqrolle.thulesius.se/Documentation/QROlle_II_Building_instructions_ver26_en.pdf · 3. Mount the M3 mm screws with 5 mm (not the 4 mm spacers) metal spacers and

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Page 1: QROlle II - Thulesiusqrolle.thulesius.se/Documentation/QROlle_II_Building_instructions_ver26_en.pdf · 3. Mount the M3 mm screws with 5 mm (not the 4 mm spacers) metal spacers and

Kit building instructions for:

QROlle IIAnalogue boards A and B

More information at:

www.qrolle.se

Version 2.6 – Nov 5, 2009 /SM0JZT / Tilman Page: 1(24)

Page 2: QROlle II - Thulesiusqrolle.thulesius.se/Documentation/QROlle_II_Building_instructions_ver26_en.pdf · 3. Mount the M3 mm screws with 5 mm (not the 4 mm spacers) metal spacers and

Index of content1.Before you start: rules and warnings to understand and follow........................................................32.Preparing the A + B + C boards and connectors................................................................................43.Power Supply Unit............................................................................................................................64.RX/TX Switch circuits......................................................................................................................65.Mode Switch......................................................................................................................................86.AF Unit..............................................................................................................................................87.RX IF Unit – BFO.............................................................................................................................98.RX IF Unit – AGC...........................................................................................................................109.RF IF Unit - IF and Active filter.....................................................................................................1110.XTAL filter Unit............................................................................................................................1311.Band Pass Filter.............................................................................................................................1312.Controller / OSC Amplifier...........................................................................................................1613.Microphone Amplifier/Compressor...............................................................................................1614.DSB / CW generator......................................................................................................................1815.TX power amplifier.......................................................................................................................1916.Appendix A: Manually wound inductors and transformers..........................................................2117.Appendix B: Calibration of displayed frequency..........................................................................24

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This is how your QROlle II should look like when all done. Have fun and take it easy.

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1. Before you start: rules and warnings to understand and follow.

The rig is built using surface mounted components (SMD), the size is mostly “0805”. It is important that you are aware of the challenge (and thrill) of working with these small components. Good tools, patience and a certain level of soldering skills are essential.

One way to mount a SMD is to put a bit of solder on right side pad of the SMD if you are right handed, on the left pad if you are left handed. Hold the component in place with a good pair of pliers and solder the component to the board. When the component is properly aligned: solder the rest of the pins/SMD-surfaces to the board.

DO NOT TRY THIS KIT IF YOU HAVE NEVER SOLDERED BEFORE.

The QROlle-team is available for support. However we cannot accept to do it for free if you have ignored the simple rules given in this document. We have put a lot of effort into getting enough space and an easy working environment and documentation to successfully assemble your QROlle. We therefore strongly encourage you to follow the steps we suggest. You will not fail if you do that.

Good practice will be to follow the schematics and the placement graphics. You avoid mistakes and will understand the design. Not all component outlines are printed on the boards to avoid cluttering. This method encourages the builder to keep track of activities and learn about the construction.

Now being warned, we wish you best of luck and great fun with the QROlle kit and rig. Forewarned is forearmed.

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The SMD components are shipped placed on a paper, so that you just have to move them across to the apropriate place, as per the instructions. Here you see the paper for Board A. There is one for Board B also.

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2. Preparing the A + B + C boards and connectorsCarefully read all the instructions before you start soldering. It is close to impossible to redo the work if you have done things wrong without damaging the boards. The A and B -boards are sandwiched together around a aluminum sheet, doubling as a cooling plate. The sheet is pushed into the case and also holding the back panel with all the connectors for external interfacing. Better safe than sorry; double check functionality and placement before applying solder.

Below two reference pictures of the analog boards when all is done.

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Here you can see how the A, B (Board A on top) and C-boards are put together. On the back you see the back panel with connectors mounted onto the aluminum sheet.

Here you see the B-board on top.

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1. First of all you need to do some mechanical work with the sandwiching of the boards. On the A-board, Solder the male pins to the underside of the board.On the B-board you mount the two 2 x 6 pin green female connectors. Make sure you put them at right angle to the underside of the board.

2. Bend the pins of the voltage regulator at a right angle 20 mm below the top of the circuit (See picture).

3. Mount the M3 mm screws with 5 mm (not the 4 mm spacers) metal spacers and line up the board as shown in the picture 3. Attach the 9V-regulator to the back side of the B board and solder it to the upper side of the board. The A + B boards are sandwiched together with help of the 2 x 6 pin connectors so that you can temporary test the functions one step at a time.

4. Mounting the C-board connectors:First adjust the 20 pin connectors so you have them set up for 16 pins. Sandwich the B and C boards together with connectors on the C board as shown in picture 4 below. Please note: 1. The male connectors mounts from the upper side of the B-board. 2. The thicker pins of the male connectors goes into the board.Now first solder two pins each on the connectors. Check that everything is aligned at a right angle with the boards parallel to each other. Also look at the reference picture on the previous page above for orientation. NOW solder the remaining pins!

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2. Bend the pins of the regulator as shown in the picture

1.2 Mounting of connector to interconnect A and B-boards1.1 Pins to the A-board and female connector to the B-board:s undersides

4. Lining up the connector strips for the C-board before soldering. The thicker pins of the male connector goes in from the top of Board B board for soldering.

3. Screws mounted with 5mm spacers (not nuts like in picture) before soldering the regulator in place.

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3. Power Supply Unit

The ”Power Supply Unit” is the first module to build using a regular linear 7809 regulator. Assemble all the components as shown in the schematics. Please take into account the polarity of the capacitors C60B and C61B: the band of the capacitors are the minus side.. Also note the cathode (band) orientation of the diode D3B. Connect a jumper wire to substitute for the power switch connection (will be reused later when connecting to the real switch) and two short jumper wires for the power supply.

Testing functionality• When above steps are completed attach a 12 to 14 V DC power source, ideally a power

supply with current limiting capability set at 200 mA. • Check that the pins on the lower part of the board have a 9V voltage.

4. RX/TX Switch circuitsThe next step is the assembly of the RX/TX switch circuitry shown in “II RX/TX Switch” schematics.

There are a number of transistors controlling the switching between receive and transmit. As you can see from the component names they are placed on both A and B boards. Put all the components EXCEPT C34B and C62A onto the boards as these two capacitors will be soldered to the boards when all is checked.As you can see from the schematics the transistors are marked with 1F, 3F and AM etc. on the top.

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Make sure you get the right type onto the right place.

Please note on board A that Q32A and its base resistor must also be soldered in place for us to do proper function testing.

Testing functionality• Before testing functionality of this part you

should (as always) make sure that all solder joints and placement of the component are correct.

• Connect the two boards together and power up with the power supply attached (preferably with a current limited power supply set at 200 mA).

• Measure 9V at C62A + positive pad (not yet in place!).

• Run 9V with a jumper cable at the pins for the C-board. Put 9V to point “IOPTT” and note that “+RX” goes to zero and “+TX” goes to 9V (at C34B + marked pad)

• If this is OK you are ready to put C62A and C34B onto the assigned positions. Please note that the band on the component goes to “+”.

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In the picture shown as "PTT". Will be "IOPTT" on your board

Board A Board B

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5. Mode SwitchNow it is time to assemble the mode switch circuitry as seen in schematics “II Mode switch”. This circuit switches mode functionality in the DSB /CW generator.Put all the components in the appropriate positions as shown in component placement above. Please note the transistor assignments. Additionally you must solder the resistors as seen above at Q32A and the 2 pcs 6K8 resistors at Q24A. These are needed for circuit testing.

Testing functionality• Before testing functionality of this part you should (as always) make sure that all solder

joints and component placements are correct.

• Measure voltage at C76A to 9V. Connect 9V with the same method as above, this time to IOMO and note that the voltage at C76A drops to zero.

• If you now measure the voltage at C75A the Voltmeter (DVM) is expected to show around 9V.

6. AF UnitThe AF circuitry is using the LM386 IC. In the schematic “IV AF UNIT” below you will also find the CW tone generator to be assembled in this step.

Put all the components in the appropriate positions as shown in the component placement above.

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SO8. Pin 1 is in the front left row on the phased side.

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Please note the transistor assignments. Make sure you get the orientation right for the IC:s. Note either/and phased side or dot at pin 1. In the picture above left you see the position of pin 1 and 8. In the placement picture above you find the position of “pin 1”.

Testing functionality• Before testing functionality of this part you should (as always) make sure that all solder

joints and component placements are correct.

• Connect a loudspeaker to the connector “phone” on board (note the connection to C65A). • Put a temporary jumper between “AF out” and “AF in” (look for the pins on the 2 x 6 pin

connector down to the left on the board), leave it in until further notice. • Power up the boards connected together and put a finger onto the jumper. A hum should be

heard in the speaker to confirm functionality.• Test the CW-oscillator by connecting Q27A collector to ground. A 700 Hz tone is supposed

to be heard.

7. RX IF Unit – BFONow we will start assembling the complete IF-chain for the QROlle. First we are building and testing the BFO-oscillator shown in the schematics cutout and Component placement below.

Put all the components in the appropriate positions seen in the component placement. Please note that the X-tal is mounted with a small distance and not flush to the board. After soldering the X-tal and C178A, C179A capacitors – remove excessive wire on the board solderside.

Testing functionalityConnect the boards together and power up.

• Before testing functionality of this part you should (as always) make sure that all solder joints and component placements are correct.

• Measure a voltage drop of about 0.086V across R87A.• Connect a frequency counter to the point “IF Carrier” and measure the output frequency. If

you have no counter, put a wire connected to the antenna input of a good calibrated receiver close to the BFO oscillator. Tune for zero beat with USB set on receiver:With IOSB low you should adjust the output signal to 5.0012 MHz for USB with C179AWith IOSB high (to 9V) you should adjust the output signal to 4.9987 MHz for LSB with C178A

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8. RX IF Unit – AGCAssembly of the AGC Generator is next. This is all according to schematics cutout and component placement drawing below.

Testing functionalityConnect the boards together and power up. Now you should be able to measure the following voltages over the resistors for reference, to check functionality:

R60A approx 0.13VR52A approx 0.05VR78A approx 0.49V

Finally you should be able to check the AGC voltage (without input signal) at the emitter of Q11AApprox 6.7V

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9. RF IF Unit - IF and Active filterNow the time have come for the rest of the components in the schematics cutout and component placement below to be put on the board. Pretty straight forward.

• Before testing functionality of this part you should (as always) make sure that all solder joints and component placements are correct.

• Please note that Q1A is a BF991 Dual Gate MOSFET. The source pin is the slightly wider pin and is to be connected as shown in the schematics to R26A and C32A.

• Make sure to place IC4A with the right orientation. Pin one is on the phased side. May also be assigned with a small dot. The notch in the footprint indicates pin 1 end!

• To be able to test this part of the assembly properly R16A (3K9) must be mounted to “ACT FILT” high. The resistor is placed to the left of Q6A. The Q6A is found on the main placement drawing, just below XTAL4 in the crystal-filter. Look up Q6A on the schematics as well to understand the connection.

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Testing functionalityIn this test quite a number of functions are tested as you can well understand from the schematics. Put the boards together, connect a speaker.

• Before testing functionality of this part you should (as always) make sure that all solder joints and component placements are correct.

• The jumper “AF in” to “AF Out” from previous test must be in place.• The resistor R16A must be soldered in place to test the active filter. R16A (3k9) is placed

directly to the left of Q6A (1F) transistor.• By putting a finger to or placing an antenna wire on Q1A you should be able to hear

broadcast stations at around 5MHz. You might need to substitute this by a signal from a generator if broadcast stations aren't strong enough.

• By grounding “ACT FILT” (at collector pad of Q2A) the active filter goes from narrow to wide low pass.

• Also: Now you should be able to measure the following voltages over the resistors for reference, to check functionality:

R36A approx 0.64V (Without input signal)R32A approx 1.23VR42A 0.32V (approx)

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10. XTAL filter UnitThis is an interesting unit that is used both for transmission and reception. Assemble the components as shown in the schematics “VI. XTAL FILTER UNIT” and the component placement drawing. Make sure the X-tal cans are elevated slightly from the board, a millimeter distance will do.

Testing functionality:• Before testing functionality of this part you should (as always) make sure that all solder

points and the placement of components are correct.

• Connect IOSB to +9V with a jumper

• Here you can test the function by feeding 9V to pin IOBW to switch between wide or narrow filter (and Active-filter). You can hear the difference in the speaker.

• By connecting an antenna at “IF MIXER” you might be hearing 5MHz signals. If you have a 5MHz signal source (a Antenna analysator like MFJ259B or an accurate grid dipper) they can be used to introduce a signal to the point between C1A and the MIXER (IC1A).

• Change IOBW-status and listen to the difference in bandwidth.• Now you should be able to measure the following voltages over the resistors for reference,

to check functionality:R3A approx 0.55V (With RX active)R199A approx 0.74V (With TX active)

11.Band Pass FilterWe will now finalize the the receiver assembly.

For this section you have a couple of inductors to solder, see the listing below.

All of the components on schematics VII Band Pass Filter / Mixer must be soldered in place. Refer to the placement drawings. As you can see they are to be placed onto both boards A and B.

Additionally you have to mount some components from schematics “X” and “XI”. These components are included in the placement drawings below. Basically we need the filter and

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amplifier for the “OSC”-signal from board C. We also need the digital potentiometer IC3B (AD8402)as well as the C72B, R54B and R55B for +TX pull down.

Testing functionalityAs you can see from the schematics you now have the band-filters available as well as mixer and preamp.

• Before testing functionality of this part you should (as always) make sure that all solder joints and component placements are correct.

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• The digital potentiometer is now active so the jumper (“AFIN” to “AFOUT”) used earlier is not needed anymore. Please remove it now.

• To test the functionality you need to get the VFO-signal injected into the mixer via the amplifier. The Front-unit (Board D) and DDS-board (Board C) must be plugged in and connected together. When doing this the D and C-boards are controlling the rig. So now you should not have any jumpers to do this.

When doing the ribbon cable for the interconnect between the Digital boards (D) and the Combo board (C): Watch out for polarity of the connectors. Cable length is being about 7 cm. Press carefully with a suitable tool.

• When powering up the rig the display on the front-unit is expected to start up showing text.

• A speaker should now also be plugged in. Change the AF-gain by holding down the AFG-button while you turn the main-dial. In the display you should see a bar graph illustrating the AF-gain. The noise from the speaker should change accordingly.

• Changing bands are done by pressing BDW (Band down) or BUP (Band up) buttons. Listen carefully for relay clicks when changing bands. These are the relays switching between the band pass filters.

• Hit the “Pre” button and you will hear the relay for the pre amp. In the display you see a “P” appearing when the pre amp is active.

• Time now to do a preliminary adjustment (final adjustment will be done with building the transmitter) of the band pass filters per band and listen for radio activity.

First you need to check that the oscillator signal is arriving at the mixer (IC1A). Best is if you have a frequency counter or oscilloscope. Measuring the frequency at “OSC” should show a frequency shown on the display added with about 5 MHz (depending on mode set).

Example: Display frequency – 3742.00 kHz , Osc signal – 8740.80 kHz (LSB), 8743.30 kHz (USB). Please note that the frequency can differ with several kHz.

• If you put in the Relays RL3B, RL4B and RL5B you will have a signal path to the antenna terminal on the back of board B.

• Connect an antenna and try out the functionality of your QROlle receiver.

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• Don't worry about the S-meter indication at this moment. We will take care of that in the next step.

• The front panel menu and user interface functionality are documented in a separate document.

• Now you should be able to measure the following voltages over the resistors for reference, to check functionality:

R214A approx 0.14V (with preamplifier active)R216A approx 5.6V

12. Controller / OSC AmplifierIn this step we are to finalize the assembly of the components in Schematics “XI”.

The schematics will show IC1B and IC2B with surrounding components as the placement drawing below. As previously mentioned, make sure you get the IC:s in the right way around. Phased side is where PIN 1 is to the left. The notch on the footprint is at the pin 1 end!

Important: For the AGC-signal to pass over into the ADC via D9B, you also have to assemble R37B 6K8 (left of D7B just below the LM7809 voltage regulator).

Testing functionality

• Before testing functionality of this part you should (as always) make sure that all solder joints and component placements are correct.

• Power up your QROlle and notice now that the ADC (IC1B) presents the AGC-level for a S.meter-indication.

• The ADC is also used to display the relative power output when transmitting. Those components are assembled later on.

13. Microphone Amplifier/CompressorWe are now ready to start assembling the microphone amplifier and speech compressor shown on the schematics VIII. MIC AMPL / Compressor. Most of components are discrete and all are on board A. Mount as shown on the component drawing below. Please note the placement of IC5. Hint: the phased side of the chip to the left: look at the component placement drawing below.

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Install a microphone connector to the microphone terminals on the board. As you can see from the schematics you can choose either usage of a dynamic (DYN) or electret type(EL) microphone.

For testing you need to ground the PTT with a toggle-switch. You could temporarily use the power switch provided.

Testing functionality

• Before testing functionality of this part you should (as always) make sure that all solder joints and component placements are correct.

• Switch on LSB or USB

• Check voltages. About 9V at “+SSB” (+ pad C75A) and about 5V at “IOCO” when enabling compression from front panel.

• Plug in your microphone to be used (electret microphones has very good price/performance).

• The best way to test this module is to use an oscilloscope and trace the signal if you cannot find a output signal at “MODUL” when whistling into the microphone. Try enabling the compressor. If you do not own a scope, you could use a regular multimeter and measure AC voltages when whistling into the mike. As a reference you should have about 60mV AC at the output of Q41A (measure between C107A and R162A). At the output of the module (measure between C99A and R147A) you should have about 400mV. Both values with the mic gain trimmer set about half way.

• When pushing the PTT-switch you should notice the QROlle switching to transmission with relay noise. No power output at this point naturally, the Power Amplifier is not assembled yet! The best gain adjustment (trimmer R152A) for the microphone amplifier is right below then when the ALC reacts. It can be set this way: Measure the voltage at the emitter of Q44A. Normally you will find 0.85V. The voltage increases when the edges in the speaking levels occur. Measurements need to be measured with a quick reacting voltage instrument.

• Now you should be able to measure the following voltages over the resistors for reference, to check functionality:

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R148A approx 0.93V (With inactive compressor)R148A approx 0.99V (With active compressor)Emitter Q40A approx 0.34VEmitter Q41A approx 1.1VEmitter Q43A approx 5.3V

14. DSB / CW generatorThis is the second last schematics to work from before assembly of your QROlle is done !

The main part in this module is the balanced modulator T1A and D10A. Here the “module”-signal from the microphone amplifier and the IF-carrier is mixed and presented as a “DSB IF” signal. The CW signaling passes the modulator and being presented as “CW IF”. Look in schematics “VI” for further signal processing in the sideband filter and amplifier.

All components are discrete and all are on board A. Solder according to placement drawing below.

The proper installation of the transformer T1A is important. Have a good look at the schematics to understand how the secondary windings are to be installed “in series”. Clean the wires from lacquer carefully and pre-solder them to make sure that you get a proper solder joint.

Testing functionality

• It is VERY easy to misread the component value or placements of the components in the rush of getting ready. It is worth walking trough all the components before firing up the rig for testing.

• Make sure LSB is selected on the front panel.

• Now check that you have an amplified “IF CARRIER” signal, Measure with a scope or frequency counter at the collector of Q31A. Measure when 9VDC at +TX (PTT-switch on). Typical value 1.4V peak to peak

• Now you should remove the carrier frequency by balancing it away in the modulator with C180A and R129A.

First set the 20 turn trim pot (R129A)half way by first turning 20 turns left and then 10 turns

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right with a trimmer tool.

Now measure signal between C96A and R138A and adjust R129A/C180A for a null carrier with PTT-switch on and no mic signal. Remember: NO mic input!

Start with C180A and continue with R129A. Repeat the adjustment several times to obtain the best suppression.

• Now you should check for proper functionality of the X-tal filter by listening with a cable inducing signal for another receiver. A suitable place is “RF” (at the interconnect between the boards). Push the PTT and whistle into the mike with the QROlle and second receiver set for LSB. You should hear a signal in the receiver. Changing the receiver sideband for USB should make the signal disappear. Now remove the microphone and and do the final adjustment with C180 A and R129A for a minimum S-meter level on the monitor receiver.

• Set CW on the front. Try CW-functionality by grounding the collector of Q27A, PTT-switch on and listen for a CW-signal in the monitoring receiver.

• Now you should be able to measure the following voltages over the resistors for reference, to check functionality:

R128A approx 0.28V (In SSB)R136A approx 0.28V (In SSB)R195A approx 0.7V (approx in CW)

15. TX power amplifierIn this section we finalize the assembly of the components on board B. The “RF”-signal is now ready to be amplified and presented via one of the band filters.

For this section you have to prepare the transformer(s) T1B and T2B.

For the feed-back circuitry and low pass filters you need to prepare the inductors L9B - L13B.

Assemble all the the components as shown below. Include Q17B and R62B at IC3B.

Make sure the windings of T1B and T2B are placed the right way around. Check with schematics to verify. The thicker 10 turn winding of T2B is to be connected to Q16B. The 20 turn winding is to be connected to the low pass filters.

Please note the orientation of D6B and D10B-D13B

Please note that Q16B and D10B – D13B are to be placed on the underside of B board, against the aluminum sheet, see photo and note the usage of isolating hardware when mounting Q16B, check with an ohm-meter that you do not have a shortage to chassie ground from the transistor cooling tab.

The leads of the components are to be soldered after the B-board has been mounted onto the aluminum sheet between the A and B-boards. Q16B must have an insulating kit, the body of Q16B will be connected to the positive DC power

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input!

Before testing the functionality with the components mounted you need to do the following:

Adjust R21B so that you measure 0 ohm to ground at the gate of Q3B. Do the same with R25B and measure 330 ohm at the gate of Q16B.

Testing functionality

• Bias level adjustment for Q3B and Q16B. Set up the rig for CW without having the key connected. Set up a ampere meter in series with the DC supply to the rig. Also connect a dummy-load to the antenna output. Apply DC supply and ground PTT.

• Now adjust the trimmer R21B to a position where the total current consumption increases with 50mA. Now you have set the bias for the driver transistor.

• Now adjust the trimmer R25B to a position where the total current consumption increases with another 150mA. Now you have adjusted the bias for the PA transistor.

• Time to adjust the band pass filters. Do it the following way:

◦ Put a power meter between the antenna output and your dummy load.

◦ Set up the rig for CW and connect a straight key and set up “straight key” in the menu.

◦ You will get RF output when holding down the key.

◦ On the front panel you can reduce the power output on the front panel,. Check for output on the power meter.

◦ First adjust the bandpass filters for 40, 30 and 17m by maxing the output with the trimmers C141A, C142A (40m), C143A and C144A (30m) and C147A, C148A (17m)

◦ Now adjust the filters for 80m C1B and C2B. Check for good adjustment on the frequencies 3530kHz, 3650kHz and 3770kHz.

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◦ 20m is trimmed with C145A and C146A. If you plan to use a transverter to your QROlle it is best to do fine tuning of the output this way:

The adjustment is best done by connecting a oscilloscope or RF voltmeter to the transverter pin “IF” (Pin 1 on 9 pole D-Sub). Set band “TA” (for transverter), adjust for maximum RF output on front panel in mode “CW”. Hit the CW key when adjusting. Adjust the TA offset frequencies 100.00 (14.100.00), 500.00 (14.500.00) and 900.00 (14.900.00). Adjust C145A and C146A and try to get to a combination where you have about the same output frequencies for the offset frequencies. Move to band 20 meter and check that you also have a output power also at the antenna terminal.

• Now increase power output from the front panel and check for output on the various bands. You should get around 10W of output depending on band.

16. Appendix A: Manually wound inductors and transformers

Wind the inductors and transformers according to the table below. Count the number of turns every time they pass the center of the core.

As you can see from the picture you have the inductor L13B as a reference with 16 turns. Please have a VERY careful look at where the wire enters and exits the core. The device needs to alight exactly as designated on the board. If it doesn't, you have most likely wound it wrong and need to redo it.

VERY IMPORTANT: Make sure you wind the toroids the right way around. If you don´t you can be close to 100% sure that your rig will not work as expected. We strongly suggest you to do all the inductors and transformers in one go. It is easier to get a good quality if you do so, rather then starting over again for each part to be wound.

The enamel is easily stripped with a tinned tip of your soldering iron. Make sure you do strip and tin the wire all the wire length to the core for proper contact when soldering to the board.

The wire length given in the table below is the length cut of for the work to have good working headroom. Cut of unneeded wire after having soldered the inductor/transformer to the board

The graphic to the right illustrates how a bifilar winding is done. Take a close look and you will not fail.

Pay close attention on how you are put windings in serial for correct functionality.

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Bifilar winding. Do not cross the wires!

When connecting these windings in serial (like in T1A secondary) your are to put the right hand side solid line wire to the left hand side dotted line wire.

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Lets have a look at the transformers in detail:T1A: First you are to do the 2x15 turns bifilar. As seen from the picture there wires are going in parallel all the way around. DO NOT cross the wires!.

When done you start on the opposite side of the and wind the primary turn of 1x 15 turns.

When done T1A should look like this. Measure with and ohmmeter that you have control of the turns for the installation on the board. Failing this will guarantee you malfunction of the rig!!

The T2B transformer is wound starting with the primary side, 10 turns with the thick wire. Distribute the turns evenly around the coil. Secondary winding is wound in between the primary winding, such that the wires never cross. So to wind the secondary winding you have to rotate the toroid twice, starting and ending at opposite sides of the primary winding start and end. See image!

Turn page for the winding details:

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T1A ready - Now with the primary on top. 4C65 TN10/6/4 core used.

T1A - First step in winding: Do the bifilar secondary winding

T1B: This one is easier. Have a good look at the picture above. Keep the wires in parallel all the way

T2B: First you should put the 10 turns evenly on the core with thicker wire (0.6mm). When done put the 20turns on top starting on the opposite side.

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Name Turns Core type Wire diam and length*L24A-L25A 16 4C65 TN10/6/4 0.4 mm, 30cmL26A-L29A 28 T37-2 0.4 mm, 39cmL30A-L31A 24 T37-2 0.4 mm, 33cmT1A Pri: 15 turns

Sec: 2x15 turns biflar4C65 TN 10/6/4 0.3 mm, 1 x 32cm

0.3 mm, 2 x 32cm

L7B-L8B 22 4C65 TN 10/6/4 0.4 mm, 42cmL9B 14 T37-2 0.4 mm, 20cmL10B 26 T37-2 0.4 mm, 34cmL11B 21 T37-2 0.4 mm, 30cmL12B 19 T37-2 0.4 mm, 26cmL13B 16 T37-2 0.4 mm, 23cmT1B Bifilar 2 x 10 turns FT-37-43

black small0.3 mm, 2 x 16cm

T2B Prim: 10 turnsSec: 20 turns

FT-50A-43 black large

0.6 mm, 25cm0.4 mm, 45cm

*) Note that the wire length given in the table is the length cut of for the work, to have good working headroom.

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Here you have them all in your hand. Looking good !!

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17. Appendix B: Calibration of displayed frequencyThe nominal DDS-reference frequency is 100MHz. The DDS-reference oscillator (5-thovertone) is adjusted for best ref-oscillator power. That will not necessarilyresult in a exact 100MHz output as it is individual X-tal dependent.

The C-boards (with DDS + DDS-ref circuits) are marked with the difference from100MHz on a white sticker. In the QROlle software the DDS-reference frequency isadjustable.

Actual DDS-ref = (100MHz + Value on white sticker)

*********Example:The C-board is marked -12.9kHz. This say that the reference oscillator frequencyis: 100MHz-12.9kHz=99.987100MHz. (Positive numbers are written without + sign.)

Press MENU-button and select the option for setting the DDS-reference frequency.Set the value (As in the example 99.987100) and it's done.********

If the BFO-frequencies are adjusted correct, the frequency shown on the LCD willbe correct.

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