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Construction Guide of High-Performance 4-Band Backpack
SSB/CW/AM Transceiver Kit TJ4A is a 4-band SSB/CW/AM backpack transceiver suitable for field operation. With high
performance DDS LO, TJ4A offers wider and birdies-free tuning range.
Doubly-Balanced Diode Ring Mixer is used as the receiving mixer, featuring low noise and
strong signal handling ability.
Features
New MCU (STM8S105C6T6)
User Friendly Operation System
New DDS LO without birdies in tuning range
Dual VFO system
Multi-Mode (SSB / CW /AM)
Automatic Bandwidth System
100 memories
Automatic keyer and straight key compatible
Dual Data Input
Dual ANT Connector
Frequency Range for KIT A
RX
Standard BPF
BAND 1: 3.5 – 3.99999 MHz
BAND 2: 6.5 – 7.49999 MHz
BAND 3: 13.5 – 14. 49999 MHz
BAND 4: 19.5 – 22 MHz
Optional Wide Band BPF
BAND 1: 1.6 – 3.99999 MHz
BAND 2: 4 – 7. 49999 MHz
BAND 3: 7.5 – 14. 49999 MHz
BAND 4: 14.5 – 22 MHz Note: Standard BPF is supplied with TJ4A.
TX BAND 1: 3.5 – 3.99999 MHz
BAND 2: 7 – 7. 49999 MHz
BAND 3: 14 – 14. 49999 MHz
BAND 4: 21 – 21. 49999 MHz
1
Frequency Range for KIT B (10m Version) RX
Standard BPF
BAND 1: 6.5 – 7. 49999MHz
BAND 2: 13.5 – 14. 49999 MHz
BAND 3: 19.5 – 21. 49999 MHz
BAND 4: 26 – 29. 99999MHz
Optional Wide Band BPF
BAND 1: 3.5 – 7. 49999 MHz
BAND 2: 7.5 – 14. 49999 MHz
BAND 3: 14.5 – 21. 49999 MHz
BAND 4: 21.5 – 29. 99999 MHz Note: TJ4A is supplied with standard BPF
TX
BAND 1: 7 – 7. 49999MHz
BAND 2: 14 – 14. 49999 MHz
BAND 3: 21 – 21. 49999 MHz
BAND 4: 27 – 29. 99999 MHz
Sensitivity
0.3 uV
Band Width
SSB: 2.1 KHz
CW: 700 Hz
AM: 6 KHz
Power Output
20 W Note: Output power is adjustable.
Power Supply
11 V – 12.5 V
2
Construction
Coils
Main Board Color code inductors refer to illustrations, p30. T2(Component Side): Broadband transformer, 8 turns on FB43-2401 core. Cut 2 pieces of 15 cm
long enameled wires. Say Wire A is red, Wire B blue. Twist the wires before winding. Connect 2
(the finish of A) with 3 (the start of B) as the tap. Leave about 1 cm for each lead. Remove about 5
mm enamel from the leads, and tin. Wind T1 of
DDS Board with the same method.
T3:Broadband transformer, 3-turn primary (C11 side), 9-turn secondary (U2 side), 0.31 enameled
wire threading through the binocular core made up
of 2 small sleeves. A length of 7.5 cm wire is the
exact length for 3 turns with about 1 cm on each
end. A length of 20.2 cm wire is the exact length
for 9 turns with about 1 cm on each end. Wind
primary first. Remove about 5 mm enamel from
the leads, and tin.
Red wire stands for the primary, blue for
secondary. Mark the primary or the secondary
with a mark pen to avoid getting confused.
3
T4, T5: 9MHz transformer, Can coil, no number on the can. T6 : Broadband transformer, 12-turn
primary, 3-turn secondary, 0.31 enameled
wire on FB-43-2402 core. The 3-turn
primary is wound on middle part the
secondary. For clearer instruction, the
yellow wire is used as the primary. The
photo shows the actual turns. Remove
about 5 mm enamel from the leads, and tin.
Cut 19.5 cm length of enameled wire for
the 12-turn secondary, leaving about 1 cm
for each lead. The length is the exact length for 12 turns with about 1 cm lead on each end. You
wouldn’t wind the wrong turns, because you don’t have extra length of wire to wind more turns.
Remove about 5 mm enamel from the leads, and tin.
T7,T8:Broadband transformer, 5 bifilar
turns 0.31 enameled wire on the binocular
core made up of 2 small sleeves. Cut a pair
of 12 cm long enameled wire, and thread
through the core. Say Wire A is red, Wire
B blue. Connect 2 (the finish of A) with 3
(the start of B) as the tap. You don’t have
to twist the wire. Leave about 1 cm for
each lead. Remove about 5 mm enamel
from the leads, and tin.
L1:23 turns on T37-2 core. Cut 30 cm
length of 0.31enameled wire for the winding,
leaving about 1 cm for each lead.
L2, L3:BFO inductor, can coil labeled 3.
L4, L5:80m BPF inductor, can coil labeled 3.
L6,L7:40m BPF inductor, can coil labeled 2.
L8,L9:20m BPF inductor, can coil labeled 1.
L10,L11:15m BPF inductor, can coil labeled 0.
Please refer to Appendix 1 for 10m version BPF information.
4
T1, T2 (on the PCB back): mixer transformers, handled with care.
Solder Components Resistors and caps are not difficult to solder. However, some SMD components are tiny.
Solder carefully. Use magnifying glass, if necessary. They are not damaged easily, but they would
fly away and hide. The transistor 108T is very small (smaller than the SMD transistor labeled J6).
Handle carefully (Refer to illustration, p31).
V11 (V12) is MOSFET. The wider lead is “S”. Solder
According too the silk print.
Q1 is hot when working. Please use a heat sink.
Use an IC socket for U6.
Notice the white line when mount RL1. There is also a line one the relay.
Solder a 10K resister across Pin 2 and Pin 5 of CN4.
5
Use the jumper cap for A and B.
Please remove the jumpers if the wide band BPF is used.
Definition of Connectors
CN1:Control port. Connect it to CN1 of PA board with the supplied 14-wire cable.
CN4, CN5:8-PIN aviation plug connector. The 5 pins are defined (starting from top) as MIC
GND, MIC INPUT, DATA OUT (for PSK service), PTT, GND. Connect to the 8-pin sockets with
5-wire cable according to the definition illustrated on p 8.
CN3:AF gain control connector. Connect it to the AF gain pot with 3-wire cable.
CN6:Control port. Connect to CN3 of DDS board with 14-wire cable.
CN7:LO input. Connect to CN4 of DDS board with coaxial cable.
CN8:Power level(DRIVE)control connector. Connect to the PWR pot with 3-wire cable.
CN9:TX output. Connect to CN2 of PA board.
KEY:CW key socket.
PH:Audio out for earphones or louder speaker.
6
Front Face Assembly
Do not use the long crews supplied with the handles. Find 4 shorter ones in the kit to fasten
the handle to the front face. Remove the stopper of the pot with pliers. The power switch should
be installed at a certain angle (See illustration).
8
Connect the AF gain pot leads to CN3 as the number indicated. DRIVE pot is also connected
the same way. Number 3 pin is connected to the GND pad.
Solder 4 wires to the power switch: Power supply control and key lock control .
Bridge the 2 contact leads as indicated. Connect the bridged leads and the arm lead to the
2-pin connector (CN5) below CN3 of the Switch board.
Connect another 2 contact leads to CN5 of the DDS board. If you do not want LOCK
function, do not
bother to solder
these 2 wires.
Simply bridge CN5
of DDS board.
You have
completed the most
difficult wiring job.
9
DDS Unit
T1: Broad band transformer, same as T2 of the main board, 8 turns on FB43-2401 core.
Most of the components have
been installed in the factory. However,
still some components are left for you
to solder. Install 100MHz XTL as
indicated. Pat attention to the dot.
Definition of Connectors
CN1:MCU communication port,
for factory only. No connection.
CN2:LCD port. Connect to LCD
with pins.
CN3:Control port. Connect to
CN6 of main board with 14-wire
cable.。
CN4:LO output. Connect to
CN7 of main board with 50 ohm
coaxial cable.
CN5:LOCK control port. If you
do not need lock function,
simply short circuit this port.
CN6:Key port. Connect to key
pad with pins.
Construct DDS Assembly
Key board
Remove the 2 plastic pins on the button back with pliers.
The clearance between the key and the key opening in the front face is a round 1mm. The
PCB mounting
holes are
manufactured
with some
clearance so that
the keys project
through the key
openings with
suitable
10
clearance on all sides.
Plug in the connecting pins. Install three 10 mm brass pillars. Fasten the key assembly to the
DDS board. Use four 10mm brass pillars to support the LCD to the DDS board. Use the two 5mm
screw end brass pillars to fasten the LCD right side at the back. These two pillars will be used to
hold the switch board.
Cut the button card, and select the color you prefer. Insert the card into the button cap. Clean
the button caps before inserting the transfer cards.
Fasten four 20mm brass pillars to the front face, using the socket head cap screws. Place a
spacer between the front face and the brass pillars. Install the DDS assembly to the front face.
You might find that the mounting hole does not align with the brass pillar tapping hole (See
picture below). This happens when the pillar is not vertical to the front face.
Use the wrench to bend the pillar slightly until it aligns with the DDS PCB mounting hole.
11
Fasten the screws and see if the buttons achieve running fit (work smoothly). If not, bend the
related pillar until the buttons run smoothly.
Don’t forget to install the IF SET button on the back. This button is seldom used. No need to
put on a cap.
12
Switch Board This board has o
a few components. It is
mounted to the back
the DDS board.
nly
of
Definition of the
connectors
CN1:External
power input
connector.
CN2:Battery input
connector.
CN3:Charging
connector.
Important! CN3 directly routes to the external power, and does not have current limiting
device. This connector only suits the battery pack with charging management. Insert a
diode between the connector and the battery charging port, if necessary, to prevent the
current flow back.
CN4:Power supply output. The power to operate the rig is from this connector. Connect to
CN3 of PA with the heavy duty wires supplied with the kit. Turn the power switch to OFF
before plug in or disconnect external power.
14
PA Board
Transformers and Inductors
T2:Broad band transformer, 4 turn-primary, 2 turn-secondary center tapped, through the small
binocular core. Use insulated wire supplied with the kit for primary, 0.31 enameled wire for
secondary. Wind secondary first.
T3:Broad band transformer, through BN43-202 core. 2-turn primary, 0.47 enameled wire, center
tapped, 4-turn secondary. Use insulated wire for the secondary winding. The illustrations below
show how to count turns and tap.
L2, L5:3 turns on the RFC toroid, 0.47 enameled wire. The
RFC core is smaller than FB43-2401.
L3, L4:A piece of wire through a bead. Resistor lead can be
used as the wire.
L6, L7:15m LPF inductor, 0.47 wire, 10 turns on T37-2 core.
Cut 14 cm long enameled wire. Remove about 5 mm enamel
from the leads, and tin.
L8, L9:20m LPF inductor, 12 t, 0.47 enameled wire on
T37-2 core. Cut 16 cm long enameled wire. Leave about 1 cm for each lead. Remove about 5 mm
enamel from the leads, and tin.
L10, L11:40m LPF inductor, 17 turns 0.47 enameled wire on T37-2 core. Cut 22 cm long
enameled wire. Leave about 1 cm for each lead. Remove about 5 mm enamel from the leads, and
tin.
L12, L13:80m LPF inductor, 0.31 wire, 23 turns on T37-2
core. Cut 30 cm long enameled wire. Remove about 5 mm
enamel from the leads, and tin.
The photo on the right indicates 10 turns.
Refer to Appendix 1 for 10m Version LPF inductors.
15
Notes:
Q1 is very hot when working. Use a heat sink. No transformer for T1. Please bridge the pads as yellow line indicated (See photo).
U1 does not need a heat sink.
Solder a 220P ceramic cap (larger disc) across the primary of T3. Wrap a piece of tape to prevent the sharp edges of T2 to damage the insulation of the wire.
Install Q1 and 2.
Bend the leads and
insert to the
mounting pads. Do
not solder. Place four 8 mm pillars on the aluminum plate (heat sink), and fasten the PA board.
Align the mounting holes of Q1 and Q2. Once aligned, use the screw to hold. If you happen to
have silicon grease, apply some between the transistors and the plate before installing the
transistors. Now solder the leads.
Position the PA assembly upright and use 2 screws to fasten it. The coaxial cable runs from
underside of the PA assembly. Use 2 thick wires to connect CN4 to the ANT sockets. Use wires as
short as possible. The 2 sockets are in parallel.
16
PA of Ver. 2: R1– 10 ohm, R8 – 8.2k, R9 – 68 ohms, C4 – 0.01 (103)
Close-up pictures of T2 and T3
18
Now let’s assemble the assemblies to the bottom case.
First, place the DDS assembly. Fasten it with flat screws. Place the main board. Use 4 screws to
fasten it to the case.
Place the power switch unit, place the PA assembly, plug in the connectors. Place the battery wall.
19
Please notice how to run the heavy duty power lines. Try to run them along the edge.
Place the back cover. Let’s move to alignment work.
20
Alignment Alignment is not very complicated. However, you need a frequency counter. Plug in
earphones, and antenna. Plug in power connector. Double check the polarity of the plug. Turn the
power switch to “ON”. Now, you can hear the relay a click sound of the relay, a Morse code of
“R”. LCD lightens. That means the switch board, U4, U6, DDS unit work.
DDS Unit
If no letters appear on the LCD, do not worry. Adjust VR1 until letters appear.
You have set up the parameter before using. Press IF SET button on the PCB back, and LSB
SETUP appears:
This is for setting up the LSB offset. Use the default value 0000. Press the IF SET again, and
USB SETUP appears:
Set up the USB offset. Press the front panel F+ and F- to set the above displayed data, +2100.
Press the IF SET again, and CW SETUP appears:
Set up the CW offset. Press the front panel F+ and F- to set the above displayed data, +0920.
Press the IF SET again, and AM SETUP appears:
Set up the AM offset. Press F+ and F- to set the above displayed data, +2000.
Press the IF SET again, and IF SETUP display appears:
Set up the XTL filter offset. Press F+ and F- to set the above displayed data, +8.998430. The
21
cursor indicates the tuning rate. Press STEP to select 10Hz, 100Hz, 1KHz rate.
Press the IF SET again, and DDS clock SETUP appears:
Set up the DDS clock. The default value is 125MHz. 100MHz is used in the kit. Press F+ and
F- to set the above displayed value, 100000000. The cursor indicates the tuning rate. Press STEP
to select 10Hz, 100Hz, 1KHz rate.
Press the IF SET again to exit setup.
Now, press B+, B-, STEP, MODE, V/M, A/B to see if they function.
Press A/B to shift VFO A to VFO B and vice versa. Press MODE to select LSB, USB, CW,
and AM. Press F+ or F- to tune frequency. Hold the button, tuning would be automatic. Band is
changed automatically during tuning.
Press V/M to enter the saved frequencies. M01 indicates me or
ency? For example, the present frequency is 7.050. Press SAVE, and
e f
The system suggests you to save the frequency in 01. However ou may save it in a different
me
cy can be measured.
The
the paddles, etc., which will
be d
to LCK, buttons are disabled.
m y N01. Mode can be changed
in memories. F+ and F- function as the memory number selection buttons. As many as 99
frequencies can be saved. Press V/M again to exit the memory.
How to save the frequ
th ollowing display appears:
, y
mory number. Press F+ or F- to select the memory number where you want to save the
frequency. Press SAVE, and the frequency is saved.
. LO frequenConnect the frequency counter to TP2 of the main board
measured frequency is always IF offset + displayed frequency.
FN is used to set up the keyer, such as speed, wpm, exchanging
iscussed in detail later.
Switch the power switch
22
M
Bency counter TP3. Adjust the slug of T5 half way into the can (About 2mm
e the can. This is around the resonant position. See photo on P26 for reference). If you
happ
SB. Adjust VC1, until the frequency counter reading is around 9.00055. Set the
mod
t when KEY or PTT is
the frequency connected to TP3.
P3.
2 and ground (See the photo at
ng the test point of R22). It is
sugg
LSB
USB 5.5 V
AM:8.5V
ain Board
FO Connect the frequ
insid
en to have an RF volt meter, trim T5 to peak. If you don’t have, never mind. It can be
calibrated later.
Set the mode to LSB. Adjust L2, until the frequency counter reading is around8.99843MHz.
Set the mode to U
e to CW. Adjust VC2, until the reading is around 9.00000MHz.
Before carrying out CW transmission calibration, check the bias of the PA transistors in case
wrong values are used (In this case the transistors would be very ho
pressed). Disconnect CN9. Connect the volt meter between T2 tap and GND to measure the DC
bias voltage of the PA transistors. Press KEY of PTT. The voltage reading is around 2.6 – 2.7V. If
the reading is very high, say, close to 4V, stop immediately, and check the bias network (8.2k and
6.8K) to see if the wrong resistor values are used. If the reading is within the range, and the heat
sink is not hot, you can carry out CW transmission calibration.
Connect a 50-ohm dummy load at ANT (You could use two 2W 100-ohm resistors in parallel
to act as a 50-ohm dummy load now). Set the mode to CW, with
For the convenience of calibration, set the KEY to the straight key mode. Hold FN button until
you hear the Morse code “.-.”, input “-.-” using your key. Now you will hear “.-.”, indicating your
instruction has been received. Press KEY and adjust L3, until the frequency counter reads
8.99935MHz. If the frequency is higher, and the slug fails to pull the frequency down, please use a
larger value for C59 (Parallel a 20P to 33P). If the frequency is lower, and the slug fails to raise
the frequency, please use a smaller value for C59 (Say 20P). Usually 33P suits the BFO crystal
with red ink mark. The BFO crystal with black ink needs a larger value for C59 (The BFO crystal
is not marked for earlier kits).
Switch to AM mode. You will hear the relay working. In this mode BFO stop working. No
frequency will be detected at T
Automatic Bandwidth Control
Connect volt meter between R2
right, the yellow arrow indicati
ested to use high impedance volt meter such as digital meter.
Adjust VR1 until the voltage reading meets the requirement:
: 5.5V
:
CW:4.1 V
23
Note: Tolerances are allowed.
2
a. Use a digital volt meter to measure the voltage of pins 4 and 6 of
2 until voltage of pin 4 is around 1.19V, pin 6 around 0.65. Now the chip works and
AGC
rn the slug to
peak
U9 – U13 and Q20 form the band and mode control switches, sending out control voltages
Band
1, D33: 0V
29: 6.8V
1, D33: 0V
AGC and U
Do not connect the antenn
U2. Adjust VR
works properly. Never short-circuit pins 2 and 3. This would damage the IC.
Another simple way to adjust U2 is to listen carefully with the maximum volume, and adjust
VR2, until you hear a relatively louder hiss sound. Adjust T4. Listen the carefully. Tu
the weak hiss sound until you hear a relatively louder hiss sound. Notice the position of the
slug of T4. The slug is about half way inside the shielding case (about 2 mm inside the can). The
photo below illustrates the slug height.
Checking Band and Mode Control Voltages
under the control of MCU.
1
D27: 6.8V
D29, D3
Band 2
D
D27, D3
Band 3
D31: 6.8V
24
D29, D27, D33: 0V
33: 6.8V
1, D27: 0V
ode and band control voltages are not correct, please check the test points as indicated.
re is usually caused by the cold solder.
Band 4
D
D29, D3
If the m
Control voltage failu
However, the voltages can be measured on the top side:
25
BPF Remove the dummy load, and connect the antenna. Connect the antenna.
Switch to Band 1. Set the slugs of L4 and L5 about 1.5 – 2 mm above the can (Photo below
ates the slug height). Tune the frequency to around 3.8MHz to get a signal or the noise. Trim
L4 a peaking L4, adjust
L5 t
t the slugs of L8 and L9 about 1.5 mm above the can. Tune the
frequ
frequ
ttery level is full or one bar to full at
illustr
nd L5 to peak the received signals. Adjust the inductors one by one. After
o peak. Then adjust L5 to peak again. Trim T4 to peak again. If the peak is not very sharp, and
hiss sound is louder, use a smaller value for C24, say 4.3P. C24 ranges from 4.3P – 20P. Never
forget T5. Trim T5 to peak.
Switch to Band 2. Set the slugs of L6 and L7 about 1.5 mm above the can. Tune the
frequency to 7.050 – 7.1 to get a signal or the noise. Trim L6 and L7 to peak the received signals.
Switch to Band 3. Se
ency to 14.1 – 14.2 to get a signal or the noise. Trim L8 and L9 to peak the received signals
Switch to Band 4. Set the slugs of L10 and L11 about 1.5 mm above the can. Tune the
ency to 21.1 – 21.2 to get a signal or the noise. Trim L10 and L11 to peak the received
signals.
Calibrating Battery Level
VR4 is the battery sampling device. Adjust it until the ba
the supply of 12.5V.
26
Calibrating S Meter
ceive a very strong signal, and adjust VR3 until all the bars appear.
Let’s take 40m for example. Tune the frequency to 7.050, switch the mode to CW, with
W POWER (Counter-clockwise to the end). Press the key, around 1W will be
mea cilloscope, 20V p-p will be measured. Trim L6 and l7 to
peak
in higher bands at USB mode when PTT is pressed
with
aller value, say 220 ohms, to reduce the drive. R98 affects
e o hms
se
ys have to withstand the frequent
With C120 in position, there will be a short delay, i.e., the relay does not release at the
The bars at the LCD left corner represent the signal strength, each long bar representing 1S,
i.e., S2 – S59+30dB. Re
Transmission
Connect a 50-ohm dummy load.
POWER to LO
sured. If you happen to have an os
. Now increase the drive by PWR LEVEL, 18 – 20W will be obtained. Warning: If you use
two 2W 100-ohm resistor as the dummy load, do not use too much power. Or measure instantly.
Otherwise the resistors would be burned.
Switch to LSB, press PTT, speak to the microphone, LCD S meter bars also work, indicating
transmission condition, and the output is around 18 – 20W at the HIGH power level.
You might find that there is output
out talking. This is carrier leakage. Reduce C50 to 4.3 – 10P, and trim VR1 with PTT pressed
until this power leakage is reduced.
If the output power is more than 20W, or self oscillation occurs (there is power output
without talking to the MIC at SSB), increase R72 to 470 ohms to reduce the drive. If this problem
is still not solved, reduce R98 to a sm
th utput power, ranging from 220 – 1K. Increase the value would increase the drive. 470 o
is the standard value.
If ANT is not matched, relay vibration sound would be heard in 10 meter bands. Plea
shorten the connecting wires between CN4 and ANT sockets.
QSK C120(1uF)determines QSK delay. For full QSK, C120 is not necessary. In this case, the
relays release as soon as the key is up. However, the TR rela
switching.
short key-up intervals to avoid the frequent relay contact motion.
27
Appendix 1 Parts list for KIT 2 (10m Version TJ4A) ain Board BPF: portant! For KIT 2, BPF arrangement is different: Band 1 is 40m, Band 2 is 20m, Band 3
2
Part No.1
C tor
C82 4.3 221
20P
2P 101
20P 82P
2P 82P
12P 68P
2P 68P
N 1 cap re used for C95 and C97. They have been modified to smaller value to increase the
MImis 15m and Band 4 is 10m. Can Former L4 Part No.L5 Part No.2 L6 Part No.1 L7
L8 Part No.0 L9 Part No.0 L10 Part No.0 L11 Part No.0
apaciC80 47P C81 221
C83
C84 47P C87
C88 101 C89
C90
C91 20P C94
C95
C96
C97
C98 20P C101
C102
C103
C104
C105 12P
ote: 15 s wedrive.
28
DDS Board: apacitor C48 270P
C49 100P
0P
150P
S ducto
H
L5 0.33UH
33UH
P LPF
SM SM
C27 100P SM 150P SM
L 10m 0 re, 8 turns on T37-2 core. Cut 12 cm long enameled wire. Remove a mm e rom t ds, and tin. L8, L9:15m ors, wire, 10 turns on T37-2 core. Cut 14 cm long enameled wire.
emove about 5 mm enamel from the leads, and tin.
eled wire on T37-2 core. Cut 22 cm long
C
C50 27
C51
C52 330P
C53 150P
C54 150P
C55 68P
C56 150P
MD In r L3 0.33U
L4 0.33UH
L6 0.
L7 0.22UH
L8 0.22UH
AC25 100P C26 220P
C28
C29 330P SM
C30 150P SM
C31 220P SM
C32 470P SM
C33 220P SM
C34 470P SM
C35 820P SM
C36 470P SM
6, L7: inductors, .47 wibout 5 namel f
induhe lea0.47ct
R
L10, L11:20m LPF inductors, 12 t, 0.47 enameled wire on T37-2 core. Cut 16 cm long enameled
wire. Leave about 1 cm for each lead. Remove about 5 mm enamel from the leads, and tin.
L12, L13:40m LPF inductors, 17 turns 0.47 enam
enameled wire. Leave about 1 cm for each lead. Remove about 5 mm enamel from the leads, and
tin.
29
Frequency Range Receiving
Standard BPF
999MHz
3.5 – 14.49999 MHz
.49999 MHz
AND 2: 7.5– 14.49999 MHz
MHz
z BPF
AND 2: 14 – 14.49999 MHz
21.49999 MHz
z
BAND 1: 6.5 – 7.49
BAND 2: 1
BAND 3: 19.5 – 21
BAND 4: 26 – 29.9999MHz
Optional Wide Band BPF
BAND 1: 3.5 – 7.49999 MHz
B
BAND 3: 14.5 – 21.49999
BAND 4: 21.5 – 29.99999 MHNote: TJ4A is supplied with standard
Transmission
BAND 1: 7 – 7.49999MHz
B
BAND 3: 21 –
BAND 4: 27 – 29.99999 MH
30
Appendix 2 10 Meter Construction Notes 10 meter is very sensitive, prone to causing the amplifier self-oscillation. If there is some power output when PTT is pushed without talking to the MIC, the self-oscillation occurs. Therefore, the following instructions should be followed to avoid such self-oscillation. 1. Keep the leads connecting the ANT connectors to CN4 of PA as short as possible (See the illustration below). Long leads would also cause relay vibration when SWR is high. Relay vibrations could be heard.
2. Solder a 10-ohm resistor across the center pad of T1 (PA board) and GND. No such a resistor is needed for PA of Ver. 2
Appendix 3 Miscellaneous 1. Auto Bandwidth Modification
Some users use different power supplies ranging from 10.6 – 13.8V. If VR1 is calibrated at 12.5V, such wide voltage change would degrade the performance of auto bandwidth control. For simplicity, the control voltage of auto bandwidth is not regulated, obtained directly from the power supply. If you are planning to work the kit in such power supply, please add an 8.2 V zener, and a 180 – 220 ohm resistor. Calibrate VR1 again in LSB mode. Now the modified auto bandwidth can handle the voltage ranging from 10.6 – 13.8V without degrading the performance.
Cut the track as indicated. This track routes the power to auto bandwidth control.
Solder a 180 – 220 ohm resistor as indicated. This is a current limiting resistor for the 8.2V zener diode. (Alternatively an 8V three terminal regulator can be used here to substitute the resistor. In this case, the 8.2 V zener is not necessary.)
Solder an 8.2V (or 9V) zener as indicated. Calibrate VR1 again at LSB mode (5.5V at R22). Modification is completed.
2. Data Port Modification Sometimes the MIC cord picks up RF voltage, which gets into PTT circuitry, causing interference to PTT circuit, or makes the PA unstable when SWR is very high or the antenna is seriously mismatched. The switching relay would hold, or the power meter indicates power output at 15m or 10m when you are not talking to the MIC. Solder two 0.01 ceramic discs to CN5 cures this problem.
The value is not critical. 0.001 – 0.01 is fine. SMD caps could be used. The two caps by-pass the harmful RF energy picked up by the MIC cord.
Appendix 4 1.6 – 30 MHz Wide Band Module Instruction TJ4A has a wide band BPF port on the main board. With the wide band BPF module installed,
1.6 – 30MHz is covered in receiving. Solder the module 1. Take the two larger SMD inductors. Solder them on L1 and L2 pads. 2. Find the inductors labeled L3 4. Solder them on L3 and L4 pads. Bridge C9 and C10 pads with
a drop of solder. Alternatively, the inductors could be soldered on C9 and C10 pads, and Bridges L3 and L4 pads with a drop of solder.
3. C1, C3: 100P; C2: 220P; C7: 1000P 4. Solder two 1000P caps in parallel for C6 and C8 respectively. 5. Short-circuit L5 pads with a piece of wire (e.g. a resistor lead). 6. Find two 470-ohm resistors. Solder one in parallel with C1 (Stack the resistor on C1). Solder
one 470 ohm on C11 pads. 7. Install Diodes D1 and D2 observing the correct polarity. 8. Only 4 pins are needed to connect up the filter, pins 1 and 2 and pins 11 and 12, as picture
shows.
Install the finished module on RX BPF. Solder it directly or use sockets. No direction requirement.
Now, enjoy 1.6 – 30MHz short wave broadcast and other stations! Such segments as 10.1 - 10.1
50, 18.068 - 18.168, 24.890 - 24.990 are surely included.
Appendix 5 Installation of Key Pad Version 2 1. Mount four 8 mm brass pillars to the front face.
2. Mount three 10 mm brass pillars to the key pad assembly as illustrated. Place a plastic between the pillar and the PCB.
3. Mount the key pad assembly to the four pillars with four screws. Adjust the key pad assembly mounting hole until the keys have a running fit. Now fasten the four screws.
4. Mount the DDS Board to the key pad assembly with three screws.
Miscellaneous 122 -- Optional. 470uF/16V could be used.
es. 821 or 103 ceramic disc can be used.
s a little distorted when very strong signal is tuned in,
ct.
C
C121 -- Absorbs interferenc
C24 -- Ranges from 4.3P – 20P. If the sound i
use a smaller value, say, 4.3P ceramic. The value is not very stri
Color Code Inductors
Electro Caps
31
J6 and BCR108
Keyer
U6 has no backup battery. When the rig is turned off, all the settings of the keyer, such as
PM, call sign, etc. would not be remembered. Next you turn on the rig, keyer will be
ad
speed, W
lo ed with the default values.
32
Spectrum TJ4A complies with the FCC spectral purity requirement. The output spurious signals are
43dB below the carrier.
36
The following is the LO spectrum, contributing to the clean tuning without birdies throughout e tuning range and the qualified transmission spectrum. th
38
Title
Number RevisionSize
D
Date: 27-Jan-2012 Sheet of File: D:\新建文件夹 (2)\Ele2\THUNDER\Th-BPFD.DDBDrawn By:
Q1
Q14
Q12Q13 Q11
Q6
R1
R2
R3
R4
R5
R6
R7
R8
R9
R10
R11
R12C1 C2
C3
C4
C5 C6
C7 C8
C9
D1
D4
D5 D6 D7 D8
RFC1
L1
R13
R14
R72
R64
R56
R61
R60R20
R73
R43
R23
R68
R25
R26
Y1Y2 Y3 Y4 Y5 Y6
D9
D10
D24
D35
D13
D26
D15
D16
D17
D32 D31
D36
RFC2
L8
C10
C65
C13
C14
C15
C15C17
C79
C21
C23
C24
C25 C26
T3
T2
T6
R26
R27R28
R29
R30
R31
R66
R33
R36
R69
R67
R62
R38
R39
R32
D25
D18
D11
VR2
VR3
SM SET
VR4
BATT LEVEL SET
C120
RL1
RL2
RL3
GN
D3
IN-B 2OUT-A4
OSC-B6
OSC-E7
OUT-B5
Vcc
8
IN-A 1
U3
12VR
PRODUCT DET/MOD
R35
R34 C36
C38
C37
C33C33
C34
AUDIO AMP
+12V
-2
+3
GND4
OUT 5
VCC 6
7
81
U4
C31
R55
12VT
R37
R65
C39
C46
C44
C42
C40
C3610uF
SM AMP
12VT
- 2
+ 3
GND 4
OUT5
VCC6
7
8 1
U5
12V
123
CN3
VOL
123
CN8DRIVE
12345
CN4DATA
12345
CN5MIC
J2PH
J1KEY
C28
C29 C30
Q7
R67
C43C67
C49
C66
C53 C54
C45
BFO/CARR OSC
R42
R41
R39
R40
C64
C48
C47
Q9 C51Y79.0000
L2
Q10
T5
R46
Q21
C52L3
VC1VC2C59
Q17
Vin1
GN
D2
Vout 3
U7
C62C61
Q15
Q16
1 2 3 4 5 6 7 8 9 10 11 12 13 14 CN6
12V
1
2
3
4 5
6
7
8
VR5
U6
Q19
C69
C68
Q20
GN
D3
IN-B 2OUT-A4
OSC-B6
OSC-E7
OUT-B5
Vcc
8
IN-A 1
U8
C74
C71
C70
R70TX MIXER
12VT
12
CN7 LO INC72
C73C75
C76C77C78
C94C98
C99C100
R71
R81
R86
R74
R87
R78
R79
R80
1
2A
C96
C95C97 RFC7L9RFC8
D34 D33
L10
C101C105
C106C107
R88R89
C103
C102C104 RFC9L11RFC10
D28 D27
L4
C80C84
C85C86
R82R83
C82
C81C83 RFC3L5RFC4
D30 D29
L6
C87C91
C92C93
R84R85
C89
C88C90 RFC5L7RFC6
R90
6
12
34
5
7
10111213141516 8
U10U11U12
U13
C108
C109
C110
C111
C112
C113
C114
C115
C116
C118 C119
C121
1
2
B
R91
R92R93
R94
R95
R96 R97
R98
R99
R100
R101
R102
R103
R104
R105
R106
R107
R108
R109
R110
Q23
Q24
Q22
Q27
Q26Q25
12VT
12VT
12VR
123456789
1011121314
CN1
D14
D37
D38 R111
D39
D23
D21 D22
R52
R53Q18
C63
C60
R51
12V
12VR
12VT
12VT
TP1
TP2
TP3
R75
R76
R77
PTT
PTT
R15 R16 R17 R18 R19
R22
VR1
C11
12VR
D19
AM
AM
Q3 Q4 Q5
AUTO BW MODUAL
Q2
CW
LSB
USB
12VR
12
CN9 C117 12VT
RX MIXER
U2
C55
CW
12V
LSBUSB CW AM B1 B2 B3 B4
B1
B2
B3
B4
U9
R54
SIDETONE SET
KEYER MCU
B1
B2
B3
B4
B1
B1
B1
B1
WIDE BAND BPF1.6 - 30MHz
T2
T8
T7
12V
12VT
CW
AM
700Hz, 2.1KHz, 6KHzMHz
FLT BW SET
10K
C32
Title
Number RevisionSize
B
Date: 27-Jan-2012 Sheet of File: D:\新建文件夹 (2)\Ele2\THUNDER\Th-BPFD.DDBDrawn By:
VR1CONTRAST
Y110.240
1 2 3 4 5 6 7 8 9 10 11 12 13 14
CN3
12
CN4
12
CN5
Vin1
GN
D2
Vout 3
U3
Vin1
GN
D2
Vout 3
U5
Vin1
GN
D2
Vout 3
U6
Y2100MHz
KEY
D3R15
U1 U4
D1
RL1
Q1, T1
1234
CN1
SWM
LOCK
Q3
Q6 D6
D5
D4
BPFBPF
LCD
DDS UNIT
LO OUT
U2
POWER MONIT
MCU DDS
AMP
Title
Number RevisionSize
A4
Date: 27-Jan-2012 Sheet of File: D:\新建文件夹 (2)\Ele2\THUNDER\Th-BPFD.DDBDrawn By:
C18
T3T2
Q1
C17
C23
C16
C9
C11
C8
C19
C21C20
C1103
R7
D18.2K
68
R10
R11
R6
R4R3
R2
L1
PA
R5
C3
Vin 1
GN
D2
Vout3
U1
C5
LPF
Q3
Q2221
C13
C14
12
CN2
1234567891011121314CN1
C7
C22
C6
12
CN3
L2
L4
L5
C15
L18
C24
U2
12
CN4
C37 -C40
C41 - C44
PA
L6, L7
L8, L9
L10, L11
L12, L13
B1
B2
B3
B4
RL9