50
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

Construction Guide of High-Performance 4-Band … Construction... · Power Output 20 W Note: Output power is adjustable. Power Supply 11 V – 12.5 V 2. Construction Coils ... 9MHz

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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

Solder coils according to the following illustrations.

7

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

Now, let’s move to SWITCH board construction.

13

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. 1

17

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

PA of Ver. 2: The 10 ohm is integrated into the PCB.

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.

How to solder 2 caps in parallel

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

Some Pictures of the Main Board

33

34

35

Spectrum TJ4A complies with the FCC spectral purity requirement. The output spurious signals are

43dB below the carrier.

36

37

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