CW Adapter construction manual - Radio-Kits
Contents
1. uv r DI his D T ea H Eu d Ka E x DC Connector gt PLS K i E TS pasas Bh a rer e soy PLAT AM a iv placate m Y gt ia Cl E ca d TRA Taye pover 1 2 ve Internal keyer S Y p Pus 220 tev Blo x r3 ibe E K m E g EH Se tev ou CN OSK delay 1N4148 a N CH gd LA ui fe cons aca T E Key e Y o Y sw O Pusa T eoa cone i PL16 1 2 M n icrophone out AA DAS E T Y crophone D aora PAR Y cis eu z m dru m ES aos Bs E E Ga wf E lus vm b I E p ES r L tev EH z o E 1c2 0 W den cz0 cis n um ie Mul te Mui pe K SS Y Loudspeaker E E 8 Y aL ag nat rza ras n Y SY E x Ro ES2. and red to If the keyer is to be housed separate from the CW adapter fit a 3 5mm mono Jack plug to one end of a suitable length of screened lead connect the other end braid to Gnd and center core to Key out If housing the keyer with the CW adapter key out is connected to Internal keyer on the main PCB Measure between R65 and ground with a resistance meter and confirm the resistance is greater than 1k Ohms O Treat the battery with respect Fire doesn t result if the terminals are short circuited but excessive heat may cause the case to rupture normal soldering though won t be hazardous ertical lithium cell Baro nN Once the battery is fitted you can measure the voltage across R65 which in standby should be less than 1mV Testing and Adjustment First carefully inspect the PCB for any solder splashes or obvious errors measure between supply the fuse is a Released 14 04 09 V2 0 handy place and ground to make sure there is no short circuit a resistance reading of over 1k Ohms is expected Connect a Morse key and loudspeaker apply power and listen for any unusual sounds or signs of heat smoke if all is well press the key and adjust the side tone level so you can hear the tone Adjust R33 tone frequency for the loudest tone Remove power and connect the MKARS80 power microphone and loudspeaker connections need to be made to the radio Fit a dummy load to the
3. Er 2 ER M TOP Vv Internal Dove vuan loudspeaker ana In Y TX Tone filter Oscillator Ea Gi ys sex is P Ki lt us P E tev t iz pr Dd e cH Tv s E T ise Ci Sen boer GI Eum p pm Sc eo a pias HE I p am 5 7 CON3 7 p g us w E xs S Se Headphone ade bes e Y 2 gt HH Y Es ji e m di sob Sp E 53 Al oie 0 22 Z20F Myler te ZnF Myler Pi E Y gt o 0 gt ae 7 x SY D Ser pde ancho E Dosos os JS ga Sis Om s RX Audio filter Headphone limiter ES Ge B Radi o Kits CW Adapter V1 2 CW adapter construction manual 17 Released 14 04 09 v2 0 Circuit Diagram Keyer PL64 1 ask PL63 1 Sounder PL62 1 PL66 1 A LED PL65 1 a M 2 E essage R66 tk SW61 Message 1 CONGO c65 InF CW adapter construction manual cos Int x Cez InF R64 18k Il PIC16F628 I P Iced 1 RA2 RAI 2 i RA3 Dag 3 RA4 Osc in 4 E RAS RAG Vss Vdd 6 Se RB wer RB RB2 RBS 9 RB4 y v C64 LnF 18 Ces L t x vRea 180k Lin BAT6Q 2032 Vertical LI Cell Released 14 04 09 PL6 1 PTT Out V2 0 9 gt EEI q NEL AIR ey best Pe adapt
4. B after assembly Where possible fit the components so their values are easily readable Some components MUST be fitted in the correct orientation as they are polarised this will be indicated in the text The components are packed in Released 14 04 09 V2 0 two bags each bag contains a list of contents which will show any substitutions that have been made Component placement Resistors are quite small and are identified by four or five colour bands if in doubt use a multi meter to confirm their value Fit the following components from bag 1 Be careful not to mix the 4K7 and 47K resistors these two values are often confused Kg Ro Ri R2 R26 R27 pRa RO R39 is hidden between the two push switches Ro TR R Ro RU R5 Ro Ra Ra 3 10R Brown black black gold ND G SS 1K Brown black red gold EM DEM NEM a M R31 R37 35 R60 RO Se R otto CW adapter construction manual 22K Red red orange gold R9 Ris Ro R42 Rei 270k Red violet yellow gold RI 3k Orange orange orange gold DM RE Mb Yellow violet orange gold EE EB ST 6R blue black gold R38 4k7 Yellow violet red gold Rio 4R7 Yellow violet gold gold EN 82K Grey red orange gold R6 RS R5 R9 10k preset Marked 103 UM is Diodes are polarised devices s
5. M386 LM358 and LM324 are similar to PIC16F628A but have different number of pins lt oo N NO Ke Lem O A Released 14 04 09 V2 0 Fault finding Most faults are due to poor soldered connections or components misplaced it is very rare to be supplied with a faulty component Before making any measurements look carefully for any poor soldered joints short circuits or incorrectly fitted components Should fault finding be necessary a table of voltages is given below transistor voltages were measured both in transmit and receive Note that the drive level control VR1 and PTT transistor TR1 and associated circuits have a ground isolated from the rest of the circuit this is to ensure there are no ground loops and resulting instability whilst transmitting When making voltage measurements ensure the CW adapter is connected to the transceiver or alternatively connect the grounds of the loudspeaker connector and microphone connector together CW adapter construction manual 14 Released 14 04 09 V2 0 Voltage table CW adapter construction manual 15 Released 14 04 09 V2 0 Block diagram and circuit description To follow CW adapter construction manual 16 Released 14 04 09 V2 0 Circuit Diagram CW Adapter
6. The Radio Kits CW Adapter Construction and user manual Author Steve Drury GGALU List of contents Section Page no 1 Specifications 2 2 Introduction 2 3 Choices 3 4 Construction 4 5 General construction practice 4 6 Component placement 5 7 Wiring up 8 8 Testing and adjustment 8 9 Boxing up 9 10 Operating instructions 10 11 In use 11 12 Plug and socket fitting instructions 12 13 Component Identification 12 14 Fault finding 14 15 Voltage table 15 16 Block diagram and circuit description 16 17 Circuit diagram CW adapter 17 18 Circuit diagram Keyer 18 19 PCB Pattern 19 20 PCB overlay 20 21 Change log 21 CW adapter construction manual 1 Released 14 04 09 V2 0 Features Adds a CW function to simple SSB transceivers Useful for CW sendin practice Shaped keying Built in side tone Approx 800Hz Adjustable side tone level hang time and drive level Switchable narrow receive filter Reverse polarity protection fuse protected Iambic memory keyer by permission from DLAYHF Typical Specifications 13 8V supply Tone frequency Approximately 800Hz Audio output Approximately 0 5W Supply voltage 10 16V Loudspeaker 8 Ohm will work into 4 Ohm CW adapter construction manual 2 Introduction For some time MKARS80 owners have asked for a CW modification this unit has been provided to add CW functionality to any SSB transceiver that has sufficient stability and a clean trans
7. and strain relief when cool carefully crimp the strain relief over both wires and fit the cover Measure the continuity of both leads through to the plug contacts and confirm there is no short circuit between inner and outer Loudspeaker and straight key plug 3 5mm mono jack Firstly remove the plug cover and slide over leads Solder one connection to the centre contact and the other to the outer contact cable grip when cool carefully crimp the cable grip around both wires to help give some strain relief Microphone PTT plug 3 5mm Stereo jack As with the loudspeaker connector remove the plug cover and slide over the double screened lead then solder the wires to connector solder tabs as follows Microphone PTT switch Microphone and PTT ground Plug tip Middle contact Outer contact CW adapter construction manual 12 When the soldered joints have cooled the cable retainer should be carefully crimped over all wires and the cover screwed in place Component identification Components have been packed in to 2 bags The contents of these bags and the order of assembly have been carefully chosen to avoid confusion between similar components For fault finding it will be necessary to correctly identify components and their values after the radio has been built methods of marking component values are given Capacitors Most of the small value capacitors ceramic and polyester used in this ki
8. antenna socket C Apply power and push the CW SSB switch in when you press the key down the transceiver should go to transmit adjust the drive control until the LED just extinguishes this is a suitable setting but may need adjusting when changing frequency power supply or antenna Adjust the hang control to suit your CW sending speed LI Connect an antenna and set the filter switch out tune the MKARS80 to find a CW station and confirm the filter functions correctly when the button is pushed in The filter is quite narrow so you may need to adjust the tuning to properly hear CW O Keyer Testing Plug in a paddle to the keyer and plug the keyer into the CW adapter Set both switches out on the CW adapter CW adapter construction manual 9 Pressing the paddle to the left generates dots and pressing to the right generates dashes Boxing up A drilling template is provided for both front and back panels Note that all vertical dimensions are referenced to the underside of the PCBs All potentiometers should be fixed to the front back panels with nuts provided If fitting an internal loudspeaker wire to the pads Internal loudspeaker PCB pads are provided for connecting an internal battery if desired the negative terminal is isolated when an external power source is plugged in note that there is no provision to recharge internal batteries Released 14 04 09 V2 0 Operating instructions WARNING B
9. e been targeted at those with some construction experience and who can identify the different components Where out of the ordinary parts have been used a short description follows the component value All components are mounted on the component side of the board The PCB silk screen gives the component locations in cases where this is difficult to read please refer to the printed overlay that is larger than actual size Note that components are numbered from left to right then top to bottom of the board excepting the keyer which has its own number sequence beginning at 60 If you have difficulty in locating a component position place a straight edge across the overlay and look along its length in this way components will be easy to locate The PCB has been designed to accommodate the components supplied so if it doesn t easily fit ask yourself if it belongs there General construction practice Leaded or lead free cored solder may be used The solder must be designed for electronics do not use plumbers solder or additional flux as the flux is very corrosive I use 228WG 0 7mm multi core type solder that seems most suitable for this type of work A double sided plated through hole PTH PCB has been used this has the advantage of greater stability and makes dry joints very unlikely however incorrectly fitted components can be very difficult to remove so it s important to fit them in the right place first time If a component is i
10. e careful when using headphones as volume is dependent on strength of received signals and at the very least this could surprise the operator when tuning through a local station The headphone socket has a limited output so should be used for headphones PHOTO HERE The CW adapter fits in line with the power loudspeaker key and power supply connect microphone straight key loudspeaker and power to the CW adapter Plug the leads integral to the CW adapter into the MKARS80 power loudspeaker and microphone sockets CW adapter rear panel connections Power 10 16V DC from power source Loudspeaker External loudspeaker plugging in isolates internal loudspeaker but not the headphone socket CW adapter construction manual 10 CW adapter front panel connections and controls from left to right Headphone socket 3 5mm Stereo socket accepts mono or stereo headphones a diode clipper limits the output level but care should be taken to avoid hearing damage if loud headphones are used Microphone 3 5mm Stereo socket for electret microphone and PTT as used with the MKARS80 Straight key 3 5mm socket for straight key If the keyer is fitted internally removal of straight key will change over to keyer operation Audio filter Pressed in for narrow approx 200Hz bandwidth and out for full transceiver bandwidth CW SSB switch Out for SSB operation and in for CW With the switch left out pressin
11. er construction manual PCB overlay ees 2408 e ie Internal loudspeaker Internal Bat lO e oe TEE een PTT Mic Internal yel Audi of ron S SE CMT Top silk Pico GC LL Q TAON 0 es Een er LED m je es O ai Power to Txcvr oe 1j s E a O CW Adapter V1 2 jeu BEBE WW E ay CW adapter construction manual 20 Released 14 04 09 v2 0 ES AS ASE IAN CW adapter construction manual 21 Released 14 04 09 V2 0
12. g the key will not actuate the PTT the radio won t transmit although the side tone still functions in this mode it is possible to accurately pet in to the received station Drive control Sets the audio drive to the transmitter with the MKARS80 this control is advanced until the modulation LED just extinguishes with the key held down Hang time Sets the delay time from when the key is released until the PTT is released Side tone level Adjust for a comfortable side tone level Released 14 04 09 V2 0 Keyer front panel connector and controls from left to right Paddle Dot to centre of pin dash to ring and common to outer Message 1 Accesses first memory block Message 2 Accesses second memory block Keyer speed Adjusts the Iambic keyer speed note that this control is quite sensitive adjust slowly The keyer functionality is the subject of a separate operation manual please follow the links on the website or go to http www qsl net dldyhf man eng html In Use Displayed frequency and operating frequency The operating frequency will be offset from the displayed frequency by the CW tone about 800Hz for example In the case of LSB the frequency displayed is 3 5500 MHz the actual transmit frequency will be 3 5500 0008 or 3 5492 MHz Remember for LSB subtract the CW offset and for USB add the CW offset Netting on to a station As the side tone is the same as the frequenc
13. in section this carries most of the circuitry and is appropriately fitted into the case so the switches controls and sockets protrude through the front panel If separated from the rear section mounting holes for 3 x 3mm screws are provided and if the rear PCB isn t separated then there are 5 mounting holes although only 4 are required There are also 3 fixing nuts on the potentiometer shafts that should be used Rear panel this will normally be separated from the main section to enable utilisation of a larger case to separate the two sections simply score the connecting lands with a sharp knife and snap them apart In final assembly the two sections will need to be electrically connected by joining pads marked A to A B to B etc This section has two 3mm fixing holes Keyer PCB this is a stand alone PCB which is intended to be fitted into a small housing of its own this is a dense board with two fixings the speed potentiometer shaft and a single 3mm screw hole and both should be used The keyer PCB can be incorporated into a case with the CW adapter a connection is made between Key out on the keyer PCB and Internal keyer on the main board When this link is made the straight key input will over ride the keyer function For ground continuity a connection also has to be made between Gnd on the keyer and point B on the main PCB CW adapter construction manual 3 Released 14 04 09 V2 0 Construction These instructions hav
14. lead goes to LED E Fit the two black knobs to the push switches Wiring up If the loudspeaker DC input section has been separated from the main board interconnections will have to be made Simply connect points A to A B to B and C to C with some hook up wire Cut an appropriate length of screened lead to go from the CW adapter PCB to the MKARS80 loudspeaker socket lead lengths will depend on how the CW adapter will be boxed and positioned relative to the MKARS80 Do not use an excessive lead length Separate the two cores of a length of twin screened cable and fit a 3 5mm mono Jack plug to one end of one of the cores if in doubt see fitting instructions later in manual Strip the other end and fit to solder pads marked Audio from Txvr braid goes to and center core goes to Cut a piece of double screened cable to go from the MKARS80 microphone socket to the CW adapter fit a stereo 3 5mm Jack plug to one end fit the other end to the CW adapter plug tip goes to Mic ring to PTT and both braids go to Screen IE CW adapter construction manual 8 The MKARS80 will be powered via the CW adapter this will help to keep the leads tidy Fit the supplied black and red power wires to the 2 1mm DC plug cut and strip the insulation to an appropriate length Note the red lead goes to the center contact The stripped ends solder to pads marked Power to Txcvr black to
15. mit spectrum To avoid polluting the CW spectrum with unwanted signals the transmitter should have a well suppressed carrier and a linear audio stage when used with a correctly adjusted MK ARS80 unwanted spurious signals are gt 40dB below the wanted carrier In most instances these artifacts will be masked by band noise The PCB carries an lambic keyer with memory function the circuit and microcontroller code were designed by Wolfgang DLAYHF and are reproduced here with his permission His web site http www gsl net dl4yhf pic key html carries full information What started off as being a simple sine wave oscillator became more complex as extra functionality was added although now quite complex this module shouldn t pose too many problems to constructors with only a little experience To avoid any build issues the constructor is strongly advised to follow the documented build sequence The CW adapter is designed to be fitted in line with the SSB radio that is the power speaker key and microphone connections are made to the radio with plugs fitted to leads integral with the adapter Released 14 04 09 V2 0 To separate PCB sections score and break at points marked Choices The PCB is intended to be packaged into a case external to the MKARS80 transceiver one possibility is to build it into a loudspeaker cabinet No case is supplied so to be as flexible as possible the PCB can be separated in to 3 parts Ma
16. nadvertently fitted incorrectly it is easiest to cut off its leads apply the soldering iron and pull them out from the topside A small solder sucker or de solder braid can be used to clear the holes out ready for a replacement component to be fitted When soldering CW adapter construction manual zd the component leads it will be noticed that the solder wicks up the hole through to the top surface this is normal For a start place just a few components in place before soldering them as experience grows you may find it more productive to fit a larger number at a time As each component is fitted put a mark in the box provided it s very easy to forget the last component fitted especially if you are distracted If you make use of the component overlay you will find it helpful if components are highlighted as they are fitted Components should be taken from one bag at a time keeping the other sealed Everyone has their preferred method of retaining components prior to soldering I pull the leads through with long nose pliers and put a bend in the component lead to stop it falling out of the board A good policy is not to crop leads until they have been soldered this should stop you from missing any soldered joints As this is a PTH plated through hole board leads can be cropped quite close to the PCB without damaging the soldered joint A suitable solvent isopropyl alcohol or proprietary chemical may be used to clean the flux from PC
17. o can only be fitted one way round match the band on one end of the encapsulation with the bar printed on the PCB Released 14 04 09 V2 0 1N5401 diode Large black package IM SE p p pa Ds pe bz ps p po pu ER ELIAS ce 060 62 Cos ot 65 EEN cor 68 Fit an 8 pin IC socket in position IC3 note the notch goes to pin 1 end Fit an 14 pin IC socket in position IC2 note the notch goes to pin 1 end a Fit an 18 pin IC socket to position IC60 noting the correct orientation m 2nF Poly Marked 22n c9 4 es pe cu cis f ko ca Transistors should be fitted so their outline matches that printed on the PCB TR Ro C CW adapter construction manual 8L08 Looks like a transistor and is marked 78L08 in very small letters O M324 Fit into previously fitted socket M358 Fit into previously fitted socket I3 PIC16F628A Fit into previously fitted socket EM IC4 should not be fitted into a socket as it uses the PCB as a heat sink M386N 1 ici Double pole push switches swi pw Fit the following components from bag 2 220nF Polyester Marked 22 Cel Released 14 04 09 V2 o ertical tact switch Sweo Swe Electrolytic capacitors are polarised so may only be fitted one way round By convention the PCB is marked with a symbol the lead of a capacitor is longest the ca
18. pacitor sleeve is also normally marked Fit the capacitors against the PCB with zero lead length but don t put excessive force on the leads as this can make the electrolyte leak out Parts with a higher working voltage than specified may be substituted uF 63V cio is Ci OuF 25V c2 20uF 16V c7 es km A7uF 16V pi es ono 3 5mm jack socket CONI CONS lmm DC socket CON2 tereo 3 5mm jack socket CON3 CON4 ONG CW adapter construction manual x x x Fit two fuse clips to position F1 note that they have to be fitted in the correct orientation for the fuse to fit Fit F1 to the fuse clips Fitting the potentiometers also applicable to keyer The knobs available for splined potentiometers are designed to be used with thick moulded plastic panels for the CW adapter to have an attractive finish the potentiometer shafts need modifying Refer to the photo hold the unwanted part in a vice a pair of pliers will suffice 1f care is used and cut about 5mm from the shaft using a junior hacksaw clean off the sharp edges with a small file Cut approx 5mm LJ from end of shaft 10k Linear potentiometer marked B10K NRI WR3 II 100k Linear potentiometer Marked B100K R60 Released 14 04 09 V2 0 470k Linear potentiometer marked B470K vR Temporarily fit the red LED between positions LED and LED the long
19. t are marked in one of the following ways Marked directly with their value for example 22 for 0 22uF 220nF Marked numerically based in Pico farads the first two digits are the value and the third is the multiplier for example 1nF 1000pF is marked 102 1 O and two zeroes 100nF is marked 104 1 0 and four zeros Electrolytic capacitors are marked directly with their value Resistors Values on all the resistors in this kit use a colour code to indicate value All have standard 4 band markings Released 14 04 09 V2 0 Colour Value Tolerance Black 0 xl Brown 1 x10 1 Red 2 x100 2 Orange 3 x1000 Yellow 4 x10000 Green 5 x100000 Blue 6 x1000000 Violet 7 Grey 8 White 9 Silver Divide by 100 1096 Gold Divide by 10 5 Examples 1kQ 5 10000 Brown 1 Black 0 Red x100 Gold 5 tolerance 2R2 5 2 20 Red 2 Red 2 Gold divide by 10 Gold 5 tolerance Note that 10000 1k 10000000 1M 2K2 22000 2R2 2 20 etc Diodes All diodes used are axial and have their cathode end marked by a band on the encapsulation CG j Ja CW adapter construction manual S3 Values are marked on the bodies although for the small glass diodes 1N4148 types they will be hard to read without a magnifying glass Transistors and Ics View from underside of package toe wet TO92 terminal identification Lead identification ii Gnd L
20. y offset it can be used to accurately net on to a received station prior to transmitting Set the CW SSB switch out this will inhibit the PTT operation Whilst the station is being tuned hold down the key and adjust the side tone level so both signals can be heard now adjust the VFO until both signals are CW adapter construction manual 1 a similar frequency Release the key and press the CW SSB switch in to re enable the PTT Operating considerations CW has a considerably higher duty cycle than SSB and will cause the circuit and case to warm up quicker than with SSB for a similar operating period be alert to any frequency drift that may take place its advisable to note down the operating frequency at the START of the QSO Generating CW by injecting a tone into the microphone causes low level unwanted signals on a correctly set up MKARS80 these are typically less than 40dB below the wanted signal The three main culprits are the leaked carrier harmonics of injected tone and the unwanted apposite side band By reducing the drive level all but the carrier leak will be reduced if you are a strong signal with the other stations in the QSO considering reducing the drive level Released 14 04 09 V2 0 Fitting Plugs and sockets Power connector 2 1mm DC plug Vi Remove the connector cover and slide over both leads Solder the positive lead to the center contact and negative to the outer contact
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