Construction manual V1.1 - Radio-Kits
Contents
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3. The Radio Kits Digital SWR meter kit Construction and user manual Author Steve Drury G6ALU List of contents Section Page no 1 Features and specifications 2 2 Introduction 2 3 Construction 3 4 General construction practice 3 5 Component placement 3 6 Initial testing 7 7 Testing and calibration 8 8 Boxing up 9 9 Component Identification 11 10 Fault finding 12 11 Block diagram and circuit description 12 Circuit diagram 14 13 Operating instructions 16 14 PCB overlay 17 15 Change log 18 RK SWR Meter construction manual l Version 1 1 Displays SWR forward power reverse power and supply voltage Auto turn on in presence of RF sensitivity about 1 Watt Optional turn off after preset time 10 240 Seconds Features LU e Peak reading power meter e Bar graph or numerical format e Reverse power alarm with adjustable threshold LU LU e Backlit LCD display with variable brightness LU Reverse polarity protection Typical Specifications 13 8V supply Power handling Operating frequency Supply voltage Current consumption Through loss QRP gt 100W HF 1 8 30MHz 7 167 About 28mA but depending on supply voltage and backlight level 0 2dB typical small signal RK SWR Meter construction manual 2 Introduction An SWR meter is an essential requirement for any radio shack this is a design for a general purpose instrument that will read SWR and power Being di
4. The template doesn t include positions for the DC connector or alarm sounder find suitable positions for these before drilling any holes The volume of the sounder can be adjusted by varying the outlet hole start with a small one 2mm suggested it can be enlarged if necessary The DC socket requires a 8mm hole To cut the display I would recommend drilling many holes close to each other just on the inside of the window then using a pair of side cutters join them up The window can then be squared up using a file Fit the main PCB to case it is secured by 4 M3 x 6mm screws with flat washers under the heads LI Fit the detector PCB to case using 8 M3 screws and plain washers refer to photo LI Fit the power socket and wire to the PCB the center contact is the terminal LI Version 1 1 The sounder is glued to the inside of the case using superglue or similar using hookup wire connect to the pads on PCB noting the polarity PE FE I have catered for two methods of fitting a front panel with a little thought I m sure there are many more For those wanting to design their own front panel critical hole dimensions and spacing are given on the drilling template l A PDF file of a front panel is provided this may be printed and glued double sided tape perhaps to the front and then covered with a sheet of acetate overhead projector film trapped under the four fixings screws 2 A negative ima
5. ag 2 fit the following components Electrolytic capacitors are polarised so may only be fitted one way round By convention the PCB is marked with a symbol the lead Transistors should be fitted so their outline matches that printed on of a capacitor is longest the capacitor sleeve is also normally marked the PCB their type number is marked in small lettering on the flat Fit the capacitors against the PCB with zero lead length but don t surface Don t confuse transistors prefix Q with ICs prefix U put excessive force on the leads as this can make the electrolyte leak out IBC327 Transistor IBC547B Transistor 55 124 8337 Transistor U1 and U2 have 3 legs and look like similar to the transistors uF 63V Electrolytic capacitor cis 0 A7uF 25V Electrolytic capacitor The display socket is fitted from the underside of the PCB and soldered on the topside Hold it flat to the PCB whilst soldering L431CLP Integrated Circuit 8 05 Integrated circuit w U3 Ensure the notch is aligned with that printed on the PCB RK SWR Meter construction manual 5 Version 1 1 16 pin 90 inline socket Dall The tact switches are fitted from the underside of the PCB and soldered to the top act switch Tact switch O sw4 ws swe oo T1 to T4 are wound on toroid cores T2 is wound in the opposite direction to T1 T3 and T4 see sketch below The ident for these transformers isn t marke
6. d on the PCB use the overlay to identify their positions Cut approximately 500mm of 27SWG enameled copper wire and wind 23 turns around a FTS0 61 toroidal core every time the wire passes through the center of the core counts as a turn Clean the enamel from the ends of wire and tin with the soldering iron RK SWR Meter construction manual Note that for correct operation it is important that exactly 23 turns are wound through the toroid to be clear the wire is passed through the toroid centre 23 times T1 T3 and T4 T2 For clarity these sketches show a reduced number of turns PHOTO SHOWING TINNED LEADS l mm Cut 50mm from the 20SWG tinned copper wire and bend into a hairpin similar to the sketch note the 10mm dimension is internal but in any case isn t critical 20mm Pass the hairpin through the center of the toroid and solder all 4 wires to the PCB make sure the hairpin passes exactly through the center of the toroid see photo Fit the toroid so the windings are about 1mm from the PCB E Version 1 1 IFT50 61 231 of 27SWG Enameled wire M The following components are fitted from bag 3 Solder the battery connector to pads marked Batt and Gnd on PCB IPP3 Battrey connector RK SWR Meter construction manual Initial testing Before connecting power make a careful inspection of soldered joints especially for any solder splashes etc At this point the m
7. ge is provided this can be printed on to acetate or a bubble jet transparency by reversing the image the non printed side is nearest the user so protecting the writing The builder is encouraged to personalise the front to his or her own taste to add some individuality RK SWR Meter construction manual 10 Version 1 1 Component identification Components have been packed in to 4 bags the contents of these bags and order of assembly have carefully been chosen so similar components shouldn t become confused 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 The ceramic capacitors used in this kit are marked numerically based in Pico farads The first two digits are the value and the third is the multiplier for example 1 1000pF is marked 102 1 0 and two zeroes 10nF is marked 103 1 0 and three 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 Several resistors are 1 tolerance types and are therefore marked with 5 coloured bands all other types have standard 4 band markings RK SWR Meter construction manual 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 Wh
8. gital it is easy to incorporate several functions that are not only useful but in the case of the reverse power alarm could avoid an expensive repair bill For input power below about 20W the unit can be powered from a PP3 type battery for gt 20W a power source of 13 8Vwill be required as the op amp needs this to achieve the required output voltage swing Two backlit display options are offered the first is grey writing on a yellow green background the other is white writing on a deep blue background note the backlight must be functional to see characters on the blue version The detector head has been designed as a separate PCB allowing it to be remote mounted if required alternatively it may be mounted in the same box as the display PCB Provision has been made to fit a screen over the back of the transformers this will allow the detector PCB to be placed in close proximity to the display board without interaction Version 1 1 Construction These instructions have 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 except for the display its socket and tact short for tactile switches 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 t
9. h the transmitter this meter and a dummy load Using moderate power 20 50W adjust the forward power reading to match that of the reference meter reverse power is adjusted by reversing the meters connections Whilst making these adjustment make sure the auto power off feature is switched off default setting Boxing up The meter hasn t been designed to fit any particular enclosure the choice is left to the constructor As previously mentioned the detector head can be used remote of the meter interconnections should be made by screened cable and can either be permanently fixed or plugged a standard 3 or 5 pin DIN type plug is suitable The meter enclosure and that for the detector should be metallic to stop any unwanted noise pickup or radiation RK SWR Meter construction manual A template has been provided to help with drilling case holes accurately Print out the drilling template and confirm the size is correct by measuring the printed dimensions they should be printed with Page scaling set to none in the print menu Stick the drilling templates to the outside of the case aligning the reference edges with the INSIDE surfaces of the box this is important for the templates to be universal no account has been made for case thickness instructions are printed on the templates Drill all holes to the sizes indicated on the template use good engineering practice start with a small drill and work up in size
10. hat is larger than actual size Note that components are numbered from left to right then top to bottom of the board 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 22SWG 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 which provides screening and allows for a small design 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 inadvertently 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 the component leads it will RK SWR Meter construction manual 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 solderi
11. hese as a single panel until PCB construction is completed Version 1 1 From bag 1 fit the following components 220R Resistor Red Red Brown Gold Resistors are identified by four or five colour bands if in doubt use a Ris R32 multi meter to confirm their value Bk3 Resistor Orange Orange Red Gold Positions 1 1 and L2 have resistors fitted R20 R23 R27 R34 R5 100R 1 Resistor Brown Black Black Black Brown 18k Resistor Brown Grey Orange Gold Doa 10k Preset resistor Marked 103 10k Resistor Brown Black Orange Gold cs B R5 Ro R R2 RT RA 9 826 R3i 00k Resistor Brown Black Yellow Gold Ik Resistor Brown Black Red Gold eee es R28 R3o PES 7k 1 Resistor Red Violet Black Red Brown Kuc ae a eS eS it HH FH SES RES SS es 8K2 1 Grey Red Black Brown Brown N N RN 470R Yellow Violet Brown Gold R10 Diodes are polarised devices so can only be fitted one way round match the band on one end of the encapsulation with the bar printed 4k7 1 Yellow Violet Black Brown Brown on the PCB Ri4 RK SWR Meter construction manual 4 Version 1 1 IBAT85 Diode Small glass diodes ILM358 Integrated Circuit D2 D5 3 eke Sey Fit the socket as indicated on PCB overlay N4001 Diode 8 Pin socket in position U4 ce SE WE From b
12. icro controller and display should not be fitted as wrong voltages applied to their pins will cause damage Measure between supply positive and ground with a multi meter on Ohms range to ensure there is not a short circuit For safety it s suggested to power the unit by battery during initial testing Connect the battery whilst pressing the power switch left most button viewed from the front measure the voltage on pin 14 of U4 PIC16F819 this should read about 5V If significantly different investigate the cause before proceeding Disconnect the battery Fit the 16 way header plug from the back of the display and solder on the front side Solder one pin first and check that the pins are square to the display PCB before soldering the remaining pins SS o O Fit the microcontroller note that pin one end is identified by a notch on the socket refer to PCB overlay PIC16F819 I P Integrated Circuit 09 909 6969 Version 1 1 Fit 4 hex spacers to the main PCB pass the threads through PCB from Plug the display into the 90 socket see photo the switch side and secure on the component side with a shake proof washer and nut Using 3 short pieces of hook up wire connect the detector PCB with the main board Connect points RE to REV GND to GND and FWD to FWD C Testing and calibration Fit the 8 hex spacers to detector PCB in RF socket fixing positions e Turn R25 LCD contrast fu
13. ite 9 Silver Divide by 100 10 Gold Divide by 10 5 Examples 1kQ 5 10009 Brown 1 Black 0 Red x100 Gold 5 tolerance 2R2 5 2 2Q Red 2 Red 2 Gold divide by 10 Gold 5 tolerance Note that 1000Q 1k 1000000Q 1M 2K2 22009 2R2 2 20 etc Diodes All diodes used are axial and have their cathode end marked by a band on the encapsulation dvs Version 1 1 Values are marked on the bodies although for the small glass diodes Fault finding 84185 they will be hard to read without a magnifying glass 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 comp w 222 i voltages were measured with both inputs from the bridge connected to Voltage tables Transistor Emitter Base Collector a Aa r Transistors and Ics Q2 0 0 5 View from underside of package 2 Q4 0 0 7 0 LM386 is similar to PIC16F819 but only has 8 pins PIC16F818 819 RK SWR Meter construction manual 12 Version 1 1 Pin Number 1 2 3 4 5 6 7 8 U1 3
14. lly clockwise note that the thread passes through the PCB and is fixed by a nut and e Turn R26 and R31 forward and reverse adjust fully shake proof washer on the component side of board Only tighten counterclockwise them finger tight at this stage Temporarily hold the RF connectors in place with 3mm screws and solder the center terminal on the component side of the PCB straighten the connectors and tighten the 8 fixing nuts Reconnect the battery Press the power button the meter should now power up and will probably show 16 squares Adjust R25 anti clockwise until the display shows correct contrast It s possible to make a reasonable calibration using the internal voltage reference Ski BK2 g RK SWR Meter construction manual 8 Version 1 1 e Connect together pads REV FWD and TP3V9 detector PCB may be left connected e Power up and using the push buttons select FWD the display top line and REV on bottom line see operating instructions e Adjust R26 and R31 clockwise to set forward power to read 23 1 Watts e Note With REV and FWD connected to TP3V9 it will not be possible to turn the unit off using the Menu button power down before disconnecting the links by removing the power source Check that the meter is functioning correctly either by fitting between a transmitter and dummy load or transmitter and antenna If a known accurate power meter is available it can be placed in line wit
15. nd 12V Gnd Batt Gnd Beeper 4 OIL G t 111111 42 5 oe o 0 0 o0 0 GES 0 11 0 gl FOO oes 2 9298 ER FO Ocu 018810 ono ol too oomo 6 SE SE gt B O 00 000 56 DER o 000000000225 R25 0 F10 00O F210 6 56 B a i pga EE 24553 Ze aeeegeegg 2 LCD Cnirst e Cee GC Re Fwd 0006000 00000000 60500500 OH H RK SWR Meter V1 0 www radio kits co uk 00000600 Operating instructions Push buttons function Menu Each sequential press advances to the next menu function Pressing the menu button in the off mode will turn the unit on To turn the unit off press and hold the menu button until Power Off is displayed then release button The unit can not power off if RF is being sensed on the transceiver input in this case Power Off will not be displayed Backlight There are 5 backlight levels selected by the up and down buttons Off to 5 Backlight 4 Reverse power alarm If there is reverse power above the threshold set an alarm will sound The threshold is adjustable by the up and down buttons in Watt steps with a maximum of 50W Rev Power Time to auto off The SWR meter can be made to automatically turn off after a preset period of no operation The limit is adjustable in 10 second steps up to a maximum of 60 second This function may also be turned off ime to autoa off f Up The function for the
16. ng 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 are taken from one bag at a time keeping the others 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 Only crop ONE lead at a time by cropping several leads its possible to crack pads off the print which can be a very difficult fault to find Note that if cleaning the PCB with solvents make sure it doesn t enter the preset resistors or they may get contaminated and fail when adjusted 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 four bags each bag contains a list of contents that will show any substitutions that have been made Component placement Both detector and main PCBs are supplied as one panel it is suggested to leave t
17. top line of the display sequentially changes on each push of the button Functions are SWR Numerical Forward power Numerical SWR Bar graph Forward power Bar graph Down SWR 1 1 FWD 2 02 Watts The function for the bottom line of the display sequentially changes on each push of the button Functions are Forward power Numerical Reverse power Numerical Forward power Bar graph Reverse power Bar graph Supply voltage FWD 2 02 Watts REV 0 Watts REV ee ee ee i a i Supply 13 8V 12 gt 20 1 The bar graphs are calibrated as follows SWR Power BAR Value 1 0 5 1 1 1 2 1 2 1 1 1 3 2 3 1 2 1 4 4 4 1 3 1 5 8 5 1 4 1 6 16 6 2 1 7 32 7 2 5 1 8 64 8 3 1 9 128 9 5 1 10 200 10 10 1 11 Not used 11 15 1 12 Not Used
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