Telstar Electronics SkyWave DX600, Assembly Manual

Page 1: ...RF Linear Amplifier PCB Assembly Manual SkyWave DX600 Revision B Last Revised 2 5 2021 9 10 AM Page 1 of 57 www telstar electronics com...

Page 2: ...pacitor C1 C2 C7 C8 24 Step 10 Ceramic Capacitor C3 C4 C5 C6 C9 C10 C11 C12 C13 C14 C15 C16 C18 26 Step 11 Mica Capacitor C17 C19 C20 C21 28 Step 12 Relay RLY1 30 Step 13 Field Effect Transistor Q2 Q3...

Page 3: ...26 30MHz Frequency Coverage LDMOS MRF300 Push Pull Configuration Class AB Temperature Tracking Bias High Output Power Low Harmonic Content Carrier Operated or Manual Transmit Receive Switching Contin...

Page 4: ...Mica 330pF 350V 5 SM C17 2 Diode High Speed Signal 1N914 DO35 Axial D1 D2 1 Diode Zener 10V 0 5W DO 35 D3 1 Fuse Holder ATC Type TH F1 1 Fuse ATC 25A F1 1 IC Operational Amplifier LM2904 Dual DIP 8 U...

Page 5: ...l T1 1 Transformer RF 2 Length 61 Material T2 1 Transistor FET N Channel MRF300AN 250MHz 50V 300W TO 247 Q4 1 Transistor FET N Channel MRF300BN 250MHz 50V 300W TO 247 Q6 1 Transistor FET N Channel 2N7...

Page 6: ...ias Adjustment 48VDC Power Supply Ammeter Capable of 400mA Several Jumper Wires w Alligator Clips Please take a few minutes before you begin assembling to review the entire assembly adjustment procedu...

Page 7: ...d of the 7 64 drill bit position the drill bit shank through a spacer and through the hole in the PCB into the piece of wood below The drill bit will aid in centering the spacer on the PCB hole during...

Page 8: ...RF Linear Amplifier PCB Assembly Manual SkyWave DX600 Revision B Last Revised 2 5 2021 9 10 AM Page 8 of 57 www telstar electronics com Details of spacer installations Figure 2...

Page 9: ...s com Step 2 Fixed Resistor R1 R28 IMPORTANT FIXED RESISTORS HAVE NO POLARITY AND CAN BE INSTALLED IN EITHER DIRECTION MAKE CERTAIN THE RESISTORS ARE FULLY SEATED IN THE PCB BEFORE SOLDERING Install r...

Page 10: ...RF Linear Amplifier PCB Assembly Manual SkyWave DX600 Revision B Last Revised 2 5 2021 9 10 AM Page 10 of 57 www telstar electronics com Details of fixed resistor installations Figure 4...

Page 11: ...nics com Step 3 Variable Resistor VR1 IMPORTANT VARIABLE RESISTORS ARE POLARIZED AND MUST BE INSTALLED IN THE PROPER ORIENTATION MAKE CERTAIN THE VARIABLE RESISTOR IS FULLY SEATED IN THE PCB BEFORE SO...

Page 12: ...RF Linear Amplifier PCB Assembly Manual SkyWave DX600 Revision B Last Revised 2 5 2021 9 10 AM Page 12 of 57 www telstar electronics com Details of VR1 installation Figure 6...

Page 13: ...ES ARE POLARIZED AND MUST BE INSTALLED IN THE PROPER ORIENTATION THE WHITE BAND INDICATED ON THE PCB INDICATES THE CATHODE THIS POLARITY BAND IS ALSO PRESENT ON THE DIODE ITSELF MAKE CERTAIN THE DIODE...

Page 14: ...RF Linear Amplifier PCB Assembly Manual SkyWave DX600 Revision B Last Revised 2 5 2021 9 10 AM Page 14 of 57 www telstar electronics com Details of diode installations Figure 8 Figure 9 Figure 10...

Page 15: ...l Operational Amplifier U2 IMPORTANT INTEGRATED CIRCUITS ARE POLARIZED AND MUST BE INSTALLED IN THE PROPER ORIENTATION USE THE OUTLINE ON THE PCB AS A GUIDE TO INSTALL THE INTEGRATED CIRCUIT WITH THE...

Page 16: ...RF Linear Amplifier PCB Assembly Manual SkyWave DX600 Revision B Last Revised 2 5 2021 9 10 AM Page 16 of 57 www telstar electronics com Details of U2 installation Figure 12...

Page 17: ...s com Step 6 Fuse Holder F1 IMPORTANT FUSE HOLDERS ARE NOT POLARIZED AND CAN BE INSTALLED IN EITHER DIRECTION MAKE CERTAIN THE FUSE HOLDER IS FULLY SEATED IN THE PCB BEFORE SOLDERING Insert F1 fuse ho...

Page 18: ...RF Linear Amplifier PCB Assembly Manual SkyWave DX600 Revision B Last Revised 2 5 2021 9 10 AM Page 18 of 57 www telstar electronics com Details of F1 fuse holder installation Figure 14...

Page 19: ...one PRIMARY pad Figure 15 Wind the unsoldered end of the wire four complete turns through the tubes of the transformer in a loop type fashion Cut and strip the wire making it just long enough to reac...

Page 20: ...RF Linear Amplifier PCB Assembly Manual SkyWave DX600 Revision B Last Revised 2 5 2021 9 10 AM Page 20 of 57 www telstar electronics com Figure 15 SECONDARY PRIMARY SECONDARY MOUNTING PRIMARY...

Page 21: ...RF Linear Amplifier PCB Assembly Manual SkyWave DX600 Revision B Last Revised 2 5 2021 9 10 AM Page 21 of 57 www telstar electronics com Details of T1 installation Figure 16 Figure 17...

Page 22: ...rity Figure 18 Solder all three pads on T2 for proper attachment to PCB Figure 18 Strip the insulation from one end of the 18 orange 16 wire Solder the stripped end to one SECONDARY pad Figure 18 Wind...

Page 23: ...RF Linear Amplifier PCB Assembly Manual SkyWave DX600 Revision B Last Revised 2 5 2021 9 10 AM Page 23 of 57 www telstar electronics com Details of T2 installation Figure 19 Figure 20...

Page 24: ...ALLED IN THE PROPER ORIENTATION THESE CAPACITORS HAVE MARKINGS INDICATING THE NEGATIVE TERMINAL THE PCB INDICATES CAPACITOR POLARITY BY DISPLAYING A POSITIVE SYMBOL CLOSEST TO THE POSITIVE TERMINAL OF...

Page 25: ...Linear Amplifier PCB Assembly Manual SkyWave DX600 Revision B Last Revised 2 5 2021 9 10 AM Page 25 of 57 www telstar electronics com Details of electrolytic capacitor installations Figure 22 Figure...

Page 26: ...ctronics com Step 10 Ceramic Capacitor C3 C4 C5 C6 C9 C10 C11 C12 C13 C14 C15 C16 C18 IMPORTANT CERAMIC CAPACITORS ARE NOT POLARIZED AND CAN BE INSTALLED IN EITHER DIRECTION Insert ceramic capacitors...

Page 27: ...RF Linear Amplifier PCB Assembly Manual SkyWave DX600 Revision B Last Revised 2 5 2021 9 10 AM Page 27 of 57 www telstar electronics com Details of ceramic capacitor installations Figure 25...

Page 28: ...57 www telstar electronics com Step 11 Mica Capacitor C17 C19 C20 C21 Insert mica capacitors C19 C20 C21 into the PCB at the designated locations Figure 26 Solder capacitors into position Cut off the...

Page 29: ...RF Linear Amplifier PCB Assembly Manual SkyWave DX600 Revision B Last Revised 2 5 2021 9 10 AM Page 29 of 57 www telstar electronics com Details of mica capacitor installations Figure 27 Figure 28 C17...

Page 30: ...lstar electronics com Step 12 Relay RLY1 IMPORTANT RELAYS ARE POLARIZED AND MUST BE INSTALLED IN THE PROPER ORIENTATION MAKE CERTAIN THE RELAY IS FULLY SEATED IN THE PCB BEFORE SOLDERING Insert RLY1 i...

Page 31: ...RF Linear Amplifier PCB Assembly Manual SkyWave DX600 Revision B Last Revised 2 5 2021 9 10 AM Page 31 of 57 www telstar electronics com Details of RLY1 installation Figure 30...

Page 32: ...fect Transistor Q2 Q3 IMPORTANT TRANSISTORS ARE POLARIZED AND MUST BE INSTALLED IN THE PROPER ORIENTATION USE THE OUTLINE ON THE PCB AS A GUIDE TO INSTALL THE TRANSISTORS WITH THE FLAT SIDE AS SHOWN I...

Page 33: ...RF Linear Amplifier PCB Assembly Manual SkyWave DX600 Revision B Last Revised 2 5 2021 9 10 AM Page 33 of 57 www telstar electronics com Details of transistor installations Figure 32 FLAT FLAT...

Page 34: ...ANT TRANSISTORS ARE POLARIZED AND MUST BE INSTALLED IN THE PROPER ORIENTATION Form the leads of Q5 at a 90 degree angle using the 1 4 drill bit Figure 34 Insert Q5 from the bottom of the PCB so the le...

Page 35: ...inear Amplifier PCB Assembly Manual SkyWave DX600 Revision B Last Revised 2 5 2021 9 10 AM Page 35 of 57 www telstar electronics com Details of lead forming Figure 34 Details of Q5 installation Figure...

Page 36: ...LTAGE REGULATORS ARE POLARIZED AND MUST BE INSTALLED IN THE PROPER ORIENTATION Form the leads of U1 at a 90 degree angle using the 1 4 drill bit Figure 37 Insert U1 from the bottom of the PCB so the l...

Page 37: ...inear Amplifier PCB Assembly Manual SkyWave DX600 Revision B Last Revised 2 5 2021 9 10 AM Page 37 of 57 www telstar electronics com Details of lead forming Figure 37 Details of U1 installation Figure...

Page 38: ...ORTANT TRANSISTORS ARE POLARIZED AND MUST BE INSTALLED IN THE PROPER ORIENTATION Form the leads of Q1 at a 90 degree angle using the 1 4 drill bit Figure 40 Insert Q1 from the bottom of the PCB so the...

Page 39: ...inear Amplifier PCB Assembly Manual SkyWave DX600 Revision B Last Revised 2 5 2021 9 10 AM Page 39 of 57 www telstar electronics com Details of lead forming Figure 40 Details of Q1 installation Figure...

Page 40: ...D MUST BE INSTALLED IN THE PROPER ORIENTATION Form the leads of the transistors at a 90 degree angle using the 3 8 drill bit Figure 43 Insert transistors from the bottom of the PCB so the leads protru...

Page 41: ...r Amplifier PCB Assembly Manual SkyWave DX600 Revision B Last Revised 2 5 2021 9 10 AM Page 41 of 57 www telstar electronics com Details of lead forming Figure 43 Details of transistor installations F...

Page 42: ...PAIR OF A LENGTH OF ORANGE BLUE 16 WIRE ONTO THE TOROID FERRITE CORE Twist the 18 orange 16 and 18 blue 16 wires together Figure 46 Wind the twisted wires ten complete turns through the toroid core Cu...

Page 43: ...RF Linear Amplifier PCB Assembly Manual SkyWave DX600 Revision B Last Revised 2 5 2021 9 10 AM Page 43 of 57 www telstar electronics com Details of L1 installation Figure 46...

Page 44: ...s the RF transistor mounting holes and the three device mounting tab holes at the edge of the PCB Remove the tape and PCB from the heat sink Use a center punch to enhance the marked centers prior to d...

Page 45: ...wer Green and Green LED1 Main Power LED Indicator Yellow and Blue S2 SSB DELAY SSB Delay Enable Purple and Purple LED2 Transmit LED Indicator Yellow and Blue Solder AWG 22 wires S1 S2 LED1 LED2 at the...

Page 46: ...RF Linear Amplifier PCB Assembly Manual SkyWave DX600 Revision B Last Revised 2 5 2021 9 10 AM Page 46 of 57 www telstar electronics com Details of wiring installations Figure 49 Figure 50...

Page 47: ...RF Linear Amplifier PCB Assembly Manual SkyWave DX600 Revision B Last Revised 2 5 2021 9 10 AM Page 47 of 57 www telstar electronics com Details of wiring installations continued Figure 51...

Page 48: ...7 www telstar electronics com Step 21 Coaxial Cable RF IN RF OUT IMPORTANT COAXIAL CABLE IS POLARIZED AND MUST BE INSTALLED IN THE PROPER ORIENTATION THE BRAIDED PORTION OF THE CABLE IS ALWAYS ATTACHE...

Page 49: ...RF Linear Amplifier PCB Assembly Manual SkyWave DX600 Revision B Last Revised 2 5 2021 9 10 AM Page 49 of 57 www telstar electronics com Details of coaxial cable installations Figure 53...

Page 50: ...ounting holes Note that Q5 has no insulator Figure 54 Apply thermally conductive paste to the bottom of Q4 and Q6 only IMPORTANT DO NOT FORGET TO APPLY THERMALLY CONDUCTIVE PASTE TO Q4 Q6 Hover the PC...

Page 51: ...HE SCREWS AS SHOWN BELOW Install three plastic insulating washers WASHER1 WASHER2 WASHER3 on three 1 4 long 4 40 machine screws and install the screws loosely for Q1 U1 Q5 Figure 55 IMPORTANT DON T OV...

Page 52: ...RF Linear Amplifier PCB Assembly Manual SkyWave DX600 Revision B Last Revised 2 5 2021 9 10 AM Page 52 of 57 www telstar electronics com Example of installed circuit board Figure 56...

Page 53: ...Insert an ammeter across jumper JMP1 terminals Rotate VR1 BIAS fully counterclockwise Temporarily connect RF IN center conductor of coaxial cable to LED1 wire The ground braid of coaxial cable remains...

Page 54: ...ll an LED to the wiring Yellow and Blue coming from LED2 XMIT LED Hook the amplifier RF IN 50 Ohm coaxial cable to the driving transmitter Hook the amplifier RF OUT 50 Ohm coaxial cable to a suitable...

Page 55: ...t of amplifier Relay engages on transmit but amplifier has no output power J1 open Check that J1 is properly shorted with solder Relay chatters during SSB operation Switch S2 is not closed Move S2 swi...

Page 56: ...CW 28MHz 3rd Harmonic 50dBc Typical 300W CW 28MHz Input Output Impedance 50 Ohms Typical Input SWR 1 2 1 Typical Power Gain 16dB Typical 28MHz Characterized Bandwidth 26 30MHz 0 5dB Gain Flatness Cla...

Page 57: ...ast Revised 2 5 2021 9 10 AM Page 57 of 57 www telstar electronics com RF Performance 65 130 195 260 325 390 455 515 555 585 605 615 622 625 0 100 200 300 400 500 600 0 1 2 3 4 5 6 7 8 9 10 11 12 13 1...