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Rev 1.03 

1

 

PA  

 

5W HF PA kit SIMPLIFIED assembly instructions 

 

1. Introduction 

This is a Power Amplifier kit (PA) for CW or FSK modes. The output power is approximately 5W in 
the middle of the HF frequency range, using a 13.8V supply. A single inexpensive IRF510 
MOSFET is the amplification device. An unusual feature of this PA is the built-in facility for 
envelope shaping, which can create a precise raised-cosine keying envelope shape. This greatly 
reduces key-clicks when using on/off keyed modes such as CW or at the 
commencement/completion of an FSK mode transmission. 

I highly recommend building the full kit as described in the assembly instructions. The kit has a 
discrete component power modulator (voltage regulator) which is controlled by an 8-bit R-2R 
Digital Analogue Converter, and allows an external microcontroller to control the amplitude of the 
output by loading the on-board 8-bit shift register using three I/O signals, and thereby create the 
raised cosine shape.  

These instructions are for a simplified assembly of the PA kit, which omits raised cosine 
envelope shaping, or the power modulator with fold-back current limiting.

 It is easier to 

build this way, but the functionality is less.  

The kit has a PCB of size 80 x 37mm, which is the same size as the other QRP Labs modules 
such as the Ultimate3S QRSS/WSPR transmitter kit, the VFO kit and the Relay-switched LPF kit. 
It is therefore physically (as well as electrically) compatible with the other QRP Labs kits and can 
be bolted behind them in the familiar PCB sandwich. Alternatively this PA can be used with your 
own homebrew projects. The PCB has space for SMA connectors (not supplied by default with the 
kit), if you wish to use SMA cables.  

The PA kit must always be followed by a low pass filter to attenuate unwanted transmitter 
harmonics, as usual for RF power amplifiers.  

Carry out an inventory of the components according to the parts list to make sure all the 
components required are present. Remember that there will be many surplus components that are 
required only for the full build and will not be used here. Read the assembly instructions first 
before starting the assembly, understand everything, and then finally start the assembly, following 
all the steps carefully! 

 

 

Summary of Contents for PA

Page 1: ...mbly of the PA kit which omits raised cosine envelope shaping or the power modulator with fold back current limiting It is easier to build this way but the functionality is less The kit has a PCB of s...

Page 2: ...03 2 The following diagram shows the simplified circuit diagram of this HF PA This diagram includes a 10 ohm resistor modification which is highly recommended and will be described later in this docu...

Page 3: ...6 1uF capacitor 2 pieces C4 1nF capacitor Semiconductors IC1 74HC595 8 bit shift register 16 pin DIP package IC2 7805L 5V regulator TO92 package Q3 4 2N3904 NPN transistor TO92 package Q1 2 6 8 2N3906...

Page 4: ...pplied to the IRF510 gate this is supplied by 4 7K preset potentiometer R1 via the 3 3K resistor R20 A trifilar output transformer wound on an FT50 43 toroid provides matching to the 50 ohm output The...

Page 5: ...st to detect and correct any mistakes as early as possible immediately after soldering the incorrect component The board is quite compact to fit the required 80 x 37mm PCB dimensions Removing a compon...

Page 6: ...frequent intervals by vias Note that the heatsink is not electrically connected to ground or anything else The area right under the heatsink has no ground plane on the top layer This is to prevent the...

Page 7: ...Rev 1 03 7 3 1 Inventory parts This is the full list of parts Many are not used in this simplified build Please refer to the parts list...

Page 8: ...GREEN The 4 7K preset bias adjustment potentiometer with label 472 PURPLE Optionally you can install header pins Many people prefer to solder wires to header pins rather than in holes Or you may wish...

Page 9: ...ease read and follow these steps carefully Firstly the wire The best way to un wind it without tangling it up is to think of what the kit packing person that wound it up did Then reverse his steps So...

Page 10: ...a vice if you have one If you don t then you have to get creative and think of something Here I taped it to the edge of the desk Now you can twist the screwdriver at the free end repeatedly until you...

Page 11: ...idal core Now tin the last few mm at the ends of each wire You can do this by scraping off the enamel then tinning with the soldering iron or hold the wire end in a blob of molten solder for a few may...

Page 12: ...The photograph right shows a joint where the soldering iron has not been held long enough on the joint The enamel has not properly burnt off the wire and there will be no electrical connection to the...

Page 13: ...icture shows how the transistor assembly must be put together before soldering On the side of the heatsink with the large gap the silicone pad is placed on the heatsink where the IRF510 transistor wil...

Page 14: ...nk this is to ensure that even if the soldermask accidentally got scratched there would be no contact between the heatsink and ground or any other electrical connection 3 6 A recommended modification...

Page 15: ...Rev 1 03 15 The modification is illustrated in the following diagram and picture...

Page 16: ...requires a supply voltage of typically 12 or 13 8V The amplifier may draw 1 or 1 5A of current so remember to use a well regulated good quality power supply capable of this Use thick wires to the PA...

Page 17: ...r the gate of the MOSFET is where there is zero idle current through the IRF510 transistor and where increasing the bias voltage any further would result in idle current starting to flow This point ha...

Page 18: ...output power of this PA kit in your application has a significant bearing on how you enclose the project Remember that the heatsink will dissipate a considerable amount of heat The heat dissipation w...

Page 19: ...made with the full assembled kit This simplified kit assembly does not suffer voltage drop across the power modulator nor does it have any attenuation in the leakage gate Due to this the output power...

Page 20: ...y 02 Jan 2017 1 0 Initial revision 09 Mar 2017 1 01 Corrected typos in toroid core type 04 May 2017 1 02 Corrected section 3 3 to say four jumper wires not three 29 Nov 2018 1 03 Corrected BS170 in pa...

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