EA3GCY EGV-40 User manual

EGV-40 CW QRP Transceiver Page 1
EGV-40
QRP transceiver for CW in kit form
In memory of Miguel Montilla, EA3EGV (SK)
Assembly manual
Last update: Octubre 1st, 2013
[email protected]
For last minute updates and news, please got to:www.qsl.net/ea3gcy
Thanks for buying and building the kit for the EGV-40 transceiver
Enjoy building and working QRP! 73, Javier Solans, ea3gcy

EGV-40 CW QRP Transceiver Page 2
INDEX
INDEX……………………………………………………………………………………….………. 2
INTRODUCTION…………………………………………………………………………………… 3
SPECIFICATIONS………………………………………………………………………………….. 4
TIPS FOR FIRST TIME BUILDERS………………………………………...……………………. 5
PARTS LIST SORTED BY VALUE/QUANTITY………..…………………………..…………… 7
INDIVIDUAL PARTS LIST………………………..……….……………………………………….. 9
LOCATION MAP…….…………………………………………………………………………….. 13
ASSEMBLY…….………..……………….…..……………………………………....................... 14
ADJUSTMENTS AND CHECKS…………..…………………………………………………...... 24
APPENDICES………….…...……………………………………………………………….……… 28
IF YOUR KIT DOES NOT WORK AFTER ASSEMBLY.………………..……………………... 31
WARRANTY CLAUSES………........…………………………………………………………...... 33
SCHEMATICS..……..……………………………………………………………………………… 34
WIRING……..………..……………………………………………………………………………… 35

EGV-40 CW QRP Transceiver Page 3
INTRODUCTION
This EGV-40 transceiver is probably the kit that I have produced with more care and illusion in my life.
It is a great honor to name this kit "EGV", the callsign suffix of the late Miguel Montilla, EA3EGV (SK).
With no doubt, this is the kind of kit he liked most.
It was my privilege to establish and share with him the first years of the EA-QRP Club. He has always
been a referent in my life; when I remember those wonderful years his humbleness, work capacity and
generosity are the virtues which shine his image.
How lucky I was to be able to share the path with you, Miguel! Thanks!
Javier Solans, ea3gcy
Miguel Montilla, EA3EGV (SK)
Miguel got his A class callsign in 1983. He hold previously the call EC3BAY. He was a good CW
operator, highly respected among their peers. Holder of many awards and winner of several contests,
Miguel enjoyed both the competition and sharing his time with a novel operator, patiently providing
information to make a QSO.
He published articles on the journal from URE (Spanish Radio Amateur Union) Unión de
Radioaficionados Españoles, on “CQ Radio Amateur” (Spanish edition) and on the G-QRP bulletins, etc.
But, without doubt, what he liked most it was QRP kit building. He loved to build a kit over a weekend
and enjoy some placid QSOs made with his new fresh transceiver. Of course, always with the minimum
power required!
Miguel EA3EGV was the founder member #1 of the EA-QRP CLUB.
On September 1994 a group of four hams, Miguel Montilla EA3EGV, Miguel Molina EA3FHC, Vicenç
Llario EA3ADV and myself, Javier Solans EA3GCY, founded the EA-QRP.
Every April the club celebrates a CW contest: “EA-QRP-CW In memoriam EA3EGV”.
EGV-40
The EGV-40 is not a novel design.
The EGV-40 kit is a low power, CW transceiver designed to be simple and compact, using the legendary
NE/SA602 mixer chips. The circuit is a “tutti frutti” mix of several well known designs from the last 20-25
years, very similar among them. In the EGV-40 I have tried to gather the best ideas of all these little
jewels but keeping in mind the philosophy of making an easy to build, compact, reasonably cheap circuit
with good characteristics.
The EGV is not a technical marvel but... will something so simple work well?
Build it, and you will be able to answer this question.
A high stability VXO covers around 40 kHz in the lower part of the band with very low drift: less than 200
Hz in the first 5 minutes of the start-up. A "fine" tuning has been added, so no mechanical or electrical
band-spread of the main tuning is required.
Also, a variable attenuator has been included in the RX path to avoid the overload with the typical strong
signals in the band.

EGV-40 CW QRP Transceiver Page 4
Acknowledgments
I want to thank Viçens EA3ADV, Lluís EA3WX and Alfons EA3BFL for their support and help to make
this kit happen. To Dave K1SWL (smallwonderlabs.com) for granting me permission to use on the EGV-
40 some details of the transmitter circuit of his legendary SW-40.
To Jon EA2SN for translating this manual into English, and to the “EA-QRP-CLUB” for keeping alive the
homebrewing, even on difficult times.
And, in special, to Montse, Miguel's widow, for allowing me to link this EGV-40 kit with the memory of his
late husband, and for generously providing me with information and support.
SPECIFICATIONS
GENERAL:
Frequency coverage: By means of a Variable Crystal Oscillator (VXO), tuning the CW segment of the 40
meter band (40 kHz).
Frequency control: High stability VXO, with a couple of crystals on 11.981 MHz.
Antenna impedance: 50 ohm.
Power requirements: 12-14 V DC, about 25 mA in reception (without signal), 380 mA (2.5 W) on
transmission.
Part count: 36 resistors, 65 capacitors, 1 trimmer resistor, 2 trimmer capacitors, 3 potentiometers
(volume, fine tune and attenuator), 7 IC's, 12 transistors, 6 diodes, 11 inductors, 5 IF transformers, 1
variable capacitor (tuning), and 5 crystals.
Front panel controls: Main tuning, fine tuning, volume.
Back panel controls: RX attenuator.
External connections: Headphones, key, antenna, DC connector.
Board dimensions: 100x85 mm (around 4 x 3 1/2 in).
TRANSMITTER:
RF output: from 0 to 3.5 W (at 13.8 V) internally adjustable (2.5 W recommended).
2nd. harmonic output: -40dBc below the fundamental (at 2.5 W).
Other spurs: all other spurs are -50dBc o lower with respect to the fundamental.
T/R switching: Semi or full break-in (internally defined by changing a capacitor).
Adjustable RX/TX shift.
Sidetone monitor: through the receiver, picking an attenuated signal of the transmitter.
Sidetone level: internally defined by changing a resistor.
RECEIVER:
Type: Superheterodyne, one conversion Balanced mixer.
Coverage: 7.0 to 7.04 MHz approx. (CW segment)
Sensitivity: 0.25 µV MDS (minimum discernible signal).
Selectivity: ladder filter with 3 crystals. Bandpass: 800 Hz nominal (at -6 dB)
IF frequency: 4.915 MHz.
Dual AGC system, controlling both the RX mixer and the product detector.
Audio output: on headphones 150 mW (on 30-100 ohm loads).

EGV-40 CW QRP Transceiver Page 5
PLEASE, READ AT LEAST ONCE AND
THOROUGHLY ALL THE ASSEMBLY INSTRUCTIONS
PRIOR TO BUILDING SESSIONS.
TIPS FOR FIRST TIME BUILDERS
Tools Required:
- Small tipped soldering of about 25-30 W rating, good quality soldering tin for electronic work, small side
cutters, wire strippers, long strippers, long nosed pliers, a sharp knife hobby "cutter”, a screw driver for
the M3 bolt, trimming tool for the IF cans.
- You need a good light and a magnifying glass to see fine print on the parts and other building details.
Instruments required:
- Multimeter, Oscilloscope (desirable but not essential). Frequency counter or HF receiver. RF power
meter. 50 ohm, 5W load. RF Generator (desirable not essential).
Soldering:
There are two important things which need to be done to ensure the successful operation of a kit. One is
getting the right part into the proper place on the board, the second is good soldering.
To solder properly, you must use the correct type of iron and the right quality of solder. Use a small
tipped soldering iron which has a bit that is short and almost pointed at end. The iron should be about
25-30 Watts (if it is not thermostatically controlled). Use only electronic type multicored solder. NEVER
use any extra flux. You should hold the hot iron in contact with both the board and component lead for
about two seconds to heat them up. Then, keeping the iron in place, touch the solder onto the junction of
lead and track and wait about two second or so until the solder to flow along the lead and track to form a
good joint. Now remove the iron. The iron should have been in contact with the work piece for a total
time of about 4 seconds in all. When soldering leads going to the ground plane of the board, you will
need to preheat the union longer to get a good flow of the molten tin.
It is highly recommended to clean and remove the remaining tin from the iron tip after each soldering
(most of the holders have a sponge for this); this helps to avoid old tin on the tip and residues from
previous operations.

EGV-40 CW QRP Transceiver Page 6
Finding the right part:
IC’s
The outline on the board for the IC's has a “U” notch on one end, indicating pin 1 end of the IC. There is
also a notch on one end of the sockets. This end goes over the “U” notch outline on the board. Finally,
pin 1 of the IC is marked with a round dimple or dot; this end of IC will go towards the notch on the
socket or “U” on the outline.
Diodes
Be sure to observe proper polarity of diodes. There is a black band towards one end of the diode. This
band should face the line shown on the diode outline of the board.
Electrolytic capacitors:
These must be installed with the correct polarity. The positive (+) lead is always the long lead. The
negative (-) lead is marked by a stripe on the body of the capacitor can. Make sure the plus end of the
cap goes toward the hole labeled with the (+).
Coils and Transformers:
You can find it convenient to wind and prepare all the coils and transformers before you start inserting
parts. That way you don’t need to stop and possibly loose concentration to wind them.
Is the part of the build considered by some to be the most difficult. I find it one of the easiest stages,
personally, and almost relaxing. Just take your time. The assembly instructions and pictures illustrate the
process.

EGV-40 CW QRP Transceiver Page 7
PARTS LIST SORTED BY VALUE/QUANTITY
Resistor list
Qty
Value
Checked
Ref.
Identified
2
1 Ω
R10, R18
brown-black-gold
3
10 Ω
R12, R16, R34
brown-black-black
4
22 Ω
R4, R5, R17, R27
red-red-black
2
56 Ω
R35, R36
green-blue-black
1
270 Ω
R26
red-violet-brown
1
470 Ω
R33
yellow-violet-brown
2
1K
R13, R22
brown-black-red
1
1K5
R25
brown-green-red
1
1K8
R3
brown-grey-red
--
2K2/2K4
X
R2 SMD resistor. Factory soldered.
--
1
2K2
R32
red-red-red
2
4K7
R11, R15
yellow-violet-red
5
10K
R1, R8, R9, R29, R30
brown-black-orange
6
22K
R20, R21, R23, R24, R28, R31
red-red-orange
2
100K
R14, R19
brown-black-yellow
1
3M3
R7
orange-orange-green
1
4M7
R6 (sidetone level, see Annex)
yellow-violet-green
1
1K
P1 1K shaft potentiometer
1K
1
500 Ω/1K
P2 500/470 or 1K shaft potentiometer.
470 or 500 or 1K
1
10K
P3 10K shaft potentiometer
10K
1
500
P4 500 adjustable resistor (TX power output adjust)
501 or 52Y
Capacitor list
Qty
Value
Checked
Ref.
Identified
17
100n
C7, C14, C16, C17, C18, C19, C25, C28, C29, C32, C33, C45, C51, C55,
104 or 0.1
C57, C60, C61
1
33n
C20
333 or 0.033
11
10n
C5, C11, C21, C26, C30, C37, C41, C49, C54, C56, C58
103 or 0.01
1
1n
C39
102 or 0.001
1
1n
C63 Styroflex
1000
2
470p
C62, C64 Styroflex
470
2
470p
C8, C9 (no styroflex)
n47 or 471J
2
220p
C6, C47,
n22 or 221
6
100p
C12, C13, C34, C35, C42, C43
n10 or 101
4
82p
C1, C3, C46, C48
82P or 82J
1
68p
C10
68P or 68J
2
47p
C36, C65
47P or 47J
1
27p
C4
27P or 27J
1
22p
C31
22P or 22J
1
15p
C40
15P or 15J
1
8p2
C2
8P2
1
220uf
C59 (electrolitic)
220uf 25v or 35V
2
100uf
C23, C24 (electrolitic)
100uf 25V or 35V
8
10uf
C15, C22, C27, C38, C44, C50, C52, C53 (electrolitic)
10uf 25V or 35V
2
60p
CV1, CV4 Murata trimer
Brown
1
160+70p
CV2+CV3 Polyvaricon dual gang. Tuning. 160p + 70p
Polyvaricon

EGV-40 CW QRP Transceiver Page 8
Semiconductors list
Qty
Type
Checked
Ref.
Identified
Transistors
8
BC547
Q1, Q2, Q5, Q6, Q7, Q8, Q10, Q11
BC547
1
BC557 or BC558
Q9
BC557 or BC558
2
J310 SMD
X
Q3, Q4 SMD Factory soldered
--
1
2SC2078/1969
Q12, washer and mica spacer
C2078 or C1969
Integrated circuits
3
SA/NE602
IC1, IC2, IC6
SA602AN or NE602AN
1
LM386
IC3
LM386N-1
2
78L06
IC4, IC7
78L06
1
78L08
IC5
78L08
Diodes
4
1N4148
D1, D2, D4, D5
4148
1
47V Zener
D3 Zener 47V 1W
BZX85C47
1
BB112
DV1 Varicap diode
BB112
Inductors/RF Transformers/Crystals
Qty
Value
Checked
Ref.
Identified
4
100uH
L1, L3, L6, L8, Axial inductor
brown, black, brown
1
18uH
L2 Axial inductor
brown-grey-black
1
22uH
L4 Axial inductor
red-red-black
1
47uH
L7 Axial inductor
yellow-violet-black
2
T37-2
L10, L11 LPF toroids 16t.
9,5 mm diam. red
1
T68-2
L5 Toroid. Tuning inductor (47) 48t.
17,5 mm diam. red
2
FT37-43
T5 toroid = 8 + 1 turns ; L9 toroid = 6turns
9,5 mm diam. black
4
3334 (5u3H)
T1, T2, T3, T4 5u3H Shielded coils
K3334 or “5u3H”
5
4.915
X1, X2, X3, X4, X7 Crystals 4.915MHz.
4.915
2
11.981
X5, X6, 11.981MHz crystals
11.98
Hardware
Qty
Value
Checked
Ref.
Identified
5
nuts
hex nuts M3
-
4
spacers
5mm spacer for M3 screw
-
4
screw
5mm M3 screw
-
1
screw
10mm M3 screw
-
1
washer
M3 lock washer
-
13
pins
Phone(2), KEY(2), VDC(2), ANT(2), VXO(2), J1A/B(3)
-
1
jumper
jumper for J1
-
4
IC socket
IC’s socket 8 pin
-
1
Shaft Poly.
6mm Shaft Polyvaricon Hardware
-
1
Heatsink
Q7 (Output Amp) Heatsink
-
70cm
wire
70cm enameled copper wire 0,5mm
-
110cm
wire
110cm enameled copper wire 0,3mm
-
1
EGV PCB
100mm x 85mm ILER V2 PCB
-

EGV-40 CW QRP Transceiver Page 9
INDIVIDUAL PARTS LIST
Resistors
Checked
Ref.
Value
Ident./Comment
Circuit section
Located
R1
10K
brown-black-orange
Rx mute
C-8
X
X
R2
2K2/2K4
SMD factory soldered
AGC
F-9
R3
1K8
brown-grey-red
Q2
C-7
R4
22 Ω
red-red-black
IC1
E-10
R5
22 Ω
red-red-black
IC2
E-10
R6
4M7
yellow-violet-green
Q3 Mute (see text)
H-8
R7
3M3
orange-orange-green
Q4 Mute
H-9
R8
10K
brown-black-orange
Q5 Mute
G-9
R9
10K
brown-black-orange
Q5 Mute
G-10
R10
1 Ω
brown-black-gold
IC3 Audio out
G-5
R11
4K7
yellow-violet-red
IC3 Audio out
F-6
R12
10 Ω
brown-black-black
IC3 Audio out
F-6/7
R13
1K
brown-black-red
Q6 AGC
G-7/8
R14
100K
brown-black-yellow
Q6 AGC
H-7
R15
4K7
yellow-violet-red
Q6 AGC
H-7
R16
10 Ω
brown-black-black
earphones out
H-9/10
R17
22 Ω
red-red-black
IC3 Audio out
H-5
R18
1 Ω
brown-black-gold
Fine
G-3
R19
100K
brown-black-yellow
Fine
H-1/2
R20
22K
red-red-orange
VXO Q7
E-3
R21
22K
red-red-orange
VXO Q7
G-4
R22
1K
brown-black-red
VXO Q7
F-4
R23
22K
red-red-orange
VXO Q8
E-3
R24
22K
red-red-orange
VXO Q8
F-4
R25
1K5
brown-green-red
VXO out
E-4
R26
270 Ω
red-violet-brown
VXO out
E-4/5
R27
22 Ω
red-red-black
Q10
C-4
R28
22K
red-red-orange
Q10
C-3
R29
10K
brown-black-orange
Q10
C-2
R30
10K
brown-black-orange
Key in Q9
E-6
R31
22K
red-red-orange
Key in Q9
E-6
R32
2K2
red-red-red
Q11
B-4/5
R33
470 Ω
yellow-violet-brown
Q11
B-4/5
R34
10 Ω
brown-black-black
Q11
B/C-4/5
R35
56 Ω
green-blue-black
Q11
B-5
R36
56 Ω
green-blue-black
Q12
A-2
Potentiometers
Checked
Ref.
Value
Ident./Comment
Circuit section
Located
P1
1K shfat potentiometer
1K
RX atten.
A-9
P2
500 Ω/1K shaft potentiometer
500 or 470 or 1K
Audio volume
I-9
P3
10K shaft potentiometer
10K
Fine Tune
I-2
P4
500 Ω adjustable resistor
501
Power level
B-3

EGV-40 CW QRP Transceiver Page 10
Capacitors
Checked
Ref.
Value
Ident./Comment
Circuit section
Located
C1
82p
82, 82p or 82J
RX BPF
C-10
C2
8p2
8p2 or 8.2
RX BPF
C-9
C3
82p
82, 82p or 82J
RXBPF
C-10
C4
27p
27, 27p or27J
RX BPF
C-9
C5
10n
103 or 0.01
RX MIX
C-8
C6
220p
220p, 220 or n22
RX MIX
E-8
C7
100n
104 or 0.1
RX MIX
E-9
C8
470p
471 or n47
IF Filter
D-7
C9
470p
471 or n47
IF Filter
E-7
C10
68p
68, 68p or 68J
CW DETEC.
F-7/8
C11
10n
103 or 0.01
CW DETEC.
F-8
C12
100p
100, 100p or n10
CW DETEC.
F-10
C13
100p
100, 100p or n10
CW DETEC.
F-9/10
C14
100n
104 or 0.1
IC4
C-7
C15
10uF
10uF
IC4
C-6
C16
100n
104 or 0.1
CW DETEC.
E-9
C17
100n
104 or 0.1
MUTE
G-8/9
C18
100n
104 or 0.1
MUTE
I-7/8
C19
100n
104 or 0.1
MUTE
I-7/8
C20
33n
333 or 0.033
MUTE
I-7
C21
10n
103 or 0.01
AGC
F-7/8
C22
10uF
10uF
AGC
H-7/8
C23
100uF
100uF
Audio AMP
G-7
C24
100uF
100uF
Audio AMP
H-6
C25
100n
104 or 0.1
Audio AMP
F-7
C26
10n
103 or 0.01
Audio AMP
F-5/6
C27
10uF
10uF
Audio AMP
G-5
C28
100n
104 or 0.1
Audio AMP
H-5
C29
100n
104 or 0.1
Audio AMP
H-4/5
C30
10n
103, 0.01
VXO
G-3
C31
22p
22, 22p or 22J
VXO
G-2
C32
100n
104 or 0.1
VXO
H-1
C33
100n
104or 0.1
VXO
H-2
C34
100p
100p, 100 or n10
VXO
G-4
C35
100p
100p, 100 or n10
VXO
F/G-4
C36
47p
47, 47p or 47J
VXO
F-4
C37
10n
103 or 0.01
IC5
G-4
C38
10uF
10uF
IC5
H-4
C39
1n
102 or 0.001
TX MIX
E-5
C40
15p
15, 15p or 15J
TX MIX
E-4
C41
10n
103 or 0.01
TX MIX
C-4
C42
100p
100, 100p or n10
TX MIX
D-3
C43
100p
100, 100p or n10
TX MIX
E-3
C44
10uF
10uF
IC7
D-4
C45
100n
104 or 0.1
IC7
D-3/4
C46
82p
82, 82p or 82J
TX MIX
D-2
C47
220p
220, 220p or n22
TX MIX
C-1
C48
82p
82, 82p or 82J
TX MIX
B-1
C49
10n
103 or 0.01
DRIVER
B-2
C50
10uF
10uF
DRIVER
E-5
C51
100n
104 or 0.1
DRIVER
E-5
C52
10uF
10uF
Q9 Key in
F-7
C53
10uF
10uF
DRIVER
C-3
C54
10n
103 or 0.01
DRIVER
C-3
C55
100n
104 or 0.1
DRIVER
C-5
C56
10n
103 or 0.01
DRIVER
B-4
C57
100n
104 or 0.1
DRIVER
C-5
C58
10n
103 or 0.01
Output AMP
A-3
C59
220uF
220uF
Supply
D-5

EGV-40 CW QRP Transceiver Page 11
Capacitors (continued)
C60
100n
104 or 0.1
Output Amp
C-5/6
C61
100n
104 or 0.1
Output Amp
A/B-6
C62
470p
470 (Styroflex)
LPF
A/B-6
C63
1000p (1n)
1000 (Styroflex)
LPF
A-6/7
C64
470p
470 (Styroflex)
LPF
A-7/8
C65
47p
47, 47p or 47J
RX switch
C-7
CV1
60p
Trimmer (brown)
CW Detector
G-10
CV2+CV3
160+70p Var
Tuning Polyvaricon
VXO
I-5/6
CV4
60p
Trimmer (brown)
TX Mix
E-1
Crystals
Checked
Ref.
Frequency
Ident./Comment
Circuit section
Located
X1
4.915Mhz
4.915
IF
D-7/8
X2
4.915Mhz
4.915
IF
E-7/8
X3
4.915Mhz
4.915
IF
E-7/8
X4
4.915Mhz
4.915
RX DETEC.
F-10
X5
11.981Mhz
11.98
VXO
F-3
X6
11.981Mhz
11.98
VXO
F-3
X7
4.915Mhz
4.915
TX MIX
E-2
Semiconductors
Cheked
Ref.
Type
Ident./Comment
Circuit section
Located
Transistors
Q1
BC547
BC547
MUTE
B/C-9
Q2
BC547
BC547
IF
D-8
X
X
Q3
J310
SMD factory soldered
MUTE
H-8
X
X
Q4
J310
SMDfactory soldered
MUTE
H-9
Q5
BC547
BC547
MUTE
G-9
Q6
BC547
BC547
AGC
G-7/8
Q7
BC547
BC547
VXO
F/G-4
Q8
BC547
BC547
VXO
E-4
Q9
BC557or BC558
BC557 or BC558
KEY switch
E-6
Q10
BC547
BC547
DRIVER
C-2/3
Q11
BC547
BC547
DRIVER
C-4
Q12
2SC2078 or 1969
C20178 or C1969
Output Amp
A-5
IC's
IC1
NE602/SA602
NE602/SA602
RX MIX
D-8/9
IC2
NE602/SA602
NE602/SA602
CW DETEC
F-9
IC3
LM386N
LM386N
Audio AMP
G-6
IC4
78L06
78L06
RX
C/D-6
IC5
78L08
78L08
VXO
H-3
IC6
NE602/SA602
NE602/SA602
TX MIX
D-3
IC7
78L06
78L06
TX MIX
D-4
Diodes
D1
1N4148
1N4148
AGC
H-7
D2
1N4148
1N4148
Output AMP
A-2
D3
Zener 47V 1W
BZX85C47
Output AMP
C-5
D4
1N4148
1N4148
RX limiter
B-8
D5
1N4148
1N4148
RX limiter
B-9
DV1
BB112
Varicap diode BB112
VXO (Fine)
G/H-1

EGV-40 CW QRP Transceiver Page 12
Inductors/RF Transformers
Checked
Ref.
Value/Type
Ident./Comment
Circuit section
Located
L1
100uH Axial inductor
brown-black-brown
CW DETEC
C-8/9
L2
18uH Axial inductor
brown-grey-black
IF
F-7
L3
100uH Axial inductor
brown-black-brown
CW DETEC
F-8
L4
22H Axial inductor
red-red-black
CW DETEC
G-10
L5
T68-2 red toroid
48 turns (see text)
VXO
F-1/2
L6
100uH Axial inductor
brown-black-brown
VXO
G/H-3
L7
47uH Axial inductor
yellow-violet-black
TX MIX
E-1
L8
100uH Axial inductor
brown-black-brown
DRIVER
D-5
L9
FT37-43 black toroid
6 turns (see text)
Output AMP
B-6
L10
T37-2 red toroid
16 turns (see text)
LPF
B-7
L11
T37-2 red toroid
16 turns (see text)
LPF
B-8
T1
5u3H (shielded)
RF transf. 5u3H
RX BPF
B-10
T2
5u3H (shielded)
RF transf. 5u3H
RX BPF
D-10
T3
5u3H (shielded)
RF transf. 5u3H
TX MIX
D-1
T4
5u3H (shielded)
RF transf. 5u3H
TX MIX
B-1
T5
FT37-43 black toroid
8 + 1 turns (see text)
Output AMP
A-4

EGV-40 CW QRP Transceiver Page 13
LOCATION MAP

EGV-40 CW QRP Transceiver Page 14
ASSEMBLY
You may use “individual parts list” or the “value/quantity parts list”. The “value/quantity parts list” is the
quickest way to place components because all parts of the same value or type can be placed one after
each other. You will need, however, the “individual parts list” to know how each part is identified and its
location on the board. According to your personal experience you may prefer to use the individual list, to
play on the safe side. The location of all parts is very easy when using the 90 quadrants map. After
placing each component, you can mark it in the “checked column list”.
It is highly recommended to inventory all parts to make sure everything is available and ready for
assembly. Each builder may have his/her own way of organizing parts, but if you do not, you might try
using a block of Styrofoam packing material and poke the parts on it. Parts may be sorted by type, value,
and size (ohms, micro-farads etc).
RECOMENDED ASSEMBLY SEQUENCE

Resistors
The resistors are installed first. Place all resistors from R1 to R36 and the P4 trimmer (transmitter output
power adjustment).
DO NOT install now the potentiometers P1 (RF attenuator), P2 (volume) and P3 (fine tuning).
Refer to the parts list, select the first resistor, R1 and locate its place on the board. This resistor is placed
vertically; you need to bend only one leg. Most of the resistors are placed horizontally; bend their leads
as close to the ends as possible, and fit them into the holes marked on the silkscreen of the PCB. Take
care and avoid mixing resistors and axial inductors, which are a bit thicker. All resistors have a light
yellow body color with a gold band at one end. The resistor's leads once inserted, push the body down to
lay flat on the PCB, and on the other side bend slightly out the legs to hold the resistor in place. Then
turn the PCB over and solder the leads to the PCB pads. Make sure the resistor body lays flat over the
board to keep its legs as short as possible.


EGV-40 CW QRP Transceiver Page 15
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Please read the notes on soldering Poor soldering is the most common cause of a kit failing to work first
time, so please take the soldering advice at heart! Once soldered cut off the excess length of the part
lead as close to the joint as possible. Install all resistors from the parts list and carry on until all resistors
are soldered in place.
Values which are in decade increments may be easily confused, such as 470, 4K7 and 47K. So, take a
good look at the colors before you solder the part in place! In case of doubt, use a multimeter to check
the resistor value.
R2 is an SMD resistor, factory installed.

Axial inductors
L1, L2, L3, L4, L6, L7, L8.
These components look just like fat resistors, but they have a blue or green colored bodies. Inside the
device is a small coil wound on ferrite material. As before, refer to the parts list to select the correct one
for each position. L1, L2, L3, L4, L6 and L7 are mounted vertically. L8 is the only inductor horizontally
placed, and we recommend to separate it from the board approximately 1-1.5 mm (1/16 in).
Fit them on their designated places as with resistors.
Note: L5 is the VXO toroidal coil, which will be wound and placed later.

EGV-40 CW QRP Transceiver Page 16

Diodes
Now install the diodes, taking care to place them with the right orientation. There is one band at one end
of each diode’s body which has to match the silkscreen of the PCB.
D1, D2, D4 and D5 are 1N4148 types, these are usually orange with a black band, marked with “4148”
on their body. D4 and D5 are placed vertically, all others are placed horizontally.
D3 is similar to the 1N4148 ones but thicker, and it is marked as BZX85C47.
DV1 is a BB112 varicap diode and is similar to a transistor with only two legs; its outline should fit the
silkscreen of the PCB.


Capacitors
There are Ceramic, Polyester, Styroflex and Electrolytic type capacitors. All these have their value
printed on the body. Go to the parts list' “identified” column.
When fitting them, keep their leads as short as possible.
C62, C63 y C64 are Styroflex capacitors, they are axial and must be placed vertically.
Values which are in decade increments may be easily confused, such as 8p2, 82p and 820 p. So, take a
good look at the printed numbers before you solder the part in place!
Electrolytic capacitors must be fitted the right way around: the LONGER LEAD goes to the hole marked
“+”, the shorter lead is "-" and it is indicated by a band along the body of the capacitor with “-“.
CV1 and CV4 are capacitor trimmers brown in color. They have no printed marks. Place them following
the outline on the silkscreen of the PCB.
CV2 + CV3 are part of the two-section tuning “Polyvaricon” variable capacitor. DO NOT INSTALL it now.

EGV-40 CW QRP Transceiver Page 17

Pin “headers”
Place and solder pins for “Phone”(2)(H-10), “KEY”(2)(D-6), “VDC”(2)(D-6), “ANT”(2)(A-7), “VXO”(2)(F-5),
and J1 A/B(3)(I-4).
Turn the board over and hold the headers in place with the help of a female jumper while you solder
them avoiding burning your fingers. Use the other hand for the soldering iron and move the board
towards the tin to solder the headers in place. If you have someone to help out, much better!

Transistors
All of them have their type numbers marked on their body. Place and solder Q1, Q2, Q5, Q6, Q7, Q8,
Q9, Q10 and Q11 following the outline on the silkscreen.
Q3 and Q4 are SMD J310 transistors, and they are factory soldered on the tracks side of the PCB.
DO NOT INSTALL Q12 now (TX power amplifier).

Integrated Circuits
The outline on the board for the ICs has a “U” notch on one end, indicating the pin 1 end of the IC. There
is also a notch on one end of the sockets. This end goes over the “U” notch outline on the board. Finally,
pin 1 of the IC is marked with a round dimple or dot; this end of IC will go towards the notch on the
socket or “U” on the outline.
Install sockets for IC1, IC2, IC3, and IC6 on their PCB locations. Make sure that all sockets lie flat
against the board. Next, insert IC1, IC2, IC3, and IC6 on their sockets.
IMPORTANT: Make sure that all IC’s are fully inserted on their sockets, push them if need be. It is a
good idea to clean or scratch the legs of the chips prior to their insertion on their sockets. If contact fails
in the sockets it may cause a malfunction of the rig.
Now, place the voltage regulators IC4, IC5, and IC7, following the outline of the silkscreen.

EGV-40 CW QRP Transceiver Page 18
Crystals
Install X1 to X7.
X1, X2, and X3 are part of the CW filter, X4 is the RX BFO crystal, and X7 is the oscillator for the TX
mixer. These crystals have been hand picked (have handwritten numbers on their body) to have the
same resonating frequency, in order to obtain the best filter quality. The X5 and X6 pair are the VXO
crystals.
The crystal housing should not touch the board, place them slightly separated from the board. 0,5-1 mm
(less than 1/16 in) may be sufficient.


Toko shielded coils (cans)
T1, T2, T3 y T4 are Toko “5u3“ cans (Toko KANK3334). RF transformers for the bandpass filters Make
sure their body lay flat against the PCB.
You may need extra heat to solder the shield tabs.

EGV-40 CW QRP Transceiver Page 19
When you turn the board over the cans may fall. Fit the can in place, hold it with one hand, and turn the
board over. Use the other hand for the soldering iron, and move the board towards the tin to solder the
can in place. If you have someone to help out, much better!

Toroids L10 y L11 for the LPF
L10 and L11 are identical. T37-2 cores (red toroids with OD 9.5 mm / 0,375 in) are used.
Cut 25 cm (10”) of 0.5 mm enameled wire and wind 16 turns on the red toroidal T37-2 core. Wind the
wire tightly on the core, avoiding loose turns, and spread the turns evenly around the core. They should
be uniformly spread around the circumference of the toroid. Leave pigtails of about 10 mm (0.4”).
Remove the enamel with a cutter to solder the toroids on the board.
The nominal value for L10 and L11 is 1.02 µH.
Counting turns: every time the wire passes through the toroid center hole counts as one turn.
Important: Wind the toroid exactly as shown in the pictures.
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Toroidal transformer T5
T5 is an impedance matching transformer. A FT37-43 is used (black toroid with an OD of 9.5 mm /
0.375 in). It has a primary of 8 turns, going to “b” and “b1” holes in the PCB and one secondary of 1 turn
going to “a” and “a1” holes.

EGV-40 CW QRP Transceiver Page 20
- Cut 15 cm (6”) of 0.5 mm enameled wire and wind 8 turns on the black FT37-43 toroidal core. Wind
the wire tightly on the core, avoiding loose turns, and spread the turns evenly around the core. They
should be uniformly spread around the circumference of the toroid. Leave pigtails of about 10-20 mm
(0.70”).
- Now take a resistor leftover of 15 – 20 mm (1/2-3/4 in) to make the 1 turn secondary (remember, one
turn means that the wire goes once through the toroid core). Please try to make a snug fit of this turn to
the core.
- Prior to its soldering, use a cutter, or sandpaper to scrape the enamel from the pigtails of the 8 turn
winding.
IMPORTANT: Wind the T5 transformer exactly as shown in the pictures. You must follow both the
number of turns and the winding direction.
