HobbyPCB HARDROCK-50 User manual

Hardrock-
500 Assembly Instructions
Run 1 - 2020
Jim Veatch
WA2EUJ
30 August 2020
500 Assembly Instructions
500 Assembly Instructions

TABLE OF CONTENTS
1. INTRODUCTION........................................................................................................................................................ 1
2. ADVISORY AND WARNINGS ..................................................................................................................................... 2
AC VOLTAGE............................................................................................................................................................................ 2
WATER/MOISTURE ................................................................................................................................................................... 2
HIGH LEVEL RF ......................................................................................................................................................................... 2
PHYSICAL CONSIDERATIONS ........................................................................................................................................................ 2
3. GENERAL ASSEMBLY INSTRUCTIONS ........................................................................................................................ 3
AC LINE CORD ......................................................................................................................................................................... 3
4. LOW-PASS ASSEMBLY INVENTORY ........................................................................................................................... 4
5. POWER SUPPLY ASSEMBLY INVENTORY ................................................................................................................... 5
6. REAR PANEL ASSEMBLY INVENTORY ........................................................................................................................ 7
7. FRONT PANEL ASSEMBLY INVENTORY ..................................................................................................................... 9
8. CHASSIS PACK INVENTORY ......................................................................................................................................10
9. LARGE ITEM INVENTORY .........................................................................................................................................12
10. LPF ASSEMBLY ....................................................................................................................................................14
BUILD OPTIONS ...................................................................................................................................................................... 15
ASSEMBLY INSTRUCTIONS ......................................................................................................................................................... 15
11. POWER SUPPLY ASSEMBLY .................................................................................................................................25
ASSEMBLY INSTRUCTIONS ......................................................................................................................................................... 26
12. REAR PANEL ASSEMBLY ......................................................................................................................................34
ASSEMBLY INSTRUCTIONS ......................................................................................................................................................... 35
13. FRONT PANEL ASSEMBLY ....................................................................................................................................39
ASSEMBLY INSTRUCTIONS ......................................................................................................................................................... 39
14. FINAL ASSEMBLY ................................................................................................................................................44
15. SETTING THE BIAS ...............................................................................................................................................61
PREREQUISITES ....................................................................................................................................................................... 61
APPENDIX A – AN-1819 INVENTORY ................................................................................................................................64
APPENDIX B – AN-1819 ASSEMBLY INSTRUCTIONS .........................................................................................................65

[1]
1. INTRODUCTION
This assembly manual covers the Hardrock-500 HF Amplifier Support Package manufactured by HobbyPCB, LLC
The Hardrock-500 is an Amplifier Support Package and contains everything needed to support in operation of a RF
amplifier capable of operation in the 1.8 – 30 MHz band at power levels up to 500W.
To create a complete amplifier using the Hardrock-500, the builder must supply a suitable amplifier deck. HobbyPCB
engineers have extensively tested the Hardrock-500 with the RF Power Tools, AN-1819 amplifier board that uses a pair
of Microsemi VRF2933 LDMOS FETs and is capable of 400-500W output with 5 watts of drive.
ITEM SPECIFICATION
Manufacturer HobbyPCB, LLC.
Model Number Hardrock-500
LPF Bands 160, 80, 60, 40, 30, 20, 17, 15, 12, 10 meter Amateur Radio Bands
AC Power Input 90-260 Volts AC, 47-63Hz, 13A max. @ 115V, 6.5A max @ 230VAC
DC Power 57V Volts, 22 Amps maximum, 1250 watts
DC Output 13.5V, 2A max for powering transceiver
Cooling RF deck: 3 fans, 32CFM Power Supply : 1 Fan 26 CFM
In/Out Jacks Three UHF connectors; 1 radio, 2 antenna
Size 9” W by 7” H by 14.2” D
(229mm W by 178mm by 361mm)
(not including switches and connectors)
Weight 16.5 lbs/7.2 Kg under 18 lbs/8.2 Kg with ATU
Metering VDD : 0 – 60 Volts
IDD : 0 – 20 Amperes
Forward Power: 0 – 500 Watts
Reflected Power: 0 – 50 Watts
Drive Power: 0 – 10 Watts
Temperature: 0 – 70°C
VSWR: 1.0 – 9.9:1
Hardrock-500 features:
 Completely self-contained - built-in power supply for 80-260 VAC
 Light weight - 7.5 Kg (16.5 lbs.) including power supply
 Dual color LCD touch screen displays for metering and operating controls
 Full HF coverage of 160-10M amateur bands
 Seamless integration with transceivers from HobbyPCB, Elecraft, Yaesu, Elad and Xiegu
 Internal ATU and input attenuator for 100W transceivers (coming soon)
 Arduino Mega controller - 100% open source firmware
 Automatic protection for SWR, temperature, voltage, current and excessive drive
 13.8V, 2A DC output to power QRP transceivers
 USB control for unattended/remote operation

[2]
2. Advisory and Warnings
There are several risks associated with assembling, testing and operating high power RF equipment. At HobbyPCB, LLC.
safety is our highest priority and we have taken every reasonable precaution to ensure the safety of our builders when
assembling and operating our products. Take a moment to read through the advisories and warnings and if you are not
comfortable assuming the risks associated with this product you should return it unassembled in its original packaging
for a complete refund.
AC Voltage
The AC voltages inside the Hardrock-500 are potentially dangerous. We have taken precautions inside the case of the
Hardrock-500 to prevent high voltages on exposed surfaces but the potential for electrical shock still exists in the bottom
portion of the chassis around the AC wiring and the power supply boards. Under no circumstances should AC power be
connected to the Hardrock-500 with the bottom cover removed. There are no adjustments, measurements or tests
that require the builder/operator to open the bottom cover with power applied to the unit. Always connect the chassis
to a suitable ground using the ground stud on the rear of the unit.
Water/Moisture
The Hardrock-500 is designed to be operated indoors in a dry location. The forced air cooling system used by the
Hardrock-500 moves large quantities of air in through the front, top and bottom of the enclosure and forces it out
through the rear of the enclosure. Any moisture, (rain, beverages, drips, leaks, etc), can be drawn inside the Hardrock-
500 chassis creating a potentially dangerous conditions. Never operate the Hardrock-500 if there is the potential for
water in or near the environment surrounding the Hardrock-500. If liquids are present or inadvertently enter the
Hardrock-500’s enclosure, immediately remove the AC power by disconnecting it at the source and do not operate the
Hardrock-500 until completely dry conditions can be assured.
High Level RF
Even though an amplifier is not included with the Hardrock-500, we anticipate that the majority of builders will add a
high power amplifier to the Hardrock-500 which can create high power RF which has some inherent dangers. In the top
of the chassis, the RF deck, LPF board and rear panel board all carry high-level RF energy. Under no circumstances
should the Hardrock-500 be operated at high RF power levels with the top cover removed. There are no adjustments,
measurements or tests that require the builder/operator to open the top cover with RF applied to the unit.
Once the Hardrock-500 is fitted with a RF amplifier, the operator should ensure that the RF power is being delivered to a
suitable load or antenna. The Hardrock-500 has protection circuitry and algorithms for internal circuitry but not for
external equipment like loads and/or antennas that could be damaged if not sufficiently rated for the applied RF power.
Antennas should be installed in a manner that prevents excessive RF exposure.
Physical Considerations
The Hardrock-500 weighs up to 18 lbs (8.2 Kg). Avoid dropping the unit. The fans on the rear of the unit pose a potential
risk to fingers and other small objects. Do not block the opening in the top, bottom, front or rear of the chassis. Some of
the internal parts may have sharp edges so use caution (and gloves) to prevent cuts.

[3]
3. General Assembly Instructions
Assembling the Hardrock-500 amplifier kit should be an enjoyable and rewarding experience. If at any time you feel
frustrated or are having difficulty, take a break, ask questions on the forum or email, and remember that if you are
having a problem with something there’s a good chance that someone else has had the same issue. We have a “no
questions asked” replacement part policy, so if you lose a part or need an extra length of wire or find something missing
an email is all it will take to get you a replacement. Contact [email protected] if you need any help.
The assembly is organized into the following subassemblies:
 Low-pass Filter assembly
 Power Supply Assembly
 Rear Panel Assembly
 Front Panel Assembly
 Amplifier Deck
 Final Assembly
 Setting the Bias
There are a few required tools:
 Soldering iron – A small temperature controlled unit is the best.
 Solder – Rosin core, fairly thin
 Screwdrivers –All of the screws in the kit are Philips
 Tweezers – For holding small parts and reaching tight areas
 Wire Stripper – For making the coax jumpers
 Long-nose pliers – For general mechanical assembly
 ¼” Nutdriver– Not essential but helps with panel assembly. If only metric tools are available use pliers or an
adjustable wrench.
 Toothpick – For unbraiding coax
 Adjustment tool or small flat blade screwdriver – Turning pots
 Thread locker – Loc-Tite 242 or similar to prevent screws from loosening (optional)
 Digital Multimeter – Doing resistance checks
 QRP Transceiver – The reason you bought the amp in the first place
In a production environment, an assembly station would also include an anti-static mat and all work would be
performed while wearing an anti-static wrist strap. If you are equipped with these, I encourage you to use them. If you
don’t have these items, use caution when handling the PCBs and touch a grounded surface before picking up the device.
AC Line Cord
Due to the worldwide variations in AC connections, we do not supply a AC line cord for the Hardrock-500. The amp has a
IEC320-C13 power connector. Make sure to use a cord made with #16 AWG or larger wire and only connect the amplifier
directly to a wall output. Do not use a power strip. The performance of the unit will be compromised by an inferior AC
line connection.

4. LOW-
PASS ASSEMBLY
DESCRIPTION
#6
-
32X1.75" F
-
F STAND
-
OFF
#6
-
32X3/8" PAN HEAD SCREW
#4
-
40x1/4"M
-
F THREADED
SPACER
#4
-
40X1/4" PAN HEAD SCREW
#4
-
40 HEX NUT WITH LOCK
WASHER
#4
-
40X1/4" FLAT HEAD SCREW
T80
-
6 CORE
YELLOW
T80
-
2 CORE
RED
#20 ENAMELED WIRE
#28 ENAMELED WIRE
#18 TEFLON WIRE
(color may vary)
FT82
-
43
GRAY
[4]
PASS ASSEMBLY
INVENTORY
PICTURE
QUANTITY
15'
QUANTITY
4
4
4
4
4
6
4
8
15'
5'
6”
2

5.
POWER SUPPLY ASSEMBLY INVENTORY
DESCRIPTION
#4
-
40x1/4"M
-
F
THREADED
SPACER
#4
-
40 HEX NUT
WITH LOCK
WASHER
#4
-
40X1/4" PAN
HEAD SCREW
#4
-
40 3/6" JACK
SCREW W/ NUT
& WSR
#4
-
40X1/4" FLAT
HEAD SCREW
CAP ALUM
10000UF 20%
80V SNAP
CAP ALUM
1000UF 20% 63V
JST 3
-
PIN SHE
LL
CABLE TIES
COLOR MAY
VARY
AC NEUTRAL
CABLE
[5]
POWER SUPPLY ASSEMBLY INVENTORY
PICTURE QUANTITY
16
16
16
2
MAYBE
INSTALLED IN
ACC JACK
6
1
1
3
5
1

AC LINE CABLE
AC SWITCH WIRE
#14 WIRE 19”
#14 RED
-
BLACK
ZIP WIRE
WITH SPADE
TERMINALS
4”, 6”, 9”
#14 RED
-
BLACK
ZIP WIRE
6”
[6]
1
1
3
1

6.
REAR PANEL ASSEMBLY INVENTORY
DESCRIPTION
#4
-
40 3/16" JACK SCREW
W/ NUT & WSR
#4
-
40 1/4" STEEL PAN
HEAD SCREW
#4
-
40 1/4" M
-
F THREADED
ALUMIN SPACER
#4
-
40 HEX NUT WITH LOCK
WASHER
#6
-
32 HEX NUT NYLON
BLACK
#6
-
32 1" NYLON SCREW
BLACK
#6
-
32X1/2" PAN
HEAD
SCREW (GROUND LUG, AC
INLET)
#6
-
32 HEX NUT WITH LOCK
WASHER
#6
-
32 WING NUT
#4
-
40 1/2" STEEL PAN
HEAD SCREW
(FAN MOUNTING)
Ground Wire
[7]
REAR PANEL ASSEMBLY INVENTORY
PICTURE QUANTITY
12
13
1
1
12
12
3
3
1
4
1

[8]
POWER ENTRY MODULE
(AC INLET)
1
80MM X 25MM 12VDC FAN
W/ 2-PIN CONN
1
CONN UHF C
HASSIS
MOUNT
3
FAN AXIAL 40X20MM
12VDC
3