HPSDR HERCULES User manual

...the Making of HERCULES
© DL6KBF 2010 Ver. 1.3 DJ8AY100W PA for PENELOPE incl. Low Pass Filtering for 160m to 6m --- MicroProcessor Controlled and Protected
1
High Performance Software Defined Radio
Open Source Hardware and Software Project
Project Description: http://openhpsdr.org
Hardware Project #6
HERCULES Board
Part #2
The Making of HERCULES
Schematics / Board Design Gerd Loch, DJ8AY
Text Horst Gruchow, DL6KBF
Graphics and Layout Horst Gruchow, DL6KBF

...the Making of HERCULES
© DL6KBF 2010 Ver. 1.3 DJ8AY100W PA for PENELOPE incl. Low Pass Filtering for 160m to 6m --- MicroProcessor Controlled and Protected
2
Vorwort
Seit dem Beginn der HPSDR Entwicklung im März 2006 hat sich viel
in diesem offenen und öffentlichen Amateurfunk-Projekt bewegt.
Zum jetzigen Zeitpunkt (Februar 2010) stehen erstmals alle
Komponenten für einen vollwertigen 100W-Transceiver zur
Verfügung und das Interesse der Funkamateure an diesem Projekt
nimmt Tag für Tag zu. Dieses kommt in Gesprächen auf den
Amateurfunk-Bändern deutlich zum Ausdruck.
Die Verbreitung so eines komplexen Projektes steht und fällt ja mit
der Verfügbarkeit der Hardware, nachdem auf der Software- bzw.
Firmwareseite aktuell ein hoher 'Reifegrad' erreicht ist. Besonders
in Europa war die Akzeptanz des HPSDR-Projekts bisher ein
Problem, da die Hardware aus den USA bezogen werden musste.
Da gab es Berührungsängste.
Dieses Problem ist nun durch das hervorragende Engagement von
Gerd Loch, DJ8AY, gelöst, der nach dem weltweit ersten
verfügbaren MERCURY-Digitalempfängerboard im Frühjahr 2008
und seinem Antennenschalter seine dritte Eigenentwicklung in das
HPSDR-Projekt einbringt – eine 100W Transistorendstufe, die direkt
von PENELOPE angesteuert werden kann.
Gerd bietet die Endstufe sowohl in vorbestückter Bausatzform als
auch als Leerplatine an. Für alle, die wie ich Tod und Teufel nicht
fürchten und das Projekt von Grund auf selber bauen wollen, habe
ich die folgende Bauanleitung verfasst. Mit der von mir schon an
anderen HPSDR-Projekten ausprobierten Schritt-für-Schritt-Metho-
de sollte das Bestücken der Platine kein Problem sein. Ich wünsche
allen Nachbauern viel Erfolg.
73
Horst
DL6KBF
Preface
Since the start of the HPSDR development in March 2006 quite a
lot has been achieved within this open and public HAMRADIO
project. At present (Feb. 2010) it is the first time that all
components for a full 100W transceiver are available and the
interest of HAM operators is increasing day by day. This can be
heard everyday on the HAM bands.
The acceptance of such a complex project sinks or swims with the
availability of the hardware after the software and firmware has
reached a high degree of 'ripeness'. Especially in Europe the
acceptance of the HPSDR project was a problem because the
hardware had to be purchased from the US. This caused a lot of
reluctance.
This problem has been solved due to the outstanding commitment
of Gerd Loch, DJ8AY, who – after the worlds first available
MERCURY digital receiver board and his antenna switch – now
presents his third HPSDR development – a 100W power amplifier
that can be directly connected to PENELOPE.
Gerd offers the PA as a pre-assembled kit as well as an empty PCB.
For everybody who does not fear death and devil and wants to
build the project from scratch I have written the following assembly
instructions. The step-by-step method - already approved in other
HPSDR projects - should not give any problems. Much success for
all who accept the challenge.
73
Horst
DL6KBF

...the Making of HERCULES
© DL6KBF 2010 Ver. 1.3 DJ8AY100W PA for PENELOPE incl. Low Pass Filtering for 160m to 6m --- MicroProcessor Controlled and Protected
3
PCB Backside

...the Making of HERCULES
© DL6KBF 2010 Ver. 1.3 DJ8AY100W PA for PENELOPE incl. Low Pass Filtering for 160m to 6m --- MicroProcessor Controlled and Protected
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It em 1 BOTTOM
CAP CER 10nF 50V 0603
Pos Reel/Tick
C070
C071
C072
C073
C120
C121
C122
C123
C124
C125
C126
C127
It em 2 BOTTOM
RES 10k 0603
Pos Reel/Tick
R33
R34
R35
R36
R37

...the Making of HERCULES
© DL6KBF 2010 Ver. 1.3 DJ8AY100W PA for PENELOPE incl. Low Pass Filtering for 160m to 6m --- MicroProcessor Controlled and Protected
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It em 3 BOTTOM
CAP CER 100nF 0805
Pos Reel/Tick
CK00
CK01
CK02
CK03
CK04
CK05
CK06
CK07
CK08
CK09
CK10
CK11
CK12
CK15
CK16
It em 4 BOTTOM
LM75AD SO8
Pos Reel/Tick
IC9
IC9
IC9
Item 4a BOTTOM
BAS40
Pos Reel/Tick
D101
D102

...the Making of HERCULES
© DL6KBF 2010 Ver. 1.3 DJ8AY100W PA for PENELOPE incl. Low Pass Filtering for 160m to 6m --- MicroProcessor Controlled and Protected
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PCB Frontside

...the Making of HERCULES
© DL6KBF 2010 Ver. 1.3 DJ8AY100W PA for PENELOPE incl. Low Pass Filtering for 160m to 6m --- MicroProcessor Controlled and Protected
7
Item 1 TOP
CAP CER 100nF 0603
Pos Reel/Tick
C052
C085
C086
C087
C150
C152
C153
C154
C155
C156
C157
C158
C159
C160
C150

...the Making of HERCULES
© DL6KBF 2010 Ver. 1.3 DJ8AY100W PA for PENELOPE incl. Low Pass Filtering for 160m to 6m --- MicroProcessor Controlled and Protected
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Item 2 TOP
CAP CER 100nF 0805
Pos Reel/Tick
C044
C045
C047
C055
C056
C058
C062
C064
C065
C090
C091
C092
C147
CK13
CK14
CK13
C090
C091

...the Making of HERCULES
© DL6KBF 2010 Ver. 1.3 DJ8AY100W PA for PENELOPE incl. Low Pass Filtering for 160m to 6m --- MicroProcessor Controlled and Protected
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Item 3 TOP
CAP CER 100nF 1206
Pos Reel/Tick
C006
C007
C008
C009
C010
C012
C036
C037
C076
C077
C078
C079
C108
C109
C110
C111
C136
C137
C012

...the Making of HERCULES
© DL6KBF 2010 Ver. 1.3 DJ8AY100W PA for PENELOPE incl. Low Pass Filtering for 160m to 6m --- MicroProcessor Controlled and Protected
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Item 4 TOP
CAP CER 10nF 0603
Pos Reel/Tick
C048
C051
C054
C060
C061
C063
C066
C068
C069
C075
C093
C094
C095
C151
C161
C048
C061
C063
C066
C093
C094
C095
C151

...the Making of HERCULES
© DL6KBF 2010 Ver. 1.3 DJ8AY100W PA for PENELOPE incl. Low Pass Filtering for 160m to 6m --- MicroProcessor Controlled and Protected
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Item 5 TOP
CAP CER 100pF 0805
Pos Reel/Tick
C050
Item 6 TOP
CAP CER 10uF/6.3V 0805
Pos Reel/Tick
C088
Item 7 TOP
CAP CER 1uF/16V 0805
Pos Reel/Tick
C089
Item 8 TOP
CAP CER 3.300pF/50V 0805
Pos Reel/Tick
C043
C046
C143
C146
Item 9 TOP
CAP CER 330nF 0805
Pos Reel/Tick
C074

...the Making of HERCULES
© DL6KBF 2010 Ver. 1.3 DJ8AY100W PA for PENELOPE incl. Low Pass Filtering for 160m to 6m --- MicroProcessor Controlled and Protected
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Item 10 TOP
Pos Reel/Tick
C039
C083
CAP MICA 12pF Code C1
Item 11 TOP
Pos Reel/Tick
C034
C041
C081
C082a
CAP MICA 15pF Code E1
Item 12 TOP
Pos Reel/Tick
C027
C032
CAP MICA 22pF Code J1
Item 13 TOP
Pos Reel/Tick
C020
C029
C084
CAP MICA 47pF Code S1
Item 14 TOP
Pos Reel/Tick
C019
C080
CAP MICA 68pF Code W1

...the Making of HERCULES
© DL6KBF 2010 Ver. 1.3 DJ8AY100W PA for PENELOPE incl. Low Pass Filtering for 160m to 6m --- MicroProcessor Controlled and Protected
13
Item 15 TOP
Pos Reel/Tick
C031
C035
C038
C040
C040a
C042
C082
CAP MICA 100pF Code A2
C040/C040a
piggyback
C082/C082a
piggyback
C026
C030
Item 16 TOP
CAP MICA 120pF Code C2
Pos Reel/Tick
C028
C028a
Item 17 TOP
CAP MICA 150pF Code E2
Pos Reel/Tick
C028/C028a
piggyback
C016
Item 18 TOP
CAP MICA 180pF Code G2
Pos Reel/Tick
Item 19 TOP
Pos Reel/Tick
C002
C004
C033
CAP MICA 220pF Code J2

...the Making of HERCULES
© DL6KBF 2010 Ver. 1.3 DJ8AY100W PA for PENELOPE incl. Low Pass Filtering for 160m to 6m --- MicroProcessor Controlled and Protected
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C040/C040a
piggyback
C082/C082a
piggyback
C028/C028a
piggyback
Item 20 TOP
Pos Reel/Tick
C014
C021
C024
CAP MICA 390pF Code Q2
Item 21 TOP
Pos Reel/Tick
C013
CAP MICA 680pF Code W2
Item 22 TOP
Pos Reel/Tick
C015
C017
C018
C022
CAP MICA 750pF Code X2
Item 23 TOP
Pos Reel/Tick
C001
C003
CAP MICA 1200pF Code C3
Item 24 TOP
Pos Reel/Tick
C003a
C005
CAP MICA 1500pF Code E3

...the Making of HERCULES
© DL6KBF 2010 Ver. 1.3 DJ8AY100W PA for PENELOPE incl. Low Pass Filtering for 160m to 6m --- MicroProcessor Controlled and Protected
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CAP MICA 180pF 1206
C023
C023a d.n.p.
Item 24a TOP
Pos Reel/Tick
CAP CER 33pF 1206
C057
C057a d.n.p.
Item 24b TOP
Pos Reel/Tick
CAP MICA 680pF 1210
C025
C053 d.n.p.
C067 d.n.p.
Item 24c TOP
Pos Reel/Tick
These capacitors should be
soldered to the corresponding
end plates of RF transformers
T1 resp. T2

...the Making of HERCULES
© DL6KBF 2010 Ver. 1.3 DJ8AY100W PA for PENELOPE incl. Low Pass Filtering for 160m to 6m --- MicroProcessor Controlled and Protected
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Item 25 TOP
RES 0R0 0603
Pos Reel/Tick
R59
R60
Item 26 TOP
RES 2R2 0805
Pos Reel/Tick
R01
R02
R47
R48
R49
R50
Item 27 TOP
RES 10R 0603
Pos Reel/Tick
R52
Item 28 TOP
RES 22R 0603
Pos Reel/Tick
R08
R15
Item 29 TOP
RES 47R 0603
Pos Reel/Tick
R30
R31

...the Making of HERCULES
© DL6KBF 2010 Ver. 1.3 DJ8AY100W PA for PENELOPE incl. Low Pass Filtering for 160m to 6m --- MicroProcessor Controlled and Protected
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Item 30 TOP
RES 100R 0805
Pos Reel/Tick
R07
Item 31 TOP
RES 120R 0603
Pos Reel/Tick
R12
R12A
Item 32 TOP
RES 220R 0805
Pos Reel/Tick
R13
Item 33 TOP
RES 330R 0805
Pos Reel/Tick
R51
Item 34 TOP
RES 470R 0603
Pos
R28
R39
R43
Reel/Tick
Item 35 TOP
RES 1k5 0805
Pos
R20
R21
R22
R23
R24
R25
R26
R27
R40
Reel/Tick

...the Making of HERCULES
© DL6KBF 2010 Ver. 1.3 DJ8AY100W PA for PENELOPE incl. Low Pass Filtering for 160m to 6m --- MicroProcessor Controlled and Protected
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Item 36 TOP
RES 3k3 0603
Pos Reel/Tick
R10
R11
R16
R17
R18
R19
R29
Item 37 TOP
RES 4k75 0603
Pos Reel/Tick
R09
Item 38 TOP
RES 10k 0603
Pos
R14
R32
R38
R44
R56
R57
R58
Reel/Tick
Item 39 TOP
RES 100k 0603
Pos Reel/Tick
R53
R54
R55
R16 R17

...the Making of HERCULES
© DL6KBF 2010 Ver. 1.3 DJ8AY100W PA for PENELOPE incl. Low Pass Filtering for 160m to 6m --- MicroProcessor Controlled and Protected
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Item 40 TOP
1N4148-DO35H/V
Pos Reel/Tick
V2
V3
BAS70-00 SOT23
D1
D2
Item 41 TOP
Pos Reel/Tick
Item 42 TOP
BAT54A
Pos Reel/Tick
D3
D4
Item 43 TOP
BC807-40-SOT23
Pos Reel/Tick
Q06
Item 44 TOP
BC817-40-SOT23
Pos Reel/Tick
Q08
Q09

...the Making of HERCULES
© DL6KBF 2010 Ver. 1.3 DJ8AY100W PA for PENELOPE incl. Low Pass Filtering for 160m to 6m --- MicroProcessor Controlled and Protected
20
Special Instructions: Placing LEDs
How to determine the polarity of
the 0805 LEDs?
It can be difficult to find out the polarity of
the tiny 0805 LEDs if you don't know what
to look for.
The Lite-ON®LEDs used in the JANUS
BOM are easy to determine the polarity.
Looking on them under a magnifying glass
you can see that the LED dice (photo) is
visible and off-center from the body. This
is the anode (+) side which has to match
with + on the PCB.
The ones which I am using have a little
mark printed on the bottom:
LED Dice
Cathode Anode
Anode
Cathode