Inspire VLF-3 User manual

VLF-3 Rev #1C Assembly Instructions
1
INSPIRE VLF-3 Rev #1C Receiver Kit
ASSEMBLY INSTRUCTIONS
The following assembly instructions should be followed carefully. The INSPIRE VLF-3
receiver kit is NOT a simple electronic assembly. If you follow the instructions carefully
you should be successful in building a receiver that works. If you are not careful, you
run the risk of having a problem that is very difficult to locate and fix.
TOOLS NEEDED:
Philips head screwdriver
Small standard screwdriver
Wire cutters
Wire stripper
Soldering iron (15-25 watt, small tip)
Light duty resin core solder (60/40)
Sponge
Magnifying glass
Solder sucker or solder wick

VLF-3 Rev #1C Assembly Instructions
2
KIT CONTENTS:
1. Black plastic enclosure
2. Face Plate
3. Printed Circuit Board (PCB)
4. Four bags of components:
Bag 1 resistors, inductors
Bag 2 capacitors
Bag 3 ICs, diodes, sockets
Bag 4 switches, jacks, knobs, antenna terminal, wires, miscellaneous hardware

VLF-3 Rev #1C Assembly Instructions
3
Printed Circuit Board (PCB):
Faceplate
Front Control
Panel
Component Side / Battery Side
All electronic components are
inserted from this side and soldered
on the other side. The battery holder
is inserted from this side also.
Switch Side
The four DPDT slide switches, the
two 10k pots and the two LEDs
are inserted from this side and
soldered on the other side.

560K
2. 2M
24pF
GND
3. 9mH
24pF
0. 01uF
3. 3VDC
3. 3VDC
GND
22M
NTE132
GND
220 680
0. 1uF
GND
330uF
10uF
GND
GND
GND
0. 01uF
150mH
GND
0. 01uF
GND
2N2222
10k 43k
100
470
220 2.2k
0. 1uF
2. 2k
1uF
GND
GND
LM358
LM358
LM386
100
100
100uF
GND
0. 1uF
10
GNDGND
1N4001
1N4001
GND
GND
10K
GND
270K
10K
GND
1uF
1K
0. 1uF
1K
20K
0.001uF
GND
15K
0.001uF
10K
330uF
1K
GND
0. 1uF
GND GND
GND
100K
20K
20K
10uF
GND GND
1K
GND
0. 1uF
GND
10uF
ANTENNA
R1
R3
C3
L1 C1
C2
Z2
Z1
R4
F1 D
SG
R6 R5
C5
C14
C4
C6 L2 C7
Q1
R9 R8
R25
R11
R12 R10
C9
R13
C8
I C2A 2
3
1
I C2B
6
5
7
I C1
1
2
3
8
5
6 4
7
S4
5
6
4
S4
2
3
1
# 7# 6# 5# 3# 4# 29V# 1
R27
R19
C19
C22
R2
S2
5
6
4
S2
2
3
1
D1
D2
R26
S3
5
6
4
S3
2
3
1
R28
R7
C13
R22
C15
R21
R20
C12
R18
C11
R17
C16
R24
LED2
LED1
C17
R14
R15
R16
C10
R23
C21
S1
5
6
4
S1
2
3
1
C18
VCC1 VCC2
MI C I NPUT
DATA OUT 2
DATA OUT 1
AUDI O OUT 1
AUDI O OUT 2
GROUND
BATTERY
EXT POWER
4
8
+
+
+
+
VLF-3 RECEI VER SCHEMATI C
Number VLF-3 Revision # 1C

VLF-3 Rev #1C Assembly Instructions
5
Instructions Outline
1. Solder components to the Printed Circuit Board (PCB)
2. Connect wires to PCB
3. Install jacks and connectors to the faceplate
4. Attach the PCB to the faceplate
5. Solder wires to jacks and
6. Test receiver
7. Diagnostics Guide – First Steps

VLF-3 Rev #1C Assembly Instructions
6
(Check off boxes as each step is completed)
1. SOLDER COMPONENTS TO Printed Circuit Board (PCB)
These instructions refer to assembling the INSPIRE VLF3 receiver kit with the PCB
marked on the edge as “NASA VLF-3 REV #1C”. A few things need to be noted before
you begin assembly.
1) The transistor (Q1) and the field effect transistor (J-FET with ferrite bead) have
been preinstalled.
2) Capacitor C20 has a place for it screen printed on the PCB, but it is not to be
populated, even if you end up with an extra 0.1 uF capacitor in the parts
provided. Leave that location on the PCB empty.
3) Capacitor C12 needs additional attention for it to be installed correctly. A PCB
trace is missing from the side of C12 nearest R20, which should have connected
this end to ground. To fix that you will need to scrap of a small part of the green
coating on the trace that runs directly under C12 and connect this lead to that
ground trace when you install C12. Check out the pictures below. The first is
centered on the location with an arrow pointing to the lead in question. The
second shows some of the insulating green coating removed, and the third
shows how the lead from C12 can be bent over for soldering to the ground trace.
It is a simple fix if you are patient and careful.
4) Variable resisters (potentiometers) R7 and R26 are installed on the non-
component side of the PCB after the other small components are installed. Note
that there is a small tab that may protrude from the potentiometer body that will
need to be removed if present. The picture below shows one of them with the
tab noted. To remove the tab, grab is with pliers and bend back and forth at the
base until it breaks away at the base.

VLF-3 Rev #1C Assembly Instructions
7
5) Let’s take some time to talk about soldering. If you are comfortable with
soldering, skip along to the next section and have at it. If not, let’s start with a
brief overview of how to solder.

VLF-3 Rev #1C Assembly Instructions
8

VLF-3 Rev #1C Assembly Instructions
9
IMPORTANT Note for New Soldering Irons:
A new soldering iron must be “tinned” in order to work well. Follow these steps:
1. Plug in the iron.
2. When it first heats up, apply solder liberally to the tip.
3. Wipe off the excess solder onto a damp sponge and you are ready to go!
When done soldering a joint, the solder should be shinny and appear to wick onto the
component lead and onto the copper pad on the PCB (a concave shape). If the solder
curves inward away from either, a convex shape, then that might be a cold solder joint
where there is not a good electrical connection between the parts. Too much solder will
be bulbous at the joint. Insufficient heat to the wire or PCB will result in solder not
flowing onto the metal to make good contact. Solder is used to make that good
electrical connection; it is not good for making a strong mechanical connection. If
necessary, briefly reheat the component lead and copper pad to try to flow the solder.
If necessary had a very small additional amount of solder, but avoid prolonged contact
with the soldering iron or you may damage the component or PCB copper pad. You will
likely see an amber colored brittle material near joints you have soldered. That is rosin
that is inside the solder to begin with. It helps the solder to wick onto the lead and
copper pad. It can be scraped away gently if you want to clean up the job after
finished. The solder you use should be for PCB use, not plumbing on copper pipes.
The PCB variety has a very small diameter, perhaps a millimeter. The plumbing kind
might be 3mm in diameter. Don’t go to a plumbing supply place to get solder. Also, do
not use a soldering gun for this work; it gets too hot. Use a 15-25 Watt soldering iron.
It takes little heat to do this, though more than enough to burn yourself. If you happen
to splash liquid solder onto yourself, fear not. It will hurt, but only briefly and not with
much consequence to your skin usually. This isn’t like having hot glue wick onto your
finger. Trust me, you do not want to experience that. Learn from my mistakes young
Padawan.

VLF-3 Rev #1C Assembly Instructions
10
1a. Sort and Install Resistors
Remove the resistors from Bag 1. Leave the inductors for later installation.
The colored bands on the resistors indicate the
resistance using a color code. This table indicates
how to convert each color to its numerical equivalent.
To read a resistor code, first locate the gold band and
read the colors in order from the other end. (All
resistors in this kit have a gold band indicating 5%
tolerance.) The first two bands indicate digits in the
resistance, the third band (called the multiplier)
indicates the number of zeroes to be added to the
digits to obtain the resistance.
(NOTE: 1000 = kilo = k ; 1,000,000 = mega = Meg)
What is the resistance for each of the following?
Example 1
Example 2
Example 3
Example 4
Band 1
Band 2
Band 3
brown
black
brown
yellow
violet
orange
red
black
green
orange
orange
orange
Band 1
Band 2
Band 3
1
0
1
4
7
3
2
0
5
3
3
3
Resistance
100
100 Ω
47000
47 kΩ
2000000
2 MegΩ
33000
33 kΩ
Use the resistor code to identify and sort all of the resistors. One good way to keep
them sorted is to tape one end to a piece of paper and write the resistance and
component number (R1, R2, etc.). Once you have identified and sorted all of the
resistors, you are ready to solder them to the PCB.
Bag 1 Contents
Resistors:
R1 560 kΩ
R2 10 Ω
R3 2.2 MegΩ
R4 22 MegΩ
R5 680 Ω
R6, R12 220 Ω
R7, R26 10k pots in Bag #4
R8 43 kΩ
R9, R17 10 kΩ
R10, R13 2.2 kΩ
R11 470 Ω
R14 100 kΩ
R15, R16, R20 20 kΩ
R18 15 kΩ
R19, R25, R27 100 Ω
R21, R22, R23, R24 1 kΩ
R28 270 kΩ
Inductors:
L1 3.9 mH
L2 150 mH

VLF-3 Rev #1C Assembly Instructions
11
Care should be used in identifying R3 (2.2 MegΩ) and R4 (22 MegΩ). The green band
and the blue band can look similar. For best results, identify both components together
so differences can be noted.
To prepare a resistor for insertion into the board, bend the
two leads so that they form a right angle to the resistor body.
Resistor locations on the component side of the PCB are
indicated with the “R” number from the parts list between the
two holes for insertion of the leads.
Part of the PCB showing location of R1, R3, R4 and R6
To install, place the leads of the resistor through the appropriate holes and press the
resistor down against the component side of the PCB. There is no required orientation
for resistors. Either lead may be inserted in either hole. Turn the board over while
holding the resistor in position and bend the leads slightly outward to hold the resistor in
place and solder the leads to the circuit side. Feel free to insert all the resistors at once
or in groups like that shown below and then solder the leads for each in the group and
trim before going on.

VLF-3 Rev #1C Assembly Instructions
12
After installing the resistors you will have something like the following picture. The capacitors,
inductors, and diodes are installed in the same way.

VLF-3 Rev #1C Assembly Instructions
13
1b. Install the IC sockets
Remove the IC sockets and IC1 (LM386) and IC2 (LM358) from Bag #3. When
installing IC sockets and ICs, alignment is very important. One end of the IC symbol on
the PCB has a half-hole at one end of the symbol. One end of the socket has a half-
hole. The IC itself has a circular dot near one end.
Install the sockets so that the half-hole end coincides with the half-hole on the PCB.
Press the sockets firmly against the component side of the PCB. Solder the 8 pins on
the other side of the PCB taking care not to create any solder “bridges” between the
pins.
Install the IC so that the end with the dot is at the end of the socket with the half-hole.
Carefully fit the 8 pins in the socket holes and press the IC firmly into the socket. Note
that the IC pins come to you slightly spread apart. That is normal, but without bending
them to be more perpendicular to the body, they will be hard to match up to the socket
holes for insertion. The picture below shows one of the ICs before and after bending
the legs. To bend the legs hold each IC on its side with its leg’s flat against a table and
gently rotate the body to bend all the legs on one side at the same time. Turn it over
and do the same to the other side.

VLF-3 Rev #1C Assembly Instructions
14
C 10
+
1c. Solder capacitors to the PCB
Capacitor Identification Guide
The small-value ceramic capacitors may be installed
in either orientation, but the larger-value cylindrical
capacitors (C4, C8, C10, C14, C16, C18, C19) must
be installed with the proper polarity.
240 = 24 pF
102 = 0.001
103 = 0.01
104 = 0.1
154 = 0.15
The polarity is indicated on the PCB by a “+” sign near
one end of the capacitor location. The polarity is
indicated on the body of the capacitor with a stripe
with a minus (-) sign located on the negative side of
the capacitor. Also, the shorter lead is the negative
lead.
To install a capacitor, insert the leads in the appropriate holes and press
the capacitor down near the PCB. Solder using the same technique as
used for resistors. The polarity is not marked on the component side of the
board for capacitor C10. The proper polarity is indicated here.
NOTE: There may be some variation in capacitor markings due to
using different suppliers.
Bag #2 Contents
Capacitors:
C1, C3 24 pF
C2, C6, C7 .01 µF
C4, C10, C18 10 µF
C5, C9, C13, C15,
C17, C21, C22
C8 1 µF
C11, C12 .001 µF
C14, C16 330 µF
C19 100 µF
C20 .15 µF
}
.1 µF

VLF-3 Rev #1C Assembly Instructions
15
1d. Install the inductors (L1 and L2)
The inductors are the two remaining parts in Bag #1. Inductor L1 is marked “LH 239”.
Inductor L2 is marked “LJ 415”. From the component side, press the inductor firmly
down against the PCB and solder the other side. There is no required polarity for the
inductors.
1e. Install the diodes from Bag #3
Polarity is very important in the installation
of diodes.
D1 and D2 are black cylinders with a silver
stripe near one end.
On the PCB, the D1 and D2 locations are
shown as a rectangle with a stripe near one
end.
Align the striped end of the diode with the striped end of the PCB symbol. Press the
diode firmly against the component side of the PCB and solder the other side.
Z1 and Z2 are small components with a black stripe near one end. The symbol on the
PCB is the same as for D1 and D2. As with D1 and D2, align the black stripe end with
the striped end on the PCB. Press the diodes firmly against the PCB and solder the
other side.
Return the LEDs to Bag #3. They will be installed later.
D1
1N
4004
Remaining Bag #3
D1, D2
Z1, Z2
LED1, LED2

VLF-3 Rev #1C Assembly Instructions
16
1f. Install the battery holder
From Bag #4, take the following parts:
1 Battery holder
2 PCB standoff post
2 4-40 3/8 “ screw
4 4-40 1/4” screw
2 4-40 nuts
2 nylon washers
2 #4 washers
The following diagram shows the assembly of the battery holder to the PCB:
.
1. Place the battery holder
leads through the PCB
from the component side
and press the holder firmly
against the PCB.
2. Insert 1/4” screws through
the holes nearest the
leads, through the PCB
and tighten the nuts on
the switch (solder) side.
3. Insert 3/8” screws through
the other two holes,
through the PCB, through
the nylon washers and
tighten the standoffs on
the switch (solder) side.
4. Solder the battery leads
on either (or both) side of
the PCB.
5. Temporarily insert 1/4”
screws through the #4
washers in the other ends
of the standoffs. These
will be used later to attach
to the faceplate.

VLF-3 Rev #1C Assembly Instructions
17
1g. Install the potentiometer and switches
From Bag #4, remove the two 10k pots (R7 and R26) and the four Double Pole Double Throw
(DPDT) slide switches.
Slide the three contacts for the pots through the holes provided from the switch side of
the PCB (non-component side). Push the switch firmly against the PCB and solder
either (or both) sides.
Insert the six contacts for each DPDT slide switch into position and press the switch
firmly against the switch side of the PCB. Solder each contact on the component side.
1h. Install the LEDs
Align the LED leads as shown with the
shorter lead closest to the line in the PCB
symbol. Either color can be used for LED1
and LED2 even though red is shown as
LED1 and green as LED2 on pages 9 and
13.
Insert the LEDs and place the PCB against
the face plate, letting it push the LEDs into
the PCB. Adjust until they only protrude
slightly above the surface of the face plate,
then solder in place to either side of the PCB.
Carefully trim the excess leads.
THIS COMPLETES THE INSTALLATION OF ALL PARTS ON THE PCB

VLF-3 Rev #1C Assembly Instructions
18
2. ATTACH WIRES TO THE PCB
Bag #4 contains the following wires:
3” red
4” orange
4” yellow
3” blue
3” black
5” white
Cut each color wire to produce the following lengths (the blue wire is not cut):
1 red: 1”, 2”
1 orange: 2”, 2”
1 yellow: 2”, 2”
1 blue: 3”
1 black: 1”, 2”
1 white: 2”, 1.5”, 1.5”
To prepare a wire for soldering, strip about 1/8” of insulation from each end. To solder a
wire to the PCB:
1. Insert the wire into the component side,
2. Press the soldering iron to the wire and to the metal pad on the PCB for about 5
seconds to heat both the wire and the pad,
3. Apply solder to the wire side away from the soldering iron making sure that the
wire and pad melt the solder, not the soldering iron.
Solder the 1” red wire to the ANT connection on the PCB.
Solder the 1” black wire to the RTN connection on the PCB.
The wire connections to the PCB are numbered 1-7.
Connect the following wires to the appropriate locations:
Connection 1: 2” red wire
Connection 2: 2” black wire and 2” white wire twisted together
Connection 3: 2” orange wire
Connection 4: 2” orange wire
Connection 5: 2” yellow wire
Connection 6: 2” yellow wire
Connection 7: 3” blue wire
See photos on the following page.
ANT
RTN

VLF-3 Rev #1C Assembly Instructions
19
Wires installed (component-side view)
Wires installed (switch-side view)
Close up of white and black wire
twisted together prior to being soldered
to location #2 on the PCB

VLF-3 Rev #1C Assembly Instructions
20
3. INSTALL THE JACKS AND CONNECTORS TO THE FACEPLATE
Install the jacks and the external power connector to the faceplate by inserting them
from the back side and tightening the knurled nut on the front side. Mount the 2-screw
antenna terminal to the faceplate by placing the terminal in front of the faceplate and
using the two remaining 4-40 1/4” screws and nuts. Mount the BNC connector by
removing the nut and washer, inserting the connector from the front of the panel and
tightening the nut over the washer.
4. ATTACH THE PCB TO THE FACEPLATE
Remove the nuts and washers from the standoffs and the nuts from the shafts of the
10k pots. Attach the faceplate to the PCB by fitting the faceplate over the switches and
LEDs. Tighten the screws and washers to the standoffs. Tighten the nuts on the 10k
pot shafts.
5. SOLDER WIRES TO JACKS AND CONNECTORS
To solder the wire to a jack contact:
1. Insert the wire through the hole in the tab,
2. Press the soldering iron to both the wire and the tab and heat for 5 seconds,
3. Apply the solder to the side away from the soldering iron, making sure that the
wire and tab melt the solder, not the iron.
Use the following figure as a guide for wiring connections to the jacks and the external
power connector. See also the photo on the next page.
The monaural jack
(white body) is the MIC
jack. The blue wire
connects to this jack.
The center two are the
Audio and Data jacks
and are the black body
stereo type.
The round one is the
external power
connector.
2
White
White
White
MIC
AUDIO
DATA
POWER
Yellow
Blue
Orange
Orange
Black
Red
Yellow
NOTES:
1. The yellow and orange wires must cross to
reach the correct jacks.
2. The white ground wire and the black wire both
connect to Location 2.
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