JOVE RJ1.1 User manual

Assembly Manual
JOVE
RJ1.1 Receiver Kit

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JOVE
RJ1.1 Receiver Kit
Assembly Manual
March 1999
Receiver Kit and Manual
developed for NASA JOVE Project
by
Richard S. Flagg, RF Associates
1721-I Young Street
Honolulu, Hawaii 96826
[phone] [email protected]

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Contents
Theory of Operation .......................................................................................1
Components ....................................................................................................2
Circuit Diagrams.............................................................................................7
Tools .............................................................................................................12
Soldering.......................................................................................................13
The Work Area..............................................................................................13
Identifying Parts ...........................................................................................13
Assembling the Enclosure ............................................................................18
Wiring the PC Board ....................................................................................21
Assembly of the PC Board and Enclosure....................................................24
Testing and Alignment..................................................................................28
Troubleshooting ............................................................................................34
Appendix A: Soldering Techniques ..............................................................39
Appendix B: Resistor Color Code ................................................................41

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1
Radio JOVE
You are about to embark on building a short-wave receiver which will pick
up radio signals from the planet Jupiter and also from the Sun. This receiver
contains over 100 electronic components and pieces of hardware. Fabrica-
tion will include the handling of small, delicate, electronic parts, most of
which will be mounted and soldered on a printed circuit (PC) board.
The radio uses many different types of electronic components, with each
part performing a different job. However, before discussing these compo-
nents and what they do, we will look at the overall receiver (depicted in the
block diagram in Figure 1).
CONSTRUCTION TIME ESTIMATES
Part Identification approx. 1 hr.
Receiver Construction approx. 9 hrs.
Testing and Alignment approx. 1 hr.
Total Time approx. 11 hrs.
THEORY OF OPERATION
Radio signals from Jupiter are very weak—they produce less than a mil-
lionth of a volt (1 microvolt, 1µV) at the antenna terminals of the receiver.
These weak radio frequency (RF) signals must be amplified by the receiver
and converted to audio signals of sufficient strength to drive headphones or a
loudspeaker. The receiver also serves as a narrow filter, tuned to a specific
frequency to hear Jupiter while at the same time blocking out strong earth
based radio stations on other frequencies. The receiver and its accompany-
ing antenna are designed to operate over a narrow range of short-wave fre-
quencies centered on 20.1 MHz (megahertz). This frequency range is opti-
mum for hearing Jupiter signals.
Antenna
The antenna intercepts weak electromagnetic waves which have traveled
some 500 million miles from Jupiter to the Earth. When these electromag-
netic waves strike the wire antenna, a tiny RF voltage is developed at the

2
antenna terminals. Signals from the antenna are delivered to the antenna
terminals of the receiver by a coaxial transmission line.
RF Bandpass Filter and Preamplifier
Signals from the antenna are filtered to reject strong out-of-band interference
and are then amplified using a junction field effect transistor (JFET). This
transistor and its associated circuitry provide additional filtering and amplify
incoming signals by a factor of 10. The receiver input circuit is designed to
efficiently transfer power from the antenna to the receiver while developing
a minimum of noise within the receiver itself.
Local Oscillator and Mixer
The local oscillator (LO) and mixer perform the important task of converting
the desired radio frequency signals down to the range of audio frequencies.
The local oscillator generates a sinusoidal voltage wave form at a frequency
in the vicinity of 20.1 MHz. The exact frequency is set by the front panel
tuning control. Both the amplified RF signal from the antenna and the LO
frequency are fed into the mixer. The mixer develops a new signal which is
the arithmetic difference between the LO and the incoming signal frequency.
Suppose the desired signal is at 20.101 MHz and the LO is tuned to 20.100
MHz. The difference frequency is therefore 20.101-20.100 = .001 MHz,
which is the audio frequency of 1 kilohertz. If a signal were at 20.110 MHz,
it would be converted to an audio frequency of 10kHz. Since the RF signal
is converted directly to audio, the radio is known as a direct conversion
receiver.
Low Pass Filter
To eliminate interfering stations at nearby frequencies, we use a filter which
is like a window a few kilohertz wide through which Jupiter signals can
enter. When listening for Jupiter or the Sun, the radio will be tuned to find a
“clear channel.” Since frequencies more than a few kilohertz away from the
center frequency may contain interfering signals, these higher frequencies
must be eliminated. This is the purpose of the low pass filter following the
mixer. It passes low (audio) frequencies up to about 3.5 kHz and attenuates
higher frequencies.
Audio Amplifiers
The purpose of the audio amplifiers following the low-pass filter is to take

3
RF
Preamp
J310
LO / Mixer
NE602
Audio
Preamp
LM387
5 Pole
Low Pass
Filter
RF
Bandpass
Filter
Antenna
Volume
Tuning
(20.1 MHz +/- 150 kHz)
JOVE RJ1.1
Jupiter Receiver
Block Diagram
Audio
Amp
Audio
Out 1
External
Amplified
Speaker
20.000 MHz
Test
Oscillator
Audio
Out 2
Figure 1. JOVE receiver block diagram

4
the very weak audio signal from the mixer and amplify it enough to drive
headphones directly, or to drive an external amplified speaker assembly.
COMPONENTS
The JOVE receiver uses many different electronic components (Figure 2)
including wires, resistors, capacitors, inductors, diodes, transistors and inte-
grated circuits. Each performs different functions.
Wires are made of conducting metal—they direct the flow of electrical
current from one place to another. Since wire is a good conductor, it has a
low resistance to the flow of electricity. The printed circuit (PC) board used
in this kit uses traces of copper etched on an insulating fiberglass back plane
in place of individual wires.
Resistors conduct electrical current, but they are designed to impede the
flow of electrons. This characteristic of resistance limits the amount of
current flow according to Ohm’s law. Resistors dissipate electrical power by
generating heat. The value of a resistor is given in Ohms (Ω), while its
maximum power dissipation is given in watts. There are fixed resistors and
variable resistors. Two variable resistors are used in this kit—one as the
volume control and the other as the tuning control. The fixed resistors in this
kit have several different values of resistance, but they are all 1/4 watt size.
See Appendix B for reading resistor value color codes.
Capacitors appear as an open circuit to direct current (DC) but pass audio
and radio frequency signals. The value of a capacitor is given in Farads (F),
although it is most common to use capacitors with values in the range of
microFarads (µF) or picoFarads (pF). Since the capacitor is physically made
of two conducting plates separated by a very thin layer of insulation, it is
possible for an electrical voltage to arc between the plates and destroy the
capacitor. For this reason capacitors have a maximum voltage rating. Ca-
pacitors store energy in the electrical field between the plates but do not
dissipate power like resistors.
Inductors are simply coils of wire which pass direct current and have the
property of resisting changes in current flow. The value of inductance is the
Henry (H), although it is most common to use coils whose inductance is

5
A
B
Resistors
A - Variable Resistor (10K ohm Tuning Control)
B - Fixed Resistor (10K ohm, 1/4 watt)
Capacitors D - 10 pF, Disc Ceramic
A - 1 µF, Metal Polyester E - 0.1 µF, Dipped Ceramic
B - 330 µF, 25 vdc, Electrolytic F - 10 µF, 35vdc,Tantalum
C - 0.1 µF, Metal Film G - 4-40 pF, Variable Capacitor
ABCD
EF
G
A
B
C
Inductors
A - Variable Inductor (1.5 µH)
B - Fixed Inductor (3.9 µH)
C - Fixed Inductor (82 mH)
Figure 2. Components

6
Solid State Devices
A - Diode 1N4001
B - Diode 1N914
C - Transistor 2N-3906
D - Varactor Diode MV-209
E - Integrated Circuit SA-602
F - Oscillator Module
AB
C
D
F
E
Connectors and Hardware C - 2.1 mm Power Connector
A - Solder Lug D - 3.5 mm Stereo Audio Jack
B - Spacer E - Chassis Coaxial Connector
e
bc
Resistor Inductor Capacitor Transistor Diode
+-
Ground
Variable
Resistor Variable Inductor Variable Capacitor
Band on cathode (-) end
+-
+
-
Battery
Schematic
Symbols
Figure 2. Components, continued
ABCD
E

7
measured in milliHenries (mH), or microHenries (µH). Inductors store en-
ergy in the magnetic field surrounding the coil. When inductors and capaci-
tors are used together they form a resonant circuit which swaps energy be-
tween the magnetic field of the inductor and the electric field of the capaci-
tor. This has the effect of forming a resonant circuit which is tuned to a
certain audio or radio frequency, much as an organ pipe is resonant at a
particular audio frequency. Such a circuit acts like a filter, selecting only a
narrow range of desired frequencies and rejecting others. Resonant circuits
often use variable capacitors or variable inductors which must be adjusted
for optimum performance at the desired frequency.
Resistors, capacitors, and inductors are used to route signals and DC volt-
ages within a circuit and to select or reject certain frequencies by filtering.
Certain capacitors (electrolytic type) have a (+) and (-) terminal and must be
installed with the proper orientation in a circuit. Resistors, inductors, and
non-electrolytic capacitors may be installed in any orientation.
Diodes are solid state devices which allow current flow in one direction
only. The diode has an anode (+) and a cathode (-) and must be installed
with the proper orientation.
Transistors are generally three-terminal solid state devices used to amplify
signals. Bipolar transistor terminals are known as the base (b), emitter (e),
and collector (c). A small signal injected into the base will appear amplified
at the collector. Another type of transistor is the field effect transistor (FET).
The terminals of this device are known as the gate (g), source (s), and drain
(d). The transistor requires power to amplify signals so there is always a
connection to a source of DC power.
Integrated Circuits are often made up of hundreds of transistors, diodes,
and resistors all interconnected to perform specific functions. This kit uses
three integrated circuits (ICs), each with 8 pins. The orientation of the IC in
the circuit is important as each pin has a different use.
CIRCUIT DIAGRAMS
We have already seen a block diagram of the JOVE receiver, which shows
the radio as a group of functional blocks connected together. While this type

8
of diagram does not show individual components like resistors and capaci-
tors, it is useful in understanding signal flow and the various functions per-
formed within the radio.
The next level of detail is the schematic diagram. A schematic is used to
represent the wiring connections between all of the components which make
up a circuit. The schematic diagram uses symbols for each of the different
components rather than pictures of what the components actually look like.
The symbols and pictures of several of the components used in this kit are
seen in Figure 2. Aschematic diagram of the complete receiver is seen in
Figure 3. On this schematic, the part types are numbered sequentially. For
example, inductors are denoted L1 through L7, and resistors are denoted R1
through R31.
Signal flow as shown in the schematic is as follows. The signal from the
antenna connector (J2) is coupled to a resonant circuit (bandpass filter L1,
C2, C3) and then to the J-310 transistor (Q1), where it is amplified. The
output of the J-310 goes through another resonant filter (L3, C6) before
being applied to the resonant input circuit (L4, C9, C10) of the SA602 inte-
grated circuit (IC1), which serves as the local oscillator and mixer. The
center frequency of the local oscillator is set by inductor L5 and adjusted by
the tuning control R7. The audio output from IC1 passes through the low-
pass audio filter (L6, L7, C20, C21, and C22). The audio signal is next
amplified by IC2 (an LM387) before going to the volume control R15. The
final audio amplifier stages comprise IC3 (another LM387), and the output
transistors Q2 (2N-3904) and Q3 (2N-3906). After the receiver has been
assembled, the variable capacitors C2 and C6 and variable inductors L4 and
L5 will be adjusted to tune the receiver for operation at 20.1 MHz.
Another useful representation of the circuit is a PC board layout diagram
(Figure 4). This is a pictorial representation showing the actual parts place-
ment on the printed circuit board. This X-ray view from the component side
of the board shows the components as rectangles or circles, and the trace
side of the board as faint gray areas. A similar PC layout diagram (Figure 5)
just shows the components, without the X-ray view of the traces. This view
of the components is identical to the component outlines marked on the
actual PC board.

9
Figure 3. Schematic diagram
C1
L1 C2 C3
C4
L2
R1
C5
Q1
L3
R5
C6
C7
C8
C42
R2
R3
R4
R7
R8
C38
R6
C20
C19
C18
C9
C10
C11
L4
C12
C13
C14
C15
L5
VD1
R9
1 27
65
4
3
8
C21
L6 L7
C22
R11
C23
R14
R13
R12
C24
R15
R16 C28
C29
R17 C30 R18
R19
R20
R21
C31
R22
R23
C33
D2
D3
C32
R24
C34
Q2 Q3 R30
R31 J4
8 7
5
6
3
8
73
65
IC3
IC2
IC1
e
bc
e
c
b
Audio
Output
C27
J1
DC IN
D1
C39 C40 C41
S1 R27
+
+
C43 R10 C44
C16
ZD1
C17
+
C25
C26
+
+
+
Tuning
sgd
J2
RF IN
Audio
Gain
C35
R25
ZD2
C36
C37
R26
OSC1
TP1
+
+
JOVE RECEIVER
12/21/98
R. S. FLAGG
DATE REV
SCHEMATIC DRAWING
R.F. Associates ebc
Q2-2N3904 Q3-2N3906
J310
dsgQ1- J310 4
5
3
678
21
IC1-SA602
IC2-LM387 IC3-LM387
VD1- MV209
+
R28
R29 J3
1.1
14
7
8
+
+
LED1
+
(Long)
LED1 A
A

10
L1
C3
C1
C4
C2
L2
R1
Q1
C5 C8 L3
C7
R5
R2
R3
R4
C6
L4 C9
C10
C11
C18
IC1
SA602AN ZD1
C17
C16
C13
C12
C14
C15
L5
R9
R6
R8 R7
G
S
D
VD1
Jmpr9
R10
C19
C20
L6
C21
L7
R11
R13
C22
C23
R12
R14
C24
IC2
LM387N
C26
C25
IC3
LM387N
R18
C30
R17
R19
R21 D2
R22
D3
R23
R20
C29
C28
R16
LED1
R15
S1
D1
C40
C39
C41
C31
R27
C33
C34 R24
C32
C37
R26
OSC1
C35
R25 ZD2
C36
C42
C38
+
+
+
+
+
+
C44
C43
+
+
C27
Q2
E
B
C
Q3
EBC
+12 VDC IN
J1
R28
R29
AUDIO OUT ANTENNA
J2
TUNING
PWR/AUDIO
GAIN
Jmpr1
Jmpr2
Jmpr3
Jmpr4
Jmpr5
Jmpr6
Jmpr7
Jmpr8
TP1
JOVE
20.1 MHz Receiver
RJ1.1
Jmpr10
+
+
R30
R31
J3 J4
+
J-310
2N3904
2N3906
+
Figure 4. X-ray view of PC board from component side

11
L1
C3
C1
C4
C2
L2
R1
Q1
C5 C8
L3
C7
R5
R2
R3
R4
C6
L4 C9
C10
C11
C18 IC1
SA602AN
ZD1
C17
C16
C13
C12
C14
C15
L5
R9
R6
R8 R7
G
S
D
VD1
Jmpr9
R10
C19
C20
L6
C21
L7
R11
R13
C22
C23
R12
R14
C24
IC2
LM387N
C26
C25
IC3
LM387N
R18
C30
R17
R19
R21 D2
R22
D3
R23
R20
C29
C28
R16
R15
S1
D1
C40
C39
C41
C31
R27
C33
C34
R24
C32
C37
R26
OSC1
C35
R25 ZD2
C36
C42
C38
+
+
+
+
+
+
C44
C43
+
+
C27
Q2
E
B
C
Q3
EBC
+12 VDC IN AUDIO OUT ANTENNA
Jmpr1
Jmpr2
Jmpr3
Jmpr4
Jmpr5
Jmpr6
Jmpr7
Jmpr8
TP1
JOVE
20.1 MHz Receiver
RJ1.1
Jmpr10
+
+
+
J-310
2N3904
2N3906
LED
+
.47µH
1µH
3.9µH
56pF39pF
22pF
68Ω
100Ω
294Ω
294Ω
4-40pF
4-40pF
17.4Ω
1.5µH
1.5µH
10µF
10µF
10µF
0.1µF
0.1µF
.01µF
47pF
47pF
47pF
.01µF
0.1µF
270pF
0.1µF
0.1µF
0.1µF
10
pF
10 kΩlinear
100KΩ
2.2KΩ
2.2KΩ
220Ω
MV209
1N753
(6.2v zener)
.068µF
.068µF
1µF
82 mH
82 mH
0.1µF
220Ω
0.1µF
0.1µF
1.5KΩ
0.1µF
0.1µF
10µF
10µF
10µF
100µF
330µF
10pF
50Ω
1KΩ
10KΩ
10 kΩaudio
0.1µF
0.1µF
1KΩ
1KΩ
2Ω
2Ω1Ω
0.1µF
1N4001
0.1µF
100KΩ
100KΩ
10µF
10µF
10µF
27KΩ27KΩ
220pF
1.5KΩ
1KΩ
1N5231
5.1 v zener
1N914
1N914
Figure 5. PC board - component side

12
An exploded view (Figure 6) shows the PC board and the enclosure, with
connectors and controls mounted on the front and rear panels of the box.
The parts list (Table 1) identifies each component by its value and part num-
ber. As you begin construction, the first step will be to identify each compo-
nent and check it off on the parts list to make sure that you have received all
of the parts. This table is an important link between the bag of parts which
you have received and installing those components in the right place in the
radio as shown by Figures 4, 5, and 6.
Although this is a complicated project, it can be built successfully. You are
urged to take great care to install the right parts in the right places on the PC
board. Before soldering make sure you have the right component. Also be
sure the orientation is correct—some parts MUST be installed with a certain
orientation (electrolytic capacitors, transistors, integrated circuits and diodes).
TOOLS
(Radio Shack parts numbers follow many of the items)
Wire stripper (RS64-2129)
Soldering iron, 25 watt fine tip (RS64-2070C)
Solder, 60/40, .050 inch diameter rosin core (RS64-006), or finer
Diagonal cutters, 5 inch nippy cutters (RS 64-1833)
Needle nose pliers (RS 64-2033)
*Allen wrench (hex) 1/16 inch
*Sandpaper
X-actoknife (or equivalent)
Scissors

13
Phillips screwdriver
Crescent wrench
Metal edge ruler
*Small screwdriver for adjusting variable capacitors
*Tuning tool for adjusting variable inductors
* these tools are included with the kit
SOLDERING
Key to successful fabrication of this JOVE receiver kit is your ability to
solder. It is important that each solder joint be made correctly. Heat the
joint so that the solder flows and joins the component lead to the solder pad,
without applying so much heat that the component is damaged. See Appen-
dix A for a guide to good soldering techniques.
THE WORK AREA
Select a work area with good light and an electrical outlet. The area should
be large enough for a comfortable work space for a couple of people, a
soldering iron, tools, the instruction manual, and the kit parts. Keep the
work space clean so parts don’t get lost.
IDENTIFYING PARTS
Go through the parts which you have received and check them off against
the list in Table 1 (JOVE Parts List). With the aid of Figure 2, make abso-
lutely sure you have identified each part correctly.

14
CAPACITORS Note polarity on all electrolytic capacitors
C1 39 pF, disc ceramic (390)
C2 4-40 pF, variable capacitor
C3 56 pF, disc ceramic (560)
C4 22 pF, disc ceramic (220)
C5 .01 µF, dipped ceramic
C6 4-40 pF, variable capacitor
C7 not used
C8 .01 µF, dipped ceramic
C9 47 pF, disc ceramic (470) or (47)
C10 270 pF, disc ceramic (271)
C11 0.1 µF, dipped ceramic (.1K)
C12 47 pF, disc ceramic (470) or (47)
C13 47 pF, disc ceramic (470) or (47)
C14 0.1 µF, dipped ceramic (.1K)
C15 10 pF, disc ceramic (100)
C16 10 µF, 25 vdc, electrolytic
C17 0.1 µF, dipped ceramic (.1K)
C18 0.1 µF, dipped ceramic (.1K)
C19 1 µF, metal polyester (105)
C20 0.068 µF, 5% metal film (683)
C21 0.1 µF, 5% metal film (104)
C22 0.068 µF, 5% metal film (683)
C23 0.1 µF, dipped ceramic (.1K)
C24 10 µF, 25 vdc, electrolytic
C25 10 µF, 25 vdc, electrolytic
C26 0.1 µF, dipped ceramic (.1K)
C27 10 µF, 35 vdc, tantalum, stripe, long lead +
C28 220pF, disc ceramic (221)
C29 0.1 µF, dipped ceramic (.1K)
C30 10 µF, 25 vdc, electrolytic
C31 10 µF, 25 vdc, electrolytic
C32 330 µF, 25 vdc, electrolytic
C33 10 µF, 25 vdc, electrolytic
C34 0.1 µF, dipped ceramic (.1K)
C35 0.1 µF, dipped ceramic (.1K)
Table 1
JOVE Receiver Parts List
Actual marking found on component is shown in parentheses ( ). Two columns
of check-off boxes are provided: use one for parts identification, and the other,
for installation.