QRPKits Weber Dual Band User manual

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Dual Band HF CW transceiver
Hendricks kits and KD1JV Designs
QRPKITS.COM
Specifications:
Any two ham bands, 80, 40, 30, 20, 17 or 15 meters, choose at time of order.
5 watts output on all bands with 13.8V supply
Built in Iambic keyer with 5 to 40 wpm code speed, selectable Iambic A or B modes and two 63 character
message memories.
Receiver sensitivity, 0.2 uV MSD
DDS VFO for rock steady stability with 50 Hz and 200 Hz tuning rates
Easy to read four digit LED display with leading zero suppression.
Rotary knob tuning
RIT (receive incremental tuning)
Four IF crystals for excellent selectivity and opposite side band rejection
600 Hz audio filter
Audio derived AGC circuit
500 mw audio amplifier with built in speaker
Small size, 4.6” wide, 1.6” tall and 5.5” deep.
Light weight, 13 ounces.
Modest supply current requirements, 55 ma on receive (no signal) and 550 to 750 ma on transmit at 5W out
(current depends on band, higher bands draw more current)

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Assembly Instructions:
The quickest and easiest way to build the rig is in “layers”. The lowest profile parts are installed first, such as resistors and diodes, then
higher profile parts such as capacitors and so on. Once the board is populated with all the parts, testingwill be done by inserting the various
Integrated Circuit chips one at a time and testing the associated stage they are used with.
Before you start assembly, it is helpful to sort the parts into types and values.
In general, parts are numbered on the board in rows, starting with the lowest part number in the upper left corner of the board (this is the
back end) and then run left to right and then zig-zag down the board to the front end. Parts will be inserted in that order. Part values are
marked in red on the parts placement diagram on the next page for easy reference. There are two placement diagrams included. The first is
in color, which makes the various parts types stand out better, but would use a lot of ink to print out. A second, inkjet friendly diagram is also
included. At least one of these diagrams should be printed out for easy reference as you build up the board.
Parts filled in with dark blue / light blue are band specific values. Refer to chart for values. SMT parts filled in with dark gray are pre-installed.
Experienced builds should be able to simply sort the parts and follow the placement diagram to assemble most of the board. It is still a good
idea to review all the assembly instructions in case there are some details to pay attention to.
Parts check list:
QTY VALUE QTY VALUE QTY VALUE
1 10 ΩBRN/BLK/BLK/GLD 2 2.2 pfd 2.2 NPO disk 1 FQPF7P06 PMOSFET/TO-220
1 51 ΩGRN/BRN/BLK/GLD 3 22 pfd 22 NPO disk 3 BS170 NMOSFET TO-92
6 270 ΩRED/VOL/BRN/GLD 1 47 pfd 47 NPO disk 3 2N7000 NMOSFET TO-92
1 470 ΩYEL/VOL/BRN/GLD 8 100 pfd 101 NPO disk 1 2N3819 NJFET TO-92
3 1 K RED/BLK/RED/GLD 1 470 pfd 471 disk 2 2N3904 NPN TO-92
13 2.2 K RED/RED/RED/GLD 9 0.001 ufd 102 disk 1 78L05 5V reg TO-92
3 10 K BRN/BLK/ORG/GLD 3 0.01 ufd 103 film (green) 2 SA612A mixer osc 8 pin dip
2 22 K RED/RED/ORG/GLD 21 0.1 ufd 104 mono (yel) 1 LM358 dual op amp 8 pin dip
1 47 K YEL/VOL/ORG/GLD 1 0.47 ufd/16 or 25V 0.47 electrolytic 1 LM386 audio amp 8 pin dip
2 100 K BRN/BLK/YEL/GLD 2 10 ufd/16 or 25V electrolytic 1 ATMEGA48 MPU 28 pin dip
2 220 K RED/RED/YEL/GLD 4 100 ufd/16 or 25V electrolytic 1 74AC02 quad NOR gate, 14 pin
3 470 K YEL/VOL/YEL/GLD 1 30 pfd Trimmer (green) 1 1N5817 power diode
3 1 MEG BRN/BLK/GRN/GLD 1 1N4756A 47V, 1W zener
1 50K Audio pot 1 Rotary Encoder
W/PBSW 3 1N4148 SS diode
2 3.3 uHy RFC ORG/ORG/GLD/GLD 1 DPDT Toggle switch 1 4 digit LED display module
2 10 uHY RFC BRN/BLK/BLK/GLD 2 5V relays DPDT 1 Red display filter
1 T37-43 Ferrite toroid, black 1 DC power Jack 2.1 mm
5 4.9512 MHz HU-6S crystals, matched 2 Band specific parts bags
1 1 foot # 28 Magnet wire 1 1/8” stereo Panel jack 1 Main circuit board
1 1/8” stereo Switched jack 1 Display board
4 8 pin dip sockets 1 Cabinet assy 2 knobs
1 14 pin dip socket 1 Tilt stand 1 2” dia speaker
1 28 pin dip socket 4 Cabinet feet 2 Speaker clips and 3/8” FH 4-40
screws
1 18 pin SIP Right angle pins 6 #4-40 1/4” Pan head screws 2 knobs
8 #4-40 1/4” Flat head screws 1 DD push button sw

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Silk screen of Q10 missing from board
Parts placement guide. (color)

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Parts placement diagram, inkjet friendly.
Parts with no value indicated have band specific values.
Q10 silk screen missing from board.

Assembled board, mounted in case.
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Speakermounting
:

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Part by part placement guide: Resistors
√location Value Color code √Location Value Color code
R1 100 K BRN/BLK/YEL/GLD R21 270 ΩRED/VOL/BRN/GLD
R2 47 K YEL/VOL/ORG/GLD R22 270 ΩRED/VOL/BRN/GLD
R3 51 ΩGRN/BRN/BLK/GLD R23 1 MEG BRN/BLK/GRN/GLD
R4 100 K BRN/BLK/YEL/GLD R24 1 K BRN/BLK/RED/GLD
R5 270 ΩRED/VOL/BRN/GLD R25 2.2 K RED/RED/RED/GLD
R6 270 ΩRED/VOL/BRN/GLD R26 1 MEG BRN/BLK/GRN/GLD
R7 470 ΩYEL/VOL/BRN/GLD R27 1 K BRN/BLK/RED/GLD
R8 3.9 K SMT PREINSTALLED R28 2.2 K RED/RED/RED/GLD
R9 270 ΩSMT PREINSTALLED R29 1 K BRN/BLK/RED/GLD
R10 270 ΩRED/VOL/BRN/GLD R30 2.2 K RED/RED/RED/GLD
R11 2.2 K RED/RED/RED/GLD R31 22 K RED/RED/ORG/GLD
R12 22 K RED/RED/ORG/GLD R32 2.2 K RED/RED/RED/GLD
R13 220 K RED/RED/YEL/GLD R33 2.2 K RED/RED/RED/GLD
R14 2.2 K RED/RED/RED/GLD R34 2.2 K RED/RED/RED/GLD
R15 470 K YEL/VOL/YEL/GLD R35 2.2 K RED/RED/RED/GLD
R16 10 K BRN/BLK/ORG/GLD R36 2.2 K RED/RED/RED/GLD
R17 1 MEG BRN/BLK/GRN/GLD R37 2.2 K RED/RED/RED/GLD
R18 220 K RED/RED/YEL/GLD R38 2.2 K RED/RED/RED/GLD
R19 470 K YEL/VOL/YEL/GLD R39 2.2 K RED/RED/RED/GLD
R20 10 K BRN/BLK/ORG/GLD R40 10 BRN/BLK/BLK/GLD
Moldedinductors:
There are four (4) molded inductors (RFC) to install. These look like resistors but are a little shorter and fatter. Like resistors, the value is also
color coded on the body of the part.
•Install L3/L4 – 3.3 uhy ORN/ORN/GLD/GLD
•Install L6/L7 – 10 uhy BRN/BLK/BLK/GLD
Diodes: Be sure to observe proper polarity. Band near end of part goes towards line on part outline.
•Install D1 – 1N5817 large plastic body.
•Install D2 – 1 N4756A large glass body
•Install D3/D4/D5 – 1N4148 small glass body
Crystals:
The crystals are now installed, the locations are shown filled in with light gray. All the crystals are matched and the same frequency, so it
doesn't matter which ones go where. The cans of the X1 to X4 crystals should be tack soldered to the solder pad located next the the body
of the crystal. This should be done now, as getting an iron in after the near-by capacitors are installed will be difficult.
• InstallX1toX5
IC sockets:
IC sockets are now installed. Before soldering, make sure they are flush to the board and that all the pins are sticking out of the holes on the
bottom of the board. If a pin gets bent over as you are inserting the socket, this will be difficult to fix once the other pins have been soldered.
•U3, U4, U6, U9 – 8 pin socket
•U2 – 14 pin socket
•U7 – 28 pin socket

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Capacitors:
There are four types of capacitors used.
● Multi-layer (MONO) caps, which are generally yellow and rectangular is shape.
● NPO type disks will have a black dot on the top edge of the cap. Note. Some of the ceramic disk caps will have lead spacing wider
then the hole spacing on the board. In this case, use your needle nose pliers to kink both leads inward slightly to match the board
hole spacing.
● Film capacitors. These will be green in color.
● Aluminum Electrolytic. These are round cylinders and have polarity. They must be installed with the correct polarity. Electrolytic
caps inserted with the wrong polarity across the DC supply can heat up and explode! The negative lead is marked with a black
stripe and the positive lead is always the longer lead.
Capacitor value markings:
The capacitor value is marked on the part with a two or three digit number and is read in picofards. The third digit is the zero multiplier.
Values of less than 100 pfd generally show only two digits, but sometimes three. Therefore, if a part is marked 470, that means it is a 47 pfd
cap and not a 470 pfd cap. A 470 pfd cap would be marked 471. Mono caps also often have letters printed on the part. These letters
indicate the type or tolerance and can be disregarded.
NOTE: Although the electrolytic caps are listed in the table below, they should be installed last.
√location value type √location value type
C1 BAND SPEC SEE BAND TABLE C23 0.1 ufd (104) MONO, YELLOW
C2 0.1 ufd (104) MONO, YELLOW C24 100 pfd (101) NPO DISK, OR MONO YELLOW
C3 0.1 ufd (104) MONO, YELLOW C25 2.2 pfd (2.2) NPO DISK, BROWN
C4 100 ufd /16 or 25V ELECTOLYTIC C26 2.2 pfd (2.2) NPO DISK, BROWN
C5 100 ufd /16 or 25V ELECTOLYTIC C27 0.1 ufd (104) MONO, YELLOW
C6 BAND SPEC SEE BAND TABLE C28 22 pfd (22) NPO DISK, BROWN
C7 BAND SPEC SEE BAND TABLE C29 47 pfd (47) NPO DISK, BROWN
C8 BAND SPEC SEE BAND TABLE C30 22 pfd (22) NPO DISK, BROWN
C9 0.1 ufd (104) MONO, YELLOW C31 0.1 ufd (104) MONO, YELLOW
C10 0.01 ufd (103) FILM, GREEN C32 100 pfd (101) NPO DISK, OR MONO YELLOW
C11 BAND SPEC SEE BAND TABLE C33 10 ufd /16 or 25V ELECTROLYTIC
C12 BAND SPEC SEE BAND TABLE C34 100 pfd (101) NPO DISK, BROWN
C13 BAND SPEC SEE BAND TABLE C35 100 pfd (101) NPO DISK, OR MONO YELLOW
C14 0.1 ufd (104) MONO, YELLOW C36 0.1 ufd (104) MONO, YELLOW
C15 0.1 ufd (104) MONO, YELLOW C37 100 pfd (101) NPO DISK, OR MONO YELLOW
C16 BAND SPEC SEE BAND TABLE C38 100 pfd (101) NPO DISK, OR MONO YELLOW
C17 0.1 ufd (104) MONO, YELLOW C39 100 pfd (101) NPO DISK, OR MONO YELLOW
C18 22 pfd (22) DISK C40 100 pfd (101) NPO DISK, OR MONO YELLOW
C19 BAND SPEC SEE BAND TABLE C41 .1ufd SMT PREINSTALLED
C20 BAND SPEC SEE BAND TABLE C42 .01 ufd SMT PREINSTALLED
C21 BAND SPEC SEE BAND TABLE C43 .01 ufd SMT, PREINSTALLED
C22 BAND SPEC SEE BAND TABLE C44 22 pfd SMT, PREINSTALLED
C45 .01 ufd SMT, PREINSTALLED C58 0.1 ufd (104) MONO, YELLOW
C46 100 ufd/16 or 25V ELECTROLYTIC C59 .001 ufd (102) DISK, BROWN

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C47 0.1 ufd (104) MONO, YELLOW C60 0.1 ufd (104) MONO, YELLOW
C48 .001 ufd (102) DISK, BROWN C61 0.1 ufd (104) MONO, YELLOW
C49 .01 ufd SMT, PREINSTALLED C62 .001 ufd (102) DISK, BROWN
C50 0.01 ufd (103) FILM, GREEN C63 10 ufd/16 or 25V ELECTROLYTIC
C51 0.47 ufd/16 or 25V ELECTROLYTIC C64 0.1 ufd (104) MONO, YELLOW
C52 0.01 ufd (103) FILM, GREEN C65 0.1 ufd (104) MONO, YELLOW
C53 470 pfd (471) DISK, BROWN C66 .001 ufd (102) DISK, BROWN
C54 .001 ufd (102) DISK, BROWN C67 0.1 ufd (104) MONO, YELLOW
C55 0.1 ufd (104) MONO, YELLOW C68 100 ufd/16 or,25V ELECTROLYTIC
C56 0.1 ufd (104) MONO, YELLOW C69 .001 ufd (102) DISK, BROWN
C57 .001 ufd (102) DISK, BROWN C70 0.1 ufd (104) MONO, YELLOW
•Trimmer capacitor CT5 – Green trimmer. Make use flat side of part is facing the line drawn in the circle outline on
the board.
•L11 – L11 is wound with 15 turns of # 28 wire on the black T37-43 core. However, do not install L8 yet. Put it aside
for now. It will be installed after the initial tests have been completed.
Transistors:
Be sure to properly ready the part number on the three legged transistors so they go in the proper place. A magnifying glass
maybe helpful for this. When installing the part, look out of thin shavings of the plating on the leads which might come off as
you push the legs into the holes. These can cause shorts between the leads. Space the package about 1/8” above the board –
no not push real close to the board. Also, be sure to orientate the flat side of the package with the flat side of the part
outline.
•Install Q2, Q3, Q4 – BS170 mosfets – these are static sensitive!
•Install Q1, Q5, Q6 – 2N7000 mosfets – these are also static sensitive.
•Install Q7, Q8 – 2N3904 NPN
•Install Q9 – 2N3819 j-fet
•Install U1 – 78L05 5V regulator
•Install Q10, FQPF7P06 – line up the long side with the black rectangle on the board outline. Note: Q10 is labeled
Q7 on circuit board.
•Now install all the Electrolytic capacitors. Be sure to observe proper polarity. Long lead is plus side. Black stripe on
the body of the can indicates negative side. C5 can explode if installed backwards!
□ C4, C5, C46, C68 100 ufd/16 or 25V
□ C33, C63 10 ufd/16 or 25V
□ C51 0.47 ufd/16 or 25V
DC power jack relays and the right angle SIP pin strips.
•Install DC power jack
•Install the two relays, RYL1 and RYL2. Note the line on one end of the relay and match this with the line on the relay
outline.
•Install right angle SIP pin strips. You will need to cut 2 pins from the strip, as these two pins are offset from the rest of
the pins to the left. Simply snip the plastic between the pins with your side cutters. Insert the short pins into the main
board. The pins will not quite stick all the way through the board, so make sure the pins are well seated. DO NOT
SOLDER the pins to the board yet. Do this after trial fitting the main board with the display board attached into the
cabinet.

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Band specific parts:
In the color parts layout, the transmitter low pass filter and associated receiver input parts are filled in with the same color. Band “A” parts
are colored in light blue and Band “B” is colored in dark blue. It doesn't matter which specific band you call “A” and which you call “B”,
that will be programmed later. Just note which one is which. Keep in mind that since the relays are non-latching, a small amount of
additional current will be drawn by the rig when band “B” is selected, so you might want to put the band you think will be used most often as
band “A”. Part locations are indicated in the table for band “A” first, then band “B”.
● Be sure to count the turns on L7/L8/L9 and L1 0 properly. Each time the wire passes through the center of the core, this is one turn.
Having one extra turn, which is a common mistake, will result in reduced power output. Also the turns should be reasonably tight to
the core. Sloppy winding can result in reduced performance. Evenly space the turns around the core.
Winding T1/T2: See next page for instruction on winding T1/T2 so leads end up in proper locations for the outline.
80 meters
Value Type
40 meters
Value Type
C16 or C1 100 pfd 101 NPO Disk C16 or C1 68 pfd NPO disk
C11 or C8 680 pfd 681 mono C0G C11 or C8 330 pfd (331) C0G
C12 or C6 1500 pfd 152 mono C0G C12 or C6 680 pfd (681) C0G
C13 or C7 680 pfd 681 mono C0G C13 or C7 330 pfd (331) C0G
C22 or C19 68 pfd 68 NPO Disk C22 or C19 47 pfd disk
C21 or C20 15 pfd 15 NPO Disk C21 or C20 10 pfd NPO disk
CT3 or CT4,
CT1 or CT2
70 pfd Brown trimmer CT3 or CT4,
CT1 or CT2
70 pfd trimmer Brown
L10 or L8 24 turns #30 wire T37-2 Red L10 or L8 18 turns #28 wire T37-2 Red
L9 or L7 29 turns #30 wire T37-2 Red L9 or L7 20 turns #28 wire T37-2 Red
L2 or L1 18 uHy BRN/GRY/BLK/GLD L2 or L1 8.2 uHy GRY/RED/GLD/GLD
T1 or T2 60 turns/ 6 turns #32 wire T37-2 Red T1 or T2 45 turns / 4 turns #30 wire T37-2 Red
30 meters 20 meters
C16 or C1 47 pfd 47 NPO Disk C16 or C1 22 pfd 22 NPO Disk
C11 or C8 220 pfd 221 mono C0G C11 or C8 150 151 mono C0G
C12 or C6 560 pfd 561 mono C0G C12 or C6 330 331 mono C0G
C13 or C7 220 pfd 221 mono C0G C13 or C7 150 151 mono C0G
C22 or C19 4.7 pfd 4.7 NPO Disk C22 or C19 2.2 pfd 2.2 NPO Disk
C21 or C20 None C21 or C20 None
CT3 or CT4,
CT1 or CT2
30 pfd Green trimmer CT3 or CT4,
CT1 or CT2
30 pfd Green trimmer
L10 or L8 13 turns #28 wire T37-2 Red L10 or L8 13 turns # 28 wire T37-6 Yellow
L9 or L7 16 turns #28 wire T37-2 Red L9 or L7 16 turns #28 wire T37-6 Yellow
L2 or L1 8.2 uHy GRY/RED/GLD/GLD L2 or L1 5.6 uHy GRN/BLU/GLD/GLD
T1 or T2 45 turns / 4 truns # 30 wire T37-2 Red T1 or T2 38 turns / 4 turns # 30 wire T37-2 Red
17 meters 15 meters
C16 or C1 15 pfd 15 NPO disk C16 or C1 15 pfd 15 NPO disk
C11 or C8 47 pfd 47 mono C0G C11 or C8 47 pfd 47 mono C0G
C12 or C6 220 pfd 221 mono C0G C12 or C6 220 pfd 221 mono C0G
C13 or C7 100 pfd 101 Disk C13 or C7 100 pfd 101 Disk
C22 or C19 none C22 or C19 none
C21 or C20 2.2 pdf 2.2 NPO Disk C21 or C20 2.2 pfd 2.2 NPO Disk
CT3 or CT4,
CT1 or CT2
30 pfd Green trimmer CT3 or CT4,
CT1 or CT2
30 pfd Green trimmer
L10 or L8 13 turns # 28 wire T37-6 Yellow L10 or L8 11 turns #28 wire T37-6 yellow
L9 or L7 16 turns # 28 wire T37-6 Yellow L9 or L7 14 turns #28 wire T37-6 yellow
L2 or L1 3.3 uHy ORG/ORG/GLD/GLD L2 or L1 3.3 uHy ORG/ORG/GLD/GLD
T1 or T2 25 Turns/ 4 Turns #30 wire T37-2 RED T1 or T2 25 Turns/ 4 Turns #30 wire T37-2 RED

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T1/T2 winding: Hold the core in your left hand and start winding by passing 1/2” of the magnet wire up through the
“bottom” side of the core as shown in the diagram. Then continue winding the remaining required
number of turns by passing the long end of the wire in and down from the top of the core. When you
get to the end of the required number of secondary turns, make about a 1/2” loop and continue
winding the four link turns.
Snip the loop to separate the secondary (S) from the link (L) winding, then tin the wires. Insert the
core into the board and solder. It will not matter along which side of the board outline the wide side of
the core faces.
Front panel board assembly:
•Install resistor R42, 10 K (BRN/BLK/ORG/GLD)
•Install resistor R41, 470 K (YEL/VOL/YEL/GLD)
•Install C71 and C72, 0.001 ufd Disk cap. (102)
•Install 7 segmentLED display module. This will only go in one way, due to missing pins on display module and
corresponding missing holes in board.
•Install SW1, momentary TACT switch. This will go in one of two ways, both of which are correct, due to pins being
spaced farther apart along one edge as opposed to the other.
•NOTE: Make sure volume control and encoder are pushed firmly square to board and are not tilted. Trial fit into front
of cabinet before soldering pins.
•Install V1 volume control. Solder mounting tabs to board. Clip tab along bottom edge of board, flush to board.
•Install ENC1, the tuning encoder. Solder mounting tabs to board.
This completes assembly of the front panel board. Proceed to initial tests before soldering front panel board to main board.
Initial board tests:
Before applying power to the main board, it would be a good idea to inspect your workmanship. Look for any unsoldered part
leads and IC socket pins. A fresh 9 volt radio battery can be used to power the board for initial tests. A 9 V battery has limited
current capacity, so if there are any problems, it is unlikely any damage will result from too much current.
1. Wire up power source to power plug. Plus (+) goes to center pin
2. Plug power plug into DC jack
3. Check for +5 volts (+/- 0.25V) on pin 14 of U2, pin 8 of U3 and U4.
4. If no voltage is present, check for proper soldering of the U1 pins, shorts at input and output of U1 and that the
supply voltage is getting to U1. A short could be present at any connection point along the 5 volt supply bus or DC
input bus. Look carefully at where these supply buses are by-passed, such as at C5, C15, C23, C27, C58 and C65
for the 5 volt bus and C2, C3 and C4 for the DC supply bus. There may be a solder short across these one of these
parts.
5. Remove power
6. Temporarily wire up the speaker and paddle jack to the main board. (See diagram next page)