QRPproject Blue Cool Radio User manual
Rev:Nobember 20. 2006
1
The blue cool Radio BCR
© QRPproject Motzener Straße 36-38 12277 Berlin http://www.QRPproject.de Telefon: +49(30) 85 96 13 23 e-mail: support@QRPproject.de
Rev: November 20 2006
2
Welcome to start assembling your BCR - Blue Cool Radio. We divided the
complete kit into functional groups which can be tested individually after
assembling. Please follow the manual while assembling because each group
except the first one need the groups built before to be tested. The follow
up inside a group also is not by chance but follows logical and safety rules.
Besides this rules we tried to make it easier for you by using a graphical
coordinate system. Behind all parts you find the coordinates of the part, in
the placement plans you find the same system as a drawing. Following the
coordinates will make it easy to find the correct place for any part.
The first group to be built ist the voltage regulator section
Group 1 Voltage Regulation
BCR should be powered by a 12 Volt power supply or a package of 10 AA
NiMH cells which also give 12,0 V (Working range is 11 to 15 V). Most
stages in BCR work at stabilzed 8 V. We desided to use 8V to protect a
batterie package against low voltage which may destroy it. The choosen
regulator IC 7808 needs 9,5 V to work properly, a NiMH pack with ten AA
cells never should be used below 9,5 V.
The seperate 5V Regulator generates the supply for the central PIC
Processor which controlls the BCR.
Start at the upper left corner at coordinates A/2
Find IC 6, an 78L05 Integrated Circuit in a TO92 housing. It´s flat side
must be positioned as shown in the drawing. As allways good in RF
technique, do not solder it with
„long legs“, the lower part of the IC
should be not more the 2-3 mm
above the PCB.
[ ] IC6 8L05 TO92 A-2, solder
Tantalum Caps are polarised The PLUS side is marked either with a plus sign
(+) or a bar. Also the longer leg identifies the PLUS side. Most Tantalum
caps look like a drop.
[ ] C90 1uF 35V Tantal A-2
[ ] C91 1uF 35V Tantal A-2
Go ahead at F/5 in the lower right corner. The blocking caps often have a
right angle edge in their legs. Please take the time to rework this with a
long nose plier to make it possible to place them very flat to the PCB. If
they are placed to high above the PCB this will cause failures.
[ ] C87 100nF (104) H-4
+-
Akku 12V,intern
Bu4
12V,extern
Ladebuchse
Si1
C87D16
S2
IC5IC6 C88C89C90C91
+12V+8V+5V
Ein-Aus
100nF
1N5402
1uF1uF 780878LO5 1uF1uF
Rev:Nobember 20. 2006
3
[ ] C88 1uF 35V Tantalperle E-5
[ ] C89 1uF 35V Tantalperle E-5
Attention: The following Diode must be placed the right way. The Kathode
of a Diode is marked by a band. If the Tyoe of the Diode is completely
coded by bands, the thickest one markes the cathode. Place the band
according to the placement plan.
[ ] D16 1N5402 G/H-5
IC5 is a voltage regulator in a TO220 Housing, which can handle about 1
Ampere at the desired Voltafe. It must be screwed directly to the PCB´s
ground plane. Because the metall plate of the IC is Ground, we need no
isolation. The printing of the IC looks to the upper side. Before installing
bend the 3 legs 90 degrees down just behind its body. Use a small
screwdriver to get a soft bent.
Screw the IC to its place before you solder it. However, it shoud lay flat on
the PCB to enable the heat to flow away.
[ ] IC5 7808 TO220 F-5
[ ] S2 Toggle Switch 2xUmupright Typ MS500 G-5
[ ] Si1 Fuse Holder G/H-5
[ ] Bu4 DCBU 2,1-PR DC Jack 2,1mm H-4/5
[ ] Si1 Put a fuse into the holder.
Now recheck all your work to find eventually solder failures. Use an
Ohmmeter to check the resistance between the switch and ground, it must
be in the range of several Kilo Ohm.
Connect a power supply. Best choise is a Laboratory supply with adjustable
current limit. Connect it to Jack BU4. Dont short the BCR Fuse with a wire,
there have been others burning their project, you better should not do so.
If you didn´t see any smoke, you now can test your work.
[ ] Test the 8 Volt stabilized line. A good access point is the solderlug at B/
5 (see picture)
[ ] Now the 5V stabilized. You find a solderlug in B1 for good access.
If both Voltages are stable at 8V and 5V +/- some percent, go ahead to
group 2, the controller section.
Rev: November 20 2006
4
Group 2 Controller Section
This section we call the digital heart of our BCR. All functions of the radio
are controlled by the Common PIC Controller. If the controller is in
function, it gives you some internal tools as an advantage: The controler
side tone enables testing the AF part, and the Controllers RF part gives us a
complete signal Generator to
test the IF section later on.
[ ] R63 not used with green
display
[ ] R54 220R 1Watt D-1
[ ] D15 1N4148 C-1
[ ] R56 1K C-1
[ ] R55 2M2 C/D-1
[ ] R62 6,8K C/D-1
[ ] R61 3,3K C/D-2
[ ] R59 1K C-1/2
[ ] R57 2,7K C-2
[ ] R58 4,7K C-2
[ ] R60 22k C-2
[ ] C86 10nF (103) C-2
[ ] C77 10nF (103) C-2
[ ] Q5 4,0MHz Resonator C-1/2
[ ] C84 1,5uF C/D-2
(This one must be installed
lying, with legs bent down by
90 degrees, otherwise you will have trouble with the display later on.
[ ] C83 1,5uF 63V Folie Also Lying D-1/2
[ ] C85 10nF (103) B-2
[ ] C80 1000pF(102) B-2
[ ] C79 1000pF (102) B-2
[ ] C78 1000pF (102) B-2
[ ] R52 100R A-2
[ ] C76 1000pF (102) B-2
[ ] C81 100nF (104) B-1/2
[ ] R53 100R A/B-1/2
[X] C82 100nF SMD 0805 Bottom
[ ] Bu1 3,5mmStereo Jack A-1/2
The following trimmer
potentiometer must be placed
at the bottom side of the PCB
[ ] P7 5K PIHER PT6 A/B-1
Now solder the socket for the PIC
and the socket for the display.
Carefully think what you are
doing, before you solder them,
especially the big PIC socket is
the hell to desolder if it is wrong.
Look at the PIC socket (PLCC
socket). One of its 4 corners
shows a 45 dgree angle. This corner must be placed into the lower left
corner as can be seen in the picture below. Place the socket on the part side
of the PCB. Again compare the 45 degree corner with the drawing. All pins
must find there way into their holes easily without forcing the socket . If it
is at its place, hold it with your fingers and control at the solder side if all
pins found their way
through the PCB. If this is
ok, firmly press the socket
against the PCB and solder
two pins at diagonal
corners. Recheck if the
socket is placed absolutely
flat on the PCB. If not,
resolder the 2 pinst while
pressing the socket down.
If it is ok, solder carefully
all remaining pins.
Use bright light and a
magnifier to controll if all
pins are soldered properly.
[ ] IC4 Socket PLCC44 B/C-
1/2
Rev:Nobember 20. 2006
5
Now the socket for the display. It helps a lot, if you use the display itself as
a justify tool. Take the display, a 16pin connector male and a 16PIN
connector female plus 4 of the 12mm spacers and the small 2mm Screws.
Do not solder yet.
Place the 16pin female connector into the mainboard.
Plug the 16pin male connector into the female connector
Place the display on the upper pins of the male connector. The ends of the
pins look through the holes of the display. Now mount the 4 spacers at all 4
corners of the display between main board and display. Fasten all 4 screws
while holding the display. 16pin connectors must be as exact as possible in
a 90 degree angle on to the mainboard. If this is ok, solder the pins at the
bottom of the mother board and the display board. The ends of the
connector Pins will just flush with the PCB but this is ok because the boards
are throughplated. Start with the outer pins, check again the right angle. If
ok, solder the remaining pins.
[ ] Disp1 16 PIN male, straight A/B/C-1
[ ] Disp2 16 PIN female straight A/B/C-1
[ ] DiSP3 LCD-Display DEM 16216 SYH-LY
[ ] Remove the Display and put the Display, screws and spacers to a safe
place.
Now the C-Mos Transistors. Remember, they are extremly ESD sensitive. Use
ESD tools or decharge yourself by touching a metal ground plate.
(Drawing = first picture section 2)
[ ] T16 BS170 C/D-2
[ ] T17 BS170 C/D-1 There ar e only a few parts left: :
[ ] L10 33mH radial Choke C-2/3
[ ] P8 10K Potentiometer SMC-10-V
B/C-3
[ ] DG1 Shaft encoder ALPS
A/B-3
To complete the controller section, you
now need the DDS Modul. If you got it ready built and tested from
QRPproject, go ahead to the next page where the connectors are installed.
Otherwise assemble the DDS Module now.
Assembling the DDS Modul:
If you have own expierience in soldering SMT parts, you may start
immediate. If not, I recommend to read something about SMT soldering or
to ask an OM with some expierience.
Start with IC1. Adjust it carefully above the Pads, the Dot mus show to the
Callsign upper left corner. Solder to edge pins, controll the pposition again
and solder the remaining pins.
[ ] IC 1 AD9834
Now the other parts from left to rights:
[ ] C1 100nF 0805 [ ] R1 150R 0805
[ ] C2 100nF 0805 [ ] R3 10R 0805
[ ] R2 10R 0805 [ ] C4 10uF Tantal Gr. B
[ ] C3 10uF Tantal Gr. B [ ] C6 100nF 0805
[ ] C5 100nF 0805 [ ] C9 10nF 0805
[ ] C10 100nF 0805 [ ] R4 6k8 0805
[ ] C7 100nF 0805 [ ] C8 10nF 0805
[ ] R5 220R 0805 [ ] R6 220R 0805
[ ] C11 39pF 0805 [ ] L1 1,8uF 0805
[ ] C12 5,6pF 0805 [ ] C13 68pF 0805
[ ] L2 1uH 0805 [ ] C14 5p6 0805
[ ] C15 39pF 0805 [ ] C16 10nF 0805
This manual suits for next models
1
