QRPproject Speaky User manual

Version: 13. September 2004
1
DL-QRP-AG
Speaky 5 Band CW SSB PSK Transceiver
© QRPproject Motzener Straße 36-38 12277 Berlin http://www.QRPproject.de Telefon: [phone] e-mail: [e-mail]
Manual: fiservice Peter Zenker DL2FI email:[e-mail]

Version: 13. Sepe,mer 2004
2
Preface to building 3
The Speaky Transceiver, preface 3
technical data 4
Description of individual stages 4
Band Switching 4
Local Oscillators 5
RX Input 5
RX IF section 6
Sideband oscillator 7
8MHz SSB Generation 7
Transmitter 8
CW Logic, T/R switching 8
Stabilization 9
Options 9
Building the speaky 10
Section 1, Voltage Regulation 10
Testing section 1 11
Section 2, T/R Switch 12
Testing Section 2 13
Section 3, DDS VFO 14
Assembling the S-Meter 15
Testing Section 3 15
Section 4, AF Amplifier 16
Testing Section 4 17
Section 5, Carrier osc. and Switch 18
Testing Section 5 19
Section 6, BFO IF Amp, AGC 20
Testing Section 6 21
Section 7, IF Amplifier, IF Filter 22
Torroid School 23
Testing Section 7 25
Section 8, PLL 26
Testing Section 8 29
Section 9, RX/TX Mixer, LPF1 30
Winding Instructions TR1 31
Testing Section 9 32
Section 10, SSB Generator/Amp 33
Testing Section 9 34
Section 11, TX driver and PA 35
Winding Instructio TR5 36
Pin Placement 38
TrimPot Placement 38
Adjustments 39
Building the Frequency Counter 40
Partlist Bandmodul 80m 44
Partlist Bandmodul 40m 45
Partlist Bandmodul 20m 46
Partlist Bandmodul 15m 47
Partlist Bandmodul 10m 48
The Low Pass Filter 49

Version: 13. September 2004
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Preface to building
Please note a few basic rules, before you begin building. Even the most
proficient kit builder makes errors. A few rules and experiences keeps the
error count low. You will find lots of good advice in the FI Workbench
Manual, contained in the kit. In the Workbench Manual, we describe parts,
tell about soldering, help in winding coils on the different coil forms used
in RF electronics. As our kits primarily are directed towards beginners, old
hands will find lots of known material. But repetition isn‘t that bad, and
even experienced builders will probably find helpful advice. We advice
reading through the Workbench Manual, as well as the present manual,
before beginning assembly. Reading is very important. The developers have
built several kits, the last of which were original kits like the one you have
bought. We have tried to avoid any tricky procedures, to simplify the job
for the beginner. It will pay off to read the manual before proceeding. Read
every section in its full length before soldering!
The manual
As the Speaky is quite complex, all diagrams and parts lists are put
into a separate cover. This is to avoid flipping back and forth in the
manual. The Speaky manual is divided in eleven sections. For every
section you will find a text part with a check list, and a separate dia-
gram and parts placement diagram. All parts belonging to the relevant
section is printed in black. When needed for understanding function,
parts from other sections are presented in grey. In the parts place-
ment diagram, all parts to be mounted are in black, and already moun-
ted parts are in grey. In the text, parts are listed in order of mounting.
Please use the check boxes. This will in our experience reduce errors to
a large degree. New parts are introduced in the text, when used. As the
density doesn‘t allow a placement mask on the pc board, , we have
introduced a coordinate grid on the board. The pc board is divided into
56 20 by 20 mm squares. Horizontally marked from A to H, and verti-
cally 1 to 7. Every part is easy to find from this square grid.
At the end of each text section, you will find a test description. Please
don‘t continue till the assembled kit passes these tests.
And when you don‘t know what to do?
Please come to me. Easiest via email to [email protected] or by
phone to [phone].
To give you an impression of to whom you are speaking, I will present
myself briefly.:
DL2FI, Peter, known as QRPeter. Ham operator since 1964.
I am a passionate home brewer and QRP‘er, and have been for years. It is
my belief that the great chance for ham radio
lies in the rediscovery of home brewing. My
motto is: ham radio will be true again, when
it is true to its roots. (Der Amateurfunk wird
wieder wahr, wenn Amateurfunk wird, wie er
war).
Based on this, I founded the DL-QRP-AG in
1997, the german QRP working group. Since
then the group has grown to 2300 members,
who have developed several designs helping
to promote QRP world wide. Since january
2002, I also spend a lot of time on being
chairman of the local Berlin chapter of the
DARC (German ham radio club), as I rather prefer doing something to just
quarrelling. Because of my work, I have been elected to the QRP Hall of
Fame.
I wish you lots of fun on building the Speaky (Gonzales)
73 de Peter, DL2FI
DK1HE QRP SSB/ CW- Transceiver SPEAKY
Preface:
Till recently ham operators equalled QRP work to CW. QRP’ers were ridiculed
or considered masochist, who made it difficult for their fellow hams with
their weak signals. This changed with the marketing of the FT-817 and its
rapidly increasing sales. In several QSO’s, it was noted, that the FT-817 was
only some 2 S degrees below a standard 100 W rig. Previously impossible
SSB DX contacts were now possible. [.... EMVU .... pleas fix this: Die Scheu
vor der Abgabe der EMVU- Selbsterklärung] made for a QRP renaissance.
Thanks to the new licensing rules for VHF/UHF licensees, we can expect a
further increase in QRP SSB activity. This couldn’t be ignored by the DL-
QRP- AG developers, and is was decided at the HAM- RADIO 2003 confe-
rence, to produce a SSB / CW- Transceiver in kit form for at least two

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switchable HF bands. Based on the Black Forest, the Tramp and the Spar-
row, it was possible to develop a kit in 4 months, primarily using conventi-
nal parts (only some 12 SMD’s), for a 5 band SSB/CW transciever, leaving
nothing to want for its price class. Peter, DL2FI, nicknamed it SPEAKY (
Gonzales) as complement to the Miss Mosquita. The following data speaks
for themselves:
Speaky technical data:
- From 1 to 5 HF bands switchable from the front of the box.
- Modulation: SSB/ CW/ PSK31 etc.
- Power input: 10W PEP
- DDS/ PLL- frequency control, with programmable frequency
steps.(rotary encoder)
- choice of RIT or XIT; integrated keyer
- VFO tuning range 500KHz
- optional digital frequency readout.
- automatic bandwith selection ( 2,4KHz/ 600Hz) of the 4pole 8MHz-
crystal filter
- tunable high Q preselector
- High current RF input circuit with dynamic feed back.
- +7dBm- Schottky- ring mixer ( TUF- 1)
- High current J- FET IF amplifier
- > 90dB IF dynamic range (A244 IC)
- AGC production with peak to peak rectifier.
- AF section with power for loudspeaker
- robust PA with 2 x 2SC1969
- Transmitter output of 10W PEP
- switchable harmonics filter
- integrated speech compressor with a compression of max. 15: 1
- [please change this] Modulationsklirrfaktor of the compressor < 1% !!
- adjustable transmitter power
- CW- VOX with adjustable decay
- 10,8- 15V power supply
- Stable enclosure with prepunche holes
- Digital Frequency readout - measuring LO frequency
- Bargraph S-meter/relative Power Meter
Description of the individual stages:
1. Band switching:
One of the main qualities of the transceiver is the ability to switch up to 5
HF band modules. To conserve space, only electronic switching was conside-
red. All band specific parts are mounted in replaceable band modules. The
following sections are switched when changing bands.:
- VCO
- Band set oscillator
- RX/ TX preselector
The inputs and outputs of all band modules are connected via the PIN
diodes D1- D2- D5- D6 to a common bus. The 10V switching signal activates
the diodes of the corresponding HF module. The chosen module is RF-wise
connected to the bus. All other diodes on the inactive modules are blocked
and high impedance. The systems impedance of the RF ports is some 50-
100 Ohms, so the inactive modules are effectively decoupled.

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2. Local oscillator signals:
The LO signal needed for transmitting and receiving is created directly on
the frequency. Via a PLL the VCO is tied to a 4,0- 4,5MHz DDS- VFO. This
approach reduces the need for filtering the harmonic rich DDS output
before entering the transmitter/receiver mixer.
The MOSFET (T2) VCO in the band module oscillates on a frequency 8 MHz
(the IF frequency) higher than the actual working frequency. The oscillator
proper works a Hartley. D4 stabilizes the amplitude. The signal from P1/Dr3
is coupled via D2 to the common VCO bus. Because of the cascode coupling
of T2, the VCO is effectively decoupled from the oscillator tuned circuit. The
tuning diode D3 is coupled so hard via C20 to the VCO tuned circuit of L1-
C9-C11, that it gives the proper tuning steepness. This gives a good side-
band noise distance. The band set oscillator of the band module swings
with T1 and Q1 4 MHz lower to the band frequency of the VCO. C3-Cr1
avoids 1. harmonic function of the overtone crystals (necessary on 15, 12,
10m). The crystal signal of R4-Dr2 is coupled to the bus via D1. IC1 handles
the mixing of the VCO and band set XO frequencies. The mixer output cir-
cuit of L1-C5 is tuned to the difference between the two inputs; the fre-
quency range is the range of the DDS- VFOs (4,0- 4,5MHz) . The via L1
inductively coupled amplifier T1 serves to raise the output signal of the
mixer to the required input level of the following 64: 1 divider, IC2. At the
output of IC2 is some 66 kHs, to feed to the frequency/phase comparator of
IC3. The 2. port of IC3 gets another 66 kHz signal from the division of the
DDS VFO frequency by 64 in IC4. IC4 will give a tuning voltage, depending
on the size and direction of the difference between the output frequency of
IC2 and IC4. This voltage is smoothed in the loop filter of R3-R4-C1 and
passed to the VCO to give equal phase of the two ~66 kHz signals. If the
VFO frequency changes, the VCO follows the change. As both VCO and XO
are switched in a band change, it is possible to use the same VFO range for
all bands.
3. VFO
We use a direct digital synthesis (DDS) VFO. The AD9835 chip is the heart
of the circuit. With a 25 MHz clock from IC8 and serial data from the CPU
(IC7), the DDS signal is taken from pin 14 of the AD9835 and passed on to
the PLL. The low pass filter of L2-L3 dampens the side bands and phase
noise typical of the DDS. Tuning of the VFO is done by a rotary encoder, and
the frequency step can be chosen with a push button. IC7 also gives the
possibility to program a transmission (XIT) or reception (RIT) offset. IC7
gives a CW marking of the mode, using the keyer function of IC7. LED’s
show the frequency range of the VFO in 100 kHz steps. An optional 7 seg-
ment LED display is available. Transmission or reception offsets are sig-
nalled on a LED. The VFO has a tuning range of 4,000 to 4,500 MHz (+/- 5
kHz. The stability of the VFO is based on the 25 MHz clock, and thus is the
crystal stability needed for PSK31.
4. RX input:
The input signal from the antenna passes through the 33 MHz transmitter
low pass filter and goes via relay RL1 to the electronic switch of PIN diode
D8. D8 conducts and leads the antenna signal to the band module/preselec-
tor bus via C35. This is followed by an undercritical double band filter with
a out of band suppression (L2-L3). The antiserially coupled capacity diodes
D7-D8-D9-D10 changes the pass band for the SSB or CW band segment. Due
to this good preselector, the RF stage and the input mixer is free of large
BC signals. The steep preselector filter also gives a high mirror suppression
and a minimum of IF throughput. The output from the preselector is led via

Version: 13. Sepe,mer 2004
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PIN diode D5 to the bus, and from there via C36 on to the RF input stage of
T9. The amplifier works with a combined voltage and current feed back, and
uses a large signal BK transistor. The working point is at Ic = 30 mA to give
good large signal data in conjunction with the feed back mechanism. The
broad band transformer Tr1 in the collector circuit adapts the ~200 Ohm
amplifier output to some 50 Ohms. The amplification is at some 18 dB. The
amplified RF signal is led via the PIN diodes D4-D5 to the RF port of the
Schottky ring mixer M1, where it is mixed to an IF of 8 MHz. The broad
band amplifier of T10 raises the signal level of the LO from the VCO bus to
the +7 dBm necessary for M1. Setting jumper J1 to the 47 Ohm terminating
resistance, you can measure this level, when adjusting it with P1 on the
band module.
5. RX IF section:
The 8 MHz signal at the IF port of M1 is led on via the conduction PIN
diode D13 and C81 to the input of the gate coupled IF preamplifier. By
parallel coupling of JFETs T12-T13 a 50 Ohm termination is achieved for
M1; the forward steepness of some 20 mS gives a stage amplification of
some 15 dB. The gate coupling gives good large signal characteristics
and reduces the risk of intermodulation. The 1:1 transformer Tr7 gives a
potential free copuling of the IF signal to the IF filter. We use a 4 pole
8 MHz Cohn filter with electronically adjustable filter band width. The
usual capacitors are replaced by capacity diodes BB112. The crystals
are chosen for less than 50 Hz difference around 8 MHz. P4 and P3
adjusts the filter width for SSB or CW. At 4,5 V on R102 the band width is
some 2,5 kHz, at 2 V the width is some 500 Hz (100 pF/350 pF). The filter
is terminated at 330 Ohm as a compromise for pass band dampening. C93
leads the signal from the filter to the IF IC, IC9. IC9 is a TCA440 (or its
replacement A244), having excellent RF data never achieved by any succes-
sor.
The TCA440 was originally developed as an AM receiver, but isn’t used as
such here. The integrated, regulated input amplifier is used as an 8 MHz IF
amplifier. The following mixer works as a product detector with an external
BFO. The part originally used a regulated 455 kHz IF amplifier is used as a
regulated AF preamplifier. The AF signal of pin 7 is limited to a band width
of 0-2800 Hz by C105. The following high pass filter of C106-R75 dampens
signals below 300 Hz. This is followed by the AGC amplifier of IC10. This
bridge amplifier with an amplification of some 32 dB leads the signal on to
the symmetrical rectifier D24-D25-D26-D27. The DC voltage at the charge
capacitor C103 is proportional to the IF signal and is fed to the regulating
input of IC9 (pin 9). The two way rectifier gives a frequency doubling,
producing only half the AC swing on C103 compared to the classical ap-

Version: 13. September 2004
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proach. Unpleasant overloading effects from insufficient regulating voltages
at low speech frequencies is thus minimized. The decay is regulated by R72.
R76-R77 defines the attack. You can attach an optional 100 µA instrument
at P5 to give a relative field strength indication. The combined IF/AF
regulation is more than 90 dB!!! Input signals of S9+60dB are regulated
distorsion free. After a further 2800 Hz low pass at R78-C110, the signal is
fed to an 800 mW AF PA in IC11. T16 blocks the regulating voltage during
transmission. T17 blocks the AF amplifier during T/R switching to reduce
switching noise.
6. Side band oscillator:
The carrier needed for modulation and demodulation is generated by the
capacitative three point circuit (Colpitts) at T20. The produced frequency is
determined by the parallel coupled 8 MHz crystals Q6-Q7. The tuning diodes
D29-D30 in conjunction with L7 leaves a tuning range of some 6 kHz for
the VXO. P7 adjust the RF signal to some 300 mVpp and leads the signal via
C97-C137 to the product detector of IC9 and the balanced modulator of
IC16. The tuning voltage for D29-D30 comes from potentiometers P8 and
P11, switched by the analog switch in IC12. This circuit gives the necessary
carrier frequencies for the different modulation types, and for the varying
center frequencies, in an easy way.
7. 8MHz SSB generation:
The microphone signal is led via the mic gain potentiometer to the input of
the preamplifier IC18. The circuit of C150-Dr12-C149 reduces transmitter RF
in the modulation amplifier. The amplification of the stage is set to some
26 dB byt R126-R127. C148-C147 cuts speech frequencies below 300 Hz.
The level of the amplified microphone signal is adjusted in P16 before
going into the dynamic compresson IC17. The utilized IC SSM3165 from
Analog Devices was made for studio techniques and gives a compression of
max. 15:1, that is 15 dB input dynamic range for 1 dB og output dynamic
range. The [klirrfaktor - please change!!!] of the output signal is less than 1
%. This compressor will allow the PA to swing to the QRP allowance of 10W
PEP. This gives a subjective power level of some 50W uncompressed!! P15
allows individual adjustment of the compression. P14 leads the compressed
signal on to the balanced modulator of IC15. C139 gives a further low pass
cut off. The modulator uses the universal Gilbert cell NE612. The internal
oscillator isn’t used. C137 leads the appropriate signal in from T20. P13
adjust the carrier suppression. In CW mode the modulator is debalanced by
T29-R116, that is the carrier signal is no longer suppressed, but led on to
the modulator output. to avoid swing in problems at the modulator at T/R
switching, IC16 is at permanent power. For this reason T30 blocks the
modulation path during reception and disallows a DSB signal at open micro-
phone. This guarantees against feed through to the high amplification IF.
The 8 MHz DSB signal is led from pin 5 of IC15 to T14. The collector of T14
sees the transformed filter terminating resistance via the 1:1 transformer of
Tr8. This gives a stage amplification of 6 dB in conjunction with R66.
During reception T15 breaks the emitter circuit of T14, blocking the collec-
tor-basis voltage at R65. Pin 12 on the pc board is at ground potential at
this moment, also blocking the PIN diode D22. This serves to dampen the
residual carrier signal at the input of IC9. During transmission the amplified
8 MHz DSB signal is led the other way through the Cohn filer and shows up
a an SSB signal with suppressed carrier at Tr7. The MOSFET T23 gives a
voltage amplification of some 6 dB. Choice of side band is by the carrier
frequency from T20. C85 couples the SSB signal to the amplifier at T23. A
positive voltage at the source of T23 is used to adjust TX power. In CW
mode, keying is done by breaking the drain voltage at pin 30. Tr6 trans-
forms the output impedance determined by R98 to the 50 Ohm level. PIN
diode D14 leads the 8 MHz signal to the IF port of M1. D13 blocks and T12-
T13 are decoupled.

Version: 13. Sepe,mer 2004
8
8. Transmitter:
The transmission frequency is obtained by mixing the 8 MHz signal with the
LO signal. M1 works as a transmitter mixer with changed siganl direction.
The signal at the RF port is coupled via PIN diodes D6-D7 and C35 to the
input bus of the preselector filter, now working as a transmitter prefilter.
The high selectivity of the filter reduces unwanted signals from the mixer.
The filtered output signal is led via the output bus over C36 to T9, the
transmitter preamplifier. The 18 dB signal at Tr1 is led via PIN diode D3 to
the predriver at T3. The stage amplification is chosen to be able to drive
the two stage PA fully. Tr3 serves to impedance match T3 to T5. The circuit
at T5-T6-T7 is a slightly modified DL-QRP-PA:
The PA quiet current is adjustable by P1, and independent of the
board voltage.
The push-pull stage uses robust 2SC1969’s with a large collector
current reserve, given good intermodulation characteristics.
The ferrite volume of Tr5 is enlarged to reduce distorsion due to
TR7 1:2
power adj ust
TR 6 2 : 1
PIN 30 KE Y I N
PIN 31 +10VS
D1 4 T23
Mischer TUF1
LO
Local Oscillator
T10
TR2 2: 1
31+10VS
D7
D6
T9
TR1
Bandfilter Bandmodul
Abs ti mmspannung
Preselektor
35 +10VS
T3
TR3
T5
1R
1R
1R
1R
Tr.4
T6
T7
Tr.5
1
2
3
4
1
2
3
4Wdg 2Wdg 2Wdg
2Wdg
5Wdg
+ 13,8V
+10VS
L4 L5 L6
52
51
Ant enne
Ti efpas sfi l ter
T4
Io Komp T5
T8
Io Komp T6/7
P1 Io PA
saturation
The transmitter is followed by a 3 stage Chebychef low pass filter with a cut
off frequency of 33 MHz, to reduce harmonics in the BC/TV bands by more
than 60 dB. The in band variation is a maximum of 0,3 dB. The band 80 to
17 meters, this should be followed
by the electronically switched
output filter, developed for the
“Tramp”, to reduce emissions in
higher ham bands. D11 works as a
measuring rectifier for the relative
power output meter. To avoid un-
controlled feed back in the trans-
mitter, the decoupling between
transmitter output and the T/R
switch diode should be at least 70
dB. Experiments with electronic
switching showed problems with
the high RF voltage (up to 70 Vpp).
As the switch carries no RF current
(only active during reception), the
choice was a small DIL Reed relay,
which also allowed shorting the the
[Übersprechsignal - please
change!!], in a painless way. The
attack time of the relay is only some 0.5 mSec. The life time at some 10
million cycles. Thanks to the low weight of the moveable parts, no clicks
are heard.
9. CW logic, T/R switching:
Pin 2 of the CPU (IC7) is bidirectional, having the following functions:
During reception pin 2 is kept at high potentil by an internal pull up resis-
tor. When the integrated keyer is activated, pin 2 is pulled low in the rhytm
of the CW signal. Synchronously pin 15 of IC7 generates a side tone. And
further an optional RIT/XIT is activated.
When the internal keyer isn’t used, external keying is possible. In this mode
pin 53 is grounded via R103-D31 in keying rhytm. In SSB mode the PTT
keys the same pins, but T18/T19 quiets the side tone input at IC11.

Version: 13. September 2004
9
In CW mode soldering pin 9 is left at +10V, that is pin 10 of IC13 shifts low
to high in keying rhytm. R106-C127 rounds the attack and decay soft
keying T23 via T25. T26 leads during the high phase of pin 10 (IC13), and
charges C128 via R108 with at very low time constant. Below th triggering
point of pin 6 of IC14, pin 4 goes high and pin 3 goes high, resulting in
blocking T27 and opening T28 (both P channel MOSFETs). The transceiver is
switched to transmission. After releasing the key/PTT, this status is kept as
long as C128 takes to discharge over the delay potentiometer of P12 and
R107 to the triggering point of pin 6 of IC13. Then T28 blocks and T27
opens. The transceiver goes back to reception mode.
During SSB pin 9 is open, that is the gate is blocked and T25-T26 are
inactive. Pin 5 at IC14 is now controlled directly by the PTT button. The T/R
switch now works without decay control.
10. Stabilization stages:
To make the voltage dependent characteristics of the transceiver indepen-
dent of the supply voltage, all critical parts are supplied by a stabilized 10
V derived from the low drop regulator IC15. This concept limits the supply
voltage for the transceiver to 10,8 to 15 Volts. The 5 Volt regulator at IC5
served to feed IC1-IC6-IC7. D2 reduces the effect loss at IC5. The R11-C12
filter reduces regulation noise at the PLL in conjunction with D1, during
the short breaks in the 10 Volt supply during T/R switching (reducing chirp
in the first CW character sent). The 6 Volt regulator IC14 feeds IC16-IC17
and T20.
11. Optional circuits:
The JFET source follower T11 serves as a load free decoupling of the LO
signal. 100 mVeff is found at soldering pins 16 and 17 for feeding an exter-
nal frequency display.
Author: Peter Solf DK1HE
11. 12. 2003
In the mean we designed a 3 digit frequency display for to the Speaky. This
should be used if you use the very small tramp enclosure or a similar small
one. The standard kit with the bigger enclosure as shown on the manual
frontpage will contain an LCD display. This backlight display is counting the
LO frequency.
The number of SMT parts had to be increased to abt. 25 to prevent the
amplifier stages against Meißner oscillation. All SMT parts are premounted
when the kit is shipped.
March 2004, DL2FI

Version: 13. Sepe,mer 2004
10
Building description for the Speaky
Please follow the prescribed building order for all sections. Check each part
in the parts list with a pencil, to keep track. To the right of each part in
the lists, you will find its coordinates on the pc board. C3 means that the
component is at square C3. B/C3 means that the component is located at
the border between grid squares B3 and C3.
Start with the voltage regulators.
Section 1, Voltage regulators
In this first section, the necessary voltages are produced. The Speaky needs
+5V, +6V und +10V. In a later section theses voltages will be divided in two
groups, one for the receiver and one for the transmitter. But here we will
only make the raw voltages. The order of building is mainly decided by the
height of the components.
First the resistors.
We recommend measuring the resistors individually. The colour
coding is often misinterpreted because of the body colour of
the resistors. By experience we now wrong resistor values to be
a common source of errors.
As the Speaky is very small, yet not use SMD parts, most resistors are
mounted vertically. To do this one lead must be bent back parallel to the
resistor. In the placement diagram, the circle marks the position of the
resistor body.
[ ] R11 39R B6
[ ] R112 120R metal foil 1% E1
[ ] R113 820R metal foil 1% E1
Now the diodes. Please check the type with a loupe. D32 is a comparatively
large component, D1 and D2 looks alike, but have a printed marking. The
cathode is marked by a ring. When diodes are mounted
standing up, it is always the cathode lead, that is bent back
parallel to the body of the diode. The ring on the placement
diagram marks the place for the body.
[ ] D1 1N4148 B6
[ ] D2 ZPD 2V7 (500mW) A6
[ ] D32 1N5822 o.Ä. F1
Please note the polarity of the electrolytic capacitors. The long lead is
always the positive lead. Further a minus on the body marks the nega-
tive lead.
[ ] C20 1µF/63V rad. A6
[ ] C21 1µF/63V rad. A6
[ ] C129 1µF/63V rad. B/C 1
[ ] C130 1µF/63V rad. C1
[ ] C131 10µF/35V rad. D/E 1
[ ] C132 10µF/35V rad. D/E 1
[ ] C133 470µF/25V rad. E/F 1
The following parts are the integrated voltage regulators
for 5 and 6 Volts in T092 casings. Voltage regulation with
these parts look eay but is quite complicated. They con-
tain several dozens of components. They output a con-
stant voltage, as long as the input is at least 1 Volt higher
than the output voltage. Please take care to mount the correct regulator in
the correct place!! Many small signal transistors and voltage regulators are
made in T092 caisngs. The placement diagram shows most parts from abo-
ve. Pleas take care to mount these TO92 parts with the round side oriented
correctly, as shown in the placement diagram. Mount them close to the pc
board, not more than 2-3 mm above the board. This is obtained with a
SLIGHT pressure, - no violence! Don‘t mix up the two regulators. The 8 Volts
regulator is marked LO8, the 6 Volt one is marked LO6.
[ ] IC5 78L05 TO92 A6
[ ] IC14 78L06 TO92 C1

Version: 13. September 2004
11
The next part is a higher effect version in a TO220 casing. This is
kept at 10 Volts by an external circuit. NOTE: The casing of this
regulator is NOT at ground potential, so it must be mounted
isolated. The picture shows the TO220 casing. In the placement
diagram, the parts is shown from above. The fat, black line shows
the metal strip, and show the mounting direction. In the kit you
find a heat sink for this part.
[ ] IC15 LT1086CT TO220 E1
The following fuse holder consists of two parts. To make them fit
later on, it makes sense to mount the fuse during soldering.
[ ] SI-1 Fuse holder F1
[ ] Fuse 2,5A F1
Finally we mount the soldering pins. Press the short end of the pin through
the hole in the pc board with a pair of pliers. No violence, but some pressu-
re is needed. Solder to the down side of the pc board.
[ ] PIN50 + 12V G1
[ ] PIN51 Ground G/H1
[ ] PIN46 E1
[ ] PIN45 E/F1
[ ] PIN47 E1
[ ] PIN18 C5
To connect the external power, you will
need a coaxial power connector and proper
wires. In the bag with peripheral parts, you
will find the connector . Solder two wires of
about 10 cm to the connector.
To avoid later damage, it makes sense to
use a red wire for the plus, and a black wire
for the minus pole.
[ ] Connect pin 47 of the pc board with pin 18 with a short piece of wire
and two [Steckhülsen - please change!], to supply the upper part of the
board with +10 Volts.
[ ] Connect pin 45 and 46 with a short piece of wire and two of the
plugs provided for the pins. Here you will mount a switch later on.
Testing Section 1
1. Visual inspection.
As a first test, inspect every section with a loupe to find shorts. Take this
test seriously. Even a master solderer makes shorts with bent leads or small
blobs of solder. Or even unsoldered soldering spots! Parts are overlooked
more often than you think. Also check the values of all parts: Right part in
right place? Electrolytic capacitors correctly polarized? Diodes?
2. Resistance test
Measure the resistance from plus to minus at the pc board (pin 50 and 51).
This should be larger than 50 kOhms.
Allways use the black lead of your ohm-meter conncted to ground. Be aware
the measurement not to be stable if there are electrolytic caps in the
measuring path. The will be loaded causing a wandering restistance value.
The resistance test is done to find shorts. Shorts will be shown by the
meter by a clear ZERO Ohm resistance.
3. Smoke test
If Speaky passed the resistance test, try applying voltage to the pc board.
Put between 10 and 15 Volts between pin 50 (PLUS) and pin 51 (GROUND).
Use a laboratory supply with a current limiter, or put a 100 mA fuse in line.
Is is good sense to use a regulated power supply with a current limiter.
Reduce the current limiter to its lowest before connecting!
Allwarys turn the power supply on before turning on the device
under test. ALLWAYS! Many power supplies have an initial
voltage peak, large enough to kill your apparaturs!
Having connected the Speaky to the power supply, keep an eye on the
current level and another eye on the pc board. Smoke is a definite sign of
malfunction, as is a current of more than 20 mA.
4. Funkctional test:

Version: 13. Sepe,mer 2004
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Measure at test point, 47 = 10V +/- 5%
Measure at test point U2 = 6V +/- 5% (Track from c129 field B1 to the
left)
Measure at test point U3 = 5V +/- 5% Track from C21 field A6/7 up
When the measurements are OK, remove the power supply and the shorts,
and turn to the next section.
Section 2 T/R Switching
We begin with the trimming potentiometer P12, as mounting this is easier,
when no other parts ar present. PT6 lying means a 6 mm diameter compo-
nent. The value is printed sideways on the casing, and often difficult to
read. The mounting position is given by the three leads, placed in an equi-
lateral triangle.
[ ]P12 100K PT6 lying A/B5
Now the capacitors. After the electrolytic capacitors comes for the first
time a multilayer capacitor. It has a marking of 104, meaning 100 nF.
As examples of this type of marking, we present a few values:
101 100 pF 0,1nF 0,0001uF
102 1000 pF 1,0nF 0,001uF
103 10000 pF 10nF 0,01uF
104 100000pF 100nF 0,1uF
221 220pF 0,22nF 0,00022uF
222 2200pF 2,2nF 0,0022uF
223 22000pF 22nF 0,022uF
224 220000Pf 220nF 0,22uF
Note that the last figure marks the number of zeros. This type of capacitor,
type X7R, is often used to bypass RF. There Q isn’t very his, making them
unusable for resonant circuits. You will find more on capacitors in the FI
Workbench Book.
[ ]C126 100nF 104 A6
Now follows a film capacitor. WIMA film capacitors are nonpolarized, ma-
king the mounting direction unimportant. Good practice though is to
mount them, so the marking can be read. They are used at AF because of
their high Q. RM5 means raster measure 5 mm, most parts of the kit has a
raster measure of RM2,5 equalling 2,5 mm.
[ ]C127 0,22µF Film RM 5mm B5/6
Now follows a new component, the tantalum capacitor. These are
polarized as electrolytic capacitors. You will usually find their value
as text on the drop shaped body, and a small plus sign at one lead.

Version: 13. September 2004
13
When no plus is found, the positive terminal is marked by a dash. The
longer lead allways shows the positive terminal. Tantalum capacitors are
often used, when low leak currents are needed at high capacities.
[ ]C128 6,8µF 16V Tantalum pearl B5
Now follows an integrated circuit. TAKE CARE. The device is static
sensitive. Before handling it, you must discharge your hand to
ground. The soldering iron MUST be potential free, the best
thing is a potential levelled soldering station.
Due to production circumstances, ICs have their leads spread a little wider
than the standard raster. By careful rolling, the leads are brought to their
proper position. Pin 1 is marked on the top of the IC,
either by a notch or by a dot. The notch is marked in the
placement diagram. Mount the IC as shown, and begin
by soldering two diagonal leads. Check that the IC is
flush to the pc board, and corect it, befor soldering the
rest of the leads.
[ ]IC13 4093 DIL 14 A/B6
The following transistors are all in TO92 casings as the voltage regulators of
section 1. Check the marking with a loupe, to avoid mixing them
up. The mounting direction is shown in the placement diagram.
For the MOSFETs remember to discharge your hands before
handling them!
[ ]T24 BS170 MOS take care of statics A6
[ ]T26 BS170 MOS take care of statics B5
[ ]T25 BC546B B5
[ ]T27 BS250 MOS take care of statics E1/2
[ ]T28 IRF9520 take care of statics E1
Note the mounting direction with the following diode.
[ ]D31 1N4148 A5
The resistors should pose no problem.
[ ]R104 10K A6
[ ]R105 39K B6
[ ]R103 220R A5
[ ]R107 8,2K A5
[ ]R109 33K A/B5
[ ]R108 39R B5
[ ]R106 22K B5
[ ]R110 56K E1/2
[ ]R111 56K D/E1
Now follows the pins for connecting the peripheral parts.
[ ]PIN 9 A/B6
[ ]PIN10 A5
[ ]PIN11 A5
[ ]PIN13 B5
[ ]PIN39 E2
[ ]PIN40 E1
[ ]PIN41 E1/2
[ ]PIN42 E1/2
[ ]PIN53 A/B5
To test this section the connection between pins 47 and 18 of section 1 is
needed again. And also pin 9 should be connected to +10 Volts. A short is
need between pin 11 and pin 41, and one from pin 10 to pin 42.
Test Section 2
1. Visual inspection (see Section 1)
2. Resistance test (see Section 1)
[ ] Apply supply voltage as in Section 1 test.
current should be abt 20mA
3. Smoke test (see Section 1)
4. Functional test
When pin 53 is grounded,

Version: 13. Sepe,mer 2004
14
pin 13 must measure +10 Volts
Pin 39 should be at +10 Volts, when not keyed,
and when keyed, at 0 V
Pin 40 should be at 0 Volts , when not keyed,
and at 10V when keyed.
For a closer look to the function have a look at the logic plan in the sche-
matic part.
Section 3 DDS VFO
The heart of the DDS VFO is the IC AD9835BRU, which is already mounted
on delivery. most other parts are well known. As allways, take care to check
the markings to avoid mixing up parts. It is often impossible to read the
markings on the small ceramic capacitors. This is unfortunately impossible
to change, so they will have to be measured. As most cheap multimeters
today measures capacitors to below 1 pF, this should pose no problem.
(Multimeters are offered by QRPProject at 29 Euro).
[ ]C13 1nF 102 C6
[ ]C14 8p2 8p2 C6
[ ]C15 220pF 221, n22 C6
[ ]C16 68pF 68p C6
[ ]C17 470pF 471, n47 C6/7
[ ]C18 68pF 68p C7/6
[ ]C19 220pF221, n22 C7
[X] C22 100nF SMD 0805 B6
[X] C23 10nF SMD 0805 C6
[X] C24 10nF SMD 0805 C7
[ ]C25 22pF 220,22p B6
[ ]C26 22pF 220,22p B6
[ ]ST3 3 Pin Connector A6
[ ]C27 10nF 103 A6
[ ]C28 10nF 103 A6
[ ]C29 470pF 471, n470 A7
[ ]C30 100nF 104 A7
[ ]C33 10nF 103 C7
[ ]C31 10nF 103 B7
[ ]C32 10nF 103 B7
[X] C34 100nF SMD 0805 B7
Now mount the socket for the processor. Please take care to mount it as
shown in the diagram. The notch on the short side should be mounted as in
the placement diagram.
[ ]IC7 socket 20 PIN A/B7
Take care of statics, the Processor is very sensitice against
Electro Static Discharge (ESD)

Version: 13. September 2004
15
[ ]IC7 AT90S2313 (programmed) A/B7
The following part is an integrated 25 MHz oscillator. Pin 1 is marked on
the part and in the placement diagram.
[ ]IC8 25MHz oscillator C7
Take care of statics, the next transistor is very sensitice against
Electro Static Discharge (ESD)
[ ]T2 BF199 C6
[X] IC6 AD9835 TSSOP16 B6/7 SMD
[ ]R9 1,5K B6
[ ]R10 100K C6
[ ]R12 270R C7
[X] R13 3,9K SMD 0805 C7
[ ]R14 680R B7
[ ]R15 not used B7
[ ]R16 10K A7
Now follows two SMCC RFCs. They look like fat resistors. Measu-
ring them with an ohmmeteres, they are close to 0 Ohm. The
colour coding is as with resistors, but due to their light bodies,
they are easier to read.
[ ]L2 4,7µH SMCC C6
[ ]L3 4,7µH SMCC C7
Now we mount a crystal in HC18 casing. Mounting crystals, it is necessary
to avoid shorts on the pc board from the casing. To avoid this, the crystal
is mounted at a short distance from the pc board, or by putting an isola-
ting disc below the crystal. A common way to do it is to place to cut off
leads from resistors temporarily under the crystal as placeholders, during
soldering. Remember to remove the resistor leads again after soldering!
[ ]Q1 4,096MHz HC18 B6/7
[ ]St3 connector A6
[ ]St4 connector A/B7
[ ]PIN7 A/B7
To use the section, the rotary encoder
should be connected. If you got the kit
including the Bargraph.S-Meter, go to
step “Building the S-Meter now. The 3-Pin Plug, ready with 3 wires is do
make the connection to ST3 on the main board. Twist the 3 wires and solder
them directly to the encoder solderlugs as you can see in the drawing right.
Assembling the S-Meter / Power-
meter / Encoder- PCB
This is a single sided PCB. You need 3
wire bridges to make functional. Solder
the 3 wires first. Solder them at the
parts placement side of the PCB. Us
thin wire to make it possible to place
the bargraph flat in the next step.
[ ] Wire from A to A1
[ ] Wire from B to B1
[ ] Wire from C to C1
Next place the bargraph, DO NOT USE a
Socket. Be carefull to identify PIN 1,
compare the chip to the drawing.
[ ] Solder the bargraph
[ ] Solder the Encoder
[ ] Solder the control IC (Steuer IC), attention PIN 1!
Attention, the next parts have to be placed and soldered to the solder Side
of the PCB
[ ] Trimpot
[ ] 2 Pin Jack for jumper
[ ] Solder PINs

Version: 13. Sepe,mer 2004
16
Now prepare the wires for this group. The 3-Pin Plug, ready with 3 wires is
do make the connection to ST3 on the main board. Twist the 3 wires and
solder one of the SolderPin Plugs to each end. Isolate them partially to
prevent against shorts. ST3/1 MUST go to PIN Y. ST3/2 and ST3/2 can be
interchanged to change tuning direction of the DDS VFO. The other connec-
tions are not used in this section.
Test Section 3
1. Visual inspection (see Section 1)
2. Resistance test (see Section 1)
[ ] rotary encoder at St 3
[ ] connect bridge from pin 18 to pin 47 (see Section 1)
[ ] Apply supply voltage as in Section 1 test.
3. Smoke test (see section 1)
current abt 50 mA
4. Functional test
Method 1:
After turning on, the DDS VFO should oscillate at 4.030 MHz. This is easy to
check with a short wave radio. Make a wire link from isolated wire. The free
ends should be twisted. Leave a small sling at the closed side, and connect
the free ends to ground and antenna input of the receiver respectively. Put
the sling over T2. Turn on power. The receiver should now have a strong
4.030 signal.
Method 2:
Oscilloscope owners could inspect the signal at C13. It should be some 2-3
Vpp.
Method 3:
With an absorbtion frequency meter (or a grid dip meter in absorbtion
position), you should be able to demonstrate the function of the DDS.
Methode 4:
Those who have allready built the speaky counter or own anothe counter
may measure the frequency at C13.The counter should show 4030 +/- 2 kHz
Remove the supply voltage and the bridges, and proceed to the next sec-
tion.
Section 4 IF
The following trimming potentiometer was supposed to be standing. In
practice, this has shown to be difficult to trim. Instead we mount a PT6
lying. The raster is a little too small for this, so the leads of the trimming
potentiometer must be bent carefully. This is a little clumsy to do, but
better clumsy now, than when trimming!
[ ]P6 2,5K PT6 lying E2
IC 11 should be rolled gently, as we did previously.
[ ]IC11 LM386-4 DIL8 E2/3
Now the capacitors
[ ]C111 0,1µF Film RM 5mm D3
[ ]C112 2,2nF 222 E2/3
[ ]C113 22nF 223 E2
[X] C114 10µF/6,3V (SMD) E3/2
Don’t forget to polarize electrolytic capacitors correctly. The
long lead is plus.
[ ]C115 10µF/35V rad. F2/3
[ ]C116 220µF/16V rad. F2
[ ]C117 220µF/16V rad. F2
[X] C118 47nF SMD 0805 E2
[ ]C125 10nF 103 D2
[ ]R79 22K E2/3
[ ]R80 1M D3
[ ]R83 100k D2

Version: 13. September 2004
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[ ]R84 22K E2
[ ]R85 39K E2
[X] R86 SMD 0805
[ ] R87 3,3R F1
[X] R88 4,7R SMD 0805 E2
Diode D28 will be mounted standing up. The cathode will be bent back, the
body is placed where the circle on the layout is drawn.
[ ] D28 1N4148 D3
There is an extreme risk to destroy CMOS Transistors by ESD.
Use a potential free Soldering Station, at least discharge
yourself by touching a blank, metall ground plane before you
handle any electronical part
[ ] T17 BS170 MOS Caution ESD! D3
[ ] T18 BS250 MOS Caution EDS! E2
[ ] T19 BS170 MOS Caution ESD! E2
[ ] PIN33 E3
[ ] PIN34 E3
[ ] PIN43 E/F 1/2
[ ] PIN44 F1/2
[ ] PIN 8 D2/3
Test Building Group 4 (BG 4)
1. Visual inspection (see Section 1)
2. Resistance test (see Section 1)
[ ] Connect power supply as described at building Group 1 (BG1)
[ ] Connect PIN 7 and PIN 8
[ ] Connect headset between PIN 44 and ground
3. Smoke test (see section 1)
4. Functional test
Put the finger on PIN 33. You will hear a clear hum in the Phones. You may
measure the current during this test. Without hum it should be about
60mA. If you touch PIN 33 it may increase to as much as 150 mA.
Connect PIN 7 or PIN 8 of connector 4 to ground. If you tune up Trimpot
P6, you will hear the internal CW generator in the headphones.
Remove the power supply and the headset and continue with the next
building group

Version: 13. Sepe,mer 2004
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Building Group 5, Carrier Oscillator and Switches
The Neosid coil, used in this group is completely different from the known
Neosid cylinder coils. Here we are
using a so called BOBIN coil. The
kernel is made from ferrite mate-
rial, which is looking like a reel.
The windings on this kernel are
not brought on, turn for turn, but
simply winded as are. The only
importance is the right number of
windings.
1=Shield Can 2= Guidance from Plastic 3 Kernel
4= Coilbody 5= Socket
Take the socket of the Bobin and put a little drop of Super glue between
the kernelholders and press carefully the Ferrit bobbin into the holders.
Wait until the glue is dry before continuing the work. You are free to solder
other parts in the meantime.
Caution! IC12 is sensitive against static charging. Discharge
yourself before rolling the part.
[ ] IC12 4066 DIL14 D2
PT6 we already knows. These are the little black trim-potentiometers
[ ]P71K PT6 lying B2
Spectrol 75H are precision-trim-potentiometers in a metal case.
Caution, first compare the three terminals exactly with the
respective holes on the pc board. The trim-potentiometers are
gliding very easy into the holes, if they are mounted right. If
you need pressure, they are mounted the wrong way!
[ ] P8 10K Spectrol 75H D2
[ ] P9 10K Spectrol 75H D1
[ ] P11 10K Spectrol 75H D2
[ ] P10 10K Spectrol 75H D1
[ ] D29 BB109G / BB409 or equivalent C1
[ ] D30 BB109G / BB409 or equivalent C1
The following transistors are mounted according to the place-
ment diagram. Caution! they are sensitive against static char-
ging. Discharge yourself before rolling the part.
[ ] T20 BF199 B2
[ ] T21 BS250 MOS beware of static! E2
[ ] T22 BS250 MOS beware of static! E2
The crystal is mounted with the help of two cut off resistor leads.
[ ] Q6 8,000MHz HC18 B1
[ ] Q7 8,000MHz HC18 B1
[ ] R89 47K B2
[ ] R90 47K B2
[ ] R91 68k C1
[ ] R92 39K C/D2
[ ] R93 39K D2
[ ] R94 39K D/E2
[ ] R95 100K D1/2
[ ] C97 1nF 102 B3
[ ] C119 22nF 223 A/B2
[ ] C120 330pF 331 or n33 B2
[ ] C121 220pF 221 or n22 B2
[ ] C122 10nF 103 C1/2
[ ] C123 100nF 104 C2
Now the coil form should be glued properly, and the coil can be wound.
The picture shows the coil from below. Start at pin „anfang“, by twisting
the 0.1 mm wire three times around the pin, and then through the notch

Version: 13. September 2004
19
onto the body. Put 22 turns on the body,
and then again go down through the
notch at pin „ende“. Put the turns around
the lead. And you‘re done.
Fix the coil in a vice and solder wire and
pins at the same time. This is easy: Touch
the wire and solder with the soldering iron
at the same time (LITTLE solder!). Don‘t
push too hard. The leads become hot, and
the plastic soft! Check for contact with an
Ohmmeter.
All well? Then screw the core into the plastic holder till it is flush with the
top. Please take care not to set it askew. Solder the coil onto the pc board,
and put on the covering core. Loosely fit the can, but don‘t solder it yet.
[ ] L7 Neosid filter 7.1 F10b B1
22 turns 0.1mm lacquered copper wire (AWG 38).
We only have to put in 3 pins, to finish this section
[ ] pin 28 C/D2
[ ] pin 29 D2
[ ] pin 38 E2
Test Section 5
1. Visual inspection (see Section 1)
2. Resistance test (see Section 1)
[ ] Apply supply voltage as in Section 1 test.
3. Smoke test (see Section 1)
current about 65 mA
4. Functional test
Connect pin 29 to +10V (e.g. pin 18 or pin 47)
Put trimming potentiometer in centre position.
Put your link wire from Section 3 close to T10 position and tune the recei-
ver to about 8.000 MHz. You should hear the BFO loud and clear. P8 should
tune the BFO +/- 1 kHz.
With an oscilloscope, you should be able to see the 8 MHz signal at C97
and adjust it to some 300 mVpp.
If you have no Scope, you may use the calibrated RF probe available from
QRPproject or another type of RF probe.
If everything is OK, proceed to Section 6.

Version: 13. Sepe,mer 2004
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Section 6 BFO, IF amplifier, AGC
[ ] IC9 Socket 16 PIN A/B3
If you install the IC now, be very carefully. All IC pins must go
straight into the corresponding part of the socket. Dont bent
the IC pins. Discharge yourself before you handle the IC.
[ ] IC9 TCA440/A244 DIL16 A/B3
[ ] IC10 TDA7050 DIL8 B/C2
[ ] D23 1N4148 B2
The following germanium diodes have quite sensitive, large
glass bodies. The raster on the pc board is too small for them
to be mounted horizontally. All 4 diodes should be mounted
obliquely.
[ ] D24 AA143 or the like C2
[ ] D25 AA143 or the like C2
[ ] D26 AA143 or the like C2
[ ] D27 AA143 or the like C2
[ ] T16 BC337-40 B2
[ ] C93 1000pF RM 5mm A3
[ ] C94 10nF 103 A3
[ ] C95 22nF 223 B3
[ ] C96 10nF 103 B3
[ ] C98 100µF/16V rad. A4
[ ] C99 100nF RM 5mm A3
[ ] C100 22nF 223 A4
Remember to polarize the tantalum capacitors correctly. The
long wire is PLUS.
[ ] C101 10µF/16V Tantalum pearl A/B4
[ ] C102 1µF/35V Tantalum pearl B4
[ ] C104 10µF/16V Tantalum pearl B4
Mount the electrolytic capacitors correctly. The long lead is PLUS.
[ ] C103 33µF/16V radial B4
[ ] C107 10µF/35V radial B/C2
[ ] C108 10µF/35V radial B2
[ ] C109 47µF/35V radial C2
[ ] C105 0,1µF Film RM 5mm B3
[ ] C106 0,033µF Film RM 5mm B3
[ ] C110 0,1µF Film RM 5mm C1/2
[ ] R70 120R B3
[ ] R71 2,2K A4
[ ] R72 100k B4
[X] R73 27R SMD 1206 B3
[ ] R74 560R B3
[ ] R75 18K B3
[ ] R76 470R C2
[ ] R77 470R C2
[ ] R78 27K C2
[ ] R81 33K B2
[ ] R82 12K B2
[ ] P5 2k5 PT6 lying B3
[ ] PIN20 B4
[ ] PIN25 B2
[ ] PIN26 B1/2
[ ] PIN27 B1
As shown in the wiring plan (see schematic section of the manual) you
must solder a 100nf (104) cap and a 1k0 resistor between pin 20 and
ground. Solder at the solder side of the PCB.be carefull not to short any
other tracks.
[ ] 100n 104
[ ] 1k0
To test this section, we need the link to the AF amplifier. Prepare the
volume potentiometer (2k2 log). Logarithmic potentiometers are identified