Tablerock Shortwave Daddy User manual

SHORTWAVE DADDY
USB AM/FM/SHORTWAVE RADIO
ASSEMBLY AND OPERATING MANUAL

TABLEROCK INSTRUMENTS CO.
PLEASE VISIT OUR WEBSITE AT:
WWW.SHORTWAVEDADDY.COM
FOR UPDATES AND ADDITIONS
COPYRIGHT 2012
ALL RIGHTS RESERVED
No part of this manual may be reproduced without the
express written consent of Tablerock Instruments Co.

Table of Contents
INTRODUCTION......................................................................... 1
TAKE ADEQUATE SAFETY PRECAUTIONS.......................................................... 1
SHORTWAVE DADDY FEATURES:............................................. 2
CONTENTS OF KIT: .................................................................... 5
ASSEMBLY INSTRUCTIONS:......................................................8
TOOLS AND MATERIALS REQUIRED FOR ASSEMBLY:..........................................8
GENERAL INSTRUCTIONS: .............................................................................8
STEP 1:...................................................................................... 10
STEP 2: ..................................................................................... 14
STEP 3: ..................................................................................... 16
STEP 4: ..................................................................................... 21
STEP 5:...................................................................................... 23
OPERATIONAL INSTRUCTIONS: ............................................. 27
CONNECTING TO WINDOWS PC OR LAPTOP: .................................................. 27
CONNECTING TO MAC OS XSYSTEMS AND LINUX (UBUNTU)SYSTEMS:............ 29
IF USB PORT FAILS TO OPERATE AFTER DISCONNECTION AND RECONNECTION TO
USB PORT (WINDOWS): ............................................................................30
CHANGING TO AM MODE (WHICH ALSO INCLUDES SHORTWAVE):................... 31
CHANGING TO FM MODE: ......................................................................... 31
ENTERING A FREQUENCY ON THE AM/SHORTWAVE BAND: .............................. 31
ENTERING A FREQUENCY ON THE FM BAND:.................................................. 32
USING AM/SHORTWAVE MODE SEEK/TUNE FUNCTION:............................ 32
USING FM MODE SEEK/TUNE FUNCTION: ................................................... 32
CHANGING THE BANDWIDTH FOR THE AM/SHORTWAVE CHANNEL FILTER: ....... 33
RDS/RDBS DISPLAYED INFORMATION:....................................................... 33
RSSI AND SNR DISPLAYED INFORMATION:................................................... 34
IN-CIRCUIT PROGRAMMING OF THE MICROPROCESSOR: .................................. 34
ANTENNA AND GROUND CONNECTIONS: ........................................................ 36
RESET PUSH-BUTTON: ...............................................................................38
WARRANTY INFORMATION:...................................................38

1
Introduction
Thank you for purchasing the ―Shortwave Daddy‖—an easy to assemble PC based
and USB powered AM/FM/Shortwave radio kit with many features that will delight
both DX shortwave enthusiasts and experimenters seeking to learn more about
microprocessor controlled radios.
The radio circuit and PCB (printed circuit board) have been designed to make
assembly easy for electronics novices who have minimal soldering skills. All
components for soldering are ―though hole‖ and require none of the harder surface
mount skills that tend to frustrate many newcomers to the electronics hobby.
The few surface mount components on the main PCB or sub-assembly PCB have
already been soldered. Our goal is to make this kit as enjoyable as possible for both
novices and experts to build and enjoy.
When operating the radio, the radio frequency is ―tuned‖ and band selection is
made utilizing a 10-key touchpad, push-button switches and LCD display. The radio
broadcast is heard through the PC or laptop speakers. No drivers need to be installed.
The PC or laptop USB port is used to power the radio. No external batteries or other
power source is required.
We want your feedback!
Please visit us at www.shortwavedaddy.com and tell us what you like about the
kit and how we can improve it. Your ideas can make future versions of the Shortwave
Daddy even better!
Take Adequate Safety Precautions
1. Make sure your work area is un-cluttered and well-lighted.
2. Make sure your work areas is well-ventilated while soldering. Do not breathe
soldering fumes. Use a fan to blow the fumes away from your face while you are
working or use appropriate safety equipment such as a fumes extractor or hood.
3. Wear eye-protection (safety glasses) at all times while working. No project is
worth the loss of your vision.
4. Ensure that your soldering iron is placed in a non-flammable stand when not in
use.
5. Wash your hands after you finish work for the day or before eating or drinking.

2
6. Quit working for the day if you become tired or inattentive.
7. Never connect the Ground Header or any connector on the Shortwave Daddy to
a mains ground (outlet plug ground) or mains line connection (outlet plug ―hot‖
terminal—110Volts) or the neutral terminal. Connection to a mains ground
or mains line connection or the neutral connection may result in a
serious electrical shock to the user which can cause serious bodily
injury or death.
Shortwave Daddy Features:
Kit Assembly:
Easy to assemble kit with no surface mount soldering skills required. All
components are ―through-hole‖. Assembly time is estimated at six to ten
hours for most enthusiasts.
Kit comes complete with everything necessary for assembly except for a
soldering iron, hand tools, solder, flux and clean-up supplies.
Connection to PC or Laptop:
Radio connects to PC or laptop through any open USB port with a standard
USB type ―B‖ to USB type ―A‖ printer cable and is powered solely by the USB
port. No batteries or other power source is required to power the radio.
The radio uses the sound system and speakers of the PC or laptop. No
external speakers or connections are required.
Radio broadcasts can be recorded utilizing software on the PC or laptop such
as Audacity. This allows for easy verification of reception reports for QSL
purposes and the archiving of broadcasts.
The radio does not require ANY drivers to be loaded when it is plugged
in to the USB port. Simply plug the radio in and enjoy.
Compatibility:
Radio is compatible with Windows XP, Vista, Windows 7 and most other
legacy versions of Windows
Radio is compatible with MAC (Apple) operating systems with the addition of
a free program ―LineIn‖ available at: http://www.rogueamoeba.com/freebies

3
Radio Specifications:
Worldwide AM Band 520kHz –1710kHz
Shortwave Band 2.3MHz –26.1 MHz
Worldwide FM Band 64MHz –108 MHz
Advanced AM/FM/Shortwave seek tuning
AM/FM/Shortwave digital tuning
Seven selectable AM/Shortwave channel filters (1kHz, 1.8 kHz, 2kHz, 2.5kHz
with gradual roll off, 3kHz, 4kHz, 6kHz)
RSSI (Received Signal Strength Indicator)
SNR (Signal to Noise Ratio Indicator)
RDS/RDBS processor displays FM call letters and category of station
received (Rock, Country, Classic Rock, etc.)
Multiple antenna connectors including a female BNC, 3.5mm jack and a
ground connection header allow the use of a variety of antennas including
telescoping, long wire, various aerials, and the use of ear buds for an FM
antenna. This allows for extensive DX (Long Distance Reception)
experimentation.
ESD (Electrostatic Discharge) protection built into circuit
10-key touchpad for easy entry of frequency and channel filters
Easy to read 4 x 20 character LCD display
Band selection and seek functions are chosen by four (4) tactile push-buttons
Reset push- button can be used to reset the circuit
Compact design ( 7‖ x 4‖) (177mm x 111mm)
Radio can easily be mounted in an enclosure if desired (enclosure not
included)

4
Radio IC:
Radio functionality is achieved through the use of the Silicon Labs SI4735
broadcast radio receiver IC (integrated circuit).
The SI4735 is a digital CMOS AM/FM/Shortwave radio receiver IC that
integrates the complete tuner function from antenna input to audio output.
USB Audio Codec:
The utilization of the PC or Laptop sound system without the requirement of
drivers to be installed is achieved through the Texas Instruments PCM2906C
stereo audio codec with USB interface.
The PCM2906C is a single-chip, USB, stereo audio codec with a USB-
compliant full-speed protocol controller. The USB protocol controller
requires no software code.
The PCM2906C is fully compliant with the USB 2.0 Specification
Microprocessor Control of Radio:
The Silicon Labs SI4735 IC is controlled utilizing a Microchip PIC18F2550
microprocessor
The existing preloaded software program can be modified or replaced by the
user with user’s own version of software. This allows users to experiment
and write their own program to take advantage of the capabilities of the
SI4735 IC
A new microprocessor program can be compiled and then downloaded to the
microprocessor using a Microchip Pickit 2 programmer and the in-circuit
Programming Header on the PCB without having to remove the PIC18F2550
(the LCD display does have to be unplugged to re-program the PIC)

5
Contents of Kit:
Quantity Description
1 Printed Circuit Board
3 .1uF Capacitor
3 .22uF Capacitor
1 .47uF Capacitor
1 .022uF Capacitor
6 1.0uF Capacitor
1 2.2uF Electrolytic Capacitor
2 15pF Capacitor
3 18pF Capacitor
2 22pF Capacitor
1 33pF Capacitor
2 330pF Capacitor
2 1800pF Capacitor
5 10uF Electrolytic Capacitor
3 1K Resistor
1 1 Meg Resistor
4 1.5K Resistor
1 2.2 Resistor
2 3.9K Resistor

6
Quantity Description
10 10K Resistor
4 12K Resistor
3 22K Resistor
2 22 Resistor
2 100 Resistor
1 LCD Contrast Resistor
1 .18uH Inductor
1 4.7uH Inductor
1 220uH Inductor
2 1N5819 Diode
1 12.000 MHz Crystal
1 20.000 MHz Crystal
1 32.768 KHz Crystal
1 3.5mm Antenna Jack
1 BNC Jack
1 USB Type B Connector
1 Ground Header (2 pin male)
1 Keypad Header (7 pin female)
1 LCD Header (16 pin female)
1 LCD Header (16 pin Male)
1 Programmer Header (6 pin male)
1 Dip Socket (28 pin)
1 3.3V Voltage Regulator
5 Tactile Momentary Push-button Switches

7
Quantity Description
1 LCD Display
1 10 Key Keypad
1 OPA2353 PCB sub-assembly
1 PCM2906 PCB sub-assembly
1 SI4735 PCB sub-assembly
1 PIC18F2550 microprocessor
4 14 Pin male Headers
2 4 Pin Male Headers
8 Mounting Hardware (spacers, sleeves, washers, 2-56
X 7/8‖ screws and nuts)

8
Assembly Instructions:
Tools and Materials Required for Assembly:
Soldering Iron
Solder (Radio Shack 62/36/2 Rosin-Core Solder .022 diameter, part
number 64-013 or equivalent)
Tip tinner and cleaner (helpful to clean soldering tip; Radio Shack part
number 64-020 or equivalent)
Flux (Radio Shack Rosin Soldering Flux, part number 64-022 or Chipquik
SMD291 Paste Flux or equivalent)
ESD Wrist Strap (Radio Shack part number 276-2397 or equivalent)
Wire cutters and small pliers
Isopropyl Alcohol and old toothbrush/Q-tips to clean flux off PCB
Compressed Air or Hair Dryer to dry PCB after cleaning
Small screw driver
Magnifying eye glasses (helpful to prevent eye strain)
General Instructions:
Take Adequate Safety Precautions
1. Make sure your work area is un-cluttered and well-lighted.
2. Make sure your work area is well-ventilated while soldering. Do not breathe
soldering fumes. Use a fan to blow the fumes away from your face while you are
working or use appropriate safety equipment such as a fumes extractor or hood.
3. Wear eye-protection (safety glasses) at all times while working. No project is
worth the loss of your vision.
4. Ensure that your soldering iron is placed in a non-flammable stand when not in
use.

9
5. Wash your hands after you finish work for the day or before eating or drinking.
6. Quit working for the day if you become tired or inattentive.
7. Never connect the Ground Header or any antenna connector or any part of the
Shortwave Daddy radio to a mains ground (outlet plug ground) or mains line
connection (outlet plug ―hot‖ terminal—110Volts) or the mains neutral terminal.
Connection to a mains ground or mains line connection or the mains
neutral connection may result in a serious electrical shock to the user
which can cause serious bodily injury or death.
Take a Leisurely Pace
One of the enjoyable aspects of building electronics projects is the leisurely pace that
can be taken to build a project. We highly recommend that you take this approach in
building the Shortwave Daddy. A much better final project will result if you spread the
work over several days or nights.
If you find yourself becoming tired or inattentive, quit for the night (or day).
Take Time to Learn How to Solder (If you need to)
Unfortunately, we can’t include a tutorial on how to solder. However, there are
many resources on the internet that will teach you everything you need to be able to
competently build the Shortwave Daddy.
We recommend that you Google ―How to solder through-hole components‖ and also
study the many YouTube videos on through-hole soldering.
Also, we further recommend that you practice your soldering skills on perforated
copper clad board prototyping board (available at Radio Shack and other electronics
retailers) before attempting to build this kit.

10
Step 1:
1. Without soldering any components, insert all of the resistors, capacitors,
inductors and diodes into their locations on the PCB in accordance with the
values printed on the PCB next to the number of the component. (Figure 1)
When inserting each component, make sure that the component is pulled
down as close to the surface of the PCB as possible. In other words, there
should be as little space as possible between each component and the surface
of the PCB. As you insert each component, make an angle bend on each lead
on the bottom of the PCB so that the component will not fall out and will
remain in position until it is soldered. (Figure 2)
All other capacitors, resistors and inductors can be inserted without
regard to polarity orientation.
2. After making certain that all components are in their proper place, turn the
PCB over and apply a small amount of flux on each solder hole that has a lead
protruding through it. (Figure 4) It is important that you can see the flux on
each solder joint to make sure enough has been applied.
Special Note!
When inserting capacitors and diodes, there are two types of components that
must be inserted in a particular orientation on the PCB: These are the electrolytic
capacitors, C4, C12, C17, C21, C22 and C27; and the two diodes, D1 and D2.
Electrolytic capacitors have polarity. This means that the longer lead is ―positive‖
and the shorter lead is ―negative‖. (Figure 3) This is also marked on the
electrolytic capacitor by an arrow running along the side of the capacitor on the
side that is negative. When inserting and soldering the capacitor onto the PCB,
the negative, shorter lead must be inserted into the round pad marked ―-―. The
positive, longer lead must be inserted into the square pad marked ―+‖.
Diodes D1 and D2 have to be inserted in a particular way too. One end of the
diode body is marked with a stripe. This is the ―cathode‖ end and must be
inserted onto the PCB in accordance with the stripped end of the diode printed
on the PCB. The other end of the diode is the ―anode‖ end and is inserted on the
end that is not marked with a stripe.

11
Figure 1
Figure 2

12
Figure 3
Figure 4

13
3. Starting from one end of the reverse side of the PCB, solder all of the
capacitors, resistors, diodes and inductors.
4. Using a wire cutter, trim the excess length of the components leads. Be
careful not to cut the solder joint. (Figure 5) It is acceptable for the
residual component lead to protrude 1mm - 3mm from the solder joint.
(Figure 6)
Figure 5
Figure 6

14
Step 2:
1. Insert the 20.000 MHz, 12.000 MHz and 32.768 KHz crystals (XTAL) and apply
a small amount of flux on the bottom solder hole where the leads protrude. Then,
solder the 20.000 MHz, 12.000 MHz and 32.768 KHz crystals and trim the
excess length of the crystal leads on the bottom of the PCB.
2. Insert the 3.3V voltage regulator. The regulator is oriented with the black
part of the regulator body facing the USB Type B connector. See the
top left corner of the PCB in Figure 24 below. Apply a small amount of
flux on the bottom solder hole where the leads protrude. Then, solder the 3.3V
voltage regulator and trim the excess length of the regulator’s leads on the bottom
of the PCB.
3. Insert the USB Type B connector and apply a small amount of flux on the bottom
solder hole where the four (4) pins and the two (2) larger posts protrudes. Take
care in inserting the four smaller pins into the PCB. Make sure that the pins are
not bent. Then, solder the USB Type B connector.
4. Insert the BNC connector and apply a small amount of flux on the bottom solder
hole where the two (2) mounting posts and the two (2) pins protrude. Then,
solder the BNC Connector.
5. Insert the 3.5mm antenna jack and apply a small amount of flux on the bottom
solder hole where the leads and mounting posts protrude. Then, solder the
3.5mm antenna jack.
6. Note in Figure 7 how all of the solder joints of the BNC connector, USB type B
connector and the 3.5mm antenna jack are completely filled in with solder.

15
Figure 7
7. Insert the six pin male Programming Header, apply a small amount of flux on the
bottom solder holes where the leads protrude and solder the Programming
Header.
8. Insert the two pin male Ground Header, apply a small amount of flux on the
bottom solder holes where the leads protrude and solder the Ground Header.
9. Insert the seven pin female Keypad Header, apply a small amount of flux on the
bottom solder holes where the leads protrude and solder the Keypad Header.
Make sure that the Keypad Header is aligned perpendicular to the
PCB, i.e. not cocked to one side.
10. Insert the sixteen pin female LCD header, apply a small amount of flux on the
bottom solder holes where the leads protrude and solder the LCD Header. Make
sure that the LCD Header is aligned perpendicular to the PCB, i.e. not
cocked to one side.
11. Insert the 28 pin DIP socket for the PIC18F2550, apply a small amount of flux on
the bottom solder holes where the leads protrude and solder the DIP socket.
(Figure8) The notch on the end of the DIP socket should be oriented to the right.
Do not insert the PIC18F2550 microprocessor IC at this time.

16
Figure 8
Step 3:
1. The next step requires handling and soldering of the SI4735, PCM2906C and
OPA2353 PCB sub-assemblies.
Special Note!
The SI4735, PCM2906C and OPA2353 PCB sub-assemblies are susceptible to
damage from ESD (electrostatic discharge). ESD is more commonly known as
static electricity.
While handling and soldering these sub-assemblies, you should ground yourself
using an ESD wrist strap.
In addition, particular care should be taken on days when the humidity is low.
As a rule of thumb, if you are receiving a static electricity shock when you touch
doorknobs and other metal objects, you should exercise additional care when
handling the PCB sub-assemblies or better yet, wait for another day when the
humidity level is higher.
The PCB has ESD protection built in through the inclusion of surface mounted
ESD suppressors which will help protect the circuit once assembly is complete.

17
2. Although not absolutely necessary, the use of a breadboard makes soldering the
male headers to the PCB assemblies much easier. If you have a breadboard,
insert the 14 pin male headers on the breadboard such that the PCB sub-
assemblies can be inserted on top of the male headers. (Figure 9) After applying
a little flux on each pin, solder the SI4735 and PCM2906C PCB sub-assemblies
on two (2) 14 pin male headers and solder the OPA2353 PCB sub-assembly on
two (2) 4 pin male headers. (Figures 10 and 11)
Figure 9
Figure 10