Telstar Electronics SkyWave DX600 User manual

RF Linear Amplifier PCB Assembly Manual
SkyWave DX600 Revision-B
Last Revised - 2/5/2021 9:10 AM
Page 1 of 57
www.telstar-electronics.com

RF Linear Amplifier PCB Assembly Manual
SkyWave DX600 Revision-B
Last Revised - 2/5/2021 9:10 AM
Page 2 of 57
www.telstar-electronics.com
Table of Contents
Introduction ......................................................................................................................................3
Parts List...........................................................................................................................................4
Before You Start ................................................................................................................................6
Assembly Instructions.........................................................................................................................7
Step #1 - Spacer (SPACER1, SPACER2, SPACER3, SPACER4)................................................................7
Step #2 - Fixed Resistor (R1-R28).....................................................................................................9
Step #3 - Variable Resistor (VR1).................................................................................................... 11
Step #4 –Diode (D1 through D5) ...................................................................................................13
Step #5 –Dual Operational Amplifier (U2) .......................................................................................15
Step #6 - Fuse Holder (F1)............................................................................................................. 17
Step #7 –Input Transformer (T1) ................................................................................................... 19
Step #8 –Output Transformer (T2) ................................................................................................. 22
Step #9 - Electrolytic Capacitor (C1, C2, C7, C8,) .............................................................................24
Step #10 - Ceramic Capacitor (C3, C4, C5, C6, C9, C10, C11, C12, C13, C14, C15, C16, C18) ............... 26
Step #11 –Mica Capacitor (C17, C19, C20, C21) .............................................................................. 28
Step #12 - Relay (RLY1) ................................................................................................................ 30
Step #13 - Field Effect Transistor (Q2, Q3)....................................................................................... 32
Step #14 –Bipolar Power Transistor (Q5) ........................................................................................ 34
Step #15 - Voltage Regulator (U1) .................................................................................................. 36
Step #16 –Field Effect Power Transistor (Q1)...................................................................................38
Step #17 –Field Effect RF Power Transistor (Q4, Q6) ........................................................................40
Step #18 - Toroid RF Choke (L1)..................................................................................................... 42
Step #19 - Heat Sink Marking, Drilling, and Tapping.......................................................................... 44
Step #20 - Switch, LED, and DC Power Wiring (ON/OFF, PWR LED, SSB DELAY, XMIT LED, +48V) ..........45
Step #21 –Coaxial Cable (RF IN, RF OUT) .......................................................................................48
Step #22 - PCB Mounting to Heat Sink............................................................................................. 50
Step #23 - Bias Adjustment............................................................................................................ 53
Step #24 –Amplifier Operation .......................................................................................................54
Troubleshooting ............................................................................................................................... 55
Specifications .................................................................................................................................. 56
RF Performance ............................................................................................................................... 57

RF Linear Amplifier PCB Assembly Manual
SkyWave DX600 Revision-B
Last Revised - 2/5/2021 9:10 AM
Page 3 of 57
www.telstar-electronics.com
Introduction
Congratulations on your purchase of the new SkyWave DX600 RF Amplifier PCB. This PCB is a result of
quality engineering to provide high performance and reliability.
Listed below are some of the key features:
High Reliability Design
+48VDC Operation
All Mode (AM, FM, SSB)
26-30MHz Frequency Coverage
LDMOS MRF300 Push-Pull Configuration
Class-AB Temperature-Tracking Bias
High Output Power / Low Harmonic Content
Carrier Operated or Manual
*
Transmit / Receive Switching
Continuous Reverse Voltage Protection without Damage to Amplifier or Fuse
Fuse Protected
Selectable SSB Delay
Power and Transmit Indicators
Low Stand-By Power Consumption
Premium Quality Printed Circuit Board & Components
We have developed a logical step-by-step procedure that we hope will make your assembling experience
enjoyable & efficient…
*
Contact Telstar Electronics for details on using the “manual switching” feature.

RF Linear Amplifier PCB Assembly Manual
SkyWave DX600 Revision-B
Last Revised - 2/5/2021 9:10 AM
Page 4 of 57
www.telstar-electronics.com
Parts List
Quantity
Description
Reference
24”
Cable, Coaxial, RG174A/U Type, 52-Ohm
RF IN, RF OUT
1
Capacitor, Ceramic, 0.01uF, 100V, 20%, Z5U, Radial (LS=0.197")
C6
1
Capacitor, Ceramic, 0.1uF, 100V, 10%, X7R, Radial (LS=0.197")
C5
10
Capacitor, Ceramic, 0.1uF, 50V, 10%, X7R, Radial (LS=0.197")
C3, C4, C9, C10, C11,
C12, C13, C14, C15,
C16
1
Capacitor, Ceramic, 1000pF, 500V, 10%, X7R, Radial (LS=0.197")
C18
2
Capacitor, Dipped Mica, 330pF, 1000V, 5%, Radial (LS=0.232")
C19, C20
1
Capacitor, Dipped Mica, 47pF, 500V, 5%, Radial (LS=0.232")
C21
1
Capacitor, Electrolytic, 100uF, 25V, 20%, Radial
C8
1
Capacitor, Electrolytic, 10uF, 25V, 20%, Radial
C1
1
Capacitor, Electrolytic, 10uF, 63V, 20%, Radial
C2
1
Capacitor, Electrolytic, 1uF, 50V, 20%, Radial
C7
1
Capacitor, Metal Clad Mica, 330pF, 350V, 5%, SM
C17
2
Diode, High Speed Signal, 1N914, DO35, Axial
D1, D2
1
Diode, Zener, 10V, 0.5W, DO-35
D3
1
Fuse Holder, ATC Type, TH
F1
1
Fuse, ATC, 25A
F1
1
IC, Operational Amplifier, LM2904, Dual, DIP-8
U2
2
Insulator, Phase Change, TO-220
Q1, U1
1
PCB, SkyWave DX600 Revision-B
N/A
1
Potentiometer, 1K, 0.1W, Vertical Adjust, TH
VR1
1
Regulator, Voltage, Adjust, 60V, 1.5A, TO-220
U1
1
Relay, DPDT, 12V, 8A, DIP
RLY1
1
Resistor, Carbon Film, 1.2K, 0.25W, 5%, Axial
R16
2
Resistor, Carbon Film, 100, 0.25W, 5%, Axial
R5, R15
3
Resistor, Metal Film, 10K, 0.25W, 1%, Axial
R2, R8, R12
5
Resistor, Carbon Film, 10K, 0.25W, 5%, Axial
R6, R9, R17, R27, R28
5
Resistor, Carbon Film, 1K, 0.25W, 5%, Axial
R7, R14, R24, R25,
R26
1
Resistor, Metal Film, 3.3K, 0.25W, 1%, Axial
R3
2
Resistor, Carbon Film, 4.7K, 0.25W, 5%, Axial
R19, R20
1
Resistor, Carbon Film, 47K, 0.25W, 5%, Axial
R10
1
Resistor, Carbon Film, 5.6K, 0.25W, 5%, Axial
R4
1
Resistor, Carbon Film, 560, 0.25W, 5%, Axial
R18
1
Resistor, Carbon Film, 8.2K, 0.25W, 5%, Axial
R11
2
Resistor, Carbon Film, 820, 0.25W, 5%, Axial
R1, R13
1
Resistor, Metal Oxide, 24, 1W, 5%, Axial
R23

RF Linear Amplifier PCB Assembly Manual
SkyWave DX600 Revision-B
Last Revised - 2/5/2021 9:10 AM
Page 5 of 57
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Quantity
Description
Reference
1
Resistor, Metal Oxide, 33, 3W, 5%, Axial
R22
1
Resistor, Metal Oxide, 27, 3W, 5%, Axial
R21
3
Screw, Machine, Philips Pan Head, #4-40, 1/4", Stainless Steel
U1, Q1, Q5
4
Screw, Machine, Philips Pan Head, #4-40, 5/16", Stainless Steel
BOARD TO SINK
ATTACHMENT
2
Screw, Machine, Philips Pan Head, #4-40, 3/8", Stainless Steel
Q4, Q6
4
Spacer, Round, 0.250"D, 0.125"ID, 0.100" Thick
SPACER1, SPACER2,
SPACER3, SPACER4
1
Thermal Compound, 8.5W/mk, 0.5-gram
Q4, Q6
1
Toroid, 0.825"OD, 0.520"ID, 0.250"W, #43 Material
L1
1
Transformer, RF, 1/2" Length, #61 Material
T1
1
Transformer, RF, 2" Length, #61 Material
T2
1
Transistor, FET, N-Channel, MRF300AN, 250MHz, 50V, 300W, TO-247
Q4
1
Transistor, FET, N-Channel, MRF300BN, 250MHz, 50V, 300W, TO-247
Q6
1
Transistor, FET, N-Channel, 2N7000, TO-92
Q3
1
Transistor, FET, P-Channel, SUP70101EL, 100V, 120A, TO-220
Q1
1
Transistor, FET, P-Channel, TP0606, TO-92
Q2
1
Transistor, NPN, 3055, 60V, 10A, TO-220
Q5
2
TVS, Uni-Directional, DO-15
D4, D5
1
Washer, Locking, Split-Ring, #4, Stainless Steel
Q4, Q6
3
Washer, Shoulder, Black Plastic Insulating, TO-220
Q1, U1, Q5
2
Washer, Flat, #4, Stainless Steel
Q4, Q6
18”
Wire, #16, Teflon, Orange, Stranded
L1
18”
Wire, #16, Teflon, Orange, Stranded
T2
18”
Wire, #16, Teflon, Blue, Stranded
L1
24”
Wire, Zip Cord, #12, Red/Black
N/A
24”
Wire, #22, Teflon, Blue, Stranded
PWR LED, XMIT LED
24”
Wire, #22, Teflon, Yellow, Stranded
PWR LED, XMIT LED
24”
Wire, #22, Teflon, Green, Stranded
S1 (ON/OFF)
24”
Wire, #22, Teflon, Purple, Stranded
S2 (SSB DELAY)

RF Linear Amplifier PCB Assembly Manual
SkyWave DX600 Revision-B
Last Revised - 2/5/2021 9:10 AM
Page 6 of 57
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Before You Start
This kit assumes an understanding of electronics, soldering, and operation of hand tools. In addition to
basic hand tools, the following items will be required for proper assembly.
PCB Assembly:
Soldering Iron
†
Electronic Solder
‡
7/64” Drill Bit (Installation of SPACER1, SPACER2, SPACER3, SPACER4)
1/4” Drill Bit (Lead-Forming of Q1, U1, Q5)
3/8” Drill Bit (Lead-Forming of Q4, Q6)
Scrap Piece of Wood (Installation of SPACER1, SPACER2, SPACER3, SPACER4)
Needle-Nose Pliers
Diagonal Cutting Pliers
Wire Stripper
PCB Assembly to Heat Sink:
Heat Sink (See Page 49 for Suggested Sources)
Power Drill
#4-40 Tap (Mounting Holes in Heat Sink)
#42 Drill Bit (Mounting Holes in Heat Sink)
Masking Tape
Transfer Punch
Bias Adjustment:
48VDC Power Supply
Ammeter (Capable of 400mA)
Several Jumper Wires w/ Alligator Clips
Please take a few minutes before you begin assembling to review the entire assembly &
adjustment procedure.
A few things to remember during the assembly:
Several components in this design are sensitive to static electricity. Precautions should be taken to
avoid static buildup during assembly by using a grounded workstation mat and wrist band.
References are made to the top and bottom side of the PCB. The top side contains the printed
reference designators and component outlines. Most components are inserted from top and
soldered from the bottom. Follow the specific instructions given in each assembly step.
If at any time, you are unsure how to perform an assembly step or have a question, email us for
assistance at [e-mail]
†
35W-65W recommended. Temperature controlled soldering equipment is always preferred.
‡
Solder recommendation is Kester 331. This solder has a flux that can be washed off with warm tap-water.

RF Linear Amplifier PCB Assembly Manual
SkyWave DX600 Revision-B
Last Revised - 2/5/2021 9:10 AM
Page 7 of 57
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Assembly Instructions
Step #1 - Spacer (SPACER1, SPACER2, SPACER3, SPACER4)
Locate the four positions on the bottom of the PCB where the spacers will be attached. (Figure 1)
Drill a 7/64” hole into a scrap piece of wood.
With the aid of the 7/64” drill bit, position the drill bit shank
§
through a spacer and through the
hole in the PCB into the piece of wood below. The drill bit will aid in centering the spacer on the
PCB hole during the soldering process. (Figure 2)
IMPORTANT - MAKE CERTAIN THE SPACERS ARE FLAT AGAINST THE BOTTOM SIDE OF THE PCB
BEFORE SOLDERING INTO POSITION. USE A MINIMAL AMOUNT OF SOLDER
MAKING CERTAIN NOT TO OBSTRUCT THE CENTER OF THE SPACER.
Solder spacers into position.
Figure 1
§
The drill bit shank is the solid portion that does not contain the spiral cutting flutes.

RF Linear Amplifier PCB Assembly Manual
SkyWave DX600 Revision-B
Last Revised - 2/5/2021 9:10 AM
Page 8 of 57
www.telstar-electronics.com
Details of spacer installations.
Figure 2

RF Linear Amplifier PCB Assembly Manual
SkyWave DX600 Revision-B
Last Revised - 2/5/2021 9:10 AM
Page 9 of 57
www.telstar-electronics.com
Step #2 - Fixed Resistor (R1-R28)
IMPORTANT - FIXED RESISTORS HAVE NO POLARITY AND CAN BE INSTALLED IN EITHER
DIRECTION. MAKE CERTAIN THE RESISTORS ARE FULLY SEATED IN THE PCB
BEFORE SOLDERING.
Install resistors into the PCB at the designated locations. (Figure 3)
Solder resistors into position.
Cut off the excess lead length.
Figure 3

RF Linear Amplifier PCB Assembly Manual
SkyWave DX600 Revision-B
Last Revised - 2/5/2021 9:10 AM
Page 10 of 57
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Details of fixed resistor installations.
Figure 4

RF Linear Amplifier PCB Assembly Manual
SkyWave DX600 Revision-B
Last Revised - 2/5/2021 9:10 AM
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Step #3 - Variable Resistor (VR1)
IMPORTANT - VARIABLE RESISTORS ARE POLARIZED AND MUST BE INSTALLED IN THE PROPER
ORIENTATION. MAKE CERTAIN THE VARIABLE RESISTOR IS FULLY SEATED IN
THE PCB BEFORE SOLDERING.
Insert VR1 into the PCB at designated location. (Figure 5)
Solder VR1 into position.
Cut off the excess lead length.
Figure 5

RF Linear Amplifier PCB Assembly Manual
SkyWave DX600 Revision-B
Last Revised - 2/5/2021 9:10 AM
Page 12 of 57
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Details of VR1 installation.
Figure 6

RF Linear Amplifier PCB Assembly Manual
SkyWave DX600 Revision-B
Last Revised - 2/5/2021 9:10 AM
Page 13 of 57
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Step #4 –Diode (D1 through D5)
IMPORTANT - DIODES ARE POLARIZED AND MUST BE INSTALLED IN THE PROPER
ORIENTATION. THE WHITE BAND INDICATED ON THE PCB INDICATES THE
CATHODE. THIS POLARITY BAND IS ALSO PRESENT ON THE DIODE ITSELF. MAKE
CERTAIN THE DIODES ARE FULLY SEATED IN THE PCB BEFORE SOLDERING.
Insert diodes into the PCB at the designated locations. (Figure 7)
Solder diodes into position.
Cut off the excess lead length.
Figure 7

RF Linear Amplifier PCB Assembly Manual
SkyWave DX600 Revision-B
Last Revised - 2/5/2021 9:10 AM
Page 14 of 57
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Details of diode installations.
Figure 8
Figure 9
Figure 10

RF Linear Amplifier PCB Assembly Manual
SkyWave DX600 Revision-B
Last Revised - 2/5/2021 9:10 AM
Page 15 of 57
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Step #5 –Dual Operational Amplifier (U2)
IMPORTANT –INTEGRATED CIRCUITS ARE POLARIZED AND MUST BE INSTALLED IN THE
PROPER ORIENTATION. USE THE OUTLINE ON THE PCB AS A GUIDE TO INSTALL
THE INTEGRATED CIRCUIT WITH THE NOTCHED SIDE AS SHOWN.
Insert U2 into the PCB at the designated location. (Figure 11)
Solder U2 into position.
Cut off the excess lead length.
Figure 11

RF Linear Amplifier PCB Assembly Manual
SkyWave DX600 Revision-B
Last Revised - 2/5/2021 9:10 AM
Page 16 of 57
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Details of U2 installation.
Figure 12

RF Linear Amplifier PCB Assembly Manual
SkyWave DX600 Revision-B
Last Revised - 2/5/2021 9:10 AM
Page 17 of 57
www.telstar-electronics.com
Step #6 - Fuse Holder (F1)
IMPORTANT - FUSE HOLDERS ARE NOT POLARIZED AND CAN BE INSTALLED IN EITHER
DIRECTION. MAKE CERTAIN THE FUSE HOLDER IS FULLY SEATED IN THE PCB
BEFORE SOLDERING.
Insert F1 (fuse holder) into the PCB at the designated location. (Figure 13)
Solder F1 (fuse holder) into position.
Cut off the excess lead length.
Figure 13

RF Linear Amplifier PCB Assembly Manual
SkyWave DX600 Revision-B
Last Revised - 2/5/2021 9:10 AM
Page 18 of 57
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Details of F1 (fuse holder) installation.
Figure 14

RF Linear Amplifier PCB Assembly Manual
SkyWave DX600 Revision-B
Last Revised - 2/5/2021 9:10 AM
Page 19 of 57
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Step #7 –Input Transformer (T1)
IMPORTANT - TRANSFORMERS ARE POLARIZED AND MUST BE INSTALLED IN THE PROPER
ORIENTATION.
Position T1 on the PCB noting the proper transformer polarity. (Figure 15)
Solder all three mounting pads on T1 for proper attachment to PCB. (Figure 15)
Strip the insulation from one end of the 6” orange #22 wire. Solder the stripped end to one
PRIMARY pad. (Figure 15)
Wind the unsoldered end of the wire four complete turns through the tubes of the transformer in a
loop type fashion.
Cut and strip the wire, making it just long enough to reach to the remaining PRIMARY pad. (Figure
15)
Solder the wire to the remaining PRIMARY pad. (Figure 15)
Strip the insulation from one end of the 12” orange #22 wire. Solder the stripped end to one
SECONDARY pad. (Figure 15)
Wind the unsoldered end of the wire two complete turns through the tubes of the transformer in a
loop type fashion.
Cut and strip the wire, making it just long enough to reach to the remaining SECONDARY pad.
(Figure 15)
Solder the wire to the remaining SECONDARY pad. (Figure 15)

RF Linear Amplifier PCB Assembly Manual
SkyWave DX600 Revision-B
Last Revised - 2/5/2021 9:10 AM
Page 20 of 57
www.telstar-electronics.com
Figure 15
SECONDARY
PRIMARY
SECONDARY
MOUNTING
PRIMARY