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JOVE RJ1.1 Assembly Manual

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JOVE
RJ1.1 Receiver Kit
Assembly Manual

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  • Page 1 JOVE RJ1.1 Receiver Kit Assembly Manual...
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  • Page 3 JOVE RJ1.1 Receiver Kit Assembly Manual March 1999 Receiver Kit and Manual developed for NASA JOVE Project Richard S. Flagg, RF Associates 1721-I Young Street Honolulu, Hawaii 96826 (808) 947-2546 rf@aloha.net...
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  • Page 5: Table Of Contents

    Contents Theory of Operation ..................1 Components ....................2 Circuit Diagrams..................... 7 Tools ......................12 Soldering ....................... 13 The Work Area ....................13 Identifying Parts ................... 13 Assembling the Enclosure ................18 Wiring the PC Board ..................21 Assembly of the PC Board and Enclosure............ 24 Testing and Alignment ..................
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  • Page 7: Theory Of Operation

    Radio JOVE You are about to embark on building a short-wave receiver which will pick up radio signals from the planet Jupiter and also from the Sun. This receiver contains over 100 electronic components and pieces of hardware. Fabrica- tion will include the handling of small, delicate, electronic parts, most of which will be mounted and soldered on a printed circuit (PC) board.
  • Page 8 antenna terminals. Signals from the antenna are delivered to the antenna terminals of the receiver by a coaxial transmission line. RF Bandpass Filter and Preamplifier Signals from the antenna are filtered to reject strong out-of-band interference and are then amplified using a junction field effect transistor (JFET). This transistor and its associated circuitry provide additional filtering and amplify incoming signals by a factor of 10.
  • Page 9 LO / Mixer NE602 JOVE RJ1.1 Tuning Jupiter Receiver Block Diagram (20.1 MHz +/- 150 kHz) 5 Pole Low Pass Filter Audio Preamp LM387 Volume Audio Audio Audio Out 1 Out 2 External Amplified Speaker Figure 1. JOVE receiver block diagram...

  • Page 10: Components

    OMPONENTS The JOVE receiver uses many different electronic components (Figure 2) including wires, resistors, capacitors, inductors, diodes, transistors and inte- grated circuits. Each performs different functions.
  • Page 11 Resistors A - Variable Resistor (10K ohm Tuning Control) B - Fixed Resistor (10K ohm, 1/4 watt) Capacitors D - 10 pF, Disc Ceramic A - 1 µF, Metal Polyester E - 0.1 µF, Dipped Ceramic B - 330 µF, 25 vdc, Electrolytic F - 10 µF, 35vdc,Tantalum C - 0.1 µF, Metal Film G - 4-40 pF, Variable Capacitor...
  • Page 12 Solid State Devices A - Diode 1N4001 B - Diode 1N914 C - Transistor 2N-3906 D - Varactor Diode MV-209 E - Integrated Circuit SA-602 F - Oscillator Module Connectors and Hardware C - 2.1 mm Power Connector A - Solder Lug D - 3.5 mm Stereo Audio Jack B - Spacer E - Chassis Coaxial Connector...

  • Page 13: Circuit Diagrams

    (ICs), each with 8 pins. The orientation of the IC in the circuit is important as each pin has a different use. IRCUIT IAGRAMS We have already seen a block diagram of the JOVE receiver, which shows the radio as a group of functional blocks connected together. While this type...
  • Page 14 of diagram does not show individual components like resistors and capaci- tors, it is useful in understanding signal flow and the various functions per- formed within the radio. The next level of detail is the schematic diagram. A schematic is used to represent the wiring connections between all of the components which make up a circuit.

  • Page 18: Tools

    An exploded view (Figure 6) shows the PC board and the enclosure, with connectors and controls mounted on the front and rear panels of the box. The parts list (Table 1) identifies each component by its value and part num- ber.

  • Page 19: Soldering

    DENTIFYING ARTS Go through the parts which you have received and check them off against the list in Table 1 (JOVE Parts List). With the aid of Figure 2, make abso- lutely sure you have identified each part correctly.
  • Page 20 Table 1 JOVE Receiver Parts List Actual marking found on component is shown in parentheses ( ). Two columns of check-off boxes are provided: use one for parts identification, and the other, for installation. CAPACITORS Note polarity on all electrolytic capacitors...
  • Page 21 0.1 µF, dipped ceramic (.1K) 10 pF, disc ceramic (100) 10 µF, 25 vdc, electrolytic 100 µF, 25 vdc, electrolytic 0.1 µF, dipped ceramic (.1K) 0.1 µF, dipped ceramic (.1K) 0.1 µF, dipped ceramic (.1K) 0.1 µF, dipped ceramic (.1K) 10 µF, 25 vdc, electrolytic DIODES Note Polarity...
  • Page 22 Table 1, continued 2.2 Kohm (red, red, red) 100 Kohm (brown, black, yellow) 220 ohm (red, red, brown) 1.5 Kohm (brown, green, red) 1 Kohm (brown, black, red) 27 Kohm (red, violet, orange) 100 Kohm (brown, black, yellow) 10 Kohm potentiometer /switch 10 Kohm (brown, black, orange) 1.5 Kohm (brown, green, red) 27 Kohm (red, violet, orange)
  • Page 23 OTHER MATERIAL Allen Wrench 1/16 inch for knobs Sandpaper Tuning tool White - for tuning inductors L4, L5 Plastic screw driver For tuning capacitors C2 and C6...

  • Page 24: Assembling The Enclosure

    SSEMBLING THE NCLOSURE The receiver enclosure comprises 6 aluminum plates, 4 lengths of extruded channel, and 8 small Phillips screws. The front, rear, and bottom panels have been pre-punched with holes for controls, connectors and mounting screws. The exploded view (Figure 6) shows the proper orientation of these panels.
  • Page 25 Preparing the enclosure panels: Peel the thin plastic film coating from each panel. Using the supplied sandpaper (or a fine file), remove the sharp edges and corners from each panel. Sand the edges only, being careful not to mar or scratch the panel surface. Applying the front and rear panel decals: Thoroughly clean the front and rear panels to remove any dirt or ®...
  • Page 26 When viewed from the front side (where the decal is to be applied), the holes must be closer to the lower edge than the top edge. JOVE RECEIVER PWR / VOLUME TUNING Figure 8.

  • Page 27: Wiring The Pc Board

    This completes preparation of the enclosure. Set the panels aside until the wiring of the PC board is complete. PC B IRING THE OARD The PC board should be populated according to Figure 5. Install the larger parts first, leaving the small, delicate devices until last. This assembly order will give you a chance to sharpen your soldering skills before getting to the transistors and integrated circuits which may be damaged by excess heat.
  • Page 28 When you are cutting leads, shield the cut with your hand, or aim the work down, to prevent the cut wire from flying into someone’s face. Be very careful to use the correct component values. It’s a lot easier to double check before soldering, than it is to have to unsolder and replace a part.
  • Page 29 Install all remaining capacitors. Note polarity of C27, C32, C39. Install all inductors, L1 - L7. See Figure 2 for parts identification. Install all transistors, Q1-Q3. Note the orientation. Install diodes D1, D2, D3, VD1, ZD1, ZD2. Note the orientation. Install all integrated circuits IC1-IC3, and OSC1.

  • Page 30: Assembly Of The Pc Board And Enclosure

    PC B SSEMBLY OF THE OARD AND NCLOSURE Mount the PC board to the front panel. Simply slip the potentiometer shafts through the front panel holes and apply the lockwashers and nuts. Do not tighten nuts. Form the leads of LED1 such that the LED fits into the front panel hole and the LED leads extend through the PC board mounting holes.
  • Page 31 Prepare a 2 inch red wire and a 2 inch black wire by stripping1/4 inch of insulation from both ends of each wire. While holding the wire with the needle nose pliers, strip the insulation with the diagonal cutters or a knife, taking care not to nick the wires.
  • Page 32 Figure 12. Rear panel wiring Be sure that the power connector is installed as shown in Figures 9 and 12. Looking at the connector from the PC board side of the back panel, there should be one solder lug at 9 o’clock, one at 12 o’clock, and the third lug at the 3 o’clock position.
  • Page 33 Black Black Black +12 vdc Figure 13. Rear panel power jack (J1) wiring detail Install the spacers (Figure 14) below the rear corners of the PC board using 1/4 inch long 4-40 screws and lock washers. Remove the right side panel, slide in the bottom panel, and attach it to the spacers with 1/4 inch 4-40 screws and lock washers.

  • Page 34: Testing And Alignment

    JOVE RECEIVER PWR / VOLUME TUNING Figure 15. JOVE receiver front panel with knobs Install the two knobs. Align them on the shaft so that when the control is turned full counterclockwise, the index mark is near the 7 o’clock position (Figure 15). Once the knob is tightened down,...
  • Page 35 (Radio Shack 277-1008C or equiva- lent) to the receiver audio output (J3 or J4). These jacks accept 3.5 mm (1/8 inch) monaural or stereo plugs. Connect the JOVE re- ceiver to the 12 volt power source as shown in Figure 17.
  • Page 36 Turn the JOVE receiver ON. The LED should light. Set the JOVE volume control to the 12 o’clock position. Allow the receiver to “warm-up” for several minutes. [NOTE: troubleshooting procedures are included at the end of the manual.
  • Page 37 500 to 2000 Hz. Use procedure A as a method to use in tuning up your JOVE receiver. Procedures B-D are optional tuning methods.
  • Page 38 Use an oscilloscope to observe the audio output of the receiver. Use both audio outputs (J3 and J4) of the receiver, feeding one signal to the amplified speaker or headphones, and the other, to the oscilloscope vertical input. Listen to the tone and carefully adjust the tuning knob to keep the pitch constant.
  • Page 39 best response possible. Also make sure that the receiver stays tuned to the test oscillator during the alignment. The receiver may drift slightly in frequency just after turn-on, so you need to wait several minutes after turn-on, until the pitch of the output tone is steady, before doing the alignment.

  • Page 40: Troubleshooting

    The JOVE direct conversion receiver design does not allow clear reception of amplitude modulated (AM) stations like WWV, so the voice will probably be garbled, unless you tune very precisely. The receiver does work well on single sideband (SSB) signals and code (CW).
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  • Page 45: Appendix A Soldering Techniques

    Appendix A Soldering Techniques Use a 15-25 watt soldering iron and 60/40 rosin core solder, 0.05" diam. Lead Circuit Trace Wipe the hot iron tip on a wet sponge and tin the tip (melt a small amount of solder on the tip). This step is not necessary prior to every solder joint but should be done whenever PC Board...
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  • Page 47: Appendix B: Resistor Color Code

    Appendix B Resistor Color Code A B C D First significant figure of resistance in ohms Second significant figure of resistance in ohms Decimal multiplier Resistance tolerance in percent Color Value Multiplier Tolerance Black Brown 10 2 10 3 Orange 10 4 Yellow 10 5...

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