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Summary of Contents for Four State QRP Group Cyclone 40
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Page 1: Instruction Manual
Instruction Manual Cyclone 40 40 Meter Transceiver Revision A.0 Copyright 2013 David Cripe NM0S & Four State QRP Group Updated 2/11/14... - Page 2 Introduction Thank you for purchasing a Cyclone 40 transceiver kit. We hope you will enjoy building it and have many QSOs with it to the 40-Meter band. This kit is comprised of high-quality components, a silkscreened, solder-masked, double- sided PC board, and pre-drilled, silkscreened enclosure.
- Page 3 The transmit power amplifier utilizes power amplifier transistors Q3 and Q4 in push-pull Class-E mode to generate 4W nominally from 12v, at 85% efficiency. When the transmitter is keyed, transistor Q7 is driven on, applying DC power to the PA drain choke L4, allowing Q3 and Q4 to make power. When in the receive mode, the PTO output is fed to U2, pins 15 and 17, buffering and amplifying the sine-wave oscillator signal to create a logic-level square wave signal.
- Page 4 When the transmitter is keyed, the mute switch transistor Q15 is closed, and limits the passage of audio transients through the audio amplifier. A PIC microcontroller U4 serves both as a frequency counter, as well as the sidetone oscillator. Pressing the FREQ counter at the side of the enclosure activates the counter, which counts the VFO frequency, and sends four digits of the count (excluding the megahertz digit) as CW characters to the headphone jack.
- Page 5 Soldering is not hard if the proper procedure is followed. The soldering iron is to be used to heat up the PC pad and component lead, and the solder applied to the pad, where it melts and flows into the hole. Do not melt the solder onto the tip of the iron and then attempt to dab it onto the joint –...
- Page 6 Ceramic Monolythic Ceramic Monolythic 10u or 106 Aluminum Electrolytic 10u or 106 Aluminum Electrolytic 10u or 106 Aluminum Electrolytic 100u or 107 Aluminum Electrolytic 100u or 107 Aluminum Electrolytic 100u or 107 Aluminum Electrolytic 470u or 477 Aluminum Electrolytic 1000p 102 or 1N0 Ceramic monolythic 1000p...
- Page 7 RESISTORS Next, install the resistors. √ Value Marking Description Orange-Orange-Brown 1/4W Yellow-Red-Brown 1/4W Blue-Grey-Brown 1/4W 1.0k Brown-Black-Red 1/4W 1.0k Brown-Black-Red 1/4W 1.0k Brown-Black-Red 1/4W 1.0M Brown-Black-Green 1/4W 1.0M Brown-Black-Green 1/4W 1.0M Brown-Black-Green 1/4W 1.0M Brown-Black-Green 1/4W 1.0M Brown-Black-Green 1/4W 1.0M Brown-Black-Green 1/4W 1.0M...
- Page 8 TRANSFORMERS AND INDUCTORS Next, wind the toroids, beginning with L1. Locate the three toroids, and the 22AWG magnet wire – the heavier gauge of the pieces supplied. Cut a 20” piece from it. Take one of the toroids, and wind 21 turns around it with the wire.
- Page 9 [ ] T1 Toroidal Transformer Figure 1: Winding of T1 Install the remaining transformers at this time. Transformer T2 is a blue audio transformer. Notice there is a letter 'P' printed on one side of T2, designating the primary terminals. Be certain that that this transformer is installed with the primary corresponding to the pads marked 'P' on the board.
- Page 10 CRYSTALS Install all five 11.000 MHz crystals, X1 through X5 [ ] X1 [ } X2 [ ] X3 [ ] X4 [ ] X5 SEMICONDUCTORS Locate the 8-pin DIP IC socket. Install it in the U4 position, making certain to align the polarity notch of the socket with the mark on the PC board, facing the left side of the board.
- Page 11 2N3904 “ 2N3906 “ 2N3906 “ 2N7000 “ 2N7000 “ MPF102 w/ Heat Sink MPF102 “ ZTX749 “ ZVN4206A “ ZVN4206A “ HARDWARE, SWITCHES AND CONNECTORS Take the T-nut and the front panel. The T-nut inserts through the front of the front panel.
- Page 12 [ ] SW2 FREQ pushbutton Solder J1 and J2, the Key and Headphone jacks to the board. These are 1/8” stereo connectors. Be certain that they are pressed flush to the board before soldering, and re-solder while pressing down if necessary to assure they are as close as possible too the board.
- Page 13 required to supply sufficient heat) place a small, pea-sized, solder fillet at the upper corner of the juncture of each of the four side panels. Flip the assembly over so that it is right-side-up, and remove the aluminum spacers. Add small solder fillets on the upper corners of the four side panel junctures.
- Page 14 section of the wire where it touches the second PTO lead. Pulling the wire snug around the spacer, bend the magnet wire where it touches the PTO lead, and solder it into place. Trim off the excess wire. Trim the length of the PTO leads extending from the spacer to 1” (25mm). Using needle nose pliers to support the lead at the body of the spacer, bend it into a ‘knee’...
- Page 15 Figure 3: PTO Coil with ‘knees’ Insert the screw through the front panel T-nut until it touches the end of the PTO coil form. Gently bend the PTO leads until the end of the screw lines up with the threaded hole in the PTO coil form. Continue screwing the brass screw into the PTO coil form until the end of the screw is approximately 1/8”...
- Page 16 inspect all solder joints for quality, and touch-up any needing it. Inspect for solder blobs or other possible shorts. Double check that all polarized components have been installed properly. Install the bottom cover to the enclosure, using the 1/2” screws and 1/4” spacers at the bottom of the board, and the 1.5”...
- Page 17 Next, the transmit-mixer filter transformers must be peaked. Unscrew the PTO screw until a second birdie is heard in the headphones. This occurs at approximately 3.930 MHz PTO frequency, and serves as a mid-band indicator. Key the rig. With L4 not installed, the rig may be keyed continuously with no risk of damage to any component.
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Page 18: Troubleshooting
With this complete, remove the bottom cover, install L4, and then install top and bottom covers. You are done and ready to put your Cyclone on the air! TROUBLESHOOTING If your Cyclone does not operate after assembly, repeat the visual inspection of solder joints. - Page 19 11.3 11.5 2 - 3 2 - 3...
- Page 20 Figure 4: Component Placement...
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