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QRP PROJECT Blue Cool Radio Manual

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The blue cool Radio BCR
© QRPproject Motzener Straße 36-38 12277 Berlin http://www.QRPproject.de Telefon: +49(30) 85 96 13 23 e-mail: support@QRPproject.de
Manual written by : FIservice Peter Zenker DL2FI email:dl2fi@qrpproject.de
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Summary of Contents for QRP PROJECT Blue Cool Radio

  • Page 1 The blue cool Radio BCR © QRPproject Motzener Straße 36-38 12277 Berlin http://www.QRPproject.de Telefon: +49(30) 85 96 13 23 e-mail: support@QRPproject.de Manual written by : FIservice Peter Zenker DL2FI email:dl2fi@qrpproject.de...
  • Page 2 Welcome to start assembling your BCR - Blue Cool Radio. We divided the complete kit into functional groups which can be tested individually after assembling. Please follow the manual while assembling because each group except the first one need the groups built before to be tested. The follow up inside a group also is not by chance but follows logical and safety rules.
  • Page 3 [ ] C88 1uF 35V Tantalperle Now recheck all your work to find eventually solder failures. Use an [ ] C89 1uF 35V Tantalperle Ohmmeter to check the resistance between the switch and ground, it must be in the range of several Kilo Ohm. Attention: The following Diode must be placed the right way.
  • Page 4 Group 2 Controller Section [ ] Bu1 3,5mmStereo Jack A-1/2 This section we call the digital heart of our BCR. All functions of the radio The following trimmer are controlled by the Common PIC Controller. If the controller is in potentiometer must be placed function, it gives you some internal tools as an advantage: The controler at the bottom side of the PCB...
  • Page 5 Now the socket for the display. It helps a lot, if you use the display itself as Assembling the DDS Modul: a justify tool. Take the display, a 16pin connector male and a 16PIN If you have own expierience in soldering SMT parts, you may start connector female plus 4 of the 12mm spacers and the small 2mm Screws.
  • Page 6 Now turn around the PCB. Here you will install the Clock Oscillator and the Now place the PIC processor itself into the socket. Find at first the 45 3 connectors. degree side of the PIC. This side must look to the inner part of the PCB. Dont force too much power while pressing the PIC into the socket, it must find its place very smooth.
  • Page 7 stored. 13 tune. Switches the transmitter to TUNE. During TUNE power and SWR 2 Band 1 40m Switch to 40m by pressing the Shaft encoder. Actual fre- are displayed. quency of actual band will be stored. 14 split 1k DDS switches VFO A to receive only and VFO B to transmit only. 3 Band 2 30m Switch to 30m by pressing the Shaft encoder.
  • Page 8 store the calibration factor into memory. From now the DDS will generate very exactly th echoosen frequency 2 ZF (Hz) Here you can adjust the exact IF. The DDS at starting point generates the estimated IF of BCR which is a little bit lower the the Xtal frequency (that´s typical for ladder filters).
  • Page 9 [ ] C36 220nF Foil spaced 5mm C-3/4 [ ] R29 4,7R upright B-3 [ ] C42 100uF rad. B-3 [ ] R26 120R upright Install fullowing diode also upright. There is a convention to place the cathode (banded side) to th eupper end. The body is placed inside the printed circle in the placement plan.
  • Page 10 about 3,5mA which is significant low compared ZF-Verstärker 47nF to two seperate driven singel Amplifier stages. 47nF By T6 easily the current through the complete 18Wdg 6Wdg BF199 chain can be varied and by this, the Gain factor 47nF 47nF of T4/T5 that means the gain of the IF amplifier entfällt can be regulated.
  • Page 11 So far the theory of this Remember ESD rules while installing the following transistors, they are very new IF Amplifier design, sensitive against electrostatic discharge. let´s start to asemble it Attention: The suffix in a type is essential, it makes the difference. Never now.
  • Page 12 To prepare the Bobin take the Body, give socket from the bottom side to make clear, how the wire is fastened to the a drop of superglue between the snap in pin. The Pins are very rough so the wire will hold in place. part middle of the socket and snap the Now up through the notch to the Bobin Body and clockwise 18 turns body to the holder.
  • Page 13 Place the prepared blue plastic with its ferrite pinning as you you see it from the upper side, orinting readable. It will be cap on the the coil. Place the shield can over installed exactly as you see it here. The little Dot in the drawing remarks the the plasitk, The two noses of the shield should long drain pin.
  • Page 14 Ferrit caps of L4 and L5 should be about 1-2 mm below the copper shield. Group 5 DDS Signal preparation, Now switch on your BCR. Go to Menu, Setup and into the ZF section. The Mixer, IF buffer and Ladder Filter default frequency stored by us is 1kHz below the Xtal frequency, that is the [ ] C48 1000pF (102) normal value for this type of ladder filters.
  • Page 15 every quartz, cleaning with a glass brush or similar tool makes soldering at All ok? Dont forget to recheck your work with a magnifier. Please do not let the Quartz housing easier. out this step. OK, I know you are doing a good job here, but > 90 % of kits I get for support fail due to soldering failures! [ ] Quarzhousings to ground.
  • Page 16 Change the Generator frequency to lower frequency in small steps and Grroup 6 LPF, RX Frontend, watch the Voltmeter carefully to find the maximum voltage. The maxi- Preselector mum represents the midpoint of the filter curve. Leave the Generator at this frequency.
  • Page 17 Building the current transformer and the SWR/Power measuring unit. end of your soldering iron, then insert the wire into the hot solder You now will handle the first torroid in this kit. It is the smallest one you for a few seconds. Avoid scraping insulation off with a razor blade, as this have to deal with, it is only 4,5x1,9x2mm and it is made from N30 may nick the wire.
  • Page 18 [ ] D4 BB112 If you have allready built the 80m Option or if you dont want to use [ ] D5 BB112 80m, go on here: [ ] D6 BB112 E/F-3 [ ] D7 BB112 E/F-4 Take a piece of RG174 50 Ohm coax abt 4-7 cm long.
  • Page 19 Adjust the Preselector Pot to noise maximum. This is extrem sharp, only a mm with the knob. Adjusting the Preselector needs some training because it is so extrem sharp. If the preselector is adjusted, find the Signal with the VFO. If you do not find it, increase the signal a little bit for the first time. Now disconnect the generator because this lowers the actual Q of L1 which makes it harder to adjust.
  • Page 20 Group 7 Transmitter the kit. [ ] R32 10K [ ] T14 2N4427 +plastic socket F-4 [ ] R31 100K [ ] C57 47nF (473) F-3/4 [ ] C45 0,010uF [ ] R30 3,3K upright The choke for the TX will be wound on a ferrite [ ] C46 47nF (473) because the TX current would be too high for a [ ] C50 10nF (103)
  • Page 21 lower right to lower left. That completes 1 turn. [ ] P2 250R PIHER SMC-10-V Transfor,er TR 1 must have 4 primary and 1 secondary turns. and the TX is ready except the PA. Use 20cm of the 0,3 mm wire. Feed the wire After you have controlled your work, you can test the TX section withot any from upper left to upper right.
  • Page 22 Use an RF probe to measure the RF at the collector of the driver transistor, Bend the legs of the transistor with the help of a small screwdriver round that is the housing of the transistor. The power can be regulated by the downwards as shpwn in the picture.
  • Page 23 power and you may use higher power in practice if you want, but you must be aware of one rule: Increasing the drive by the power-pot will increase the output. Depending on the band and some indivitual specific parameters of your BCR you will find a point beyond the 5 Watt mark, where the power not longer increases if you increase the drive, but the current will increase exorbitant.
  • Page 25 St.2 100nF 10nF 100nF 10nF 10uF 100nF St.1 100n 13 14 15 220R 100nF 10uF 100n St.3 10nF MCLK 1,8uH 1,0uH 50MHz RF-Out 7,9,10 11,12,18 DDS-Unit "blue cool radio" DL4JAL / DK1HE Stand: 1.12.2005...
  • Page 26 Mithörton- 1,5uF Filter Eingabetaster 100R zu Rel.2 Keyer PIC16F877PLCC 100R Rel.2-3 gem. Ausgangsfilter zu Rel.3 10nF von T6 (AGC-Spannung) Speed Uvor von SWR-Messkopf Urück 10nF 10nF Keramik Resonator +12V (Batterieüberwachung) Steuerteil "blue cool radio" 4MHz DL4JAL Stand: 1.12.2005 zu DDS-Unit...
  • Page 27 DDS Unit...
  • Page 28 BCR Mainboard Part side complete...
  • Page 29 BCR mainboard Solderside SMT Parts...
  • Page 31 Akku 12V,intern +12V Ladebuchse Ein-Aus 78LO5 7808 100nF 12V,extern 1N5402 Stromversorgung "blue cool radio" DK1HE Stand: 6.01.2005...
  • Page 33 Mithörton- 1,5uF Filter Eingabetaster 100R zu Rel.2 Keyer PIC16F877PLCC 100R Rel.2-3 gem. Ausgangsfilter zu Rel.3 10nF von T6 (AGC-Spannung) Speed Uvor von SWR-Messkopf Urück 10nF 10nF Keramik Resonator +12V (Batterieüberwachung) Steuerteil "blue cool radio" 4MHz DL4JAL Stand: 1.12.2005 zu DDS-Unit...
  • Page 35 270R NF-Verst. 220nF 100uF RX-Lautst. 10nF Hörer LM386N-1 RX-Stummtast. 100uF 47nF BS170 100k 10uF 1N4148 120R Mithörton von CPU Mithörton-Lautst. +8V 'S' Baugruppe NF Teil...
  • Page 37 BFO/Produkt-Det. ZF-Verstärker 47nF 47nF 18Wdg 6Wdg BF199 4,915MHz 47nF 4,915 47nF 2,5-60pF entfällt 150p 150p 2Wdg 10pF BF981 47nF 47nF 33pF 18Wdg 150pF BF244A BF199 100k 1N4148 10uF 47nF 150R 100uF 270R 6,8nF 270R 47nF 47nF 270R 470k ZF-Vorverst. BC550 AGC-Spannung 0,2-1V 0,47uF...
  • Page 39 ZF-Bandbreite RX-Mixer ZF-Pufferstufe 47nF Dr1- 100uH Dr2- 100uH 47nF 47nF C4-100nF BF244B 74HC4066 150pF 4Wdg 18Wdg 150p BB112 BB112 ZF 4,915MHz 4,915MHz Cohn-Filter IC1-74HC04 INV8 IC1-74HC04 von CPU Taktaufbereitung IC1-74HC04 Taktaufbereitung, Mischer, ZF Buffer und Quarzfilter IC1-74HC04 DDS-Board 1000pF 100nF BF199 10nF ????
  • Page 41 D3 1N4148 zu T9 HF-Vorst. RX-Mixer ZF-Pufferstufe Rel 1 von PA Dr1- 100uH 47nF C5 47nF C4-100nF 1N4148 BF244B 1N4148 C1 3,3p 74HC4066 BF244B von CPU BB112 D6-BB112 150pF von CPU von CPU 11Wdg 11Wdg 4Wdg 2Wdg BB112 D7-BB112 18Wdg 150p 0 Ohm Brücke 470pF...
  • Page 43 TX-Taststufe (TX-Weichtastung) von Rel 1 BS250 Schwellwert- 100k Schalter BC546B von CPU von CPU +8V 'S' Dr7- 10Wdg FT37-43 47nF +12V DDS-Board C58 10uF 47nF 680R TX-Vorverst. 47nF 100nF 47nF 47nF 47nF Dr8-47uH 330R 4 Wdg 1 Wdg 250R BF199 10nF 47nF Senderbaugruppe...
  • Page 45 von CPU 47nF Zum Tiefpassfilter 2 Wdg 4 Wdg Sende Endstufe 2SC1969 RX-Preselektor RX-Preselektor...

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