Download
Share
Print this page
  1. Manuals
  2. Brands
  3. HPSDR Manuals
  4. Motherboard
  5. HERCULES
  6. Instructions manual

HPSDR HERCULES Instructions Manual

Hide thumbs

Advertisement

Quick Links

Download this manual
...the Making of
HERCULES
High Performance Software Defined Radio
Open Source Hardware and Software Project
Project Description: http://openhpsdr.org
Hardware Project #6
HERCULES Board
Part #2
The Making of HERCULES
Schematics / Board Design
Gerd Loch, DJ8AY
Text
Horst Gruchow, DL6KBF
Graphics and Layout
Horst Gruchow, DL6KBF
1
© DL6KBF 2010 Ver. 1.3
DJ8AY100W PA for PENELOPE incl. Low Pass Filtering for 160m to 6m --- MicroProcessor Controlled and Protected

Advertisement

loading
Need help?

Need help?

Do you have a question about the HERCULES and is the answer not in the manual?

Questions and answers

Summary of Contents for HPSDR HERCULES

  • Page 1 High Performance Software Defined Radio Open Source Hardware and Software Project Project Description: http://openhpsdr.org Hardware Project #6 HERCULES Board Part #2 The Making of HERCULES Schematics / Board Design Gerd Loch, DJ8AY Text Horst Gruchow, DL6KBF Graphics and Layout Horst Gruchow, DL6KBF ©...
  • Page 2 HERCULES Vorwort Preface Seit dem Beginn der HPSDR Entwicklung im März 2006 hat sich viel Since the start of the HPSDR development in March 2006 quite a in diesem offenen und öffentlichen Amateurfunk-Projekt bewegt. lot has been achieved within this open and public HAMRADIO Zum jetzigen Zeitpunkt (Februar 2010) stehen erstmals alle project.
  • Page 3 ...the Making of HERCULES PCB Backside © DL6KBF 2010 Ver. 1.3 DJ8AY100W PA for PENELOPE incl. Low Pass Filtering for 160m to 6m --- MicroProcessor Controlled and Protected...
  • Page 4 ...the Making of HERCULES Item 1 BOTTOM CAP CER 10nF 50V 0603 Reel/Tick C070 C071 C072 C073 C120 C121 C122 C123 C124 C125 C126 C127 Item 2 BOTTOM RES 10k 0603 Reel/Tick © DL6KBF 2010 Ver. 1.3 DJ8AY100W PA for PENELOPE incl. Low Pass Filtering for 160m to 6m --- MicroProcessor Controlled and Protected...
  • Page 5 ...the Making of HERCULES Item 3 BOTTOM CAP CER 100nF 0805 Reel/Tick CK00 CK01 CK02 CK03 CK04 CK05 CK06 CK07 CK08 CK09 CK10 CK11 CK12 CK15 CK16 Item 4 BOTTOM LM75AD SO8 Reel/Tick Item 4a BOTTOM BAS40 Reel/Tick D101 D102 ©...
  • Page 6 ...the Making of HERCULES PCB Frontside © DL6KBF 2010 Ver. 1.3 DJ8AY100W PA for PENELOPE incl. Low Pass Filtering for 160m to 6m --- MicroProcessor Controlled and Protected...
  • Page 7 ...the Making of HERCULES C150 Item 1 TOP CAP CER 100nF 0603 Reel/Tick C052 C085 C086 C087 C150 C152 C153 C154 C155 C156 C157 C158 C159 C160 © DL6KBF 2010 Ver. 1.3 DJ8AY100W PA for PENELOPE incl. Low Pass Filtering for 160m to 6m --- MicroProcessor Controlled and Protected...
  • Page 8 ...the Making of HERCULES Item 2 TOP CAP CER 100nF 0805 Reel/Tick C044 C045 C047 C055 C090 CK13 C056 C058 C091 C062 C064 C065 C090 C091 C092 C147 CK13 CK14 © DL6KBF 2010 Ver. 1.3 DJ8AY100W PA for PENELOPE incl. Low Pass Filtering for 160m to 6m --- MicroProcessor Controlled and Protected...
  • Page 9 ...the Making of HERCULES Item 3 TOP CAP CER 100nF 1206 Reel/Tick C006 C007 C008 C009 C010 C012 C036 C037 C012 C076 C077 C078 C079 C108 C109 C110 C111 C136 C137 © DL6KBF 2010 Ver. 1.3 DJ8AY100W PA for PENELOPE incl. Low Pass Filtering for 160m to 6m --- MicroProcessor Controlled and Protected...
  • Page 10 ...the Making of HERCULES C151 Item 4 TOP CAP CER 10nF 0603 Reel/Tick C048 C051 C054 C060 C061 C061 C063 C066 C066 C094 C068 C095 C069 C075 C093 C094 C095 C048 C151 C063 C093 C161 © DL6KBF 2010 Ver. 1.3...
  • Page 11 ...the Making of HERCULES Item 5 TOP CAP CER 100pF 0805 Reel/Tick C050 Item 6 TOP CAP CER 10uF/6.3V 0805 Reel/Tick C088 Item 7 TOP CAP CER 1uF/16V 0805 Reel/Tick C089 Item 8 TOP CAP CER 3.300pF/50V 0805 Reel/Tick C043...
  • Page 12 ...the Making of HERCULES Item 10 TOP CAP MICA 12pF Code C1 Reel/Tick C039 C083 Item 11 TOP CAP MICA 15pF Code E1 Reel/Tick C034 C041 C081 C082a Item 12 TOP CAP MICA 22pF Code J1 Reel/Tick C027 C032 Item 13 TOP...
  • Page 13 ...the Making of HERCULES Item 15 TOP CAP MICA 100pF Code A2 Reel/Tick C031 C035 C038 C040 C040a C042 C082 Item 16 TOP CAP MICA 120pF Code C2 Reel/Tick C026 C030 C028/C028a Item 17 TOP piggyback CAP MICA 150pF Code E2...
  • Page 14 ...the Making of HERCULES Item 20 TOP CAP MICA 390pF Code Q2 Reel/Tick C014 C021 C024 Item 21 TOP CAP MICA 680pF Code W2 Reel/Tick C013 Item 22 TOP CAP MICA 750pF Code X2 Reel/Tick C015 C028/C028a C017 piggyback C018...
  • Page 15 ...the Making of HERCULES Item 24a TOP These capacitors should be CAP MICA 180pF 1206 soldered to the corresponding Reel/Tick end plates of RF transformers C023 C023a d.n.p. T1 resp. T2 Item 24b TOP CAP CER 33pF 1206 Reel/Tick C057 C057a d.n.p.
  • Page 16 ...the Making of HERCULES Item 25 TOP RES 0R0 0603 Reel/Tick Item 26 TOP RES 2R2 0805 Reel/Tick Item 27 TOP RES 10R 0603 Reel/Tick Item 28 TOP RES 22R 0603 Reel/Tick Item 29 TOP RES 47R 0603 Reel/Tick © DL6KBF 2010 Ver. 1.3...
  • Page 17 ...the Making of HERCULES Item 30 TOP RES 100R 0805 Reel/Tick Item 31 TOP RES 120R 0603 Reel/Tick R12A Item 32 TOP RES 220R 0805 Reel/Tick Item 33 TOP RES 330R 0805 Reel/Tick Item 34 TOP RES 470R 0603 Reel/Tick...
  • Page 18 ...the Making of HERCULES Item 36 TOP RES 3k3 0603 Reel/Tick Item 37 TOP RES 4k75 0603 Reel/Tick Item 38 TOP RES 10k 0603 Reel/Tick Item 39 TOP RES 100k 0603 Reel/Tick © DL6KBF 2010 Ver. 1.3 DJ8AY100W PA for PENELOPE incl. Low Pass Filtering for 160m to 6m --- MicroProcessor Controlled and Protected...
  • Page 19 ...the Making of HERCULES Item 40 TOP 1N4148-DO35H/V Reel/Tick Item 41 TOP BAS70-00 SOT23 Reel/Tick Item 42 TOP BAT54A Reel/Tick Item 43 TOP BC807-40-SOT23 Reel/Tick Item 44 TOP BC817-40-SOT23 Reel/Tick © DL6KBF 2010 Ver. 1.3 DJ8AY100W PA for PENELOPE incl. Low Pass Filtering for 160m to 6m --- MicroProcessor Controlled and Protected...
  • Page 20 ...the Making of HERCULES Special Instructions: Placing LEDs How to determine the polarity of the 0805 LEDs? It can be difficult to find out the polarity of the tiny 0805 LEDs if you don't know what to look for. The Lite-ON ®...
  • Page 21 ...the Making of HERCULES Item 45 TOP LED-0805 GRN Reel/Tick LED1 LED2 LED3 LED4 LED6 LED7 LED8 LED9 Item 46 TOP LED-0805 RD Reel/Tick LED11 Item 47 TOP NC7ST08M5X-SOT23-5 Reel/Tick Item 48 TOP REG1117-3.3-SOT223 Reel/Tick Item 49 TOP TLC0832 SO8...
  • Page 22 ...the Making of HERCULES Item 51 TOP upper right corner ULN2003AD-SO16 Reel/Tick Item 52 TOP XC9572XL-VQFP44 Reel/Tick Item 53 TOP ATMEGA8 TQFP32 Reel/Tick Item 54 TOP 78M05-TO252-DPAK Reel/Tick Item 55 TOP ACS712ELCTR-20A-T Reel/Tick Item 55a TOP LL4148 Reel/Tick © DL6KBF 2010 Ver. 1.3...
  • Page 23 ...the Making of HERCULES Item 56 TOP IND 10uH 1206 Reel/Tick L14a L14b Item 57 TOP IND 680nH 1210 Reel/Tick L13A Item 58 TOP 0,25uH-18A-HC-6,6x7,3-Wuerth Reel/Tick Item 59 TOP 5-HOLE Ferrit Wuerth-7427512 SMD Reel/Tick Item 60 TOP RES NET 8x10k SIP9 Reel/Tick ©...
  • Page 24 ...the Making of HERCULES Item 61 TOP TRIM-C SMD 4-25pF 4,5x4 Reel/Tick C049 Item 62 TOP MINI CIRCUITS ADT1,5-1 Reel/Tick Item 63 TOP ECAP 100uF/25V SMD-D-6.6x6.6 Reel/Tick C059 Item 64 TOP ECAP 470uF/25V RM5-D10.5 Reel/Tick C011 Item 65 TOP POT 10K PT6H...
  • Page 25 ...the Making of HERCULES Item 67 TOP POT 10K 3296YW Reel/Tick Item 68 TOP POT 100R 3296YW Reel/Tick Item 69 TOP RES 10R0-2W Reel/Tick Item 70 TOP RES 2R7-2W Reel/Tick Item 71 TOP RES 39R-2W Reel/Tick Don't place R45 and R46 yet.
  • Page 26 ...the Making of HERCULES Item 72 TOP REL PCB 2XUM NA-12W-K Reel/Tick Item 73 TOP FUSEHOLDER FLR42 Reel/Tick © DL6KBF 2010 Ver. 1.3 DJ8AY100W PA for PENELOPE incl. Low Pass Filtering for 160m to 6m --- MicroProcessor Controlled and Protected...
  • Page 27 ...the Making of HERCULES Item 74 TOP PHOENIX-GMKDS3/3-7.62 Reel/Tick Main PWR Connector Item 75 TOP Molex 22-23-2021 Reel/Tick Fan Connector Item 76 TOP BNC PRINT 90° Reel/Tick Antenna Connector Item 77 TOP SMA PRINT 90° Reel/Tick J05 RF to ATU – J04 RF from ATU...
  • Page 28 ...the Making of HERCULES Item 80 TOP SMA PRINT 180° Reel/Tick RF INPUT from PENELOPE Item 81 TOP J5X2-WR10W Reel/Tick FilterRLY Control Lines for ext. Use Item 82 TOP J8X2-WR16W Reel/Tick From PENELOPE J6 Item 83 TOP JST-B6B-PH-K-S-6Pins-RM2.00 Reel/Tick XILINX Programming Connector...
  • Page 29 ...the Making of HERCULES PTT out to PAF0 6m RLY +12-14V OUT Switched to GND PTT in to PAF1 12m-10m RLY max. 2A +12-14V IN to PAF2 17m-15m RLY ADC_CLK 30m-20m RLY ADC_IN 60m-40m RLY J01 Main PWR Connector J02 Fan Connector...

  • Page 30: Contrast Adjust

    ...the Making of HERCULES MISO CONTRAST ADJUST MOSI Register Select RESET~ Data R/W N.C. ENABLE KEY1 J13 ATMega8 Programming Connector KEY2 KEY3 Attention BackLight A+ Please connect separately if your display has this kind of backlight terminals. The one I am using is of...
  • Page 31 ...the Making of HERCULES Item 86 TOP J1X2-SIP2 Reel/Tick JP01 Place this jumper if you don't use an ATU Item 87 TOP J1X2-WR2 Reel/Tick JP10 Place this jumper if you want the LP filters to be active on RX © DL6KBF 2010 Ver. 1.3...
  • Page 32 ...the Making of HERCULES Item 88 TOP Inductivity L01 4µH 160m Filter Toroids T50-2 Inductivity L02 4µH Reel/Tick Wire 0.35mm No. of Turns L01 No. of Turns L02 Inductivity L03 1.5µH Item 89 TOP Inductivity L04 1.8µH 80m Filter Toroids T50-2 Wire 0.8mm...
  • Page 33 ...the Making of HERCULES Item 94 TOP Inductivity L17 137nH 6m Filter Toroids PTFE Inductivity L18 143nH Reel/Tick Wire 1.0mm No. of Turns L17 No. of Turns L18 Cut 5mm slices from 15mm OD PTFE rod, drill 10mm hole in the center and shape edges...
  • Page 34 ...the Making of HERCULES Item 95 TOP Primary Toroid FT37-43 Wire 0.5mm Reel/Tick No of Turns Secundary Transformer SWR Sensor use a piece of RG178 (PTFE), solder core to TH P1 and braid to TH P2 stick through toroid and solder core to TH P3...
  • Page 35 ...the Making of HERCULES Building the Final Output Transformer T1 Wuerth Ferrite Tube 74270077 Dimensions valid for both plates Brass Tubes 6mm OD x 32mm Solder Brass Tubes to Copper Layer Secondary End Plate 16mm x 31mm Cu Single sided FR4...
  • Page 36 ...the Making of HERCULES Building the Final Input Transformer T2 Wuerth Ferrite Toroid 74270112 Primary End Plate Cu Single sided FR4 Full Copper Plane Brass Tubes 4.7mm OD x 11.5mm Secondary End Plate Cu Single sided FR4 Do not place the transformers T1 and T2 yet! ©...
  • Page 37 ...the Making of HERCULES Drill Pattern for Heat Sink © DL6KBF 2010 Ver. 1.3 DJ8AY100W PA for PENELOPE incl. Low Pass Filtering for 160m to 6m --- MicroProcessor Controlled and Protected...
  • Page 38 ...the Making of HERCULES Heat Sink Fischer SK519 130mm x 177,5mm Drill 2.5mm holes into heat sink using the drill pattern. Tap M3 thread into each hole. Done! © DL6KBF 2010 Ver. 1.3 DJ8AY100W PA for PENELOPE incl. Low Pass Filtering for 160m to 6m --- MicroProcessor Controlled and Protected...
  • Page 39 ...the Making of HERCULES 12x M3x10mm Screws to bolt down PCB Bolt down the PCB onto the heat sink using 12x M3 Nuts as Spacers at PCB Bottom the screws and nuts on the left. In order to get the PCB tight push it down onto the nuts in order to prevent these from turning.
  • Page 40 ...the Making of HERCULES Soldering instructions for the RF power transistors MRF492 Collector Mount the transistor to the heat sink. Apply heat to each lead pressing it down onto the solder pad with the soldering iron and a pair of tweezers. As soon as...
  • Page 41 ...the Making of HERCULES Unbolt the PCB from the heat sink for final assembly and inspection. Primary side Solder the RF transformers T1 and T2 onto their matching pads. Now wind the RF transformers according to the following instructions: Output transformer T1 a.
  • Page 42 ...the Making of HERCULES Go back to page 34 and place the toroid T8. Go back to page 25 and place the 39R-2W resistors R45 and R46. Bolt the PCB onto the heat sink for final assembly and inspection. Follow the mounting instructions on page 39.
  • Page 43 ...the Making of HERCULES Appendix A - BOM Organizer © DL6KBF 2010 Ver. 1.3 DJ8AY100W PA for PENELOPE incl. Low Pass Filtering for 160m to 6m --- MicroProcessor Controlled and Protected...
  • Page 44 ...the Making of HERCULES Appendix A - BOM Organizer © DL6KBF 2010 Ver. 1.3 DJ8AY100W PA for PENELOPE incl. Low Pass Filtering for 160m to 6m --- MicroProcessor Controlled and Protected...
  • Page 45 ...the Making of HERCULES Appendix A - BOM Organizer © DL6KBF 2010 Ver. 1.3 DJ8AY100W PA for PENELOPE incl. Low Pass Filtering for 160m to 6m --- MicroProcessor Controlled and Protected...
  • Page 46 ...the Making of HERCULES Appendix A - BOM Organizer © DL6KBF 2010 Ver. 1.3 DJ8AY100W PA for PENELOPE incl. Low Pass Filtering for 160m to 6m --- MicroProcessor Controlled and Protected...
  • Page 47 ...the Making of HERCULES Appendix A - BOM Organizer © DL6KBF 2010 Ver. 1.3 DJ8AY100W PA for PENELOPE incl. Low Pass Filtering for 160m to 6m --- MicroProcessor Controlled and Protected...
  • Page 48 ...the Making of HERCULES Appendix A - BOM Organizer © DL6KBF 2010 Ver. 1.3 DJ8AY100W PA for PENELOPE incl. Low Pass Filtering for 160m to 6m --- MicroProcessor Controlled and Protected...