Related Manuals for 4SQRP Bayou Jumper 40 Meter CW Transceiver
Summary of Contents for 4SQRP Bayou Jumper 40 Meter CW Transceiver
- Page 1 Assembly & Instruction Manual Bayou Jumper 40 Meter CW Transceiver For revB (Blue Panel) kits shipped after 1 Jan 2021 Copyright 2017, 2020 David Cripe NM0S Jim Giammanco N5IB & Four State QRP Group ACØBQ photo...
- Page 2 The transceiver is comprised of two separate circuits, a crystal-controlled transmitter and a regenerative receiver. The transmitter uses 4SQRP’s super simple, super robust NS-40 transmitter circuit, with trademark on-board spiral PCB trace inductors, and between 4 and 5 watts output power.
- Page 3 QRP. The transmitter design of the Bayou Jumper is borrowed from the 4SQRP classic ‘NS-40’. This design is a master-oscillator/power amplifier circuit, with high-efficiency spiral PCB coils serving as the transmitter’s harmonic filter.
- Page 4 Materials (pages 34 & 35). Building over a cookie sheet is recommended to minimize the chance of lost parts. If parts are missing in your kit, send an email to the kitter listed at 4SQRP.com. He will promptly provide replacements. revised 3 Feb 2021...
- Page 5 Schematics are provided separately as image files in the documentation package, as well as being incorporated into this manual. It is highly recommended that you print a couple of copies at 11 X 17 inch format at your local UPS Store, Staples, etc. As you build, use a highlighter to mark off parts that have been soldered onto the PCB on one copy.
- Page 6 Enclosure It would be best to prepare the enclosure before beginning assembly of the PC boards, in case any minor sanding or filing were to be needed to refine the fit of the boards into the box. The enclosure must be prepared to mount the circuit boards.
- Page 7 Preliminary Assembly The large components (four potentiometers, BNC jack, and rotary switch) will be installed first. In order to ensure that these components properly line up with the holes in the front panel, test fittings will be performed □ Locate the six 5/8” hex standoffs and twelve of the 6-32 x 3/8” machine screws.
- Page 8 □ Remove the front panel and set it aside for the moment. Do not yet solder the remaining tab and pins. □ Repeat the above two steps for the other two 50 k pots, R10 and R6 (marked “B5 03”), and the 5 k pot, R1 (marked “B5 02”). Again, solder only one tab of each part at this time.
- Page 9 □ Install the BNC jack in its location at the upper left corner of the PCB. Be sure it is flat and flush against the board and is vertical. Solder only the center pin at this time. □ Re-install the front panel and make another alignment check. Locate the “chicken head”...
- Page 10 Special note for builders who intend to install a NA1MH Soup’er Up’er accessory board that is described in Appendix J. That accessory is not currently available, but “previously owned” units may show up from time to time. You may wish to just tack solder R9 and C9 to the board in the upcoming steps, leaving extra long lead lengths, since these parts will be subsequently removed after the basic checkout of the Bayou Jumper, prior to installation of the Soup’er Up’er.
- Page 11 Semiconductors Identify and install the following components. Be certain that their polarity is correct, and that they match the board’s silkscreened outlines. It is not necessary to secure the TO-220 parts to the PCB, but you may safely do so if you wish (4-40 machine screw & nut - hardware not supplied with kit). No insulating film is required beneath the part.
- Page 12 Capacitors The ceramic monolithic capacitors used throughout the kit are small and their markings not always easy to read. Use a magnifier to verify their values before installing. BE VERY SURE THAT THE 120 pF CAP GOES IN C20 Electrolytic capacitors must be installed with the correct polarity. The cases are marked to indicate the negative terminal, which goes into the round pad on the board.
- Page 13 Dipped Monolithic Ceramic NP0, blue body, 0.2” lead spacing 390 pF Aluminum Electrolytic, 0.1” lead spacing, observe polarity, longer lead is + 4.7 µF 4.7 uF Aluminum Electrolytic, 0.1” lead spacing, observe polarity, longer lead is + 4.7 µF 4.7 uF Aluminum Electrolytic, 0.1”...
- Page 14 It is essential that this inductor be wound properly with the correct number of turns, the proper winding direction, and location. By following the diagram on the PCB silkscreen successful construction can be assured. For additional help with winding, read the notes at http://wa0itp.com/toroidophobia.html An additional tip –...
- Page 15 Test and Instrument Connection Points □ Provisions are made on the PC board to install several wire loops that can be used to conveniently clip test instrument leads. There are three groups of five pads (the middle pad is not used). Two of the pad sets are grounded, and one set is connected to the +12 V supply.
- Page 16 Final Main Board Hardware □ Add the contact post for the built-in key. This is a 3/8” hex standoff. Install using a 3/8” screw with at least two flat washers between the standoff and the PCB. Two extra washers are provided in case the key spacing needs to be adjusted to suit the builder.
- Page 17 □ Mount the key knob onto the leaf spring by inserting it through the top of the front panel, and fixing it in place using the 8-32 brass screw from beneath. □ Assemble the power jack. Very gently bend the solder lugs of the power jack away from the body so that Plus there will be sufficient clearance from the main board...
- Page 18 A new addition to the revB kit is a red/green LED pilot light and Tx/Rx indicator feature. This bi-color LED indicator can be treated as an option. If, after reading through these instructions, you are uncomfortable with this “Pittsburg style” of assembly, you can simply omit these steps.
- Page 19 The RED anode lead should be soldered to the pad marked RED, which already has one lead of R19 attached. The GREEN anode lead should be soldered to the pad marked GREEN, which holds a lead of R20. The cathode lead should be soldered to the GND pad. □...
- Page 20 Mating the front panel with the main PC board □ Place the front panel onto the standoffs. Secure it temporarily with two or three screws and check the motion of the pots. If they do not turn freely, re-heat the mounting lug(s), and adjust the angle(s) slightly as needed. □...
- Page 21 Should you need to separate the main board from the front panel for adjustments or troubleshooting, remove the nuts from the key, headphone, and power jacks, and remove the knobs. The crystal socket pins will slide out of the nylon insulators with some gentle pulling. Crystal Adapters The Bayou Jumper has a front panel crystal socket to fit FT-243 or FT-241A crystals, the old style Novice crystals that can still be found at hamfests.
- Page 22 Receiver Tuning Setup □ With all board-mount components installed, the next step is to set up the receiver for the desired tuning range, and the regeneration control for the proper range. A calibrated CW receiver or a calibrated 40 m signal source is needed, or use the Bayou Jumper’s spotting function to calibrate the receiver.
- Page 23 Alternately, if a calibrated receiver is not accessible, a separate transmitter may be used to generate a calibration signal. Connect the transmitter into a dummy load, and connect a short length of wire to the BNC connector of the Bayou Jumper.
- Page 24 If the tuning range is too low – below the 7000-7150 kHz range – and you have spread out the turns of the 19 turn winding as far as possible, you will need to remove a turn from that winding. Just cut the wire where it emerges from the PCB on the outside of the core and pull the wire out from under the core to remove one turn.
- Page 25 If there is no change to the hiss while adjusting the REGEN control, it means that the regeneration must be adjusted to either increase or decrease the amount of RF feedback in this circuit. If, for any setting of the REGEN control, you can hear the heterodyne of the Bayou Jumper’s regenerative oscillator in your separate calibrated receiver, or, hear the signal of a nearby CW transmitter or the spot frequency when keying, then you have too much...
- Page 26 this case, install C31, the 22p capacitor, and re-test. Re-check the receiver calibration. It’s a good idea to do a final check with the radio installed into its box, but before screwing down the panel. When the receiver calibration is satisfactory, to fix the turns in place, paint the toroid with a light coating of clear fingernail polish.
- Page 27 MPF102 2N3904 2N7000 IRF510 78L06 Voltage Chart -- values are approximate, based on a 12.0 V power supply Component ID Expected V Measured V 1.5 to 3.5 V for revA and earlier between 0.5 and 0.6 V for revB 0.65 between 2 &...
- Page 28 1 (square pad) 1 (OUT) nearest 2 (GND) middle 3 (IN) nearest C25 WIPER PIN 2 to 6 as R8 is varied WIPER PIN 0 to 6 as R10 is varied revised 3 Feb 2021 Bayou Jumper revB Assembly Manual page 27 of 46...
- Page 29 Bayou Jumper is not overly sensitive to VSWR, but it has no built-in protection against very mismatched loads that could cause damage. It is best to use a tuner with a resistive-bridge type VSWR sensor, such as the 4SQRP 4S-Tuner.
- Page 30 revised 3 Feb 2021 Bayou Jumper revB Assembly Manual page 29 of 46...
- Page 31 revised 3 Feb 2021 Bayou Jumper revB Assembly Manual page 30 of 46...
- Page 32 revised 3 Feb 2021 Bayou Jumper revB Assembly Manual page 31 of 46...
- Page 33 Top copper pattern and silkscreen, viewed from top side Bottom copper pattern and silkscreen, viewed from bottom side revised 3 Feb 2021 Bayou Jumper revB Assembly Manual page 32 of 46...
- Page 34 Front panel, top and bottom views revised 3 Feb 2021 Bayou Jumper revB Assembly Manual page 33 of 46...
- Page 35 Photos by WØEB. Populated PCB, before toroid installation – note builder-supplied socket for U1 Top: Bottom: Populated PCB, bottom view, with toroid mounted on bottom revised 3 Feb 2021 Bayou Jumper revB Assembly Manual page 34 of 46...
- Page 36 Design Notes Tuning range approximately 140 to 160 kHz – enough to cover the Extra Class CW band through the old “Novice Band.” One knob tuning – no bandset/bandspread needed. Only one toroid to wind in the receiver section. Etched PCB inductors used in the transmitter section.
- Page 37 Bayou Jumper rev B Bill of Materials (31 December 2020) Inv√ Quant Part ID(s) Description Marking Notes CAPACITORS 22 pF NP0 ceramic, 0.1” LS Optional - do not install yet C21,C30 4-20 pF trimmer capacitor pink body Note orientation of flat side 100 pf NP0 ceramic, 0.1”...
- Page 38 RESISTORS 100 Ω 1/4W 5% resistor BRN-BLK-BRN BRN-BLK-RED R19 is installed R17, R19 1.0 K 1/4W 5% resistor under the front panel RED-RED-RED installed under the 2.2 K 1/4W 5% resistor front panel RED-VIO-RED 2.7 K 1/4W 5% resistor R7,R12 3.3 K 1/4W 5% resistor ORG-ORG-RED 33 K 1/4W 5% resistor...
- Page 39 6 in AWG #22 tinned bus wire 6 in AWG #10 bare copper wire For crystal pins 3 in RED/BLACK insulated wire “Dupont” female-female jumper wire 12 in LED connections TP1, V-reg, Rx-Vcc, Header pins, 1 conductor J7-7, J7-9 DIP socket 8 pin Socket for U1 Optional parts (Not supplied with See manual...
- Page 40 APPENDICES A. Rotary Switch Options In case the indexing key washer should slip out of place while INDEX POST working with the switch, the photo at right shows the correct position of the washer relative to the index post on the body of the switch. The shaft of the stock switch is a little too long to allow the selector knob to sit down close to the panel.
- Page 41 D. Routing wires to the main PCB for installations of mods or accessories. Since there is room under the main PCB as installed in the recommended box, the possibility of adding accessories such as an audio filter, sidetone oscillator, keyer, etc, are certainly attractive.
- Page 42 G. Crystal Spotting Some builders may discover that the spotting feature does not suit their needs. The strong RF signal from the crystal oscillator, even when the final amplified stage is not in use, overloads the regenerative detector and pulls the detector to oscillate a frequency some kHz removed from the actual receive frequency as shown on the dial.
- Page 43 I. Connection points for potential modification or additions There are nineteen extra pads on the PC board that connect to strategic points in the circuit. These points have been selected because they may be useful for modifications or additions such as sidetone, audio filter, keyer, fine tuning, digital dial, etc. Each point is identified on both the top and bottom silkscreens with a circle and an alphanumeric designator, as listed below.
- Page 44 J. The NA1MH Soup’er Up’er Accessory David Martin, NA1MH, designed an add-on for the Bayou Jumper that provides a sidetone, a fine tuning control, and the NMØS HI-PER-MITE audio filter. This accessory is not currently being kitted and supplied by Four State QRP Group, but “previously owned” units are occasionally offered on various QRP forums, and documentation is available for download.
- Page 45 L. Connecting external audio devices (amplifier, filter, etc) The Bayou Jumper’s audio amplifier device (NJM2113) employs a differential output stage which is not referenced to the circuit ground. That is why only the tip and ring contacts of the stereo jack are connected, and the sleeve is left floating. This type circuit does not require the large series capacitor such as used with LM386 amplifiers, and as a result, the low frequency response of the audio stage is improved.
- Page 46 M. Measured values from a rev B, beta build Bayou Jumper Tuning range: Very tight 19 turn main winding With C30 at maximum capacitance, initial range was 6813 – 6959 kHz Adjusting C30, only, yielded the result below Dial setting Rx zero beat frequency, kHz 7002.0 7004.3...
- Page 47 Builder’s Notes: revised 3 Feb 2021 Bayou Jumper revB Assembly Manual page 46 of 46...