1. Manuals
  2. Brands
  3. Telstar Electronics Manuals
  4. PBX
  5. SkyWave DX600
  6. Assembly manual

Telstar Electronics SkyWave DX600 Assembly Manual

Rf linear amplifier pcb
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
www.telstar-electronics.com
RF Linear Amplifier PCB Assembly Manual
SkyWave DX600 Revision-B
Last Revised - 2/5/2021 9:10 AM
Page 1 of 57

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the SkyWave DX600 and is the answer not in the manual?

Questions and answers

Related Manuals for Telstar Electronics SkyWave DX600

Summary of Contents for Telstar Electronics SkyWave DX600

  • Page 1 RF Linear Amplifier PCB Assembly Manual SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 1 of 57...

  • Page 2: Table Of Contents

    Step #22 - PCB Mounting to Heat Sink ..................... 50 Step #23 - Bias Adjustment......................53 Step #24 – Amplifier Operation ....................... 54 Troubleshooting ..........................55 Specifications ..........................56 RF Performance ..........................57 SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 2 of 57...

  • Page 3: Introduction

    RF Linear Amplifier PCB Assembly Manual Introduction Congratulations on your purchase of the new SkyWave DX600 RF Amplifier PCB. This PCB is a result of quality engineering to provide high performance and reliability. Listed below are some of the key features:...

  • Page 4: Parts List

    Fuse Holder, ATC Type, TH Fuse, ATC, 25A IC, Operational Amplifier, LM2904, Dual, DIP-8 Insulator, Phase Change, TO-220 Q1, U1 PCB, SkyWave DX600 Revision-B Potentiometer, 1K, 0.1W, Vertical Adjust, TH Regulator, Voltage, Adjust, 60V, 1.5A, TO-220 Relay, DPDT, 12V, 8A, DIP RLY1 Resistor, Carbon Film, 1.2K, 0.25W, 5%, Axial...
  • Page 5 24” Wire, #22, Teflon, Yellow, Stranded PWR LED, XMIT LED 24” Wire, #22, Teflon, Green, Stranded S1 (ON/OFF) 24” Wire, #22, Teflon, Purple, Stranded S2 (SSB DELAY) SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 5 of 57...

  • Page 6: Before You Start

    35W-65W recommended. Temperature controlled soldering equipment is always preferred. † Solder recommendation is Kester 331. This solder has a flux that can be washed off with warm tap-water. ‡ SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 6 of 57...

  • Page 7: Assembly Instructions

    MAKING CERTAIN NOT TO OBSTRUCT THE CENTER OF THE SPACER. Solder spacers into position. Figure 1 The drill bit shank is the solid portion that does not contain the spiral cutting flutes. § SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 7 of 57...
  • Page 8 RF Linear Amplifier PCB Assembly Manual Details of spacer installations. Figure 2 SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 8 of 57...

  • Page 9: Step #2 - Fixed Resistor (R1-R28)

    DIRECTION. MAKE CERTAIN THE RESISTORS ARE FULLY SEATED IN THE PCB BEFORE SOLDERING. Install resistors into the PCB at the designated locations. (Figure 3) Solder resistors into position. Cut off the excess lead length. Figure 3 SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 9 of 57...
  • Page 10 RF Linear Amplifier PCB Assembly Manual Details of fixed resistor installations. Figure 4 SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 10 of 57...

  • Page 11: Step #3 - Variable Resistor (Vr1)

    ORIENTATION. MAKE CERTAIN THE VARIABLE RESISTOR IS FULLY SEATED IN THE PCB BEFORE SOLDERING. Insert VR1 into the PCB at designated location. (Figure 5) Solder VR1 into position. Cut off the excess lead length. Figure 5 SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 11 of 57...
  • Page 12 RF Linear Amplifier PCB Assembly Manual Details of VR1 installation. Figure 6 SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 12 of 57...

  • Page 13: Step #4 - Diode (D1 Through D5)

    CERTAIN THE DIODES ARE FULLY SEATED IN THE PCB BEFORE SOLDERING. Insert diodes into the PCB at the designated locations. (Figure 7) Solder diodes into position. Cut off the excess lead length. Figure 7 SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 13 of 57...
  • Page 14 RF Linear Amplifier PCB Assembly Manual Details of diode installations. Figure 8 Figure 9 Figure 10 SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 14 of 57...

  • Page 15: Step #5 - Dual Operational Amplifier (U2)

    THE INTEGRATED CIRCUIT WITH THE NOTCHED SIDE AS SHOWN. Insert U2 into the PCB at the designated location. (Figure 11) Solder U2 into position. Cut off the excess lead length. Figure 11 SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 15 of 57...
  • Page 16 RF Linear Amplifier PCB Assembly Manual Details of U2 installation. Figure 12 SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 16 of 57...

  • Page 17: Step #6 - Fuse Holder (F1)

    Insert F1 (fuse holder) into the PCB at the designated location. (Figure 13) Solder F1 (fuse holder) into position. Cut off the excess lead length. Figure 13 SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 17 of 57...
  • Page 18 RF Linear Amplifier PCB Assembly Manual Details of F1 (fuse holder) installation. Figure 14 SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 18 of 57...

  • Page 19: Step #7 - Input Transformer (T1)

    Cut and strip the wire, making it just long enough to reach to the remaining SECONDARY pad. (Figure 15) Solder the wire to the remaining SECONDARY pad. (Figure 15) SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 19 of 57...
  • Page 20 RF Linear Amplifier PCB Assembly Manual PRIMARY SECONDARY MOUNTING PRIMARY SECONDARY Figure 15 SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 20 of 57...
  • Page 21 RF Linear Amplifier PCB Assembly Manual Details of T1 installation. Figure 16 Figure 17 SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 21 of 57...

  • Page 22: Step #8 - Output Transformer (T2)

    Cut and strip the wire, making it just long enough to reach to the remaining SECONDARY pad. (Figure 18) Solder the wire to the remaining SECONDARY pad. (Figure 18) SECONDARY MOUNTING SECONDARY Figure 18 SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 22 of 57...
  • Page 23 RF Linear Amplifier PCB Assembly Manual Details of T2 installation. Figure 19 Figure 20 SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 23 of 57...

  • Page 24: Step #9 - Electrolytic Capacitor (C1, C2, C7, C8,)

    PCB BEFORE SOLDERING. Insert electrolytic capacitors into the PCB at the designated locations. (Figure 21) Solder capacitors into position. Cut off the excess lead length. Figure 21 SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 24 of 57...
  • Page 25 RF Linear Amplifier PCB Assembly Manual Details of electrolytic capacitor installations. Figure 22 Figure 23 SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 25 of 57...

  • Page 26: Step #10 - Ceramic Capacitor (C3, C4, C5, C6, C9, C10, C11, C12, C13, C14, C15, C16, C18)

    IMPORTANT - CERAMIC CAPACITORS ARE NOT POLARIZED AND CAN BE INSTALLED IN EITHER DIRECTION. Insert ceramic capacitors into the PCB at the designated locations. (Figure 24) Solder capacitors into position. Cut off the excess lead length. Figure 24 SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 26 of 57...
  • Page 27 RF Linear Amplifier PCB Assembly Manual Details of ceramic capacitor installations. Figure 25 SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 27 of 57...

  • Page 28: Step #11 - Mica Capacitor (C17, C19, C20, C21)

    Solder capacitors into position. Cut off the excess lead length for C19, C20, C21. Position C17 on T2 as shown and solder in place. (Figure 27) Figure 26 SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 28 of 57...
  • Page 29 RF Linear Amplifier PCB Assembly Manual Details of mica capacitor installations. Figure 27 Figure 28 SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 29 of 57...

  • Page 30: Step #12 - Relay (Rly1)

    ORIENTATION. MAKE CERTAIN THE RELAY IS FULLY SEATED IN THE PCB BEFORE SOLDERING. Insert RLY1 into the PCB at the designated location. (Figure 29) Solder RLY1 into position. Cut off the excess lead length. Figure 29 SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 30 of 57...
  • Page 31 RF Linear Amplifier PCB Assembly Manual Details of RLY1 installation. Figure 30 SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 31 of 57...

  • Page 32: Step #13 - Field Effect Transistor (Q2, Q3)

    TRANSISTORS WITH THE FLAT SIDE AS SHOWN. Insert transistors into the PCB at the designated locations. (Figure 31) Solder transistors into position. Cut off the excess lead length. FLAT FLAT Figure 31 SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 32 of 57...
  • Page 33 RF Linear Amplifier PCB Assembly Manual Details of transistor installations. FLAT FLAT Figure 32 SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 33 of 57...

  • Page 34: Step #14 - Bipolar Power Transistor (Q5)

    Place the PCB on a flat surface with the transistors in position and solder from the top of the PCB. Cut off the excess lead length. Figure 33 SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 34 of 57...
  • Page 35 RF Linear Amplifier PCB Assembly Manual Details of lead forming. Figure 34 Details of Q5 installation. Figure 35 SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 35 of 57...

  • Page 36: Step #15 - Voltage Regulator (U1)

    Place the PCB on a flat surface with the regulator in position and solder from the top of the PCB. Cut off the excess lead length. Figure 36 SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 36 of 57...
  • Page 37 RF Linear Amplifier PCB Assembly Manual Details of lead forming. Figure 37 Details of U1 installation. Figure 38 SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 37 of 57...

  • Page 38: Step #16 - Field Effect Power Transistor (Q1)

    Place the PCB on a flat surface with the transistors in position and solder from the top of the PCB. Cut off the excess lead length. Figure 39 SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 38 of 57...
  • Page 39 RF Linear Amplifier PCB Assembly Manual Details of lead forming. Figure 40 Details of Q1 installation. Figure 41 SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 39 of 57...

  • Page 40: Step #17 - Field Effect Rf Power Transistor (Q4, Q6)

    Place the PCB on a flat surface gently bending the transistors into their final flattened position and solder from the top of the PCB. (Figure 44) Cut off the excess lead length. Figure 42 SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 40 of 57...
  • Page 41 RF Linear Amplifier PCB Assembly Manual Details of lead forming. Figure 43 Details of transistor installations. Figure 44 SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 41 of 57...

  • Page 42: Step #18 - Toroid Rf Choke (L1)

    L1. Solder the remaining orange wire to one of the remaining L1 pads. Solder the remaining blue wire to the last remaining pad of L1. Figure 45 SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 42 of 57...
  • Page 43 RF Linear Amplifier PCB Assembly Manual Details of L1 installation. Figure 46 SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 43 of 57...

  • Page 44: Step #19 - Heat Sink Marking, Drilling, And Tapping

    ** A transfer punch is a punch of a specific outer diameter that is non-tapered and extends the entire length of the punch (except for the tip). It is used to tightly fit the tolerances of an existing hole and, when struck, precisely transfer the center of that hole to another surface. SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM...

  • Page 45: Step #20 - Switch, Led, And Dc Power Wiring (On/Off, Pwr Led, Ssb Delay, Xmit Led, +48V)

    RF Linear Amplifier PCB Assembly Manual Step #20 - Switch, LED, and DC Power Wiring (ON/OFF, PWR LED, SSB DELAY, XMIT LED, +48V) The SkyWave DX600 has been designed to accommodate two switches †† and two LED ‡‡ indicators.
  • Page 46 RF Linear Amplifier PCB Assembly Manual Details of wiring installations. Figure 49 Figure 50 SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 46 of 57...
  • Page 47 RF Linear Amplifier PCB Assembly Manual Details of wiring installations. (continued) Figure 51 SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 47 of 57...

  • Page 48: Step #21 - Coaxial Cable (Rf In, Rf Out)

    ORIENTATION. THE BRAIDED PORTION OF THE CABLE IS ALWAYS ATTACHED TO GROUND (GND). Solder the two coaxial cables at the proper designated positions on top. (Figure 52) Figure 52 SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 48 of 57...
  • Page 49 RF Linear Amplifier PCB Assembly Manual Details of coaxial cable installations. Figure 53 SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 49 of 57...

  • Page 50: Step #22 - Pcb Mounting To Heat Sink

    Figure 54 §§ There are several internet sites that sell extruded aluminum heat sinks designed for RF power amplifiers. Several are listed below. Telstar Electronics takes no responsibility for the content of the links and does not endorse any specific product or service.
  • Page 51 Install 3/8” long #4-40 machine screw with lock washer and flat washer into Q4 and Q6. Starting with Q4 and Q6, tighten all nine #4-40 screws to 6 in/lbs. SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 51 of 57...
  • Page 52 RF Linear Amplifier PCB Assembly Manual Example of installed circuit board. Figure 56 SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 52 of 57...

  • Page 53: Step #23 - Bias Adjustment

    RF Linear Amplifier PCB Assembly Manual Step #23 - Bias Adjustment The SkyWave DX600 amplifier has been designed to operate with class-AB biasing. IMPORTANT – TO KEEP AMPLIFIER HARMONICS TO SPECIFIED LEVELS, THE BIAS MUST BE ADJUSTED PRIOR TO THE AMPLIFIER BEING PUT INTO SERVICE.

  • Page 54: Step #24 - Amplifier Operation

    Set S2 (SSB DELAY) switch to the “ON” position only if transmitter is in SSB mode. Set S1 (ON/OFF) switch to the “ON” position. The amplifier is now ready for operation… SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 54 of 57...

  • Page 55: Troubleshooting

    Check for short circuits on top and bottom of circuit board from faulty soldering. Short Circuits. Check for short circuits from bottom of circuit board to heat sink. SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 55 of 57...

  • Page 56: Specifications

    Solder Mask & Silkscreen *** Decibels below carrier. ††† An antenna system with an SWR of 1.5:1 or less is critical for optimal amplifier operation. ‡‡‡ Standing Wave Ratio. SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 56 of 57...

  • Page 57: Rf Performance

    RF Linear Amplifier PCB Assembly Manual RF Performance Power Output @ 48V/28MHz (Typical) INPUT (WATTS PEP) SkyWave DX600 Revision-B Last Revised - 2/5/2021 9:10 AM Page 57 of 57...

Table of Contents