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EA3GCY ILER-40MK2 Assembly Manual

Qrp ssb transceiver kit
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ILER-40 MK2
QRP SSB Transceiver Kit
Assembly manual
Version 2, last update: June, 2017
Translated by Marlin, KC0O
ea3gcy@gmail.com
:
www.qsl.net/ea3gcy
Most recent updates and news at
ILER-20 MK2 SSB Transceiver kit
Thanks for constructing the
Have fun assembling it and enjoy QRP!
73 Javier Solans, ea3gcy
ILER-40 MK2 SSB QRP Transceiver Kit
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  • Page 1 Translated by Marlin, KC0O ea3gcy@gmail.com www.qsl.net/ea3gcy Most recent updates and news at ILER-20 MK2 SSB Transceiver kit Thanks for constructing the Have fun assembling it and enjoy QRP! 73 Javier Solans, ea3gcy ILER-40 MK2 SSB QRP Transceiver Kit Page 1...

  • Page 2: Table Of Contents

    INDEX INDEX ........................... INTRODUCTION ........................3 SPECIFICATIONS ........................ TIPS FOR FIRST TIME BUILDERS ..................PARTS LIST SORTED BY VALUE/QUANTITY ..............INDIVIDUAL PARTS LIST....................120-QUADRANT COMPONENT LAYOUT MAP ..............13 ASSEMBLY ......................... 14 ADJUSTMENT AND TESTING ................... 27 IF YOUR KIT DOES NOT WORK AFTER FINISHING ASSEMBLY ........32 LIMITED WARRANTY ......................

  • Page 3: Introduction

    INTRODUCTION What is the significance of ILER? A little bit history… The origin of LLEIDA goes back to 5th century B.C. when the Iberian people of the ILERGETAS settled on top of the "Cerro de la Seu Vella" (Hill of the Old See) and founded the city of ILTIRDA.

  • Page 4: Specifications

    Acknowledgments To Andy, SP5AHT, for his important contribution to the world of amateur radio. To Jon Iza, EA3SN, for his educational articles and contribution to technical data. To Luis EA3WX, Juan EA3FXF, Jaime EA3HFO, Alfonso EA3BFL and to J. Antonio Beltrán for the help they gave in making this kit a reality, from the first prototype to the current ILER-17.

  • Page 5: Tips For First Time Builders

    PLEASE READ ASSEMBLY INSTRUCTIONS COMPLETELY AT LEAST ONCE BEFORE BEGINNING. TIPS FOR FIRST TIME BUILDERS Tools required: - A 15-30w soldering iron with fine tip, small wire cutters for cutting component leads, wire strippers, long-nose pliers, needle-nose pliers, X-Acto knife, screwdriver for M3 screws, alignment tool for adjusting IF transformers.
  • Page 6 Finding the correct component: IC's The component outline for the IC printed on the circuit board has a “U” shaped notch on one end, indicating the end at which pin 1 of the IC is located. There is a similar notch on one end of the IC socket that should be oriented over the “U”...

  • Page 7: Parts List Sorted By Value/Quantity

    PARTS LIST SORTED BY VALUE/QUANTITY Resistor list Value Checked Ref. Identified R33, R51, R57, R60, R61 brown-black-gold brown-black-black R15, R56 red-red-black R13, R39, R50, R52 brown-black-brown red-violet-brown R46, R54 yellow-violet-brown R2, R7, R10, R16, R30, R38, R42, R47, R53, R59, R62, R63 brown-black-red brown-red-red brown-green-red...
  • Page 8 Semiconductors list Type Checked Ref. Identified Transistors BC547 Q1, Q2, Q3, Q4, Q5, Q6, Q7, Q8, Q9, Q10, Q11 BC547 2N2222 2N2222 2N5109 2N5109 1 2SC1969/2078 Q14 2SC1969 or 2SC2078, washer + mica spacer C1969 or C2078 Integrated circuits LM741 LM741CN or UA741 SA/NE602 IC2, IC3...

  • Page 9: Individual Parts List

    LIST OF INDIVIDUAL COMPONENTS Resistors Checked Ref. Value Ident./Comment Circuit section Located brown-black-black RX att. B-10 brown-black-red RX att. C-10 brown-black-orange Mic. Preamp yellow-violet-red Mic. Preamp brown-black-orange Mic. Preamp 100K brown-black-yellow Mic. Preamp brown-black-red Mic. Preamp green-blue-orange DSB gen/RX mix green-blue-orange DSB gen/RX mix brown-black-red...
  • Page 10 red-red-black TX Driver brown-black-gold TX Driver (BIAS) red-violet-brown BIAS TX Out Amp C-3/4 brown-black-red TX Out Amp brown-black-gold TX Out Amp B-1/2 brown-black-gold TX Out Amp A-1/2 brown-black-red Bi-color LED brown-black-red Bi-color LED 1K If Q14 = 2SC1969 TX Pre-driver brown-black-red 3K3 If Q14 = 2SC2078 TX Pre-driver...
  • Page 11 100n 104 or 0.1 BFO offset 220p n22 or 221 220p n22or 221 102 or 0.001 100n 104 or 0.1 10uF 10uF 25V or 35V (elec) BFO/VXO supply 100n 104 or 0.1 BFO/VXO supply 100n 104 or 0.1 K-3/4 100p n10 or 101 K-4/5 100p...
  • Page 12 BC547 BC547 Audio AGC preamp BC547 BC547 Audio AGC preamp I-10 BC547 BC547 Audio amp mute BC547 BC547 (option) BFO offset switch BC547 BC547 BC547 BC547 BC547 BC547 2N2222A 2N2222A TX Pre driver I-1/2 2N5109 2N5109 TX Driver C/D-1 2SC1969/2078 2SC1969 or 2SC2078 TX Out Amp A-2/3...

  • Page 13: 120-Quadrant Component Layout Map

    120-QUADRANT COMPONENT LAYOUT MAP ILER-40 MK2 SSB QRP Transceiver Kit Page 13...

  • Page 14: Assembly

    ASSEMBLY You can use the “individual parts list” or the “value/quantity parts list.” Using the “value/quantity parts list” is the quickest way to mount components since all the circuit board components of the same value or type can be placed one after the other. However, you will need the “individual parts list” to know how each component is identified and its location on the circuit board.
  • Page 15        Axial Inductors L1, L2, L3, L4 L5, L7, L9 These components look like thick-bodied resistors and the body is colored blue or green. In its interior there is a small coil wound on a ferrite core. Refer to the parts list to select the correct component for each location.
  • Page 16   Capacitors There are ceramic, polystyrene (styroflex) and electrolytic capacitors. They all have their value printed on the body. Refer to the “identified” column in the parts list. When you mount them, make sure to leave the leads as short as possible. C79, C80 and C81 are polystyrene capacitors;...
  • Page 17    Pin "headers" Place and solder the pins in Mic(3), 12V(2), ATT(2), P1-RXG(3), ANT(2), ALT(2), D7(2), VXO(2), BFO(2), J1(3), J2(2), K1(1), K2(1), and S(2). Place “jumpers” between pins “J2” and “J1-B” and between the active pins of “P1-RXG” (if RX gain potentiometer is not used).
  • Page 18   Integrated circuits The component outline for the IC on the circuit board has a “U” shaped notch on one end, indicating the end at which pin 1 of the IC is located. There is a similar notch on one end of the sockets. This should be oriented over the "U"...
  • Page 19 The ILER-20 has two options for the VXO crystals X6 and X7; option A uses a pair of 12.031MHz crystals and option B uses one 12.096MHz crystal. If you use 12.031MHz crystals, you must open the legs carefully to insert in its place. They have an insulating sheet and can touch the board.
  • Page 20          Toroidal transformer T5 T5 is an impedance matching transformer. A FT37-43 is used (black toroid with 9.5mm/0.375in OD). It has a 10-turn primary and a 3-turn secondary. - Take 17cm (7.5”) of 0.5mm diameter enameled wire and wind ten (10) turns on a black FT37-43 toroidal core.
  • Page 21 IMPORTANT: Wind the toroid exactly as shown in the pictures. You must pay attention to number of turns as well as to the direction of the winding.    Toroidal transformer T6 T6 is an impedance matching transformer with a bifilar winding. A FT37-43 is used (black toroid with 9.5mm/0.375in OD).
  • Page 22 - Before beginning to wind, leave 15-20mm of wire, measured from the end of the wires to the outer edge of the toroid. Now wind eight (8) turns on the toroid. Remember: Count one turn for every time the wire passes through the center of the toroid. - Spread the turns evenly around the toroid.
  • Page 23   VXO tuning Polyvaricon CV2/CV3 Install the hardware shaft onto the polyvaricon with the 12mm-long, M2.5 screw. Mount the Polyvaricon with a separation of 2-3mm or more from the board (see picture). This makes it easier to fit the variable cap to the front panel. Please, do not solder it until you are sure of how you are going to mount the board into the box.
  • Page 24   L6 VXO tuning inductor A T68-2 is used (red toroid with 18mm/0.690in OD). Cut about 113cm (44in) of 0.3mm enameled wire. The number of turns for L6 will depend on the crystal option that you have chosen for the VXO: - If you use the 12.031MHz crystal pair, then wind fifty-four (54) turns.
  • Page 25   Jumpers "E-C-x-y", positioning of the Q14 and D7 The combination of jumpers “E-x-C-y” allows the use of different types of transistors for Q14. If need be, we can use substitutes with different lead configurations. The ILER-40 kit uses a 2SC1969 or 2SC2078 for Q14 and the following the jumpers SHOULD BE INSTALLED: “E-y”...
  • Page 26   Terminals “ATT” for enabling the RX attenuator The header pins labeled “ATT” (located in quadrant D-10) can connect to a simple switch to activate the receive attenuator. The attenuation level is inversely proportional to the value of R1, which takes a part of the signal from the antenna to ground.

  • Page 27: Adjustment And Testing

    ADJUSTMENTS AND TESTS  Preliminary Testing - Adjust P3 (carrier suppression), P4 (volume potentiometer), and P5 (bias adjustment) to mid-position. - Adjust P2 (mic gain) to minimum position (counterclockwise). - Connect a speaker or headphones to the “ALT” pins on the circuit board. IMPORTANT: Use a high-quality speaker box.
  • Page 28 Option X6-X7 = 12.031Mhz. J1-B T68-2= 54 turns Maximum Minimum X6-X7 = 12.031Mhz. Coverage 12.020 7.105 11.955 7.040 65Khz Option X7 = 12.096Mhz. J1-B T68-2= 55 turns Maximum Minimum X7 = 12.096Mhz. Coverage 12.085 7.170 12.015 7.100 70Khz Values are strictly illustrative. They will be influenced by the number of turns on L6, the rear fine tuning trimmer adjustment and the component tolerances.
  • Page 29 2) The most effective and cleanest option is to use a small plastic tie-wrap, passing it through the holes in the circuit board as showing in the picture. Once the tie-wrap is fully tightened, you will still be able to move the turns slightly and make slight adjustments before securing them with a little bit of nail polish.
  • Page 30 - Adjustment with instrumentation (requires a frequency counter): Turn on the transceiver. Leave it on for about 5 minutes. Connect the frequency counter to the “BFO” header. If the input of the frequency counter is low impedance, insert a 470 ohm (or greater) resistor or a small value capacitor (try 22pF or less) between the frequency counter and the header to reduce the interaction with the BFO.
  • Page 31  Adjustment of the TX passband, T3 and T4 Note: For this adjustment you will need an “alignment” tool suitable for this type of coils; if you use a screwdriver, you risk of breaking the core of the coil. Connect a power meter with a 50 ohm load to the antenna jack. I suggest two options for adjusting the transmitter passband: 1) If you have access to an audio generator, set the mic gain (P2) to half range and injects a signal of around 800-1000Hz.

  • Page 32: If Your Kit Does Not Work After Finishing Assembly

    - If you decide that technical assistance is needed, you are welcome to send an email to ea3gcy@gmail.com. As a last resource, you may send the kit in for repair; however, I will have to charge for any repairs done, although I will try to keep the cost as moderate as possible.
  • Page 33 IC Ref. Type pin5 Rx pin5 Tx pin6 Rx pin6 Tx pin7 Rx pin7 Tx pin8 Rx pin8 Tx LM741 6.25 13.2 SA602 5.45 5.14 5.95 5.95 SA602 LM386 6.65 13.5 6.80 1.35 Transisto Type B Rx B Tx E Rx E Tx C Rx C Tx...

  • Page 34: Limited Warranty

    Please, BEFORE returning a product, request instructions by email at: ea3gcy@gmail.com Javier Solans, EA3GCY, warrants this device to function according to the specifications, provided that it is assembled and adjusted as described in this documentation, and used correctly according to all provided instructions.

  • Page 35: Schematic

    SCHEMATIC ILER-40 MK2 SSB QRP Transceiver Kit Page 35...

  • Page 36: Wiring

    WIRING The ILER-40 wiring is very simple, as long as you remember that: - For the antenna connection use a thin, RF-rated coaxial cable such as RG-174 or similar. - If you install the tuning polyvaricon off the circuit board, you should use short and stiff wires, as the mechanical stability is very important.

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