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HFPA V4 R6 CONSTRUCTION MANUAL
HF PACKER –AMP VERSION 4 REV 6
www.hfprojects.com vstamps@comcast.net
281-467-9424
Revised 10/10/15
Rev 6 of the HF PackerAmp V4 includes LED indication for
the band of operation plus all the features of Rev 5. The
amp circuit board (R5) remains unchanged but there are
significant additions warranting the Rev 6 designation for
the project. Changes are:
1. The Low Pass Filter Module (LPF) is revised to
include an interface cable for the LED module (HFPA-
FILTER-12 R1).
2. A new LED Module (LEDM-100 R0) including an
interconnecting cable between the LED and the LPF.
3. The chassis revised to include the holes for the
LED module.
4. The front panel silk screen was revised for better
clarity.
HF Packer-Amp V4 R6
Revised 10/10/2015
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Summary of Contents for HF PackerAmp V4
- Page 1 281-467-9424 Revised 10/10/15 Rev 6 of the HF PackerAmp V4 includes LED indication for the band of operation plus all the features of Rev 5. The amp circuit board (R5) remains unchanged but there are significant additions warranting the Rev 6 designation for the project.
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Page 2: Table Of Contents
Install Relays and Diodes ..........17 Contents Capacitor Assembly ............17 Circuit Details ..............5 Core Winding Table ............18 Performance ................ 6 Core Winding Technique ..........18 Terms used in the descriptions ..........6 Core Installation ..............19 Preparation ................7 Switch Assembly ............... - Page 3 TO-220 THERMASIL III with adhesive back ...... 30 Section SIX – Specifications and Operation ......42 IRF510 MOSFET Lead Bend ..........30 Specifications..............42 MOSFET Attachment to the Circuit Board ......31 Operation ................42 Circuit Board and Case Assembly Procedure ....31 Do’s and Don’ts for Successful Operation ......
- Page 4 Panel LED ..............48 MOSFET AMP HFPA 10 Schematic ......48 Pi-resistive Network ............48 L2 and T3............... 48 T2 .................. 49 T1 .................. 49 BIAS ................49 BIAS Adjustment ............49 Heat Sinking the MOSFETs ........... 49 HFPA FILTER MODULE 12 ..........50 J1, Filter Input ..............
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Page 5: Circuit Details
12 volt DC supply. In this in the 2001 ARRL Handbook and in reprint articles from the section, you are introduced to the building of the HF Packer ARRL. If you are an ARRL member, you can view the amplifier Amp. -
Page 6: Performance
The chart shows the typical gain vs frequency you can capacitors C4, C6, C8 and C1 remove RF voltages from the expect from the HF Packer-Amp. The average power out is bias supply voltage. Gate bias for Q1 and Q2 is controlled approximately 35W. -
Page 7: Preparation
• TX - Transmit After reading this document and prior to assembly you • On/Standby – TX Enable should do an inventory of parts (Appendix A-C). In the unlikely • LPF – Low Pass Filter event that you appear to have missing parts, duplicates or •... -
Page 8: Suggested Tools
ensure all circuit board pads and component leads are LCR meter (used to measure inductance and capacitance) clean (not a problem with this project because boards Crimp tools for Molex pins and Power Pole Terminals and components are new) Included Speciality Tools ensure the soldering iron tip is at its working ... -
Page 9: Care Of The Irf-510 Mosfet's
Install all low profile components first: usually resistors, required. Tuning time with full power should be limited to less capacitors, diodes, then electrolytics and active than 30 seconds with 1-2 minutes between cycles to prevent components. overheating. Operating at 29VDC does not press the MOSFET ... -
Page 10: Section Two - Amplifier Module Construction
• Section Two – Amplifier Module Construction Insert RL251 diode at D5. The leads are bent approximately 1/8 inch away from the body to fit the Circuit Board ID is HFPA-2013 V 4 R5 component outline on the board. Make sure cathode bar on the part matches the cathode symbol on the silk ... - Page 11 • leads are adjusted to fit the hole pattern. The ends are Insert one 78L05 regulator (3 pin TO92 package) at not symmetrical. Install the bent lead to the right as U1. Match the outline. • shown. Press the component flat on the circuit board. Insert four 2N5089 transistors (3 pin TO92 package) at ...
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Page 12: Spacer Assembly
part flush. Solder other pin repeating reflow and alignment. Flush cut leads and reflow. Install • Insert one 100 uF Capacitor at C15. The long lead (+) goes to the square pad of outline near the (+) symbol on the board. Solder one pin, reflow and align part flush. -
Page 13: Fabrication And Assembly Of T2
• come loose when removing the circuit board from the Separate and scrape the ends of the wires so you can case in the future. measure continuity and isolation to determine the start and • Locate two 4-40 x ¾ inch threaded round spacer and finish of each wire. -
Page 14: Fabrication And Assembly Of T3
Holding the two wires together in one hand with the cores at the bottom of the U-Shape, grasp the wire in the rear and insert the wires on the front right side through the core four additional times. Pull each wrap snug. -
Page 15: Fabrication And Assembly Of L2
• Use a ¼ inch drill bit as a winding form and wrap 10 complete turns of the wire tightly around the drill bit. • Trim the excess lead length to ½ inch and tin the leads. • Insert L1 and L3 into the L1 and L3 positions on the ... -
Page 16: Clean And Inspect The Board
• The secondary is a 10 inch white #20 AWG Teflon coated wire. There will be 3 loops through the cores. • Make a U shape of the 7 inch yellow wire and insert into the two tubes. Equal distance the wires. •... -
Page 17: Section 3 - Low Pass Filter Module Assembly
Section 3 - Low Pass Filter Module Assembly Wind the cores referring to the core winding table "REALLY CHECK THE POLARITY OF THE DIODES FOR THE RELAYS ON THE LPF BOARD" Install Relays and Diodes Install the six diodes on the circuit board observing that the stripe on the diode matches the board silkscreen for the part. -
Page 18: Core Winding Table
Core Winding Table Core Winding Technique Wire The starting position: Divide TYPE IND. Clock the wire in half letting the L1, L2 T68-1 5.08 uH core hang down. The wire (BLU) L3,L4 T50-2 2.65 uH passing through the core (RED) counts as one turn. -
Page 19: Core Installation
Switch Assembly If the core does not fit the pattern (wound wrong), do not Insert the switch on the top side of the assembly. Make sure try to make it work, strip the wire and wind it again correctly. ... -
Page 20: In-Circuit Tuning Adjustments
In-Circuit Tuning Adjustments Selector Switch Stop Pins Installation If you have a miniVNA device for your PC you can adjust the filter in real-time for the best response curve. If you do not, you can use the clock method of lead spacing and you should be pretty close. - Page 21 LED Module Assembly Note that the LED long lead is at the top. The LEDs mount on the side of the board without silk screen information. It is best The LED Module consists of 6 LED’s, a resistor and a 8-pin to use the front panel as a temporary jig to hold the LEDs in connector with a flat cable interface between the LED Module position while soldering one pin on each LED.
- Page 22 The LED Module and the Low Pass Filter Module are mated together with a 2.3 inch 8-conductor flat cable. To assemble, position the two circuit boards to be connected and plug together. Fit a length of double-side tape to the circuit board as shown and trim excess.
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Page 23: Section 4 - Case And Chassis Assemblies
• Prepare two 1 3/8 inch lengths of black TEF 24AWG Section 4 – Case and Chassis Assemblies wire by stripping 1/8 inch from each end. Tin one end. Case Preparation • Use a hobby knife to expose bare metal around the •... -
Page 24: Rf Output Cable
• Clamp the cable at the threads of the BNC with the 4 inch plastic Ty-wrap. See RF IN RF OUT and PTT Wires picture RF Output Cable HF PACKER AMP V4R6 Page 24... -
Page 25: Low Pass Filter Input Cable Fabrication
Solder the black wires to the shields. Use a heat sink • clamp next to the coax so the heat does not reach the The cable is routed along one edge under the circuit board to relieve cable congestion in the box. center conductor. HF PACKER AMP V4R6 Page 25... -
Page 26: Low Pass Filter Output Cable Fabrication
¼ inch black heat shrink tubing. View the sure that you have J2 oriented in the same way as picture on the next page for the finished cable shown in the picture at right. appearance. HF PACKER AMP V4R6 Page 26... -
Page 27: On/Bypass Switch And Led Wiring
Attach two 5 inch lengths of hook up wire to the small rocker switch. Shrink with ¼ inch red shrink tubing. Cable Pictures courtesy of Bruce Baskett The switch can be damaged with too much heat. HF PACKER AMP V4R6 Page 27... -
Page 28: Power Pole Physical Installation
LED. The depressed switch lever would The Power Pole housing can be joined in various ways. be next to the LED. There is one standard that is used on the HF PACKER-AMP. • Insert the LED into the hole adjacent to the rocker Looking at the front of the red/black housing, mate the two switch. -
Page 29: Power Wiring Connections
Crimp one end of a 4 inch length, #14AWG RED Teflon coated wire to a Blue Flag Terminal. • Crimp the other end to a Power Pole (PP) 30A Terminal. • Insert PP Terminal into the RED PP housing. HF PACKER AMP V4R6 Page 29... -
Page 30: Thermasil Iii With Adhesive Back
To aid in keeping the ceramic washers in place, I screw them down tight and let them set for a while before removing the screws. This step will encourage the washers to stay in place during final assembly. HF PACKER AMP V4R6 Page 30... -
Page 31: Mosfet Attachment To The Circuit Board
MOSFETs. You should have a very high megohm or Circuit Board and Case Assembly Procedure infinite reading on the meter. This measurement is made before any cables are attached to the board. HF PACKER AMP V4R6 Page 31... -
Page 32: Lt1270A, U4 Attachment To The Heat Sink
The LT1270A, U4 part is attached to the spacer by passing a 4-40 x ¼ inch screw through the tab of the part and screwing into the spacer. No insulator is required or desired. HF PACKER AMP V4R6 Page 32... -
Page 33: Pinet 100-Pi Option Module
• Strip ½ inch insulation from each end. Twist the braid ohm resistor at R3. This is the new 2dB pi-resistive and trim to ¼ inch. Tin the braid and attach a black network. HF PACKER AMP V4R6 Page 33... - Page 34 The silk screen shows two dashed lines indicating where the cables are attached. • Remove L2 from the circuit board if installed. It will not be used. We will attach the PI-networks to these holes. HF PACKER AMP V4R6 Page 34...
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Page 35: Attach The Model Pi-100 Module
set to 5W for testing procedure of Amp Cable Connections on the Model PI-100 Module • Plug in the two RF Cables to J1 and J2. • Attach the Power Cable to J4. HF PACKER AMP V4R6 Page 35... -
Page 36: 100-Pi Theory Of Operation
A 2dB resistive pi network is installed on the AMP module. Add additional attenuation using the PINET 100-PI module. Choices are 2dB, 6dB and 9dB corresponding to 1W, 2.5W and 5W Max RF Input scales. HF PACKER AMP V4R6 Page 36... -
Page 37: Section Five - Adjustment And Testing
The current passing through the red wire registers on • Attach a watt meter and dummy load in series to the the meter. SO239 RF Output connector. Test cable puts the meter in series with the Red wire. Test Mode Setup HF PACKER AMP V4R6 Page 37... -
Page 38: Rf Signal Testing
Measure from case ground to the right side of R18. Voltage Test • Key the XCVR. The voltage switches from 0.0VDC to It is handy to have a second multi-meter to make a about 29.5VDC. voltage measurement s while monitoring current. If a HF PACKER AMP V4R6 Page 38... -
Page 39: Lpf Rf Testing
‐DC Converter "Be careful when probing around the DC have received one user report of the chip arcing and going HF PACKER AMP V4R6 Page 39 1. The RF In cable normally at J3 on the amp board is... -
Page 40: Rf Power Testing
Frequency vs Watts vs Amps Table. • Frequency vs Watts vs Amps Plot Plot your Power Out and Amps results vs Frequency. Power Input Constant at 5W set for each band HF PACKER AMP V4R6 Page 40... -
Page 41: Ptt Connections Flex 1500 And Ft817
ACC jack on the FT817 (PTT). Do not connect the ground as the Amp and Radio are already referenced to the same ground. Using an additional ground connection has been reported to cause distortion. HF PACKER AMP V4R6 Page 41... -
Page 42: Section Six - Specifications And Operation
Fan Size: 2.25 x 2.25 x 1.2 inch (60mm) 12V, 24 CFM for other attenuation levels to work from the range of 0.1W up LP Filter Switch: 6 position 160, 80/75, 60/40, 30/20, 17/15, to a practical 5W limit. Contact HF Projects for more specific 12/10 •... -
Page 43: Do's And Don'ts For Successful Operation
Replace both MOSFETs: Always replace both. Spares Normal SSB use will exceed 2.5 seconds of carrier in normal conversation at some point. are available from Radio Shack or HF Projects. If you hear the relay chattering between syllables it •... -
Page 44: Section 7 Theory Of Operation And Troubleshooting
The thermal circuit breaker is the tan polarized correctly. The industry has a certain way of joining HF PACKER AMP V4R6 Page 44 colored tab that is mounted by its tips to the circuit board. Why... -
Page 45: Dc-Dc Converter, U4
U4 chip pin 2 switches the AMP from transmit to receive. This can be (FB) or feedback pin. The sampled voltage on pin 2 is visualized (somewhat on the timing diagram shown on the HF PACKER AMP V4R6 Page 45... -
Page 46: U4 Control
TX. K2 is used to divert the RF doing its job. What is the most likely thing to cause a short- output from the transceiver to the AMP input. (Signal name HF PACKER AMP V4R6 Page 46... -
Page 47: Tx Signal Generation
IPS signals to +5V and pin 5 of U2 will be 0V. The fan the Push-To-Talk input sensed on pin 3 of J4. This would be output does not operate in the TEST mode. HF PACKER AMP V4R6 Page 47... -
Page 48: Fan Option J6
L2 and T3 The signal out of the pi-resistive network next passes through L2 , an impedance matching, to reach T3. The function of T3, HF PACKER AMP V4R6 Page 48 1:1 BALUN is to provide two outputs with 180 degrees phase... - Page 49 PAD below. Things to consider are the cleanliness of the SIL- The bias adjustment puts the MOSFETs slightly into PAD installation (no burrs) and using alcohol to remove oily HF PACKER AMP V4R6 Page 49 conduction for each half cycle. The amount of bias was...
- Page 50 The relay input selection provides a high degree of isolation and improved filter overall performance. All of the HF bands are selected with 6 choices from the front panel switch. It is very important that the filter choice equal the band of operation. For instance operating on 15M with the filter set to 80M is a recipe for MOSFET failure.
- Page 51 29.5VDC at L2 and Grounds SW_VOLTS during (remove L2) transmit Replace R3,R7,R8 with 2dB values Set bias current, each MOSFET to 100mA Revised: 3/28/13 HF PROJECTS Title MOSFET AMP HFPAV4R5 Size Document Number HFPAV4R5 Date: Friday, April 19, 2013 Sheet...
- Page 52 FRONT 2N5089 PANEL SW_VOLTS short pins to turn on TEST R6 10K for testing +12V PIC16F688 or bias set. R10 1K 2N5089 +12V VOUT HF PROJECTS Title 78L05 CONTROL HFPAV4R5 Size Document Number HFPAV4R5 Date: Friday, April 19, 2013 Sheet...
- Page 53 F - 500 MS C - 10 MS G - 5 MS D - 15 MS H - 10 MS T/R RELAYS ACTIVATED DC-DC CONVERTER ON HOLD TIME HF PROJECTS Title INTELLIGENT POWER SWITCH ON PSU HFPAV4R5 Size Document Number HFPAV4R5 Date:...
- Page 54 F_HIGH A3020 B3020 TE 1-338068-8 8 PIN SW ROTARY 2P-6W F_LOW 580nH 470nH 430nH BAND SWITCH 100pF 220pF 220pF 47pF HF PROJECTS K5OOR Title HFPA FILTER MODULE 12 Size Document Number HFPA FM V4A Date: Thursday, March 20, 2014 Sheet...
- Page 55 LEDM100 DESIGN HF PROJECTS 3/12/14 12/10M 17/15M 30/20M 60/40M 80/75M 160M This is the LED Module Model LEDM100 R0 The dimensions are 1.525 x 0.475 inch with LED spacing 0.268 inch. JR1 is a little flat cable connector where a flat cable snaps in. ...
- Page 56 AND123G AND123G AND123G AND123G AND123G AND123G TE 1-338068-8 8 PIN HF Projects Title LED Display Module HFPA V4R5 Size Document Number Model LEDM100 R0 Date: Tuesday, March 11, 2014 Sheet...
- Page 57 APPENDIX A Inventory of Parts: HFPA V4 R5 Amplifier Module (revised: 5/17/13) HFPA 2013 V4 R5 Item Quantity Reference Description Part Number Circuit breaker 16V, 7A Hold 11.9A Trip 650-RGEF700 C1,C2,C3,C4,C6, CAP CER .1UF 50V C7,C8,C9,C22,C23 10% X7R 1206 581-SR201C104KAR CAP dip mica 47PF DM15...
- Page 58 APPENDIX A Cap, 1 uF 35V 10% Dip Radial Tantalum T350A105K035AT T350A105K035AT Mouser; Allied stk 581- 541-0548 TAP105K035SCS Diode, 1N4007 512-1N4007 Diode, MBR1060G MBR1060G Diode, 2.5A 100 PRV DO41 RL251-B Rectron Mouser 583-RL251- 583-RL251 KeyStone Electronics .25 PCB TAB 032TPBR H1,H2 Keystone 534-1287 534-1287-ST...
- Page 59 APPENDIX A Relay, 12VDC Non- latching Single coil P2 Tyco Electronics/ Axicom 655- K2,K3 V23079A1003B301 V23079A1003B301 Resistor 10K 1/8W R4,R5,R6 299-10K-RC INDUCTOR 70-IH- 5-50 RADIAL HI CUR 50uH DALE/VISHAY 70-IH-5-50 MOSFET, TO- 220AB N-Ch Power Q1,Q2 Fairchild IRF510 512-IRF510 2N5089 Small Signal Transistors NPN Gen Pur SS...
- Page 60 APPENDIX A Xicon 299-1M-RC Mouser 299-1M-RC Resistor, 27K 1/8W 299-27K-RC Socket, 14 pin DIP D2814-42 Harwin 855-D2814-42 R16, R22, Resistor, 1.2K 1/8W 299-1.2K-RC R17,R19 Resistor, 4.7K 1/8W 299-4.7K-RC Resistor, 3K 1/4W 291-3.0K-RC Core, Grey (0.5” T2,T3 FT50-43 Balun Core Binocular BN-43-3312 Intelligent Power...
- Page 61 APPENDIX A AMP PWR SWITCH REG 5 TO-220 NL27WZ14DTT1G RFM2 MODULE Pot, 10K 652- VR1,VR2 3362P-1-103 10K T93YA-10K Headers & Wire mating parts Housings 2P Molex 538-50-57-9402 Headers & Wire mating parts Housings Molex 3P 538-50-57-9403 Headers & Wire mating parts Housings Molex 4P 538-50-57-9404...
- Page 62 APPENDIX A Hex .187x.75 ALUM Spacer 4-40 tap 534-2029 Screw 4-40 x 3/16 inch Hex .187x .25 Spacer ALUM 4-40 tap 534-1891 Diode, Signal 1N4148 www.hfprojects.com vstamps@comcast.net 281-467-9424 ...
- Page 63 APPENDIX A PINET 100-PI Option Module Bill of Materials Item Quantity Reference Part Description Mfg/PN/Dist. D1,D2 Diode, 1N4007 863-1N4007G Mouser Jack Screw KeyStone 7228 839-0994 Allied Header .100 K.K. Connector 2 CKT J1,J2,J4 Molex 538-22-23-2021 Vertical PC Header .100 K.K. 3 CKT Molex 538-22-03-2031 538-22-03-2031 Relay, 12VDC Non- latching Single coil P2...
- Page 64 APPENDIX A Locking Ramp MOLEX 538-22-01- J1,J2,J4 Housing 2P 2027 J1,J2,J4 Terminals, crimp 538-08-50-0114 Wire, Black 5 inch Wire, Red, 5 inch Wire, Black 1.4 inch J1,J2 for pig tails Black Shrink Tubing J1,J2 1/2 inch length Bumper, peal/stick 517-SJ-5303CL Screw, 4-40 x 3/16 inch...
- Page 65 APPENDIX A www.hfprojects.com vstamps@comcast.net 281-467-9424 ...
- Page 66 Appendix B Inventory of Parts: Low Pass Filter Module Low Pass Filter Module Item Description and Typical Value Marking P/N Mfg C19,C24 Cap, 12pF 500V [ 120xxx ] Cap, 27pF 500V [ 27 ] C7,C20,C25 Cap, 39pF 500V [ 39 ] Cap, 47pF 500V [ 47 ] Cap, 68pF 500V [ 68 ] Cap, 82pF 500V [ 82 ]...
- Page 67 Appendix B L5,L6 Inductor T44-2 Inductor T37-6 Switch, Rotary, 18 Inch Shaft, Adjustable 71ADF30-01-2- Stop, 1 Deck, 2 Pole, Non-Shorting Wire, 24 AWG, 10 ft (24T) Belden 8052 Wire, 22 AWG, 38 inch Belden 8051 Circuit Board Headers & Wire Housings HSG 2P WITH mating parts LKG RAMP 538-50-57-9402...
- Page 68 APPENDIX C Inventory of Parts: Case Assembly Revised 1/12/2014 FAN Assembly Option Item Quantity Reference Description Part Number FS6020 Screw Set S001Z80N Heat Sink Alpha NovaTech FS6020PF FS6030PF Fan 60x25mm 12V 4500RPM 24CFM 35DB Ball Bearing OD6025- Orion OD6025HB 12HB Finger Guard 60mm Plastic Orion Fans G60-P...
- Page 69 APPENDIX C Case Assembly and Special Tools Item Quantity Reference Description Part Number Heat Sink AAVID Omit if fan (black rectangular option ordered finned) 644-PLT1M- TyWrap 4 inch Mating Power Pole 30A Connector Red/Black PP30-50 Switch Power Rocker 611- DA102J12S215HQF 676-0031 Knob BLK AL KNRLD IND LN...
- Page 70 APPENDIX C Eagle Cable Mounting & Accessories 1/8" HVY DTY CLIP 561-1250CC Alum oxide insulator Q1,Q2 TO220 DK 4171G-ND Screw 4-40 x 3/16 MSPPK0403 Screw 4-40 x 1/4 Pan PANPMS0404- Phil Black Oxide 10D4 Screw, 4-40 x 5/16 4-40 Hex Nuts Split lock Washer #4 Powerpole Mounting Clamp Pair for 2 or 4...
- Page 71 APPENDIX C 3/16 inch hex 4-40 threaded male/female Mouser 728- spacer, 5/16 inch FC4502-440- length. FASCOMP FC4502-440-SS Fabricated Cable Set Option (if ordered, uses cable components in fabrication) Item Quantity Reference Description Part Number RF In Cable RF Out Cable DC Power Cable Front Panel Cable LPF RF In Cable...
- Page 72 APPENDIX C required Shrink Tubing 1/8 inch x ¼ inch lengths as Bare Wire required FP301 1/8 Mouser 2 inch Covering RED 48" BK 5174-1184 530-CP-1094- RF In Cable Connector, BNC RF Out Cable Connector, SO239 25-7350 Switch TX On/Bypass PRK22J5BBBNN Switch, Rocker, ULTRA Front Panel...
- Page 73 APPENDIX C Wire Black #14AWG DC Power In Teflon black 4 inch Wire-TF-14- Terminals FLAG RECP 571- Power Wiring 16-14 BULK .250 x .032 35201332 Hookup wire, Black #24 Teflon 17 inch Cut to RF Cable 1.4 inch lengths for pig Ends tails LPF Control...
- Page 74 APPENDIX C LPF RF In Cable RG174 5.0 inch LED Panel Mount LED Front Indicators HI EFF RED panel switch DIFFUSED 5in WIRE 645-558- cable LEADS 0101-007F RF In, RF Out Core 23-43, 4 per cable Cable with shrink tube covers Terminals RING 22-18 RF Out Cable AWG 4...
- Page 75 Appendix D LPF Coil Set L1, L2 L3, L4 L5 L6 5.08uH 2.51uH 1.37uH 1.17uH L7 L8, L10 L9, L11 L12 580nH 470nH 430nH 360nH ...
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