ELECRAFT XV50 Assembly Manual
  1. Manuals
  2. Brands
  3. ELECRAFT Manuals
  4. Transceiver
  5. XV50
  6. Assembly manual
ELECRAFT XV50 Assembly Manual

ELECRAFT XV50 Assembly Manual

Xv series transverter
Hide thumbs Also See for XV50:
Table of Contents

Advertisement

Quick Links

Download this manual See also: Manual
Elecraft Transverter Models XV50, XV144, XV222
Assembly Manual
Rev E, Januar y 31, 2012
Copyright © 2012, Elecraft; All Rights Reserved

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the XV50 and is the answer not in the manual?

Questions and answers

Related Manuals for ELECRAFT XV50

Summary of Contents for ELECRAFT XV50

  • Page 1 Elecraft Transverter Models XV50, XV144, XV222 Assembly Manual Rev E, Januar y 31, 2012 Copyright © 2012, Elecraft; All Rights Reserved...

  • Page 3: Table Of Contents

    RF PCB ASSEMBLY – PART I ..............................26   RF PCB ASSEMBLY – PART II ..............................39     XV50 – 50 MHz Transverter....................................... 39   XV144 –144 MHz Transverter ......................................41   XV222 – 222 MHz Transverter ......................................44 RF PCB ASSEMBLY –...

  • Page 4: Introduction

    Elecraft at the time of order. Elecraft products transferred by the purchaser to a third party, either by sale, gift or other method, who is not disclosed to Elecraft at the wound with the leads tinned and ready to install from an Elecraft-qualified time of original order, are not covered by this warranty.

  • Page 5: Preparing For Assembly

    Preparing for Assembly Overview of the Kit Tools Required The Elecraft XV transverters use modular construction, both physically You will need the following tools to build this kit and electrically. This concept extends to the chassis (Figure 1). Any ...

  • Page 6: Preventing Electrostatic Discharge Damage

    Unpacking and Inventory Preventing Electrostatic Discharge Damage We strongly recommend that you do an inventory of the parts before Your XV transverter uses integrated circuits and transistors that can be beginning to assemble the kit. Even if you don’t count all the parts, an damaged by electrostatic discharge (ESD).
  • Page 7 Reading Resistor Color Codes It is very helpful if you learn to read the color codes. A color-code chart showing how to read the four-color bands on resistors with a 5% or 10% tolerance is shown in Figure 3. 1% resistors are similar except that they use a fifth band to provide a way of showing another significant digit.

  • Page 8: Assembly Process

    Note: In rare cases, a capacitor manufacturer may use “0” as a Follow the assembly process in the order given. Each part builds on what decimal placeholder. For example, “820” might mean 820 pF rather has been completed before it. For example, the front panel assembly than 82 pF.

  • Page 9: Soldering, Desoldering And Plated-Through Holes

    Take care to avoid ESD damage to components.  If in doubt about a particular repair, ask for advice from Elecraft or someone with PCB repair experience. Our e-mail reflector is an excellent source of help.

  • Page 10: Parts Inventory

    Parts Inventory You should do a complete inventory. Contact Elecraft if you find anything missing. Leave painted panels wrapped until they are needed during assembly. This will protect the finish. Cabinet and RF PCB components used in all transverters. Picture Ref.
  • Page 11 Rubber Foot, Self Adhesive E980067 A Bail kit is available as an optional accessory if desired. The Bail will hold the front of the transverter up at a convenient viewing angle. See www.elecraft.com for details J4, J5 Jack, RCA E620057...
  • Page 12 Picture Ref. Designator(s) Description Part # Anderson Powerpole® Connector Crimp Contact E620062 Anderson Powerpole® Connector Roll Pin E700071 Anderson Powerpole® Housing , Red E620059 Anderson Powerpole® Housing, Black E620060 Header Connector, 12 Pin , Right Angle E620065 JP5,JP6, JP9 Header Connector, 2 Pin E620054 JP1,JP2,JP3,JP4, JP5, Header Connector, 3 Pin...
  • Page 13 Picture Ref. Designator(s) Description Part # D10, D11 Diode, LED, Red E570007 Frequency Mixer, ADEX-10H E600050 Pre-mounted on the MMIC Amplifier, ERA-6 E600051 MMIC Amplifier, MAR-3 E600073 Voltage Regulator, 9 volt, LM78L09 E600054 Transistor, NPN, PN2222A E580001 Voltage Regulator, 5 volt, LM7805 E600024 Transistor, MOSFET, 2N7000 E580002...
  • Page 14 Picture Ref. Designator(s) Description Part # Resistor, 1/4 watt, 5%, 56 ohm (grn-blu-blk) E500096 Resistor, 1/4 watt, 5%, 4.7 ohm (yel-vio-gld) E500062 R1, R7, R9, R33 Resistor, 1/4 watt, 5% , 10K ohm (brn-blk-org) E500015 Resistor, 1/4 watt, 5%, 1K ohm (brn-blk-red) E500013 Resistor, 1/4 watt, 5%, 620 ohm (blu-red-brn) E500097...
  • Page 15 Picture Ref. Designator(s) Description Part # Electrolytic Capacitor, 22 F, 25 V C26, C60 E530012 Electrolytic Capacitor, 10 F, 16V None E530142 Molded Inductor, .47 H (yel-vio-silver) E690020 Molded Inductor, 15 H (brn-grn-blk)* E690012 L15,L16,L17 Variable Inductor, .243-.297 µH, shielded, grey plastic insert. E690025 Ferrite Bead E980029...
  • Page 16 Front panel circuit PCB components. Picture Ref. Designator(s) Description Part # Printed Circuit Board E100168 Screw, Fillister Head, 1/8 inch, 2-56 E700023 Microcontroller PIC16F872, Programmed (packaged in foam) E610014 Handle with care – ESD Sensitive. Do not remove it from its conductive foam until you are instructed to install it.
  • Page 17 Picture Ref. Designator(s) Description Part # Q1,Q2,Q3,Q4,Q5,Q6, Transistor, NPN, PN2222 E580001 Ceramic Resonator, 4 MHz E660001 Header Connector, 2 pin E620054 Header Shorting block, 2 pin E620055 - 14 -...
  • Page 18 The remainder of the parts in your kit depend upon the band of operation. Check only the list that corresponds to your transverter. XV50: The following parts are included only in the XV50 transverter. Picture Ref. Designator(s) Description Part #...
  • Page 19 Picture Ref. Designator(s) Description Part # C1, C33 Ceramic Trimmer Cap, 1-40 pF E540002 Molded Inductor, .15 H (brn-grn-silver)* E690022 Molded Inductor, .22 H (red-red-silver)* L2, L3 E690028 .198-.240 µH, Variable Inductor, Blue E690032 .333-.407 µH, E690033 Variable Inductor, Grey L12,L13,L14 Variable Inductor, .243-.297 µH, Shielded, Grey Plastic Insert.
  • Page 20 XV144: The following parts are included only in the XV144 transverter. Picture Ref. Designator(s) Description Part # Front Panel Label, XV144 E980060 Pre-mounted on the Amplifier, MMIC, ERA-5 (Four-lead device with no tab. All four leads soldered to E600052 PCB) Voltage Regulator, 5-volt, LM78L05 E600029 Transistor, NPN, NTE108...
  • Page 21 Picture Ref. Designator(s) Description Part # Molded Inductor, .1 H (brn-blk-silver)* L2, Z3 E690021 Molded Inductor, .15 H (brn-grn-silver) E690022 L10,L11 Variable Inductor, .085-0.1µH, Orange E690023 .108-.132 µH, E690024 Variable Inductor, Orange .059-070 µH, L12,L13,L14 Variable Inductor, Red Plastic Insert. E690027 Crystal, 116 MHz, 5th Overtone Series Resonant (116.000) E660016...
  • Page 22 XV222: The following parts are included only in the XV222 transverter. Picture Ref. Designator(s) Description Part # Front Panel Label, XV222 E980061 Pre-Mounted on the SGA7489, Sirenza Gain Block Amplifier (Three-lead device with tab. Two leads E600055 and tab are soldered to the PCB. Center lead is not connected) Voltage Regulator, 5-volt, LM78L05 E600029 Transistor, NPN, NTE108...
  • Page 23 Picture Ref. Designator(s) Description Part # L10, L11, L4A, L19 .064-.080 µH, E690029 Variable Inductor, .041-.044 µH, E690034 Variable Inductor, Brown L12, L13, L14 .038-.040 µH, E690031 Variable Inductor, Shielded, Brown Plastic Insert Crystal, 194 MHz 7th Overtone Series Resonant (194.000) E660017 Type “N”...

  • Page 24: Front Panel Pcb Assembly

    Front Panel PCB Assembly Place the front panel PCB on top of the heat spreader with the silk- Position the light bar in the cutout of the PCB as shown in Figure 6. screened side down as shown in Figure 4. Temporarily attach the PCB to Adjust the leads as necessary so they line up with the six solder pads at the heat spreader with a single 3/16”...
  • Page 25 Locate the silk-screened outline for Q5 near the yellow light bar. The front panel PCB has parts on both sides of the PCB. Install a PN2222 transistor on the back side of the PCB (the side that is Follow the instructions carefully. If parts are placed on the wrong not silk-screened).
  • Page 26 Install capacitor C4, .001 F (102) on the back side of the PCB (the In the steps that follow, you'll be installing groups of side that is not silk-screened). components. When working from a long list, install all of the items on one line before moving on to the next.
  • Page 27 Hold the LED with the back of the plastic housing flat against the The remaining parts will be installed on the front of the PCB (not tilted). Bend the leads outward on the bottom side to hold it in circuit PCB place.

  • Page 28: Uninstalled Components

    Sort all of the resistors by value. If the color bands are difficult to Install the two capacitors listed below on the front (silk-screened) read, use a DMM (digital multimeter) to verify their values. Tape them to side of the PCB, near the outline of the 28-pin IC socket. Check each a piece of paper with the values labeled.

  • Page 29: Rf Pcb Assembly - Part I

    RF PCB Assembly – Part I Do NOT remove the temporary wire jumper across the solder RF circuit assembly is divided into three parts: pads for L1 until instructed to do so. This jumper protects U1 from static damage until the circuits are completed. Part 1: DC, control circuits and RF components common to all of the transverters.
  • Page 30 their values. Tape them to a piece of paper with the values Adjust the L-bracket positions so the front panel PCB is aligned labeled. with the RF PCB. If the gap between the front panel PCB and the RF PCB is wider at one end than the other, you probably have one of the brackets Place the PCB with the silk-screened side up and the cutout to your installed backward.
  • Page 31 Install the following 3-watt resistors above R21 near the center of Locate the silk-screened space for D5 on the PCB near R23 in the the PCB. Space each resistor about 1/16” (1.5 mm) above the PCB just upper right quadrant of the PCB. like you did for the 1-watt resistors.
  • Page 32 Install zener diode D3 (1N5235) in the upper left quadrant of the Install transistor Q6 (PN2222) next to R21 near the center of the PCB near R12. Position it against the PCB with the banded end aligned PCB. Orient the transistor as shown by the silk-screened outline on the with the banded end of the PCB outline.
  • Page 33 Solder Q2 in place as follows: Install the monolithic capacitors listed below. Start with C71 on the edge of the PCB in the lower right quadrant and work from right to left Wet your soldering iron with a small amount of solder and touch across the lower part of the PCB.
  • Page 34 PCB are indicated by ground symbols. One is directly and receive antenna) operation. Do NOT Install Relay K1 below the “Elecraft” label and the other is in the lower left quadrant below U6. Solder the leads. Working around the PCB clockwise from the upper left quadrant, Remove the eight small relays (G6E-134P) from the carrier tube.
  • Page 35 Install resettable fuse F1 in the space provided next to relay K9 in Install JP9 next to K4 and K5. JP9 requires one 2-terminal header the upper right quadrant. F1 may be oriented either way. Solder and trim and one 3-terminal header. the leads.
  • Page 36 Install 4-pole DIP switch SW1 in the space provided in the lower left quadrant of the PCB. The DIP switch may not have a notch at one end to line up with the silk-screened outline. Orient the switch so that the ON positions are on the side with the silk-screened numbers.
  • Page 37 Install two 22 F, 25 VDC electrolytic capacitors near the notch on Position each inductor on the PCB so that its tabs and pins protrude the left side of the PCB. Be sure to observe polarity. The longer through on the bottom. The inductors can be positioned either way. Ensure that the shoulders of the tabs are against the top of the PCB, and positive lead goes in the square solder pad with a silk-screened...
  • Page 38 Separate the leads and trim them to a length of about 1” (2.5 cm). A pre-wound toroid is available from an Elecraft-approved source. See page 2. - 35 -...
  • Page 39 Insert the tinned leads in the holes on the PCB and position the Choke L7 consists of a bare wire passing through two ferrite beads toroid as shown in Figure 25. Be sure the correct lead goes to each hole. as shown in Figure 26.
  • Page 40 Locate the two RCA Jacks, J4 and J5. Use your flush cutters to trim The Anderson power connector is held in place by two heavy copper off the two small plastic feet on each jack (see Figure 27). Be sure they wires soldered to the PCB (See Figure 28).
  • Page 41 Look closely at the sides of the housings. Each has a small tongue Inspect the end of each connector. You should see the contact on one side and a groove on the other. Slide the two housings together pressing up against the end as shown in Figure 30. If necessary, press the engaging the tongue in the groove.

  • Page 42: Rf Pcb Assembly - Part Ii

    In the following steps you will install components unique to each band on the Install the two 1-40 pF trimmer capacitors as follows. Align the flat RF PCB. These components are provided in the XV50, XV144 or XV222 end of each trimmer with the flat end on the silk-screened outline band completion kit package.
  • Page 43 There will be some component locations on the PCB that are not filled. This is normal. The same RF PCB is used for the XV50, XV144 and If you are not wearing a grounded antistatic wrist strap, touch an XV222 transverters, and some components are specific to each unpainted, grounded object before performing the next step.

  • Page 44: Xv144 -144 Mhz Transverter

    Install the molded inductors listed below: XV144 –144 MHz Transverter L2, .1 H (brn-blk-silver) near U1 in the upper left quadrant of Perform the following steps on the RF PCB only if you are building the the PCB. XV144 transverter. Z3, .1 H (brn-blk-silver) near U6 in the lower left quadrant of Install the resistors listed below.
  • Page 45 If you purchased the optional crystal oven with your transverter Install L10 and L11 near the upper left corner of the PCB. Be sure (Elecraft part number E980076) install it now as follows: the plastic frames of the inductors are resting against the PCB.
  • Page 46 PCB that are not filled. This is pushing the inductor out of the shield. Run the core up and down normal. The same RF PCB is used for the XV50, XV144 and through the coil to ensure it runs smoothly (some inductors are very XV222 transverters, and some components are specific to each stiff at first) then position the core near the top of the coil.

  • Page 47: Xv222 - 222 Mhz Transverter

    Cut the Teflon tubing to a length of 3/8” (8mm). XV222 – 222 MHz Transverter Slide the 3/8” (8mm) length of Teflon tubing over the center lead of Perform the following steps on the RF PCB only if you are building the transistor Q1 (NTE108).
  • Page 48 If you purchased the optional crystal oven with your transverter If you are not wearing a grounded antistatic wrist strap, (Elecraft part number E980076) install it now as follows: touch an unpainted, grounded object before performing the next Position the oven down over the crystal so the three leads on the step.
  • Page 49 There will be some component locations on the PCB that are not filled. This is normal. The same RF PCB is used for the XV50, XV144 and XV222 transverters, and some components are specific to each band.

  • Page 50: Rf Pcb Assembly - Part Iii

    RF PCB Assembly – Part III In the following steps you will install the hardware that attaches the RF power module to the bottom cover. Follow the steps carefully to ensure the module makes good thermal contact with the In the following steps you will install the RF power module. The procedure is bottom cover and the leads line up properly with the RF PCB.
  • Page 51 Lay the bottom cover on a clean, smooth surface with the heat spreader Slide the PCB under the leads on the RF power module and over the facing up. screws until they pass through the holes in the PCB (see Figure 36). You can rock the RF Power Module slightly on the screws and bend the leads Remove the nuts from the long screws but do not remove the screws.
  • Page 52 Inspect the RF Power module to be sure you have the module and Solder the RF power module leads to their corresponding pads on the hardware installed exactly as shown in Figure 38. PCB. Before soldering, trim the leads as needed so they do not extend beyond the solder pads.

  • Page 53: Final Assembly

    Figure 39. Be sure the ground lug is on the lower screw nearest the end of the back panel and faces upward as shown. The antenna connector is an S0-239 (UHF) connector on the XV50 transverter, and a type “N” connector on the XV144 and XV222 transverters.
  • Page 54 Connect J1 to the leads already soldered to the RF PCB as follows (See Either wear a grounded antistatic wrist strap or touch an Figure 41): unpainted, grounded object before handling the processor (U1) in Solder the lead that is farthest from the edge to the center pin on the the next steps, or at any time you handle the front panel PCB antenna connector.
  • Page 55 Attach a 2-D fastener to the each screw hole at the top corners of the When U1 is pressed into its socket, you must be careful to avoid front and rear chassis end panels with 3/16” (4.8 mm) screws. Be sure jamming its pins.
  • Page 56 Optional: The supplied spring pin may be inserted as shown in the In the following step be sure to orient the Anderson power figure above to keep the red and black housing from slipping apart. The connector shells exactly as shown. Otherwise, the connector will not mate manufacturer of the connectors recommends securing the pin with a drop with the connector on the transverter.

  • Page 57: Final Test And Alignment

    Congratulations Final Test and Alignment You have completed the assembly, test and alignment of your transverter. Turn to your Owner’s Manual for complete installation and In the following steps you will connect your transverter to your station operating instructions. equipment and perform a complete alignment and test procedure. Your Owner’s Manual also describes modifications and optional Turn to the Installation Procedures in your Transverter Owner’s accessories for your transverter that you may choose to best integrate it...

This manual is also suitable for:

Xv144Xv222

Table of Contents