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DZ PSKUBE PSQ-100 Assembly Manual

20 watt psk transceiver
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DZKit
ASSEMBLY MANUAL
PSKube
20 Watt PSK Transceiver
Model PSQ-100

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Summary of Contents for DZ PSKUBE PSQ-100

  • Page 1 Price: $10.00 Page DZKit ASSEMBLY MANUAL PSKube 20 Watt PSK Transceiver Model PSQ-100...

  • Page 2: Dz Company Contact Info

    You can obtain parts directly from DZ Company by writing us, emailing us or telephoning us. And we’ll pay shipping charges to get those parts to you—anywhere in the world.

  • Page 3: Table Of Contents

    Power-up Tests ....... 52 Final Integration ......54 Operating the PSKube ....55 Appendix: Software Installation..60 In Case of Difficulty....... 60 Specifications ......... 64 Warranty....Inside Front Cover DZ COMPANY Copyright © 2003 DZ Co. LOVELAND, All rights reserved COLORADO 10-12-03...

  • Page 4: Introduction

    Page 4 INTRODUCTION The PSKube is a revolution in portable trans- updates over the LAN, connection to the ceivers. For the first time, it is possible to Internet, running of many different applica- connect a keyboard, mouse and antenna to a tion programs, easy customization of the transceiver that operates only in digital screen, and a lot more.

  • Page 5: Assembly Notes

    Page 5 ASSEMBLY NOTES This manual is organized in parts that relate Black Yellow 4 Gray to the various products that can be ordered Brown 1 Green White separately to build a PSKube. Although Blue Silver each part can stand on its own, if you are building a complete PSKube, we recom- Orange 3 Violet...
  • Page 6 Page 6 SOLDERING INSTRUCTIONS Poor soldering accounts for almost 90% of all kit building problems. The photographs below show examples of the most common types of bad solder connections and a good one. If you lo- cate any of these bad solder connections in your kit, correct them as described. Study this sec- tion carefully before you start building your kit.
  • Page 7 Page 7 STATIC PRECAUTIONS Many of the components in your kit can be damaged by exposure to static electricity. Please read this page to familiarize yourself with the causes of and solutions to this prob- lem. When the climate is dry, you can generate thousands of volts simply by walking across a carpet.

  • Page 8: Step-By-Step Assembly

    Page 8 COMPUTER (PSQ-100-3) DISK DRIVE (PSQ-100-10) IMPORTANT NOTE: The computer and disk drive must be assembled as one unit. If you have not purchased the PSQ-100-10, make sure that you have an equivalent set of parts available. This is necessary because the disk drive fastens to the underside of the computer mounting plate, and thus the disk mounting screws are underneath the computer.
  • Page 9 Page 9 Disk Drive - PSQ-100-10 PIC (√) QTY DESCRIPTION 2.5” Laptop Hard Drive Windows 98SE OEM license Hardware Pack M3 x 5mm machine screw M3 Flat washer...
  • Page 10 Page 10 STEP-BY-STEP ASSEMBLY Refer to Pictorial 1. If you want to use a Compact Flash (Type I) memory card as a secondary “disk” (not Locate the Bracket bag. Attach the captive provided), insert it into the holder at this nuts to the sides as shown in the documenta- time.
  • Page 11 Page 11 Pictorial 1...
  • Page 12 Page 12 Attach a 2.5” Hard Drive (such as the tor and move it to the other side of the con- PSQ-100-10) to the bottom side of the nector as shown in Detail 2. This allows 12V mounting plate with the connector facing the to go to the on-board amplifier and provides side where the angle brackets extend out better sound quality.
  • Page 13 Page 13 Photo 1. Top of plate Photo 2. Bottom of plate...

  • Page 14: Psq-100-11 Rf Amplifier

    Page 14 RF AMPLIFIER (PSQ-100-11) PARTS LIST PIC (√) QTY DESCRIPTION Capacitors: 220 uF/25V electrolytic (C1) 10 uF/25V electrolytic (C2, C13) 0.1 uF disk ceramic (C3, C8, C9, C10, C11, C14, C15) 47 pF disk ceramic (C16) 1/4 Watt 180 pF disk ceramic (C4, C7) 330 pF disk ceramic (C5, C6) 1/2 Watt 0.01 uF disk ceramic (C12)
  • Page 15 Page 15 Other: DPDT relay, 12V (K1) PC-mount pushbutton switch (S1) BNC PC-mount jack (J1, J2) Heat sink Yellow toroid core (L1, L2, L3) 2 hole small ferrite transformer core (T1) 2 hole large ferrite transformer core (T2) 4-40 x 5/16” panhead machine screw 4-40 keps nut D10 ( ) Tube of thermal heatsink compound...
  • Page 16 Page 16 STEP-BY-STEP ASSEMBLY L1 and L3 (Toroids) T1 (Small ferrite core with two holes) Cut 8” of magnet wire (thin, enameled Cut 11” of magnet wire and thread it wire) and thread it through the donut-shaped through the smaller ferrite core 6 times. Pull toroid cores exactly 12 times as shown.
  • Page 17 Page 17 T2 (Large ferrite core with two holes) L4, L5 (Air-wound coils) Cut 9.5” of magnet wire. Wind one turn, Cut two 10” lengths of magnet wire. Wrap then bring the end out one inch and make a each piece tightly around a pencil or other loop.
  • Page 18 Page 18 Solder all parts as they are installed and then cut leads as close as practical to the solder. Q1, Q2: Bend MOSFET leads such that they and the mounting hole line up. Dab heatsink grease on underside of MOSFET. Insert a 4-40 x 5/16”...
  • Page 19 Page 19 Detail 6. Electrolytic capacitor polarity ( ) S1: Switch ( ) C1: 220 uF electrolytic See polarity detail above. ( ) C3: 0.1 uF disk ceramic ( ) C13: 10 uF electrolytic See polarity detail above. ( ) C14: 0.1 uF disk ceramic ( ) C8, C9, C10, C11: 0.1 uF disk ceramic ( ) C12: 0.01 uF disk ce-...
  • Page 20 Page 20 Keep your soldering tip clean by wiping it off against a wet sponge periodically. ( ) L4, L5: 9-turn air-wound coil ( ) Q3, Q4: 2N3904 NPN transistor ( ) CR2, CR3: 1N4148 diode (match polarity band) ( ) Q5: 2N3906 PNP transis- ( ) R1: 470 Ohm (yellow- violet-brown) ( ) R2: 100K (brown-black-...
  • Page 21 Page 21 ( ) Cut double-stick tape to fit the rectangular area marked “FANS” on the board. Stick it to the board, then remove the backing on top. ( ) Position the two fans on the tape directly in front of each heatsink with the wires on top.
  • Page 22 Page 22 RF AMPLIFIER THEORY OF OPERATION When an RF signal is fed into this amplifier, AC that happens to get by the choke, and the it is detected by the circuit consisting of cou- resistor thus becomes the input impedance pling capacitor C12, current-limiting/load determining component.
  • Page 23 Page 23 RF AMPLIFIER SCHEMATIC DIAGRAM...

  • Page 24: Psq-100-5 Dc-Dc Converter

    Page 24 DC-DC CONVERTER BOARD (PSQ-100-5) (including option 1 — PSQ-100-5-1 PARTS LIST All resistors are 1/4 Watt, 5% PIC (√ ) QTY DESCRIPTION PC Board - single sided, 2.5" x 5.5" LM339 Quad comparator (U1) 9-18v in, 5v out, 20W DC/DC converter:WPN-20R12S05 (U2) Option 1: 9-18v in, 12v out, 20W DC-DC converter WPN20R12S12 (U3) 14-pin IC socket...
  • Page 25 Page 25 STEP-BY-STEP ASSEMBLY Solder all connections as parts are inserted, then cut off excess leads as close as pos- sible to the soldered connection on the bottom side of the board. ( ) J1: 20-pin right-angle connector ( ) U3: If you have pur- chased option 1, the 9-18V ( ) J2: 8-pin right-angle in, 12V out converter, in-...
  • Page 26 Page 26 ( ) Locate the 4-wire cable with the con- nector on the end. Strip the wires to a length of 1/8”. Tin the ends. Solder the red wire into the +5 terminal, the two black wires to the GND terminals, and the or- ange (or yellow) wire to the +12REG ter- minal.
  • Page 27 Page 27 THEORY OF OPERATION 9-18V into a DC-DC converter which pro- vides a 5V output, while S1B routes the 12V The PSQ-100-5 DC-DC Converter Board is into the board for connection directly to the designed to provide regulated 5V power to a output.
  • Page 28 Page 28 the ON state when input voltage drops below the 10V trip point. A similar comparator, U1C, is used to drive a green LED when volt- age is above 10V or when the DC-DC con- verter is not in use. The pull-up resistor that provides power to the green LED goes to the “selected”...
  • Page 29 Page 29 DC-DC CONVERTER SCHEMATIC DIAGRAM...

  • Page 30: Psq-100-4 Mounting Plate

    Page 30 MOUNTING PLATE (PSQ-100-4) NOTE: A complete PSKube contains three metal mounting plates (A1, below). One is provided with the internal computer kit. The second (middle) plate holds the PSK transceiver. The third (top) plate holds the DC-DC converter board and the optional RF amplifier board. The instruc- tions below show how to assemble the middle and top mounting plates to hold the transceiver, RF amplifier and DC-DC converter.

  • Page 31: Dzkit

    Page 31 Detail 1 Photo 1. Transceiver mounted to plate PC Board 6-32 x 5/8” machine screw #6 x 5/16” Plate spacer #6 Keps nut Detail 2 Photo 2. RF Amp and DC-DC converter mounted to plate ( ) Mount the DZKit internal RF amplifier to keps nuts.

  • Page 32: Psq-100-1 Chassis

    Page 32 CHASSIS (PSQ-100-1) PARTS LIST PIC (√) QTY DESCRIPTION Case parts Cabinet assembly (covers, front panel, rear panel, hardware bag containing 4 rubber feet and 8 self-tapping screws) Metal mounting plate for LCD, speakers 250W PC Power supply Power cord -120V Cigarette Lighter, chassis mount , with fused cable Switch - 3PDT, on-off-on (S1)

  • Page 33: Dzkit

    Page 33 PIC (√) QTY DESCRIPTION Mounting hardware 6-32 x 5/16" panhead machine screw 4-40 x 5/16" panhead machine screw 4-40 keps nut 4-40 hex nut #4 solder lug Wire 3’ 2-conductor+shield stereo cable 1’ Shielded cable (mono) 15” 20# brown hookup wire 15”...
  • Page 34 Page 34 STEP-BY-STEP ASSEMBLY REAR PANEL ASSEMBLY AND WIRING ( ) Carefully remove the protective plastic horizontal. covering from the rear panel. Note that is ex- tends along the sides also. Be sure to remove ( ) Attach the SO-239 antenna connector to all of it.
  • Page 35 Page 35 SO-239 antenna connector Red banana jack Black banana jack Pictorial 1. Rear panel connector mounting...
  • Page 36 Page 36 Pin 1 Yellow Brown Blue Green Black wires Large red wires Blue plastic crimp Pictorial 2. Rear panel cable wiring...
  • Page 37 Page 37 Apply small amount of solder only in the circled area Detail 1. Attaching connector pins to Photo 1. Inside view, rear panel wire Insert wire so that insulation is covered by wiring outer tabs and bare wire is covered by inner tabs. Close tabs using needle-nose pliers without damaging wire or insulation.
  • Page 38 Page 38 ( ) Place one nylon cable tie 4” from the con- ( ) Unscrew the outer hex nut on the black nector, and another one 8” from the connec- side of the dual banana plug and attach the tor.
  • Page 39 Page 39 Make 2 Stereo-right-angle to stereo-straight-end 1” Make 1 Stereo-right-angle-to-stripped/tinned Make 1 Stereo-straight-to-stripped/tinned Make 2 Mono-to-stripped/tinned (Center conductor and shield) 1/4” Make 1 1/4” 1” RG-58/U 50 Ohm coax Make 1 Pictorial 3...
  • Page 40 Page 40 Mono straight Place connector housing on cable BEFORE soldering wires to connec- tor! To remove the right-angle stereo con- nector from its housing, grasp with fingers and pry out. Gently crimp the long metal shroud around the gray part of the cable.
  • Page 41 Page 41 FRONT PANEL ASSEMBLY AND WIRING Refer to Pictorial 5. Sheet metal Polycarbonate overlay ( ) Carefully remove the protective plastic covering from the front panel and lay the LED body panel on a flat surface with the front facing Hex nut ( ) Remove the adhesive backing from the polycarbonate overlay and affix the overlay...

  • Page 42: Dzkit

    Page 42 picture you desire) on the front facing side of the front panel so it is visible from the front of the unit. This completes assembly of the front panel. If you have purchased the internal LCD, pro- ceed to the next section, “LCD”. Detail 8.
  • Page 43 Page 43 Polycarbonate overlay Front panel sheet metal Cut LED cable prior to installing panel-mount LED, then re-attach. Panel mount LED Peel backing off overlay before attaching to front panel Pictorial 5...

  • Page 44: Psq-100-2 Lcd

    Page 44 LCD (PSQ-100-2) PARTS LIST PIC (√) QTY DESCRIPTION TFT LCD 640x480 flat panel Inverter board LCD Cable – 2x22 20cm for V16C6448AC Hardware pack 2-56 x 3/4" panhead machine screw #2 x 5/16” spacer #2 lockwasher 2-56 hex nut 4-40 x 1/2"...
  • Page 45 Page 45 STEP-BY-STEP ASSEMBLY Refer to Photo 1 and Pictorial 1 on the next ( ) Using a small screwdriver, set the two pages. switches on the display as shown in Detail 1. ( ) Position the mounting plate with the speakers attached face down, with the back of the speakers facing you and the large notch to the right.
  • Page 46 Page 46 Pictorial 1...
  • Page 47 Page 47 Photo 1. LCD and inverter board mounting...

  • Page 48: Chassis Integration

    Page 48 CHASSIS INTEGRATION (PSQ-100A,B) Important! Once the chassis is put together, it is impossible to reach the transceiver board. Be sure you have tested the PSK transceiver according to the manufacturer’s specifications before integrating it. Refer to Pictorial 1. assembly to the rear panel with 2 6-32 x 5/16”...
  • Page 49 Page 49 Pictorial 1. Chassis integration...
  • Page 50 Page 50 CHASSIS WIRING DIAGRAM...
  • Page 51 Page 51 ( ) Place the front panel assembly in a verti- from the other cable into the “Line In” mini- cal position near the rest of the assembly. jack on the transceiver. Insert the straight ste- You can rest it against one of the angle reo mini-plug at the other end of this cable brackets.

  • Page 52: Power-Up Tests

    Page 52 POWER-UP TESTS (PSQ-100A,B) ( ) Set the AC/OFF/DC switch on the rear also be 12V on the DC power plug (+12V on panel to the center (OFF) position. Set the 1/0 the center pin with respect to ground). switch on the AC power supply to the 0 (off) position.
  • Page 53 Page 53 coming from the DC-DC converter board into the two side-by-side lugs on the RF amplifier ( ) If you have installed the internal LCD dis- board’s power switch where marked “GND” play and it is too dim or too bright, adjust the on the RF board.

  • Page 54: Final Integration

    Page 54 FINAL INTEGRATION (PSQ-100A,B) ( ) Attach the front panel to the three angle brackets using 6 6-32 x 5/16” machine screws. Do not tighten them. Be careful not to pinch any of the wires. This will be easiest if you attach one side and then slightly “spring”...

  • Page 55: Operating The Pskube

    Page 55 OPERATING THE PSKUBE Reconnect an AC power cord and/or battery/ The main O/S can access these parameters to dc supply, select AC or DC as appropriate, help it get started correctly. You can, for ex- attach an antenna to the antenna connector on ample, tell it that there’s an LCD monitor at- the rear panel., and turn the unit on.

  • Page 56: Dzkit

    Page 56 selftest of the disk drive the next time you Panel” and click it with the left mouse power up. This is not normally a problem, but button. it can be annoying. ( ) A window will pop up showing many things that can be changed to Using the Network (LAN) There may be times when you need to use...
  • Page 57 Page 57 “Network Neighborhood” folder on so the T/R relay should stay in the “pass- your other computers. through” position and you should continue to see the waterfall pattern scrolling on the screen. Virus Note! When connecting your PSKube to other computers, you can expose it to vi- ruses, worms and other threats.
  • Page 58 Page 58 from the other and is designed to fit around the bottom cover. When correctly aligned, you should not have to force the cover into place. Gently wiggle it until it snaps into place. All 4 holes should then line up with the holes in the front and rear panels.
  • Page 59 Page 59 A WORD ABOUT ANTENNAS Although the PSKube has been tested and caused by the lack of a good ground. Connec- found to work fine with attached antennas in tion of a properly grounded antenna with a close proximity, a few cautions are in order. low VSWR will cure this problem.

  • Page 60: Appendix: Software Installation

    Page 60 APPENDIX: SOFTWARE INSTALLATION Note: This section contains information for this accordingly) those who wish to install software them- Drive B: None selves. A thorough understanding of com- Video: EGA/VGA puter operation is assumed. This should not be attempted by those unfamiliar with the BIOS FEATURES concepts discussed.

  • Page 61: Dzkit

    Page 61 PERIPHERAL INSTALLATION Many peripherals can be added to the PCM- interface while using the 2.5” laptop hard 5820. In the PSKube, there is insufficient disk, a special cable is required that is not room to do this. However, for temporary con- included.

  • Page 62: In Case Of Difficulty

    Page 62 IN CASE OF DIFFICULTY Symptom Possible Cause What to do AC supply does not come on. No power to AC supply or de- Check AC line cord. Make (Fan not running) fective AC supply. sure unit is plugged into work- ing AC outlet.
  • Page 63 Page 63 Symptom Possible Cause What to do PC resets when transmitting Improperly grounded antenna, Use a different antenna or turn high VSWR off the amplifier. (See “A Word About Antennas” on p. 57.) LED color is wrong (Doesn’t DC-DC board or LED wiring Check that U1 is installed cor- come on, red instead of green, rectly.

  • Page 64: Specifications

    Page 64 SPECIFICATIONS Transmitter Frequency range..............14.070-14.073 MHz Emission type................ Phase Shift Keying, 31 baud RF output power (amplifier off) ........... 3W max RF output power (amplifier on) ..........20W max, class AB Output impedance ..............50 Ohms, unbalanced Spurious and harmonic levels ..........At least 35dB down IMD..................
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  • Page 67 Page 67...
  • Page 68 Page 68 DZ COMPANY LOVELAND, COLORADO UNIQUE electronic equipment in kit form...

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