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Insert all the components that have their values inside the footprint. They are the following:
____7 - .01 capacitors (Bag 3) Solder ____3 - 100 ohm resistors (brown, black, brown) (Bag 3) Be careful, rectangle footprints only, there is a 100pf capacitor in the area.____3 - 100K resistors (brown, black, yellow) (Bag 3) Resistors:____1 - 12K (Bag 4), Located above the MOSFET on the right side. Solder Capacitors (Going left to right on the board):____1 - 100pf NPO (Bag 3), Located to the left of the 2N5486. Orange color, short leads flared out, labeled "101". Other Parts:____1 - 50A03 455KHz IF can, Black core (Bag 6), Located below the text "455 kHz BFO". After inserting into the board, touch the soldering iron to the IF can pins first, and make sure the pin is accepting solder before flowing solder onto the PCB. Solder ____1 - 100K trim pot (Bag 5), located above the MOSFET, black or blue color, turn adjustment screw all the way counterclockwise, this gives maximum gain for initial testing and use. Black color, marked "EXP 104" on side. Blue color are smaller than the 10K blue trimmers, marked "104Fd5" on side.____1 - LED (Bag 3), Red color. Match the flat on the LED to the flat on the footprint. The short lead is on the same side as the flat. Note: If you ordered the Super Bright LEDs, one can be placed here. For details, check Modifying the LEDs. ____4 - HP5082 diodes (Bag 4), Blue band, on a reel strip all together. Note the band on the part and match it to the band on the footprint. Picture Bend the leads about 1/8" away from the body of the diode for easy insertion into the PCB. ____1 - T1-1T Minicircuits 1:1 transformer (Bag 4), Note the dot on the part and match it to the dot on the footprint. A dot is outside the footprint so that you can double check your work after it is mounted.____1 - L40 B2 455KHz Filter (Bag 6), White color, another part with fragile pins, do not bend the pins when mounting/soldering the part to the PCB. Tin the leads with solder to get a good solder joint on the PCB. There are two footprints for 455KHz IF Filters, only one is used. Use the footprint that fits the pins of your part. This is because we have several types in stock and the one included in the kit will change as more kits are made. Solder ____1 - MOSFET (Bag 2), (Picture) static sensitive part, touch a ground wire before taking it out of the bag, notice the dot on MOSFET (may be difficult to see, hold at an angle to a light source and you can see the shadow of the dot), the dot is located to the left of the second line of the text on the MOSFET. A dot is placed outside the footprint so that you can double check your placement after it has been soldered to the PCB. The leads on each side of the part need to spread apart slightly to fit the footprint. Solder BFO Capacitor ____35pf small panel mount capacitor (Bag 1), with the numbers "193-10" on top, solder a 1 1/2" bare wire going down on each solder lug.
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Insert all the components that have their values inside the footprint. They are the following:
____2 - .01 capacitors (Bag 3) Resistors:
____1 - 1.5K (Bag 6), Located above and between the .05 capacitors to the left of the Audio Pre-amp. Solder Capacitors:
____2 - .05 (Bag 5), Located to the left of the text "Audio Pre-Amp". Orange colored, small square, leads flared out, labeled "473, C1J". Even though the board is marked for a .05 capacitor, the kit uses .047 capacitors for this part. Some kits may have disc ceramic capacitors marked ".047". NOTE: There is an optional "Gain Adjust" electrolytic capacitor in the pre-amplifier. This cap should not be installed until after the kit is working. This electrolytic capacitor adjusts the gain of the pre-amplifier. The best value, to avoid motorboating, has been found to be a 2.2 mfd electrolytic. Note the "+" in the footprint for correct installation. ____4 - 10 mfd Tantalum, 3 pin (Bag 4), The center pin is positive, two outer ones are ground, this part is used in automatic insertion PCB work so that it never gets put in wrong. Orange colored, with three short pins. Two are located near the 2N3904, one above and one below. Other two are located near the box labeled "Audio Control", one above and one to the right. Be careful, do not put one in the "Gain Adjust" box.Solder ____1 - 2.2mfd Electrolytic (Bag 4), Next to 7805 Regulator, please notice that the negative (-) side of part is marked. The + (Plus) side is marked on the silkscreen.____2 - 330mfd Electrolytic (Bag 4), Note: - (Minus) is marked on the part, and the + (Positive) is marked on the board. One is above the box labeled "Audio Control". The second one is to the right of the TDA2002. ____1 - .1 (Bag 6), Located right next to the "C" on the 2N3904. Blue colored, labeled "K5M, 104" ____1 - 100pf NPO (Bag 3), Orange color, short leads flared out, labeled "101". Located above the 330mfd Electrolytic. ____1 - 1mfd Film (Bag 6), Located next to the box labeled "Speaker". Large red rectangle, labeled "105". Other Parts:____1 - 2N3904 transistor (Bag 4), Note flat on part and match to the flat on the footprint. Solder ____1 - TDA2002 Audio Amplifier and Heat Sink(Bag 6), Be careful mounting on the board so that all five pins go into the PCB. Sometimes the pins may be bent out of place from shipping. Note mounting picture below.Be careful mounting the heat sink, it is a slip on part. Use a small screwdriver to hold back the clip to help it slip on easily. Best to put the heatsink on the IC before soldering to the PCB.  Some kits may have a LM383, which is identical to the TDA2002, both in dimensions and electrical properties. Solder Audio Control PotentiometerThere is a place below and left of the Audio Control Square that has ten holes that will accommodate most PCB mount potentiometers. The pot supplied with the kit has five pins and matches the five holes in the forward part of the square. The pins are slipped through the holes and then soldered. Connection wires are run from the pins labeled "Gnd", "1", and "2" and run to the same labels in the "Audio Control" square. (Picture) Wiring the Potentiometer ____Use a 1 1/2" jumper wire and connect the Gnd hole to the Gnd hole in the "Audio Control" square. ____Use a 1 1/2" jumper wire and connect the the hole labeled "1" to the hole in the "Audio Control" square labeled "1". ____Use a 1 1/2" jumper wire and connect the hole labeled "2" in the "Audio Control" square labeled "2". S-Meter____The resistors that are used at M1 and M2, to the left and above the S-Meter Square at the AGC Detector (Picture), are set up to use a 50uA meter. (Picture) You can use any meter with a value between 50 uA to 250uA, by changing the M1 and M2 resistors. Values for different meters are given in the S-Meter page. Circuit theory is included to help you properly set up the meter any way you like. ____The S-Meter, if board mounted, is glued to the top or bottom of the board where the text "Audio Amplifier" and the "Designed by...." is located at the bottom right of the board. Silicon Rubber Sealant was used to secure the S-Meter on all the prototypes, and allows you to pull the meter off the board if you transfer the receiver to a case, where you will be mounting the S-Meter on a front panel. Picture ____Solder a wire from the + hole in the S-Meter square on the PCB to the + connection on the S-Meter.____Solder a wire from the - hole in the S-Meter square on the PCB to the - connection on the S-Meter. Picture |
Double Checking Your Work
____Place the PCB in front of a bright light. If you see light shining through any of the soldering holes, you missed a solder connection. If you have already tested Board 1, go to Mounting/Testing Board 2. |
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