DSP-610 Tranceiver - Do We Need a Bigger Boat?

 We sometimes like to get surprises here on the old radio ranch but then again sometimes...



Ahhhh...?

 

The order from Newark Element 14 came this week.  It was neatly packed and arrived intact but when I got the question form the radio wife as I arrived home from work; "What the hell exactly are you building back there?!"  she pointed to this giant sized box that arrived earlier that day, she is used to getting the small envelopes of parts but this was definitely out of the norm. I thought there may be some trouble with the latest order.  I knew there were 70 line items in the order but these are supposed to be SMALL parts!

 

New DSP610 Project's Parts~ the project's bin on top



 

I had visions of 70 reels of parts contained inside. This kind of mix up has happened before. Once, we ordered 24 ea.   Fahnestock Clips  What came from Mouser was 24ea. boxes of 100 Fahnestock clips! Yes,we had to return 2376 clips. At least they arranged the pickup!

 

 

But it turned out that the packaging was simply overkill.  I smiled as I unpacked the box as it brought back an ancient memory...I suddenly remembered the first Microprocessor I ever ordered way back in the dark ages of computer epoch, the days we had to build our own.  I had wrote a letter and enclosed a check which I sent sent to RCA Corp. for an order for 1 ea. RCA 1802  Microprocessor and weeks later when it arrived at my parents house ( I was still in HS, and yes,  the chip was brand new at the time so you do the math  :)  as a overkill plus-sized crate of a shipping box, with one chip buried in a ton of packaging. I think my my mom had a similar reaction.  I always thought that the guy who shipped that to my young self had a strange sense of humor, or at least I hoped I got the joke.

 



 

...Or Not!

 

So now, all is well once again, on the Ranch of Radios.  The parts once removed from their copious packages fit neatly in the project bin.  Although the scale of this radio is probably the biggest, at least from the sheer number of components involved, we have ever attempted in the RR.  It took nearly an hour to order these not to mention about another hour to inventory this one shipment!  I can only imagine the time the designer Jim Veatch devoted to this.  It is incredible he completed this whole effort single handed!?!  Way to go Jim!

 

Next, I will upgrade the soldering station and magnifying equipment in the lab to start putting this beast together..

 

 

  

 

~STAY TUNED!~

DSP-610 Tranceiver - Some Take Longer Than Others

Parts! The way we roll on the RR is to bin up parts for the various projects.  As we approach the winter building season, we will be ready, or not, to melt some solder and get more radios built.

DSP-610 Transceiver's hard to find parts -- are here!

 

We are now in possession of some the more unique parts.  They are the ones in outlines on the sheets I talked about in the last post. The 10.7MHz filters along with some others that have been on back orders came this week. I got the Coax relays from e-bay, but we probably won't use them...more  on why, later. 

 

The mixer seen here is a MCL SRA type from RR partsandjunk box, but will really need to check the specs on it.  There will be some additions and changes  to the list based on my control panel and connectors.

 

 BTW ~As  it  turns out, we may even have a couple of these filters in the old parts box somewhere from an old Spec Analyzer project. Who knew?  I remember that I wanted more poles in the IF for that project and was surprised the solution  from Mouser was to send two of the same filter that I already had!

 

 

100th BOM Item is...

The Radio Ranch DSP610 Parts Bin

We hit a minor milestone on the parts this week as well.  100 line items are either on order or in the project bin.  U1 and U2 were out of stock at Newark so they will be part of an additional order from Digikey or Mouser.....  I ordered several spares (about 5% - 100% more of each part) as well, depending on the size and cost split.  Some of these SMD parts will evaporate into the ether as it gets built - trust me they will.

...other parts such as headers,  LCD, and a mixer are in the bin but may be different than the ones really used.  Also I have a bunch of plugs  (MTA100) system I will use for the connectors.

 ...AND need to stock the External PA board's additional parts as well. Pretty much only some RF parts remain to be found/ordered.

You can scroll down thru the BOM...
 ( Green = in bin, RED = Out of stock, Yellow = On order)

DSP-610 TRANSCEIVER  Revised: Tuesday, September 20, 2011 STATUS AS OF: 10/27/12
BILL OF MATERIALS
NUMBER	QTY	REFERENCE DESIGNATOR	DESCRIPTION
1	3	C1,C15,C18	CAP ALUM 10UF, 16V, RADIAL
2	6	C2,C5,C16,C30,C109,C184	CAP CER 0.33UF, 16V, X7R, 0805
3	4	C3,C7,C17,C24	CAP CER 470PF 50V, C0G, 0805
4	3	C4,C107,C123	CAP CER 330PF, 100V, X7R, 0805
5	7	C6,C8,C22,C26,C81,C112,C135	CAP CER, 1000PF, 50V, X7R, 0805
6	31	C9,C12,C14,C25,C31,C32,C36,C64,C69,C89,C91,C93,C97,C98,C99,C100,C101,C110,C122,C168,C170,C171,C172,C173,C174,C175,C176,C178,C179,C181,C185	CAP CER, 0.1UF, 50V, X7R, 0805
7	78	C10,C13,C33,C34,C35,C37,C38,C41,C42,C43,C44,C45,C55,C58,C65,C66,C67,C68,C70,C71,C72,C76,C78,C79,C80,C82,C83,C84,C85,C87,C88,C90,C92,C102,C103,C104,C105,C106,C108,C111,C113,C115,C116,C117,C118,C119,C125,C126,C127,C128,C129,C130,C131,C132,C133,C134,C136,C137,C138,C139,C140,C141,C142,C144,C145,C146,C153,C154,C155,C156,C158,C159,C162,C163,C164,C165,C166,C167	CAP CER 0.01UF, 50V, X7R, 0805
8	2	C11,C28	CAP CER 0.082UF 25V, X7R, 0805
9	9	C19,C29,C56,C57,C73,C86,C169,C182,C183	CAP CER, 1UF, 16V, X7R, 1206
10	1	C20	CAP CER 0.27UF, 16V, X7R, 0805
11	1	C21	CAPACITOR ALUM ELEC 100UF, 16V, RADIAL
12	1	C23	CAP CER 0.047UF 16V, X7R, 0805
13	1	C27	CAP CER 0.039UF 25V, X7R, 0805
14	5	C39,C40,C46,C49,C74	CAP CER 33PF 50V, C0G, 0805
15	2	C48,C47	CAP CER 12PF 50V, C0G, 0805
16	2	C52,C50	CAP CER 68PF 50V, C0G, 0805
17	1	C51	CAP CER 82PF 50V, C0G, 0805
18	2	C53,C54	CAP CER 150PF 50V, C0G, 0805
19	2	C63,C59	CAP CER 39PF 50V, C0G, 0805
20	3	C60,C61,C62	CAP CER 3.3PF 200V, C0G, 0805
21	2	C161,C75	Variable Capacitors 5.2 - 30PF
22	2	C94,C95	CAP CER 560PF 50V, C0G, 0805
23	2	C120,C96	CAP CER, 10UF, 6.3V, X5R, 0805
24	3	C114,C143,C177	CAP TANT 10UF, 16V, 7OHM, 3216-18
25	1	C121	CAP CER 270PF 50V, C0G, 0805
26	1	C124	CAP CER 15PF 50V, C0G, 0805
27	2	C152,C147	CAP CER 100PF 100V, C0G, 0805
28	1	C148	CAP CER 220PF 100V, C0G, 0805
29	2	C151,C149	CAP CER 180PF 100V, C0G, 0805
30	1	C150	CAP CER 390PF 100V, C0G, 0805
31	1	C157	CAP CER 10PF 200V, C0G, 0805
32	1	C160	Variable Capacitors 4 - 20PF
33	6	D5,D6,D7,D8,D9,D10	DIODE SS 100V 200MA DO-35 1N914
34	4	D3,D4,D11,D12	LED 2X1.2MM 625NM RD
35	4	FL1,FL2,FL3,FL4	CRYSTAL FILT 10.7 MHZ, 15KHZ BW
36	4	J1,J2,J3,J18	3 PIN HEADER
37	8	J4,J5,J6,J7,J13,J14,J16,J17	2 PIN HEADER
38	1	J8	4 PIN HEADER
39	2	J11,J9	5 PIN HEADER
40	1	J10	6 PIN HEADER
41	1	J12	18 DUAL ROW PIN HEADER
42	1	J15	POWER SWITCH
43	1	L1	WW INDUCTOR, 180NH 400MA 5% 0.87MHZ
44	2	L4,L2	WW IND 680NH 540MA 5% 0.375MHZ
45	2	L28,L3	RF Inductors 1.2uH 10%
46	3	L5,L6,L7	INDUCTOR, AIR, 5T ON #1 DRILL, #24, L=0.6"
47	2	L9,L8	WW INDUCTOR, 150NH 800MA 5% 0.85MHZ
48	3	L10,L11,L16	RF Inductor 2012 5.6uH 5%
49	2	L12,L14	WIREWOUND IND, 47UH, 75mA, 5% 15MHZ
50	1	L13	RF Inductors 2012 3.9uH 5%
51	2	L15,L17	RF Inductors 2012 3.3uH 5%
52	2	L19,L18	RF Inductors 2012 0.47uH 5%
53	1	L20	CHIP FERRITE BEAD, 0805, 200mA
54	1	L21	FERRITE BEAD, 0805, 0.5OHM, 200mA
55	2	L22,L23	T50-6 Core, 5 Turns, #18 enamel wire
56	2	L24,L25	T50-6 Core, 7 Turns, #18 enamel wire
57	2	L26,L27	RF Inductors 0.82uH 5%, 1210
58	1	MX1	BLALNCED MIXER, 1-500 MHz
59	1	O1	Programmable Oscllator 10-160MHz CMOS
60	5	Q1,Q2,Q3,Q17,Q18	RF MOSFET N-CH DUAL GATE BF998
61	2	Q4,Q5	TRANSISTOR, NPN, 40V, TO-92, 2N3904
62	5	Q6,Q8,Q9,Q10,Q12	RF POWER MOSFET, 16W, RD16HHF1
63	1	Q7	MOSFET N/P-CH 30V 8.5A/7A SO8, DMC3021
64	1	Q11	TRANSISTOR, NPN, 40V, TO-92, MPSH10
65	5	Q13,Q14,Q15,Q16,Q19	N CHNL MOSFET, 25V, 220mA SOT-23, FDV301N
66	4	RL1,RL2,RL3,RL4	REED RELAY, SPST, COAX SHIELD
67	4	R1,R7,R21,R56	RES, 390OHM, 125mW, 1%
68	3	R2,R5,R99	RES, 4.7KOHM, 125mW, 1%
69	4	R3,R61,R81,R110	RES, 220OHM, 100mW, 1%
70	13	R4,R10,R15,R18,R19,R20,R22,R30,R32,R47,R90,R91,R112	RES, 1KOHM, 125mW, 1%
71	4	R6,R14,R98,R100	RES, 100KOHM, 125mW, 1%
72	12	R8,R9,R11,R16,R63,R64,R70,R82,R88,R92,R96,R97	RES, 10KOHM, 125mW, 1%
73	2	R23,R12	RES, 12KOHM, 125mW, 1%
74	3	R13,R24,R101	RES, 1.8KOHM, 125mW, 1%
75	2	R17,R28	RES, 1.3KOHM, 125mW, 1%
76	4	R25,R26,R29,R46	RES, 3.3KOHM, 125mW, 1%
77	5	R27,R48,R49,R106,R107	RES, 10OHM, 125mW, 1%
78	20	R31,R36,R37,R38,R50,R51,R52,R62,R67,R68,R71,R78,R79,R85,R89,R102,R103,R104,R105,R109	RES, 47KOHM, 125mW, 1%
79	1	R33	SHORTING JUMPER
80	2	R35,R34	LEAVE OPEN
81	12	R39,R40,R41,R42,R44,R45,R53,R58,R59,R84,R94,R95	RES, 100OHM, 125MW, ±1%
82	1	R43	RES, 68OHM, 125mW, 1%
83	2	R54,R55	RES, 5.6KOHM, 125mW, 1%
84	2	R57,R112	RES, 39KOHM, 125mW, 1%
85	1	R60	RES, 11KOHM, 125mW, 1%
86	4	R65,R66,R80,R83	RES, PWR, 680OHM, 1W, 5%
87	1	R69	RES, PWR, 56OHM, 1W, 5%
88	3	R72,R86,R87	RES, 470OHM, 125mW, 1%
89	1	R73	RES, PWR, 330OHM, 1W, 5%
90	4	R74,R75,R76,R77	RES, PWR, 100OHM, 0.5W, 1%
91	1	R108	RES, 3.6KOHM, 125mW, 1%
92	1	R111	RES, 1.6KOHM, 125mW, 1%
93	4	SW1,SW2,SW3,SW4	IC SW SPDT DC-3GHZ GAAS SC-88, AS179
94	1	T1	0.37" FERRITE CORE TYPE 43
95	1	T2	BINOCULAR CORE TYPE 43
96	1	T3	RF Transformer 0.75" Type 43
97	1	T4	BINOCULAR CORE TYPE 43
98	1	T5	0.37" FERRITE CORE TYPE 43
99	2	U1,U2	MCP6024, IC, OP-AMP, 10MHZ, 7V/µs, DIP-14
100	1	U3	LM386, IC AMP AUDIO PWR .7W MONO 8DIP
101	1	U4	AD9833, IC, PROG WAVEFORM GEN, 25MSPS
102	1	U5	RF DOUBLE BAL MIXER, SA602A
103	1	U6	LM78L05, IC, REG, 5V, TO-92
104	1	U7	SKY65017, IC AMP INGAP LF-6GHZ SOT-89
105	1	U8	PIC18F45K22 IC, 8BIT MCU, PIC18F, 64MHZ, DIP-40
106	1	U9	DSPIC33FJ12GP201, DSC, 16BIT, 12KB, 40MHZ
107	1	U10	CD74HCT4052, ANALOG MUX/DMUX, DUAL 4 X 1
108	1	U11	MCP4822, IC, DAC, 12BIT, DIP-8
109	2	VRG5,VRG1	LM7805, IC REG LDO 5V 1.5A TO220
110	2	VRG4,VRG2	MCP1825S, IC, LDO VOLT REG, 3.3V, 0.5A
111	1	VRG3	LM317T IC, ADJ LINEAR REG, 1.2V TO 37V, TO-220
112	7	VR1,VR2,VR3,VR4,VR5,VR6,VR7	TRIMPOT, 1K OHMS, Vertical
113	1	Y1	Standard Clock Oscillators 3.3V 25MHZ
114	1	PCB1	Printed Circuit Board DSP-610
115	1	LCD1	LCD Character Display Modules
116	1	LS1	SPEAKER, 8 Ohm, 0.25W
117	3	PJ1,PJ2,PJ3	3.5MM STEREO JACK WITH CUTOUTS
118	2	PJ4,PJ5	COAX CONNECTOR, SO-239
119	1	PT1	Potentiometers Audio 10K
120	2	PT3,PT2	Potentiometers Linear 1K
121	4	KN1,KN2,KN3,KN4	15MM KNOB FOR 6MM FLATTED SHAFT
122	2	P3,P1	Housings HSG 3P WITH LKG RAMP
123	3	P4,P6,P7	Housings HSG 2P WITH LKG RAMP
124	1	P8	Housings HSG 4P WITH LKG RAMP
125	1	P10	Housings HSG 6P WITH LKG RAMP
126	22	P1.P3,P4,P6,P7,P8,P10	CRIMP TERM SEL GLD 22-30 AWG
127	1	P12	HOUSING 18 POS NON-POLARIZED
128	18	P12	CONTACT GLD 24-20AWG
129	1	RE1	Encoders NO SWITCH 18 DET
130	1	RE2	Encoders No Switch No Detents
131	1	KN5	ROUND KNOB, 6.35MM SHAFT, 1.25" DIAMETER
132	10	SW1,SW2,SW3,SW4,SW5,SW6,SW7,SW8,SW9,SW10	SPST PUSH BUTTON SWITCH
133	1	SW11	S.P.S.T., on-off, push-on/push-off switch
134	1	PJ6	DUAL BINDING POST 0.75"
135	1	CHASSIS	.040" 6061-T6 Aluminum Sheet 12" X 24"
136	1	CHASSIS	3/8" {A} Sq 6061-T6511 Aluminum, Extruded-24"
137	1	U8*	CONN SOCKET IC 40-PIN T/H

Long Scroll ...Huh?

P.O.A.M. 

So what to do next? ...make a Plan of Action and Milestones! Also, this week we took a real look at the Schematics and gave some thought to the chassis and front panel.  The plan for the circuit board kind of jelled as I want to resurrect my old M620 Handheld Project. Wow! this radio would be a perfect test of the PA and RF front end of the 10 and 6M versions of that project.  Thus, the external PA would be a real easy way to patch those boards in and test them.  So the decision to not use the internal PA is made!

As far as the build...  Here is the sequence I came up with  (pretty much by schematic sheet)

1. Front Panel  - Using a 1U  size 19" rack panel...this will give me controls for the board
2. DSP & GP - and I can start playing with the  firmware...
3. Audio and 2nd IF -  It's easy to test this section.
4. 1st IF and LO2 - ...also easy to test and control these circuits.
5. RF-IF Converter - It is almost a working receiver at this point!
6. LP FILTERS LNA and TR SW- The first sheet that gets the PA mods -- we should have a two band receiver with some minor patching.
7. TX power chain - Also, includes more mods for the external PA  board- It is almost a real LP QRP at this stage....

So, for this plan to work, I will also need to make sure any parts needed for other circuits that will be difficult to populate with parts from these sheets will get installed first and any voltage regulators supplying the circuits to test are installed first as well...

~Stay Tuned ~