Sunday, November 4, 2012

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  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!~

Sunday, October 28, 2012

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 IFIt'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 ~