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 ~

It's About Time - Hacking the 360 Clock

Clocks With Radios...

Projects get done in the Radio Ranch from time to time. My in-law father is really into clocks of all kinds.  We are working on an extremely obfuscated clock linked to the NIST clock in Ft. Collins, Colorado...just having several microprocessors working to extract and uniquely display and chime in the time-of-day. (I'll post that project someday) Unfortunately, this project was far form complete to give for his holiday gift but AI came across the:

Which has 60 LEDs much like my obfuscated time piece.

http://www.pictronicsonline.com/Clock360WWVB/Description.htm

(BTW ~ my network security feature says this may b3e a malicious link...I never had any problems)
I thought, cool, I will just buy a kit...build it and take pressure off the obfuscated clock.

The PCB for this is HUGE!  The obfuscated clock will be way smaller - to be contained in an anniversary clock dome

Along with these displays.

The build went OK.  The layout was a little on the amateurish side but mostly OK.

The voltage regulator has this huge heat sink on it. ( I fixed this problem as well)

The first thing I did not like was all the LEDs came on each minute. I though an option to reduce to a single LED, would be better.  They had this cascade mode that was pretty cool but again 60 LEDs were a bit much.

Of couse, I wanted changes to the behaviour and found some ineresting defects.  Still, Brent from MyPictronics was very helpful in getting the changes to me... although they were updates he burned into a PIC, no source code or programmable files... I guess I don't blame him, it is his property and programming.

 

Then there was an annoying issue he could not solve... the clock kept getting stuck in this error mode that he had never seen:

All he could offer was my power supply was bad...  We went back an fourth with several iterations...

From: MyPictronics MyPictronics@aol.com

Sent: Sun, August 19, 2012 9:23:47 AM

Subject: RE: 360 clock w/WWB Sync Questions

Attached is the updated manual for the new feature requests. Clear as mud but let me know if you have any questions.

I tried to test everything but always miss something – let me know if you have any problems.

Brent

Sent: Tuesday, September 04, 2012 10:33 AM

To: MyPICTronics@aol.com

Subject: 360 clock w/WWVB Sync Options - Update

Hi Brent!

Thanks for the updated chip. The LED display with the burst mode looks Awesome! Even better than I thought it would, and it keeps the voltage regulator running at a better temperature as well... very nice.

 

From: MyPictronics MyPictronics@aol.com

Sent: Thu, September 6, 2012 8:10:51 AM

Subject: RE: 360 clock w/WWVB Sync Options - Update

-->

I have been running non-stop and haven’t seen this problem.

What are the power ratings of your adapter (output voltage and current)? I have only seen this happen in the past with an insufficient power adapter which would eventually cause it to shutdown and/or lockup.

Sent: Wednesday, September 05, 2012 3:26 PM

To: MyPictronics

Subject: Re: 360 clock w/WWVB Sync Options - Update

 

Hi Brent,

Yes it was a little bent - at least it was only one side of pins this time.

I have not seen it on manual sync - it happens all the time now on normal operation -- it stops running with these codes after an hour or so.

We also tried powering up with the mode switch and it gives the same result. We will try again with auto Sync off as it seems to happen during re-sync, but we have not seen exactly when it happens.

It seems Diag mode is always on because when I do a manual Sync the S, P, 1, 0 is showing and it can successfully sync...it did after I powered with the MODE key...and it also went back to the original Burst mode pattern.

From: MyPictronics <MyPictronics@aol.com>

Sent: Wed, September 5, 2012 8:21:13 AM

Subject: RE: 360 clock w/WWVB Sync Options - Update

Hope it made it without the PO crushing it again. They ignore the hand stamp sometimes.

1) Did this happen due to a manual sync? Might have been due to the change over.

2) Did you try a reset (Press and hold mode switch during power-up)?

Are these codes happening during normal operation or during resync? I haven’t seen this.

Here are some issues we have observed since last week:

1. The date rollover from 8/31/12 and 9/01/12 had a couple issues; the month rolled to 00/01/12 and it looks like the month went into the hours position as the clock was reading "9:01" after midnight. Everything seems to have corrected itself by morning with a re-sync. during the night.

2. The clock keeps halting with some codes like "P2-4" , "P3-2" on the display. I tried restarting the clock with diag. mode off, not holding the select button but it seems to have no effect.

 Thanks Brent!

We really appreciate the quick response and look forward to trying these new features out!

Hi Brent -

We were using a high current linear supply, it has been on an Astron 12A supply RS12A 12 so, Just in case there was some issue I swapped it to a 2A lab bench power supply... (see attached) It does the same thing. I tried at 8, 9, 10 and 12 V settings the current draw is minimal and even when I use the old "all LED on" display and in any case is not causing the supply to current limit.

I did a few more experiments this weekend and here is what I see:

1. This occurs during resync, at the end with a good SYNC and after all 6 frames are completed- I saw it for the first time right at the end of auto sync this morning... It does not happen all of the time. I can see syncing and force syncs OK sometimes so it is not a hard failure. The clock ran all Saturday night until late morning when I just happened to be around to see the first failure.

2. It can also happen when we do a manual resync... I got it to freeze 5 out of 5 times even after a full restart. I tried turning diag mode off and it still stops on that P3-5 display. Once it is in this mode it always happens. The signal was good and it looked like it was about to update when the crash occurs.

3. When I put the OLD PIR software chip in it does not feeze even with the same supplies and same signal strength. I did see that "P3-5" display briefly before it updated once but the clock was still running and it took the new tile OK. Of course this version only runs 15mins so it is hard to compare the two versions but when I put the second chip back in the failures repeated immediately. Then the signal was too weak to get anymore syncs.

4. After what you said, and knowing these supplies are pretty good, I thought it may be the voltage regulator so I swapped with a new 5V regulator . it still locks up. I seems to be locking up as it should be writing to the clock chip so I looked carefully around that chip to see if there may be a solder issue - but did not see anything.

Let me know if you think of anything else to try. I don't know if the chip got damaged by its shipping adventure, I had to straighten the pins to plug it in ( see attached photo)

 

 So... The Hack Began!

 Really he was pretty responsive, I got tired of the back and forth, it was not going to work out.  We ended with these fixes left it at the solution was to send the clock to him...with all the hardware mods (...Improvements, IMO) done on his board he was going to blame these.  To be fair, he had no idea that  have, well, decades of experience building and designing far more complex boards.

So, time to break out the MICROCHIP IDE, hoist up the old skull and x-bones and let the fun begin...

So much for a simple kit build!

Source Code

~ ~ ~