Elecraft XV Assembly Manual for XV222 User Manual

Elecraft Transverter Models XV50, XV144, XV222 Assembly Manual Rev E, January 31, 2012 Copyright © 2012, Elecraft; All Rights Reserved

- 7 - Parts Inventory You should do a complete inventory. Contact Elecraft if you find anything missing. i Leave painted panels wrapped until they

- 8 - Picture Ref. Designator(s) QTY Description Part # 10 Machine Screw Nut, 4--40 E700011 14 Split Lock washer, #4 (Includes two spa

- 9 - Picture Ref. Designator(s) QTY Description Part # 4 Anderson Powerpole® Connector Crimp Contact E620062 1 Anderson Powerpole® C

- 10 - Picture Ref. Designator(s) QTY Description Part # D10, D11 2 Diode, LED, Red E570007 Pre-mounted on the PCB Z1 1 Frequency Mixer,

- 11 - Picture Ref. Designator(s) QTY Description Part # R25 1 Resistor, 1/4 watt, 5%, 56 ohm (grn-blu-blk) E500096 R14 1 Resistor, 1/4

- 12 - Picture Ref. Designator(s) QTY Description Part # C26, C60 2 Electrolytic Capacitor, 22 F, 25 V E530012 None 1 Electrolytic Capacitor

- 13 - Front panel circuit PCB components. Picture Ref. Designator(s) QTY Description Part # 1 Printed Circuit Board E100168 2 Screw,

- 14 - Picture Ref. Designator(s) QTY Description Part # Q1,Q2,Q3,Q4,Q5,Q6, Q7 7 Transistor, NPN, PN2222 E580001 Z1 1 Ceramic Resonator,

- 15 - i The remainder of the parts in your kit depend upon the band of operation. Check only the list that corresponds to your transverter. XV50:

- 16 - Picture Ref. Designator(s) QTY Description Part # C1, C33 2 Ceramic Trimmer Cap, 1-40 pF E540002 Z3 1 Molded Inductor, .15 H (brn

- 17 - XV144: The following parts are included only in the XV144 transverter. Picture Ref. Designator(s) QTY Description Part # 1 Front Pan

- 18 - Picture Ref. Designator(s) QTY Description Part # L2, Z3 2 Molded Inductor, .1 H (brn-blk-silver)* E690021 L4 1 Molded Inductor, .15

- 19 - XV222: The following parts are included only in the XV222 transverter. Picture Ref. Designator(s) QTY Description Part # 1 Front Pan

- 20 - Picture Ref. Designator(s) QTY Description Part # L10, L11, L4A, L19 4 Variable Inductor, .064-.080 µH, Red E690029 L1 1 Variable Ind

- 21 - Front Panel PCB Assembly Place the front panel PCB on top of the heat spreader with the silk-screened side down as shown in Figure 4. Tempor

- 22 - i The front panel PCB has parts on both sides of the PCB. Follow the instructions carefully. If parts are placed on the wrong side of the PCB

- 23 - i In the steps that follow, you'll be installing groups of components. When working from a long list, install all of the items on one l

- 24 - i The remaining parts will be installed on the front of the circuit PCB Follow the LED installation instructions carefully to preserve the a

- 25 - Sort all of the resistors by value. If the color bands are difficult to read, use a DMM (digital multimeter) to verify their values. Tape th

- 26 - RF PCB Assembly – Part I RF circuit assembly is divided into three parts: Part 1: DC, control circuits and RF components common to all of the

Table of Contents INTRODUCTION ...

- 27 - Adjust the L-bracket positions so the front panel PCB is aligned with the RF PCB. If the gap between the front panel PCB and the RF PCB is w

- 28 - Install the following 3-watt resistors above R21 near the center of the PCB. Space each resistor about 1/16” (1.5 mm) above the PCB just like

- 29 - Install zener diode D3 (1N5235) in the upper left quadrant of the PCB near R12. Position it against the PCB with the banded end aligned with

- 30 - Solder Q2 in place as follows: _ Wet your soldering iron with a small amount of solder and touch it to one lead of Q2 tack-solder it in pla

- 31 - Use a discarded lead to create test point TP3. Two holes for TP3 are directly below R17 in the upper right quadrant of the PCB. Bend the lead

- 32 - Install resettable fuse F1 in the space provided next to relay K9 in the upper right quadrant. F1 may be oriented either way. Solder and trim

- 33 - Install 4-pole DIP switch SW1 in the space provided in the lower left quadrant of the PCB. The DIP switch may not have a notch at one end to

- 34 - Install two 22 F, 25 VDC electrolytic capacitors near the notch on the left side of the PCB. Be sure to observe polarity. The longer positiv

- 35 - i The following transistor is particularly sensitive to electrostatic discharge (ESD) damage. If you are not wearing a grounded antistatic w

- 36 - Insert the tinned leads in the holes on the PCB and position the toroid as shown in Figure 25. Be sure the correct lead goes to each hole. Us

- 1 - Introduction This is the assembly manual for the Elecraft XV50, XV144 or XV222 transverter kits. A separate manual covers the assembly of the

- 37 - Locate the two RCA Jacks, J4 and J5. Use your flush cutters to trim off the two small plastic feet on each jack (see Figure 27). Be sure they

- 38 - Inspect the end of each connector. You should see the contact pressing up against the end as shown in Figure 30. If necessary, press the cont

- 39 - RF PCB Assembly – Part II In the following steps you will install components unique to each band on the RF PCB. These components are provided

- 40 - Install R28, 1k (brn-blk-red), 1/4 watt, near L7 on the left center of the PCB. Install a jumper across the solder pads at W1 near the notch

- 41 - XV144 –144 MHz Transverter Perform the following steps on the RF PCB only if you are building the XV144 transverter. Install the resistors l

- 42 - Install crystal Y1 where indicated by the silk-screened outline inside the circular outline for OV1. The crystal may be oriented either way.

- 43 - Locate the shielded inductors with red inserts provided for L12, L13 and L14 in the R.F. Bandpass filter. Prepare the inductors for installat

- 44 - XV222 – 222 MHz Transverter Perform the following steps on the RF PCB only if you are building the XV222 transverter. Install the resistors

- 45 - If you purchased the optional crystal oven with your transverter (Elecraft part number E980076) install it now as follows: Position the oven

- 46 - Install the RF Bandpass Filter inductors in the spaces provided between relay K2 and frequency mixer Z1: __L12 __L13 __L14 Install a jumpe

- 2 - Preparing for Assembly Overview of the Kit The Elecraft XV transverters use modular construction, both physically and electrically. This conce

- 47 - RF PCB Assembly – Part III In the following steps you will install the RF power module. The procedure is the same for all three transverter m

- 48 - Lay the bottom cover on a clean, smooth surface with the heat spreader facing up. Remove the nuts from the long screws but do not remove the

- 49 - Inspect the RF Power module to be sure you have the module and hardware installed exactly as shown in Figure 38. Figure 38. RF Amplifier M

- 50 - Final AssemblyIn the following steps you’ll finish assembling the transverter. Remove paint overspray from around the screw holes on the ins

- 51 - Connect J1 to the leads already soldered to the RF PCB as follows (See Figure 41): _ Solder the lead that is farthest from the edge to the c

- 52 - i When U1 is pressed into its socket, you must be careful to avoid jamming its pins. Make sure all the pins are lined up with the associated

- 53 - i In the following step be sure to orient the Anderson power connector shells exactly as shown. Otherwise, the connector will not mate with

- 54 - Final Test and Alignment In the following steps you will connect your transverter to your station equipment and perform a complete alignment

- 3 - Preventing Electrostatic Discharge Damage Your XV transverter uses integrated circuits and transistors that can be damaged by electrostatic di

- 4 - Reading Resistor Color Codes It is very helpful if you learn to read the color codes. A color-code chart showing how to read the four-color

- 5 - Note: In rare cases, a capacitor manufacturer may use “0” as a decimal placeholder. For example, “820” might mean 820 pF rather than 82 pF.

- 6 - Soldering, Desoldering and Plated-Through Holes CAUTION: Solder contains lead, and its residue can be toxic. Always wash your hands after hand