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EA3GCY EGV-40 Assembly Manual

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EGV-40
QRP transceiver for CW in kit form
In memory of Miguel Montilla, EA3EGV (SK)
Assembly manual
Last update: Octubre 1st, 2013
ea3gcy@gmail.com
:
www.qsl.net/ea3gcy
For last minute updates and news, please got to
EGV-40 transceiver
Thanks for buying and building the kit for the
Enjoy building and working QRP!
73, Javier Solans, ea3gcy
EGV-40 CW QRP Transceiver
Page 1

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  • Page 1 Last update: Octubre 1st, 2013 ea3gcy@gmail.com www.qsl.net/ea3gcy For last minute updates and news, please got to EGV-40 transceiver Thanks for buying and building the kit for the Enjoy building and working QRP! 73, Javier Solans, ea3gcy EGV-40 CW QRP Transceiver Page 1...

  • Page 2: Table Of Contents

    PARTS LIST SORTED BY VALUE/QUANTITY………..…………………………..…………… 7 INDIVIDUAL PARTS LIST………………………..……….……………………………………….. 9 LOCATION MAP…….…………………………………………………………………………….. 13 ASSEMBLY…….………..……………….…..……………………………………....... 14 ADJUSTMENTS AND CHECKS…………..…………………………………………………..24 APPENDICES………….…...……………………………………………………………….……… 28 IF YOUR KIT DOES NOT WORK AFTER ASSEMBLY.………………..……………………... 31 WARRANTY CLAUSES………..…………………………………………………………..33 SCHEMATICS..……..……………………………………………………………………………… 34 WIRING……..………..……………………………………………………………………………… 35 EGV-40 CW QRP Transceiver Page 2...

  • Page 3: Introduction

    NE/SA602 mixer chips. The circuit is a “tutti frutti” mix of several well known designs from the last 20-25 years, very similar among them. In the EGV-40 I have tried to gather the best ideas of all these little jewels but keeping in mind the philosophy of making an easy to build, compact, reasonably cheap circuit with good characteristics.

  • Page 4: Specifications

    To Jon EA2SN for translating this manual into English, and to the “EA-QRP-CLUB” for keeping alive the homebrewing, even on difficult times. And, in special, to Montse, Miguel's widow, for allowing me to link this EGV-40 kit with the memory of his late husband, and for generously providing me with information and support.

  • Page 5: Tips For First Time Builders

    It is highly recommended to clean and remove the remaining tin from the iron tip after each soldering (most of the holders have a sponge for this); this helps to avoid old tin on the tip and residues from previous operations. EGV-40 CW QRP Transceiver Page 5...
  • Page 6 Is the part of the build considered by some to be the most difficult. I find it one of the easiest stages, personally, and almost relaxing. Just take your time. The assembly instructions and pictures illustrate the process. EGV-40 CW QRP Transceiver Page 6...

  • Page 7: Parts List Sorted By Value/Quantity

    C23, C24 (electrolitic) 100uf 25V or 35V 10uf C15, C22, C27, C38, C44, C50, C52, C53 (electrolitic) 10uf 25V or 35V CV1, CV4 Murata trimer Brown 160+70p CV2+CV3 Polyvaricon dual gang. Tuning. 160p + 70p Polyvaricon EGV-40 CW QRP Transceiver Page 7...
  • Page 8 IC’s socket 8 pin Shaft Poly. 6mm Shaft Polyvaricon Hardware Heatsink Q7 (Output Amp) Heatsink 70cm wire 70cm enameled copper wire 0,5mm 110cm wire 110cm enameled copper wire 0,3mm EGV PCB 100mm x 85mm ILER V2 PCB EGV-40 CW QRP Transceiver Page 8...

  • Page 9: Individual Parts List

    Checked Ref. Value Ident./Comment Circuit section Located 1K shfat potentiometer RX atten. 500 Ω/1K shaft potentiometer 500 or 470 or 1K Audio volume 10K shaft potentiometer Fine Tune 500 Ω adjustable resistor Power level EGV-40 CW QRP Transceiver Page 9...
  • Page 10 10uF 10uF Q9 Key in 10uF 10uF DRIVER 103 or 0.01 DRIVER 100n 104 or 0.1 DRIVER 103 or 0.01 DRIVER 100n 104 or 0.1 DRIVER 103 or 0.01 Output AMP 220uF 220uF Supply EGV-40 CW QRP Transceiver Page 10...
  • Page 11 TX MIX 78L06 78L06 TX MIX Diodes 1N4148 1N4148 1N4148 1N4148 Output AMP Zener 47V 1W BZX85C47 Output AMP 1N4148 1N4148 RX limiter 1N4148 1N4148 RX limiter BB112 Varicap diode BB112 VXO (Fine) G/H-1 EGV-40 CW QRP Transceiver Page 11...
  • Page 12 B-10 5u3H (shielded) RF transf. 5u3H RX BPF D-10 5u3H (shielded) RF transf. 5u3H TX MIX 5u3H (shielded) RF transf. 5u3H TX MIX FT37-43 black toroid 8 + 1 turns (see text) Output AMP EGV-40 CW QRP Transceiver Page 12...

  • Page 13: Location Map

    LOCATION MAP EGV-40 CW QRP Transceiver Page 13...

  • Page 14: Assembly

    PCB, and on the other side bend slightly out the legs to hold the resistor in place. Then turn the PCB over and solder the leads to the PCB pads. Make sure the resistor body lays flat over the board to keep its legs as short as possible.  EGV-40 CW QRP Transceiver Page 14...
  • Page 15 1-1.5 mm (1/16 in). Fit them on their designated places as with resistors. Note: L5 is the VXO toroidal coil, which will be wound and placed later. EGV-40 CW QRP Transceiver Page 15...
  • Page 16 CV1 and CV4 are capacitor trimmers brown in color. They have no printed marks. Place them following the outline on the silkscreen of the PCB. CV2 + CV3 are part of the two-section tuning “Polyvaricon” variable capacitor. DO NOT INSTALL it now. EGV-40 CW QRP Transceiver Page 16...
  • Page 17 If contact fails in the sockets it may cause a malfunction of the rig. Now, place the voltage regulators IC4, IC5, and IC7, following the outline of the silkscreen. EGV-40 CW QRP Transceiver Page 17...
  • Page 18 T1, T2, T3 y T4 are Toko “5u3“ cans (Toko KANK3334). RF transformers for the bandpass filters Make sure their body lay flat against the PCB. You may need extra heat to solder the shield tabs. EGV-40 CW QRP Transceiver Page 18...
  • Page 19 T5 is an impedance matching transformer. A FT37-43 is used (black toroid with an OD of 9.5 mm / 0.375 in). It has a primary of 8 turns, going to “b” and “b1” holes in the PCB and one secondary of 1 turn going to “a” and “a1” holes. EGV-40 CW QRP Transceiver Page 19...
  • Page 20 - Prior to its soldering, use a cutter, or sandpaper to scrape the enamel from the pigtails of the 8 turn winding. IMPORTANT: Wind the T5 transformer exactly as shown in the pictures. You must follow both the number of turns and the winding direction.  EGV-40 CW QRP Transceiver Page 20...
  • Page 21 You may want to mount the polyvaricon out of the board. This may be a good idea, but place it as close as possible and use short and rigid wires. Even small movements may affect the tuning! EGV-40 CW QRP Transceiver Page 21...
  • Page 22 A T68-2 is used (red toroid with an OD of 18 mm / 0.690 in). Cut 102 cm (40 in) of 0.3 mm enameled wire and wind 48 turns on the T68-2. Leave pigtails of 10-15 mm (3/8-1/2 in). EGV-40 CW QRP Transceiver Page 22...
  • Page 23 The EGV-40 kit uses as Q12 a 2SC2078 and the following bridges SHOULD BE INSTALLED: “B-x”, “C-y” and “E-z”. Cut small pieces of wire (or resistor leftovers) to prepare the connections “B” to “x”, “C”...
  • Page 24 M3 screw and nut. It is also recommended to apply a dab of thermal grease. You may also drill other hole on the heatsink if that suits better its position on your box. DO NOT OPERATE the transceiver without a heatsink on Q12 EGV-40 CW QRP Transceiver Page 24...

  • Page 25: Adjustments And Checks

    For normal use on the EGV-40 the jumper should be placed on J1 “A” (smaller capacity) you can also try the place J1 “B”. When the polyvaricon is placed out of the board, please notice that when mounted upside down, with the terminals up, the jumper connections get inverted, and you will have to place the jumper on J1 "B"...
  • Page 26 When turns are spread, the inductance and, thus, the coverage diminishes. Spreading or compressing the turns a variation of a few kHz may be achieved. The EGV-40 has been designed to have a lower limit of the tuning range around 7.000 MHz. Higher limit of frequency.
  • Page 27 Note: for this adjustment you will need a trimming tool for this kind of IF cans; if you use a screwdriver you may break and damage the coil core. Turn P1 (RX attenuator) to minimum attenuation, that is, all the way clockwise. EGV-40 CW QRP Transceiver Page 27...
  • Page 28 If you don't have access to instrumentation, do not worry, as these adjustments are not critical at all. Connect an adequate antenna for 40 meters to EGV-40 and tune a strong CW signal, as stable as possible; adjust alternately T1 and T2 until you get the best reception on the headphones.

  • Page 29: Appendices

    DDS circuit. I will recommend you the ILER-DDS from EA3GCY. Note: If you have bought the EGV-40 and the ILER-DDS you don't need to install any of the parts related to the VXO circuit. Please see Appendix 7.
  • Page 30 PSU voltage, etc. -If you have a working EGV-40 with its VXO and want to install an ILER-DDS, you need to disable the VXO by just disconnecting L6 and connecting the DDS output to the "VXO" header on the EGV-40.

  • Page 31: If Your Kit Does Not Work After Assembly

    1.39 7.90 7.90 13.8 4.10 (S)4.80 (S)4.80 4.30 3.93 1.39 1.39 1.34 Out 5.96 Out 7.98 Out 0.0 1.39 1.39 4.74 4.80 4.76 4.80 6.81 5.84 5.90 13.60 5.23 5.43 6.90 5.90 5.90 1.34 EGV-40 CW QRP Transceiver Page 31...
  • Page 32 1.39 Out 5.98 1.39 1.39 1.39 4.75 4.81 4.74 4.77 4.82 6.82 4.74 5.84 5.90 13.63 5.93 5.20 5.44 6.92 5.36 5.90 5.95 1.35 5.98 Note: Values of +/- 5% can be considered correct. EGV-40 CW QRP Transceiver Page 32...

  • Page 33: Limited Warranty

    Please, BEFORE making a return, ask for directions by email to: ea3gcy@gmail. Javier Solans, ea3gcy, warrants this device to function as described in this documentation provided that it is assembled and used correctly according to all printed instructions.

  • Page 34: Schematics

    SCHEMATICS EGV-40 CW QRP Transceiver Page 34...

  • Page 35: Wiring

    Take notice that the EGV-40 is NOT PROTECTED against polarity inversions! It is a good idea to place a diode (ex. BY255 or larger) in parallel with the PSU input on the EGV-40. The cathode (the end with the printed band) goes to the positive wire. If your PSU supports shortcircuits or has a fuse on its output, OK;...

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