Telstar Electronics SkyWave DX600 Manuale utente

RF Linear Amplifier PCB Assembly Manual

SkyWave DX600 Revision-B

Last Revised - 2/5/2021 9:10 AM

Page 1 of 57

www.telstar-electronics.com

RF Linear Amplifier PCB Assembly Manual 
 
 
 
 
 
SkyWave DX600 Revision-B 
Last Revised - 2/5/2021 9:10 AM 
 Page 2 of 57 
www.telstar-electronics.com 
Table of Contents 
 
Introduction ......................................................................................................................................3 
Parts List...........................................................................................................................................4 
Before You Start ................................................................................................................................6 
Assembly Instructions.........................................................................................................................7 
Step #1 - Spacer (SPACER1, SPACER2, SPACER3, SPACER4)................................................................7 
Step #2 - Fixed Resistor (R1-R28).....................................................................................................9 
Step #3 - Variable Resistor (VR1).................................................................................................... 11 
Step #4 –Diode (D1 through D5) ...................................................................................................13 
Step #5 –Dual Operational Amplifier (U2) .......................................................................................15 
Step #6 - Fuse Holder (F1)............................................................................................................. 17 
Step #7 –Input Transformer (T1) ................................................................................................... 19 
Step #8 –Output Transformer (T2) ................................................................................................. 22 
Step #9 - Electrolytic Capacitor (C1, C2, C7, C8,) .............................................................................24 
Step #10 - Ceramic Capacitor (C3, C4, C5, C6, C9, C10, C11, C12, C13, C14, C15, C16, C18) ............... 26 
Step #11 –Mica Capacitor (C17, C19, C20, C21) .............................................................................. 28 
Step #12 - Relay (RLY1) ................................................................................................................ 30 
Step #13 - Field Effect Transistor (Q2, Q3)....................................................................................... 32 
Step #14 –Bipolar Power Transistor (Q5) ........................................................................................ 34 
Step #15 - Voltage Regulator (U1) .................................................................................................. 36 
Step #16 –Field Effect Power Transistor (Q1)...................................................................................38 
Step #17 –Field Effect RF Power Transistor (Q4, Q6) ........................................................................40 
Step #18 - Toroid RF Choke (L1)..................................................................................................... 42 
Step #19 - Heat Sink Marking, Drilling, and Tapping.......................................................................... 44 
Step #20 - Switch, LED, and DC Power Wiring (ON/OFF, PWR LED, SSB DELAY, XMIT LED, +48V) ..........45 
Step #21 –Coaxial Cable (RF IN, RF OUT) .......................................................................................48 
Step #22 - PCB Mounting to Heat Sink............................................................................................. 50 
Step #23 - Bias Adjustment............................................................................................................ 53 
Step #24 –Amplifier Operation .......................................................................................................54 
Troubleshooting ............................................................................................................................... 55 
Specifications .................................................................................................................................. 56 
RF Performance ............................................................................................................................... 57 
 

RF Linear Amplifier PCB Assembly Manual

SkyWave DX600 Revision-B

Last Revised - 2/5/2021 9:10 AM

Page 3 of 57

www.telstar-electronics.com

Introduction

Congratulations on your purchase of the new SkyWave DX600 RF Amplifier PCB. This PCB is a result of

quality engineering to provide high performance and reliability.

Listed below are some of the key features:

High Reliability Design

+48VDC Operation

All Mode (AM, FM, SSB)

26-30MHz Frequency Coverage

LDMOS MRF300 Push-Pull Configuration

Class-AB Temperature-Tracking Bias

High Output Power / Low Harmonic Content

Carrier Operated or Manual

Transmit / Receive Switching

Continuous Reverse Voltage Protection without Damage to Amplifier or Fuse

Fuse Protected

Selectable SSB Delay

Power and Transmit Indicators

Low Stand-By Power Consumption

Premium Quality Printed Circuit Board & Components

We have developed a logical step-by-step procedure that we hope will make your assembling experience

enjoyable & efficient…

Contact Telstar Electronics for details on using the “manual switching” feature.

RF Linear Amplifier PCB Assembly Manual

SkyWave DX600 Revision-B

Last Revised - 2/5/2021 9:10 AM

Page 4 of 57

www.telstar-electronics.com

Parts List

Quantity

Description

Reference

24”

Cable, Coaxial, RG174A/U Type, 52-Ohm

RF IN, RF OUT

Capacitor, Ceramic, 0.01uF, 100V, 20%, Z5U, Radial (LS=0.197")

Capacitor, Ceramic, 0.1uF, 100V, 10%, X7R, Radial (LS=0.197")

Capacitor, Ceramic, 0.1uF, 50V, 10%, X7R, Radial (LS=0.197")

C3, C4, C9, C10, C11,

C12, C13, C14, C15,

C16

Capacitor, Ceramic, 1000pF, 500V, 10%, X7R, Radial (LS=0.197")

C18

Capacitor, Dipped Mica, 330pF, 1000V, 5%, Radial (LS=0.232")

C19, C20

Capacitor, Dipped Mica, 47pF, 500V, 5%, Radial (LS=0.232")

C21

Capacitor, Electrolytic, 100uF, 25V, 20%, Radial

Capacitor, Electrolytic, 10uF, 25V, 20%, Radial

Capacitor, Electrolytic, 10uF, 63V, 20%, Radial

Capacitor, Electrolytic, 1uF, 50V, 20%, Radial

Capacitor, Metal Clad Mica, 330pF, 350V, 5%, SM

C17

Diode, High Speed Signal, 1N914, DO35, Axial

D1, D2

Diode, Zener, 10V, 0.5W, DO-35

Fuse Holder, ATC Type, TH

Fuse, ATC, 25A

IC, Operational Amplifier, LM2904, Dual, DIP-8

Insulator, Phase Change, TO-220

Q1, U1

PCB, SkyWave DX600 Revision-B

N/A

Potentiometer, 1K, 0.1W, Vertical Adjust, TH

VR1

Regulator, Voltage, Adjust, 60V, 1.5A, TO-220

Relay, DPDT, 12V, 8A, DIP

RLY1

Resistor, Carbon Film, 1.2K, 0.25W, 5%, Axial

R16

Resistor, Carbon Film, 100, 0.25W, 5%, Axial

R5, R15

Resistor, Metal Film, 10K, 0.25W, 1%, Axial

R2, R8, R12

Resistor, Carbon Film, 10K, 0.25W, 5%, Axial

R6, R9, R17, R27, R28

Resistor, Carbon Film, 1K, 0.25W, 5%, Axial

R7, R14, R24, R25,

R26

Resistor, Metal Film, 3.3K, 0.25W, 1%, Axial

Resistor, Carbon Film, 4.7K, 0.25W, 5%, Axial

R19, R20

Resistor, Carbon Film, 47K, 0.25W, 5%, Axial

R10

Resistor, Carbon Film, 5.6K, 0.25W, 5%, Axial

Resistor, Carbon Film, 560, 0.25W, 5%, Axial

R18

Resistor, Carbon Film, 8.2K, 0.25W, 5%, Axial

R11

Resistor, Carbon Film, 820, 0.25W, 5%, Axial

R1, R13

Resistor, Metal Oxide, 24, 1W, 5%, Axial

R23

RF Linear Amplifier PCB Assembly Manual

SkyWave DX600 Revision-B

Last Revised - 2/5/2021 9:10 AM

Page 5 of 57

www.telstar-electronics.com

Quantity

Description

Reference

Resistor, Metal Oxide, 33, 3W, 5%, Axial

R22

Resistor, Metal Oxide, 27, 3W, 5%, Axial

R21

Screw, Machine, Philips Pan Head, #4-40, 1/4", Stainless Steel

U1, Q1, Q5

Screw, Machine, Philips Pan Head, #4-40, 5/16", Stainless Steel

BOARD TO SINK

ATTACHMENT

Screw, Machine, Philips Pan Head, #4-40, 3/8", Stainless Steel

Q4, Q6

Spacer, Round, 0.250"D, 0.125"ID, 0.100" Thick

SPACER1, SPACER2,

SPACER3, SPACER4

Thermal Compound, 8.5W/mk, 0.5-gram

Q4, Q6

Toroid, 0.825"OD, 0.520"ID, 0.250"W, #43 Material

Transformer, RF, 1/2" Length, #61 Material

Transformer, RF, 2" Length, #61 Material

Transistor, FET, N-Channel, MRF300AN, 250MHz, 50V, 300W, TO-247

Transistor, FET, N-Channel, MRF300BN, 250MHz, 50V, 300W, TO-247

Transistor, FET, N-Channel, 2N7000, TO-92

Transistor, FET, P-Channel, SUP70101EL, 100V, 120A, TO-220

Transistor, FET, P-Channel, TP0606, TO-92

Transistor, NPN, 3055, 60V, 10A, TO-220

TVS, Uni-Directional, DO-15

D4, D5

Washer, Locking, Split-Ring, #4, Stainless Steel

Q4, Q6

Washer, Shoulder, Black Plastic Insulating, TO-220

Q1, U1, Q5

Washer, Flat, #4, Stainless Steel

Q4, Q6

18”

Wire, #16, Teflon, Orange, Stranded

18”

Wire, #16, Teflon, Orange, Stranded

18”

Wire, #16, Teflon, Blue, Stranded

24”

Wire, Zip Cord, #12, Red/Black

N/A

24”

Wire, #22, Teflon, Blue, Stranded

PWR LED, XMIT LED

24”

Wire, #22, Teflon, Yellow, Stranded

PWR LED, XMIT LED

24”

Wire, #22, Teflon, Green, Stranded

S1 (ON/OFF)

24”

Wire, #22, Teflon, Purple, Stranded

S2 (SSB DELAY)

RF Linear Amplifier PCB Assembly Manual

SkyWave DX600 Revision-B

Last Revised - 2/5/2021 9:10 AM

Page 6 of 57

www.telstar-electronics.com

Before You Start

This kit assumes an understanding of electronics, soldering, and operation of hand tools. In addition to

basic hand tools, the following items will be required for proper assembly.

PCB Assembly:

Soldering Iron

†

Electronic Solder

‡

7/64” Drill Bit (Installation of SPACER1, SPACER2, SPACER3, SPACER4)

1/4” Drill Bit (Lead-Forming of Q1, U1, Q5)

3/8” Drill Bit (Lead-Forming of Q4, Q6)

Scrap Piece of Wood (Installation of SPACER1, SPACER2, SPACER3, SPACER4)

Needle-Nose Pliers

Diagonal Cutting Pliers

Wire Stripper

PCB Assembly to Heat Sink:

Heat Sink (See Page 49 for Suggested Sources)

Power Drill

#4-40 Tap (Mounting Holes in Heat Sink)

#42 Drill Bit (Mounting Holes in Heat Sink)

Masking Tape

Transfer Punch

Bias Adjustment:

48VDC Power Supply

Ammeter (Capable of 400mA)

Several Jumper Wires w/ Alligator Clips

Please take a few minutes before you begin assembling to review the entire assembly &

adjustment procedure.

A few things to remember during the assembly:

Several components in this design are sensitive to static electricity. Precautions should be taken to

avoid static buildup during assembly by using a grounded workstation mat and wrist band.

References are made to the top and bottom side of the PCB. The top side contains the printed

reference designators and component outlines. Most components are inserted from top and

soldered from the bottom. Follow the specific instructions given in each assembly step.

If at any time, you are unsure how to perform an assembly step or have a question, email us for

assistance at telstar.electronics@comcast.net

†

35W-65W recommended. Temperature controlled soldering equipment is always preferred.

‡

Solder recommendation is Kester 331. This solder has a flux that can be washed off with warm tap-water.

RF Linear Amplifier PCB Assembly Manual

SkyWave DX600 Revision-B

Last Revised - 2/5/2021 9:10 AM

Page 7 of 57

www.telstar-electronics.com

Assembly Instructions

Step #1 - Spacer (SPACER1, SPACER2, SPACER3, SPACER4)

Locate the four positions on the bottom of the PCB where the spacers will be attached. (Figure 1)

Drill a 7/64” hole into a scrap piece of wood.

With the aid of the 7/64” drill bit, position the drill bit shank

through a spacer and through the

hole in the PCB into the piece of wood below. The drill bit will aid in centering the spacer on the

PCB hole during the soldering process. (Figure 2)

IMPORTANT - MAKE CERTAIN THE SPACERS ARE FLAT AGAINST THE BOTTOM SIDE OF THE PCB

BEFORE SOLDERING INTO POSITION. USE A MINIMAL AMOUNT OF SOLDER

MAKING CERTAIN NOT TO OBSTRUCT THE CENTER OF THE SPACER.

Solder spacers into position.

Figure 1

The drill bit shank is the solid portion that does not contain the spiral cutting flutes.

RF Linear Amplifier PCB Assembly Manual

SkyWave DX600 Revision-B

Last Revised - 2/5/2021 9:10 AM

Page 8 of 57

www.telstar-electronics.com

Details of spacer installations.

Figure 2

RF Linear Amplifier PCB Assembly Manual

SkyWave DX600 Revision-B

Last Revised - 2/5/2021 9:10 AM

Page 9 of 57

www.telstar-electronics.com

Step #2 - Fixed Resistor (R1-R28)

IMPORTANT - FIXED RESISTORS HAVE NO POLARITY AND CAN BE INSTALLED IN EITHER

DIRECTION. MAKE CERTAIN THE RESISTORS ARE FULLY SEATED IN THE PCB

BEFORE SOLDERING.

Install resistors into the PCB at the designated locations. (Figure 3)

Solder resistors into position.

Cut off the excess lead length.

Figure 3

RF Linear Amplifier PCB Assembly Manual

SkyWave DX600 Revision-B

Last Revised - 2/5/2021 9:10 AM

Page 10 of 57

www.telstar-electronics.com

Details of fixed resistor installations.

Figure 4

Indice

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