MARS Buidathon 11 Jul 2009MARS Buidathon 11 Jul 2009 1104/19/2304/19/23

Softrock 20m SDR RX Softrock 20m SDR RX BuildathonBuildathon

Radio Play DaysRadio Play Days

11 July 200911 July 2009

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The CircuitThe Circuit

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The kitThe kit

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Stages of the BuildStages of the Build1.1. PSPS – Power Supply – Power Supply

• 2 ceramic caps; 1 SMT cap; 1 diode; 1 TO-92 voltage regulator; 9V power lead2 ceramic caps; 1 SMT cap; 1 diode; 1 TO-92 voltage regulator; 9V power lead• Smoke Test StationSmoke Test Station

2.2. LOLO – Local Oscillator – Local Oscillator• 3 ceramic caps; 1 SMT cap; 2 transistors; 7 resistors; 1 XTAL3 ceramic caps; 1 SMT cap; 2 transistors; 7 resistors; 1 XTAL• Smoke, Frequency Test StationsSmoke, Frequency Test Stations

3.3. DIVDIV – Dividers/Phasers – Dividers/Phasers• 7 SMT caps; 2 SMT ICs7 SMT caps; 2 SMT ICs• SMT, Smoke, and Frequency Test StationsSMT, Smoke, and Frequency Test Stations

4.4. OPAMPOPAMP – Operational Amplifiers – Operational Amplifiers• 3 ceramic caps; 8 resistors; 1 SMT IC3 ceramic caps; 8 resistors; 1 SMT IC• SMT, Smoke, and Op-Amp Test StationsSMT, Smoke, and Op-Amp Test Stations

5.5. BPFBPF – Bandpass Filter – Bandpass Filter• 2 ceramic caps; 1 coil; 1 transformer2 ceramic caps; 1 coil; 1 transformer

6.6. MIXMIX – Mixer – Mixer• 2 ceramic caps; 2 resistors2 ceramic caps; 2 resistors• Smoke Test StationSmoke Test Station

7.7. CONNCONN – Connect and go – Connect and go• Stereo cable /plug (or jack); antenna coax; PC; softwareStereo cable /plug (or jack); antenna coax; PC; software• Final Test StationFinal Test Station

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Fixtures/ Elmer StationsFixtures/ Elmer Stations• 1. Smoke Test – 1. Smoke Test –

– DMM (test current draw, limited and unlimited)DMM (test current draw, limited and unlimited)• 2. SMT (IC installation,)2. SMT (IC installation,)

– Soldering; Heat gun; Tweezers; lighted magnifier; Panavise Jr.Soldering; Heat gun; Tweezers; lighted magnifier; Panavise Jr.• 3. OpAmp Test (voltage gain)3. OpAmp Test (voltage gain)

– DMM; 10k resistors; clip leads (builder “borrows” resistors/leads)DMM; 10k resistors; clip leads (builder “borrows” resistors/leads)• 4. Inductors (winding, tinning)4. Inductors (winding, tinning)

– DMM; Clamps; Paste Flux/Solder; Soldering Iron; extra #30 DMM; Clamps; Paste Flux/Solder; Soldering Iron; extra #30 Magnet Wire; extra cores; rulerMagnet Wire; extra cores; ruler

• 5. Freq Test (LO, Div, phasing, audio I/Q) 5. Freq Test (LO, Div, phasing, audio I/Q) – Freq meter; Sig generator; dual trace scopeFreq meter; Sig generator; dual trace scope

• 6. Final Test (receiving)6. Final Test (receiving)– PC with SDR software; PC with SDR software; StereoStereo Soundcard; 20m dipole antenna or Soundcard; 20m dipole antenna or

hamstickhamstick• 7. Rework/Troubleshooting7. Rework/Troubleshooting

– Club-furnished solder (63/36 .015”), RG-174 Coax, spare partsClub-furnished solder (63/36 .015”), RG-174 Coax, spare parts– Solder wick, flux, heat gun, solder stationSolder wick, flux, heat gun, solder station

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Builder’s StationBuilder’s Station• DMMDMM• Soldering Station: .032” or smaller tip; .015” solderSoldering Station: .032” or smaller tip; .015” solder• Vise/Board Holder/JigVise/Board Holder/Jig• Bright light, with magnificationBright light, with magnification• Diagonal CuttersDiagonal Cutters• Wire strippersWire strippers• Tweezers recommendedTweezers recommended• UncoatedUncoated Cookie sheet: 8 x 10 or 11 x 14 w/grounding lead Cookie sheet: 8 x 10 or 11 x 14 w/grounding lead• Power stripPower strip• Safety glassesSafety glasses• 9V battery9V battery• Power leads (red/black, mate with 9V battery)Power leads (red/black, mate with 9V battery)• Stereo cable with stereo mini plug (or stereo jack)Stereo cable with stereo mini plug (or stereo jack)

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Builder Station Builder Station InfrastructureInfrastructure• See See Infrastructure DetailsInfrastructure Details• Checklist:Checklist:

– ☐☐Kit, with Components Organized(We do not have spare kits!Kit, with Components Organized(We do not have spare kits!– ☐☐DMM(labeled with your call)DMM(labeled with your call)– ☐☐Solder Station(labeled with your call)Solder Station(labeled with your call)– ☐☐3rd Hand/Vise(labeled with your call)3rd Hand/Vise(labeled with your call)– ☐☐Light and Magnification(labeled with your call)Light and Magnification(labeled with your call)– ☐☐Cookie sheet(labeled with your call)Cookie sheet(labeled with your call)– ☐☐TweezersTweezers– ☐☐StripperStripper– ☐☐CutterCutter– ☐☐Power Strip(labeled with your call)Power Strip(labeled with your call)– ☐☐ConnectorsConnectors– ☐☐Grounding wire/clipGrounding wire/clip– ☐☐PC(Optional)(labeled with your call)PC(Optional)(labeled with your call)

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Process – Pre-Build DayProcess – Pre-Build Day

• Before build day, each Before build day, each registered registered builder does builder does prep-work:prep-work:– Reviews “Getting Ready” Instructions (downloadable Reviews “Getting Ready” Instructions (downloadable

PDF)PDF)– Studys & prints out Studys & prints out documentation pagesdocumentation pages– Prints out Stage BOMs and organizes BOM components Prints out Stage BOMs and organizes BOM components

by stageby stage– Obtains Builder Station Infrastructure ItemsObtains Builder Station Infrastructure Items– (Optional) Loads (Optional) Loads Winrad Winrad and and Rocky Rocky to PC (if have PC)to PC (if have PC)– (Optional) Winds coil and transformer at home before (Optional) Winds coil and transformer at home before

coming to Buildathoncoming to Buildathon– Pack “build-day kit”Pack “build-day kit”

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Process – Build DayProcess – Build Day

• Each builder to a build station (“home”)Each builder to a build station (“home”)• Builder goes through each stage:Builder goes through each stage:

– PSPS: test at : test at smoke testsmoke test station; back to home for remaining station; back to home for remaining tests.tests.

– LOLO: test at : test at smoke testsmoke test, , freq testfreq test stations ; back to home for stations ; back to home for remaining tests.remaining tests.

– DIVDIV: go to : go to SMTSMT station for ICs (do caps at builder station); test station for ICs (do caps at builder station); test at at smoke testsmoke test, , freq testfreq test stations ; back to home for remaining stations ; back to home for remaining tests.tests.

– OP-AMPOP-AMP: go to : go to SMTSMT station for IC; test at station for IC; test at smoke testsmoke test, , OpAmp OpAmp TestTest stations ; back to home for remaining tests. stations ; back to home for remaining tests.

– BPFBPF: wind coils, tin leads at : wind coils, tin leads at InductorInductor Station ; back to home for Station ; back to home for remaining tests.remaining tests.

– MIXMIX: test at : test at smoke test smoke test ; back to home for remaining tests.; back to home for remaining tests.– EXT CONNEXT CONN: test at : test at freq testfreq test station station

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Smoke Test Elmer StationSmoke Test Elmer Station

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Smoke Test ProcedureSmoke Test Procedure

Select Resistor

DMM On

1k

100

Connect Board

Current vs.Nominal

DMM OFF, Stop>= Nominal Value

< Nominal Value

RecordLimited Value”

Press“TEST”

RecordUnlimited

Value

Start

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Frequency Test Elmer Frequency Test Elmer StationStation

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SMT Elmer StationSMT Elmer Station

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Op-Amp Test Elmer StationOp-Amp Test Elmer Station

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Inductors Elmer Station

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Final Test Elmer StationFinal Test Elmer Station

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Rework Elmer StationRework Elmer Station