Building a Bitx20 Version 3b Full Kit

February 17, 2014

These instructions are for building the full Version 3b kit. This document is based on Leonard
KC0WOX's excellent instructions and videos for building and aligning the BitX20 Ver3. Every effort
was made to ensure the integrity and clarity of his original work was captured in this document.

The full kit contains PCBs, parts, FLL Counter module and chassis.

The PCBs included in the kit are the Exciter, Power Amp (PA) and Automatic Gain Control/S-Meter.

During assembly you should review the photographs of the completed boards (part of the kit
documentation) to verify your build and answer questions you may have during your build.

The process for building the Version 3b Full Kit will be to build the PA board first. Then we'll build the
Exciter board, perform the alignment of that board, then integrate it to the PA board's driver and final
circuits. Once that is complete we'll build and integrate the AGC board, and then install everything
into the chassis.

So before we jump into building the Exciter board, we will first build up the PA board, then we'll build
the Exciter board.

The PA board provides a safe way to apply power to the Exciter board. It switches V+ to either the
receive circuits or the transmit circuits depending on the position of the Push-to-Talk (PTT) switch. A
simple SPST switch can be used as the PTT switch.

Part 1: Version 3b Power Amplifier

The Power Amplifier (PA) board can be broken into sections that can be built and tested one at a time.
This will make troubleshooting easier as any problems will be confined to one small section.

PA Board Sections
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We'll build the Power Switching section first, then the Driver and then the Final.

The Power Switching section of the PA board can be built to support either a DC or an AC power
supply:

Option 1: +12-14.5 VDC input from an external power supply, which is applied to both the Final
section and the Exciter board

Option 2: 14-18 VAC input from an external power supply, resulting in a higher voltage to the Final
and approximately +13 VDC to the Exciter board.

We will build the PA board in entirety and simply connect either a DC or an AC output power supply to
the appropriate locations.

Note: The DC power supply should provide at least 12VDC, but no more than 14.5VDC. Supplies for
ham radio rigs will meet this requirement, usually putting out about 13.8VDC. The AC supply should
provide a maximum of 18VAC. This will prevent overvoltage of the electrolytic capacitors.

Power Switching Circuit Build

First install all the indicated jumpers, show in red below. These can be bare or insulated wire; #22
wire will fit nicely through the holes. Place the jumpers where indicated by the red lines. The kit
includes bare tin wire and tubing that can also be used for making the jumpers.

Jumper Locations on PA Board, 3 Total (2 Installed Now)

At the pads for the jumper that is to be installed later solder a short wire to be used to clip on to with
a current meter. This test point will be used to set the bias current for the final output transistor, the
IRF510.

Install the following components:

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 Quantity Value Description Color Code
2 0.1uf Capacitor
1 1.0uf Capacitor
2 2,200uf Capacitor 25 volt electrolytic
2 100 ohm Resistor brn-blk-brn
1 1k Resistor brn-blk-red
5 1N4007 Diode
1 LM317 Voltage Regulater
1 Heat Sink For Voltage Regulator
1 Thermal Pad For Voltage Regulator
1 Screw, 4-40x1/2" For Voltage Regulator
1 Nut, 4-40 For Voltage Regulator

Nylon shoulder washer For Voltage Regulator

AR Heat Sink Compound For Voltage Regulator
2 Screw, 4-40x3/8" For Voltage Regulator Secures heat sink to PCB
1 SPDT Relay Relay K2
1 4-pin header for P2 (marked GVTR)
1 3-pin header for P1 Remove center pin to fit
1 3-pin header for fan
1 2-pin header for P3 (PTT)
1 SPST Switch PTT switch Not included in kit
Connects to P3 and PTT
1 2-pin cable assy Switch

Power Switching Section Components

Install components as shown below observing polarity of the diodes and electrolytic capacitors.

Power Switching Section Component Placement

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The LM317 voltage regulator is assembled onto a heat sink as seen below. For safety, to prevent the
potential for RF burns especially during checkout of the PA board, the heat sinks of the LM317 and the
IRF510 (to be assembled later) need to be grounded. There is a provision designed into the PA board
to connect the PCB ground to the heat sink via screws. There is a bit of lead bending that needs to be
accomplished in order for the component holes in the PCB to line up with the heat sink holes once the
heat sink is assembled to the IC.

First bend the leads of the LM317 as shown below.

Note: It is helpful to temporarily assemble the LM317 to the heat sink and do a test fit to figure out
what the geometry for the lead bends is. After bending the leads do another test fit to make sure the
leads poke through the PCB holes sufficiently to allow confidence in soldering.

Once the leads are bent properly, heat sink compound is applied as a thin film on the surface of the
heat sink and on the rear of the LM317. The thermal pad lays between the LM317 and the heat sink.
The nylon shoulder washer is pressed into the mounting hole on the LM317 and the nut and screw
hold everything together.

LM317 Heat Sink Assembly

Because the leads of the LM317 are necessarily close to the bottom of the heat sink, apply a small
piece of electrical tape to the bottom of the heat sink as shown below. Also, run the 4-40 screws into
the bottom of the heat sink to clear out flash and make sure the screws "bite" properly and can be
bottomed out so the heat sink will be securely attached to the PCB after installation.

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Note: This same assembly method will be used for the IRF510. You may wish to assemble the IRF510
in the same manner as the LM317 now. The IRF510/heat sink assembly will be used later in the PA
build.

Note: After assembly of the LM317 to the heat sink, and before installing the assembly to the PA
board, use a DVM to ensure there is no continuity between any of the LM317 pins and the heat sink.

Install the LM317/heat sink assembly to the PA board. Attach the heat sink to the PCB with the 4-40
screws, but do not overtighten. Next solder the leads of the LM317 to the PCB.

Note: Using a DVM ensure that the heat sink is electrically connected to the PCB ground, and check
that each lead of the LM317 is electrically connected to the appropriate PCB traces.

Next we will build the Power Distribution Cable that connects the PA board to the Exciter board. The
cable provides power to the Exciter board, FLL Counter module, the AGC board, and provides the
connection to the DC power supply if an AC power supply is not used. It also provides a means to
insert a current meter to measure current flowing into the Exciter board. The following components
are needed to build the cable:

Quantity Value Description

2 4-pin cable assy Power Cable
AR Heat shrink tubing
AR Additional wire Red, Black 22 AWG

Power Distribution Cable Components

This is the cable schematic:

Power Distribution Cable Schematic

It is built from two 4-pin cable assemblies, included in the kit. Each cable is cut 5" out from the
connector, with wire lengths soldered at the splice points as indicated.

When we build the Exciter board we will be testing each section, and one of the measurements we will
make is the current consumption of the Exciter board as we complete a section. Therefore we need to
incorporate the ability to insert a current meter into the path of the DC power supply return wire
specifically for the Exciter board. Once we complete testing we'll splice the ends of the wires that
were connected to the ammeter together.

The cable looks like this when completed (before inserting the Ammeter):

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 Power Distribution Cable

This looks a bit fussy but it will be very helpful when you are wiring power to the various components
within the chassis.

Note: If you are using an AC output power supply, which connects to P1 of the PA board, the wires of
the power distribution cable that go to a DC power supply are not needed. However, it may be wise to
build the cable as shown above and stow the DC power supply wires just in case.

Testing the PA Board with an AC Power Supply

Do not apply more than 18 VAC to the AC Supply Input or the working voltage on the 25 volt
electrolytic capacitors will be exceeded!

Connect your AC power supply to the PA board P1. You can use a 3-pin header from the kit and
remove the center pin if you wish and install at P1. See the photograph below. Use one of the
supplied 3-pin mating connector cables to connect your AC power supply to this header.

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 Suggested P1 Connector, 3-Pin Header with Center Pin Removed

Alternatively, solder wires from the AC supply directly to the PCB, using sufficient gauge wire between
your power supply and P1 to ensure no voltage drop occurs, given that the rig will consume something
on the order of 500mA when complete. Turn on your power supply and measure the voltage between
P2 - V and G. Using the resistance values listed it should measure approximately 13-14 VDC.

Volts

Measure the voltage at the right side of the LM317. This will vary depending on the AC input voltage.
It should be more than 16 and less than 25 VDC.

Volts

Note: A filament transformer can be used as the AC power supply. Choose a transformer that works
with your AC mains voltage as input to the primary and provides 14-18 VAC @1 Amp minimum at the
secondary. The output voltage of the transformer will vary somewhat with the load, so the voltage at
the LM317 after the diode bridge may be a bit higher than 25 VDC until additional circuits are
powered.

You can test the operation of the K2 relay by connecting a voltmeter to P2 - T and shorting the pins of
P3 together. This is the PTT switch connector. When the relay operates you should hear it click and
read the DC power supply voltage. Use one of the supplied 2-pin header mating connectors that have
been prewired with lengths of wire to connect P3 to an SPST switch that you have lying around. You
will be frequently checking voltages and currents on the Exciter board in either receive or transmit
mode, and this setup will come in handy.

Applying power to the R pin activates the receiver circuits of the Exciter board. This is the normal
condition of the PA board (pins of P2 not shorted together). When the PTT switch is engaged it shorts
the two pins of P2 together and V+ is applied to the T pin which then powers the transmitter circuits
of the Exciter board. The V terminal which is always hot activates the common circuits such as the
BFO and the VFO--they are always powered on.

Using the PA board to switch power between the receive and the transmit circuits of the Exciter board
ensures that both types of circuits can never be powered simultaneously.

Testing the PA Board with a DC Power Supply

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Turn on your power supply and verify the output voltage is 12-14.5 VDC. Turn off your supply. Plug
the Power Distribution Cable's designated connector to the PA board's 4-pin power connector P2.
Connect the designated wires to the power supply observing polarity. Be sure to protect the other
spliced wire ends from shorting to each other. Turn on your power supply and measure the voltage
between P2 - V and G. It should measure the DC supply voltage.

Volts

You can test the operation of the K2 relay by connecting a voltmeter to P2 - T and shorting the pins of
P3 together. This is the PTT switch connector. When the relay operates you should hear it click and
read the DC power supply voltage. Use one of the supplied 2-pin header mating connectors that have
been prewired with lengths of wire to connect P3 to an SPST switch that you have lying around. You
will be frequently checking voltages and currents on the Exciter board in either receive or transmit
mode, and this setup will come in handy.

Driver

We will need the following components.

Quantity Value Description Color Code

5 0.1uf Capacitor
2 10 ohm Resistor brn-blk-blk
1 22 ohm Resistor red-red-blk
1 56 ohm Resistor grn-blu-blk
1 470 ohm Resistor yel-vio-brn
1 1k Resistor brn-blk-red
1 2.2k Resistor red-red-red
1 10k Potentiometer Marked 103 on side
1 5.6 volt Zener Diode Marked 5V6 on body
1 2N3866 Transistor Q1
1 Heat sink For Q1 Wrap-around heat sink
FT37-43 core with 8
1 turns bifilar #34 Bifilar Transformer T1
T37-6 core with 14
1 turns #34 - 0.55 uh Toroid coil on core for L2
1 2-pin header For P4

Driver Section Components

Install components as shown below.

8
 Driver Section Component Placement

The transformer T1 is made using an FT37-43 core and wound with bifilar wire. Prepare the bifilar
wire by twisting together two 1 foot lengths of the supplied #34 gauge magnet wire using a power
drill to perhaps 7 or 8 turns/inch. You are preparing enough bifilar wire to build a similar transformer
for the Exciter board.

Wind 8 bifilar turns of the prepared bifilar wire on the core. This will take 6" of your prepared twisted
wire. One turn is counted when the wire passes through the center of the core.

Transformer T1, 8 Turns #34 Gauge Bifilar Wire

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If your wire is not heat strippable, carefully strip off the insulation on all winding leads with a hobby
knife. Tin the leads. With the specified core, the inductance should be around 22uh per winding
although it really isn't particularly critical. See

http://golddredgervideo.com/kc0wox/bitx/transformers.htm

for a discussion why.

Simplified Winding Connection Diagram, Cross Section Side View of Core

Install T1 as shown below. The numbers correspond to those shown in the Simplified Winding
Connection Diagram above.

Installation of the Bifilar Transformer in Driver Circuit

10
When installed T1 will look like this:

T1 Installed on PA PCB

Next we'll wind the inductor we need for L2 of the Driver section.

The inductor is made using an FT37-6 core which is yellow. Wind 14 turns on the core using the
supplied #34 gauge magnet wire. This will take about 6" of wire. Strip the ends and tin.

L2: 14 Turns #34 Wire on FT37-6 Core

Install L2. Continuing with component installation, Q1 should look like this after installation. Note the
orientation of the emitter tab.

11
 Q1 Orientation on PCB

Install the wrap-around heat sink onto Q1. You may need to open the heat sink up a little so it slips
over the transistor body. It should be a snug fit.

Q1 with Heat Sink Installed

12
The 10k trimpot requires a bit of fussing with the leads to get it to fit. This arrangement works:

10k Trimpot Lead Bends to Fit PCB

Note the orientation of the lead bends to the notches in the body of the trimpot.

10k Trimpot Installed on PCB

Apply power to PA board. Short the 2 pins on the PTT connector, P3, to switch to transmit mode, or
use your PTT switch, and measure Q1 voltages. Compare them to the chart below.

Transmit - Q1 voltages
Collector 11.70
Base 1.74
Emitter 1.08

Transistor Q1 voltages in transmit mode

Measure the voltage at the bottom end of the 56 ohm resistor relative to ground. Adjust the 10k
trimpot and verify that the voltage varies between 0 and the zener's voltage rating, 5.6 VDC. After
verification, adjust it for a reading of 0 VDC. This adjustment sets the DC bias of the IRF510 and will
be set as part of the alignment steps after we build the Exciter board.

13
Final

We will need the following components.

Quantity Value Description

4 0.1uf Capacitor
2 220pf Capacitor, NPO
1 560pf Capacitor, NPO
FT37-43 core with 11
1 turns bifilar #26 Toroid coil on core for L1
T37-6 core with 14 Toroid coil on core for L3,
2 turns #26 - 0.55 uh L4
FT37-43 core with 3
1 turns bifilar #26 Bifilar Transformer T2
1 IRF510 FET
1 Heat Sink For FET
1 Thermal Pad For FET
1 Screw, 4-40x1/2" For FET
1 Nut, 4-40 For FET

Nylon shoulder washer For FET

AR Heat Sink Compound For FET
2 Screw, 4-40x3/8" For FET
1 SPDT Relay Relay K1
2 2-pin Header For P5, P6

Final Section Components

Install the components as shown below.

Final Section Component Placement

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L1 will take 8" of #26 gauge magnet wire, supplied, and should measure around 42uh. The actual
value isn't too critical as this is used as a radio frequency choke and as long as it has plenty of
inductance, value really doesn't matter. Strip and tin the leads.

L1 Wound on an FT37-43 Core, 11 Turns #26 Gauge Magnet Wire

L3 and L4 will take 8" of wire and should measure .55uh. Wind 14 turns of #26 gauge magnet wire
on an FT37-6 core (yellow). Be sure to spread out the turns over the whole core. If they bunch
together it will raise the inductance. Strip and tin the leads.

L3, L4 Wound on FT37-6 Cores, 14 Turns #26 Gauge Magnet Wire

15
T2 will take 4" of #26 gauge bifilar magnet wire. Prepare the bifilar wire by twisting together two 1
foot lengths of the supplied #26 gauge magnet wire using a power drill to perhaps 7 or 8 turns/inch.
Each winding should measure about 3.15uh.

T2 Wound on FT37-6 Cores, 3 Turns #26 Gauge Bifilar Magnet Wire

Simplified Winding Connection Diagram, Cross Section Side View of Core

Strip the insulation on the leads and twist the indicated winding leads together. Flow solder into
the twisted connection. Tin the other leads. Install T2 as shown below. The numbers correspond to
those shown in the Simplified Winding Connection Diagram above.

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 Installation of the Bifilar Transformer in Final Circuit

Install all of the components except the relay and the IRF510/heat sink assembly. Do them last. This
will give you a little more finger room. The jumper will be left off as this is the current meter point to
set the bias on the IRF510.

Assemble the IRF510 to the heat sink exactly as you did for the LM317 voltage regulator. Install the
IRF510/heat sink assembly to the PA board. Attach the heat sink to the PCB with the 4-40 screws,
but do not overtighten. Next solder the leads of the LM317 to the PCB.

Note: Using a DVM ensure that the heat sink is electrically connected to the PCB ground, and check
that each lead of the LM317 is electrically connected to the appropriate PCB traces.

Testing

We will defer testing of the PA board Driver and Final sections until after we've completed the Exciter
board.

BitX20 Ver3b PA Board

17
Part 2: Version 3b Exciter Board
The Exciter board can be broken into sections that can be built and tested one at a time. This will
make troubleshooting easier as any problems will be confined to one small section.

Exciter Board Build

Now that we have a working PA board that can provide automatic switching between receive and
transmit power, we'll start building and testing the Exciter board.

Quantity Value Description Notes

AR 22 gauge wire Jumpers
for location marked Power input to the Exciter
1 4-pin header GVTR board

First Parts for Exciter Board

Install all of the wire jumpers onto the board. These can be bare or insulated wire; #22 wire will fit
nicely through the holes. Place the jumpers where indicated by the red lines. The kit includes bare tin
wire and tubing that can also be used for making the jumpers.

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 Jumper Locations, 12 total

Next solder in a 4-pin header onto the Exciter board at the location marked GVTR. Be sure to orient
the connector so it faces the correct way to accept the mating connector, and so all the connections
between the boards agree. Connect the Power Distribution Cable you made during the Power
Amplifier board build between the PA Board P2 and the Exciter board's GVTR connector. Insert a DVM
in current measurement mode into the black wire as shown in the picture of the Power Distribution
Cable photograph and schematic in the PA build section.

Note:
When setting your power supply voltage, if you have 2 meters available hook one up as the current
meter as described above, and use the other to measure the voltage where it enters the Exciter board
(the V terminal at the GVTR connection). Current meters have an internal voltage drop and if you set
the power supply to 13.25 volts there will be less voltage at the board due to the current meter's
voltage drop. This also corrects for any voltage drop over the wires from the power supply to the
setup.

Band Pass Filter Section

For the band pass filter section you will need the following components.

Quantity Value Description Notes

3 L1, L2, L3 Transformer
2 0.1ufd Capacitor
2 2.2pfd Capacitor, NPO
3 39pf Capacitor, NPO Use 39pF for all 3 places

Band Pass Filter Components

Using the component placement diagram below, assemble the band pass filter section. Be very careful
when inserting the transformers into the board. If the pins are misaligned, they will be pushed back
into the can and are hard to retrieve. It is easiest to insert the 3 pin side first. Before you seat the can
flush to the board, inspect the bottom side of the board and insure all pins are protruding. If a pin is
pushed back, very carefully pull it back out with a pair of needle nose pliers.

19
After we assemble the next section, the RF amplifier, we can test this section using a sweep
generator. We will wait until then because the RF amplifier will provide the proper load impedance to
the filter. If you don't have a sweep generator and oscilloscope, you can perform a basic alignment
after the Exciter is completed using an audio input and the Exciter as an RF signal source. More on
that procedure later.

Band pass Filter Component Placement

RF Amplifier Section
For the RF amplifier section you will need the following components.

Quantity Value Description Color Code

2 10 ohm Resistor brn-blk-blk
2 100 ohm Resistor brn-blk-brn
4 220 ohm Resistor red-red-brn
2 1k Resistor brn-blk-red
2 2.2k Resistor red-red-red
8 .1uf Capacitor
2 1N4148 Diode
1 2N3904 Transistor
1 2SC3355 RF Transistor Note different pinout

RF Amplifier Components

Using the parts placement diagram below, assemble the RF amplifier section.

Tip: If your DVM has the ability to measure transistor small signal forward current gain, hfe, then
check all the 2N3904 transistors before installation just to make sure they are ok. hfe should be
around 200.

20
Tip: If your DVM can measure capacitance then you can verify caps are the correct value and within
tolerance before installing them into the PCB.

Note:
Install the transistors with the flat as shown on the drawing. The C3355 transistor pins are not
configured the same as the 2N3904's pins so those components are not directly interchangeable.

RF Amplifier Component Placement

Turn on your power supply and verify that the voltage at the Exciter board's V connection (from the
PA board) is 13-14 VDC. The measurements made during the testing of the Exciter board sections
assumes 13.25 VDC is present at the V connection and also at the R (Receive), and at the T
(Transmit) voltage connection when the PTT switch is engaged.

Note: Voltage and current measurements may differ slightly from your measurements due to power
supply voltage and parts tolerance.

The measured current should read approximately 12 milliamps.

milliamps on Receive

Measure the Q1 voltages and compare to the chart below. There is space to document your readings
after the standard voltages.

Engage your SPST switch that is acting as the PTT switch so that 13.25 volts is applied to the Transmit
voltage connection. The measured current should read approximately 30 milliamps.

milliamps on Transmit

Measure the Q13 voltages and compare to the chart below.

21
 Receive - Q1 voltages Transmit - Q13 voltages
Emitter 2.711 Emitter 2.008
Base 1.995 Base 2.703
Collector 8.76 Collector 8.69

Transistor voltages with 13.25 volts applied at Exciter Board

VFO Section

The VFO circuit utilizes varactor diodes and a ten-turn pot for tuning, unlike the variable capacitor
approach on previous designs. The varactor VFO provides very stable and accurate tuning. As you
will see later, the FLL Counter module, included in the full kit, provides an additional function of
closing a loop between the counter and the VFO to maintain a very stable operational frequency. For
the VFO section you will need the following components.

Quantity Value Description Color Code

1 10 Resistor brn-blk-blk
2 100 Resistor brn-blk-brn
1 150 Resistor brn-grn-brn
1 390 Resistor org-wht-brn
3 1k Resistor brn-blk-red
2 1.8k Resistor brn-gry-red
1 4.7k Resistor yel-vio-red
1 6.8k Resistor blu-gry-red
1 47k Resistor yel-blu-org
2 56k Resistor grn-blu-org
1 82k Resistor gry-red-org
1 100k Resistor brn-blk-yel
1 1pf Capacitor, NPO
1 10pf Capacitor, NPO
1 15pf Capacitor, NPO
1 18pf Capacitor, NPO
1 22pf Capacitor, NPO
1 39pf Capacitor, NPO
1 100pf Capacitor, NPO
2 220pf Capacitor, NPO
2 .01uf Capacitor
6 .1uf Capacitor
2 22pf Variable capacitor
3 2N3904 Transistor
1 BF245 FET
1 MV209 Varactor diode
1 BB204 Dual varactor diode
1 3-pin header for tuning pot
1 2-pin header for FLL Counter input
1 2-pin rt angle header for FLL Counter control Mount on rear of PCB
T37-6 core with 50
1 turns #34 - 7.5 uh Toroid coil on core for L4

VFO Components

22
Using the parts placement diagram below, assemble the VFO section.

VFO Section Component Placement

Note: The 2-pin right angle header for the FLL Counter Input should be mounted on the rear of the
PC. You may have to modify the header to ensure it lays flush against the board. This will be
important when the board is installed in the chassis.

Tip: Review the included photographs for orientation of the headers.

Tip: Review the included photographs for orientation of the MV209 varactor diode.

Note: There is a provision for a jumper that is used when the desired operating frequency range is
14.000 to 14.350 MHz. For a tighter operating range of 14.100 to 14.250 MHz a capacitor select
instead of the jumper is installed. See schematic for details.

Wind 50 turns of the supplied #34 gauge magnet wire on the FT37-6 core which is yellow on one side.
It should look like this after winding:

23
 L4: FT37-6 Core Wound with 50 Turns #34 Gauge Wire

After assembly, turn on your power supply and verify that the voltage at the Exciter board's V
connection (from the PA board) is 13-14 VDC. The measured current should read approximately 30
milliamps in receive mode.

milliamps on Receive

Measure the Q5, Q6 and Q17 voltages and compare to the chart below.

Q5 voltages Q6 voltages Q17 voltages

Source 3.87 Emitter 3.09 Emitter 3.63
Gate * Base 3.79 Base 3.89
Drain 8.13 Collector 8.13 Collector 6.74

Transistor voltages with 13.25 volts applied at Exciter Board

*DVM measurement here interferes with FET operation. Just check the Source and Drain voltages.

At this point it is helpful to connect the tuning pot and the FLL Counter to verify operation of the VFO,
and it is also helpful to monitor the VFO output waveform on a scope. These steps will be performed
next.

FLL Counter and Tuning Pot Installation

You will need the following components for this step.

Quantity Value Description

1 5k 10T Pot Tuning pot
1 3-pin cable assy for tuning pot
1 2-pin cable assy for FLL Counter input
1 2-pin cable assy for FLL Counter control
SPST Momentary Temporarily used to
2 Pushbutton program FLL Counter
Red/White twisted
2 wire pairs For SPST pushbuttons
2 Shrink Tubing For SPST pushbuttons
1 FLL Counter Module Provided in full kit

FLL Counter and Tuning Pot Components

The FLL Counter Module instructions included in the kit describe how to connect the pushputton
switches to it for programming, and what connections are made to the module. The picture below
should help with the details.

24
 FLL Counter Connections

DC power to the FLL Counter module comes from the Power Distribution Cable you made in the PA
section.

NOTE: The Exciter board current consumption measurements that are made after each section is built
do not include the current consumption of the FLL Counter.

In the picture above the brown wire for both the FLL Counter Input and the FLL Counter Control cables
was chosen to be the "signal" lead. Verify that these signal leads go to the correct pin of the headers
on the Exciter board and do not get shorted to ground.

The tuning pot should be connected to the Exciter such that clockwise rotation results in increasing
VFO frequency. The schematic for the tuning pot will help with wiring it up to the Exciter Board:

Ten-Turn Tuning Pot Detail

If you find your frequency readout decreases as the pot is rotated clockwise just reverse the
connections at terminals 1 and 3.

Connect the tuning pot cable, the FLL Counter Input cable and the FLL Counter Control cable to the
Exciter board.

Apply DC power to the setup. The FLL Counter display should light up. It needs to be programmed
via the pushbuttons to display the correct operational frequency and set other options. The

25
pushbutton connected to "Set 2" on the module is used to enter the programming mode. The first
push gets you into the mode that sets the IF (BFO) frequency. For now that frequency can be entered
as 010.000.00 (10MHz). Pushing the Set 2 button steps through the digits and pushing the Set 1
button rolls numbers through each digit. If you want to read the actual VFO frequency set the IF
frequency to 000.000.00. It takes a little fiddling to get how this works.

Next set the module to compute the proper operation frequency. The BitX20 design operates at the
VFO + IF (BFO) frequency. Pushing the Set 2 button after setting the IF frequency enters into the
mode for selecting this option. Pushing the Set 1 button cycles through the options until the display
reads "VFO+IF."

After that option is selected pressing the Set 2 button again provides setting of the range that the FLL
Counter will allow the VFO to drift without correction. The default range is 25 Hz. Pressing the Set 1
button now will cycle ranges from 20 to 100 Hz. The default range of 25 Hz is fine. Pressing the Set 2
button one last time exits programming mode and the display will read the operational frequency.

The FLL Counter module's PIC processor software monitors the VFO frequency for drift, and if it
detects the drift goes beyond the programmed control range the module will adjust the signal on the
FLL Counter Control output, which drives the VFO to the desired frequency. When the LED on the
module is ON the frequency is not locked; when the LED goes out the frequency is locked.

The FLL Counter should be displaying the VFO plus the preprogrammed IF frequency. The two 22pF
variable caps can be used to set the VFO frequency of operation (the left cap is coarse and right is fine
adjust) given the position of the tuning pot. The tuning pot should be rotated fully counterclockwise,
and the desired initial frequency can be set via the variable caps. Then rotate the pot fully clockwise
and check that the highest frequency is below your desired band range. Adjusting the number of
turns on L4 provides a frequency span range adjustment.

At this point it is helpful to have a scope to see the VFO signal. With a scope probe attached to the
base of Q7 the signal should look like this, about 270mV pk-pk:

VFO Output at Base of Q7

26
Mixer Section

For the mixer section, we will need the following components.

Quantity Value Description

4 1N4148 Diode
FT37-43 cores with 8 Trifilar Transformers T1,
2 turns trifilar #34 T1a

Mixer Components

First we need to wind the trifilar transformers. You will need 2 for the mixer circuit (T1 and T1a) and 1
more for the BFO (T2) so you might as well make all 3 now as they are all the same. All 3 will be on
FT37-43 cores with 8 turns trifilar windings using the supplied #34 gauge magnet wire. You can find a
video on winding trifilar transformers at

Winding trifilar transformers

The transformers will be wound using supplied FT37-43 cores. You can investigate this topic further by
reading Wide-Band Transformers In the Bitx instructions.

These transformers will need 7" of trifilar wire for each transformer. Three 24" wire lengths are
twisted together using a power drill to perhaps 7 or 8 turns/inch to make the trifilar wire.

When winding the prepared trifilar wire onto the core, one turn is one pass through the center of the
core. Again we need 3 transformers total, two for the mixer and one for the BFO. The full kit includes
one color of magnet wire, but you can use red, green, and brown colored magnet wire to help identify
which strand belongs to what coil. Any reasonable gauge of wire should be fine as size doesn't make
much difference as long as it will fit into the core. When pulling the wire through the center of the
cores be careful not to scrape the insulation off. Since the kit includes one color of magnet wire the
following photos show winding these transformers with a single color.

If your wire is not heat strippable, carefully strip off the insulation on all winding leads with a hobby
knife. Refer to the Simplified Winding Connection Diagram to determine which leads are twisted
together to form a center tap. Flow solder into the twisted connection. Tin the other leads. When
you are through winding, it should look like this. One pair of windings are connected for a center tap.
See the winding Connection diagram below:

T1, T1a, T2 Wound on FT37-6 Cores, 8 Turns #34 Gauge Trifilar Magnet Wire

27
 Simplified Winding Connection Diagram, Cross Section Side View of Core

Install the transformers into the Mixer circuit as shown below. The numbers correspond to those
shown in the Simplified Winding Connection diagram above.

Installation of the Trifilar Transformer in Mixer Circuit

28
 Trifilar Transformer Installed at T1a

Installed, T1a should look like this. T1 looks similar.

Do not install the diodes yet. Wait until after you have performed the test below.

After winding and installing both transformers, verify continuity using an ohmmeter. There should be 0
Ohms between the following points for both T1 and T1a. This step insures that the insulation was
removed properly and you have good solder connections. Failure to completely remove the insulation
may result in a faulty solder joint. This is a common failure item.

From To Resistance
5 6 0 ohms
4 2,3 (center tap) 0 ohms
2,3 (center tap) 1 0 ohms

Turn on your power supply and verify that the voltage at the Exciter board's V connection (from the
PA board) is 13-14 VDC.

Note: When measuring Exciter board current via the Ammeter you installed in the Power Distribution
Cable you must disconnect the FLL Display Module connections to the Exciter board to ensure an
accurate reading.

The measured current should read approximately 73 milliamps in receive mode.

milliamps on Receive

Now measure the Q7 voltages and compare to the chart below.

29
 Q7 voltages
Emitter 3.71
Base 4.40
Collector 8.85

Now install the mixer diodes. Using the parts placement diagram below, install the 4 diodes observing
the proper polarity. The band is the cathode end.

Orientation of Mixer Diodes

Bend the leads and position them observing the black bands as shown above and below.

30
Turn on your power supply and verify that the voltage at the Exciter board's V connection (from the
PA board) is 13-14 VDC. If you have an oscilloscope, using a x10 probe, connect to the collector of
Q7.

VFO Output at Q7 Collector

The frequency should be variable using the tuning pot.

The signal should be clipped to about +/- 0.7 volts as the diodes bias on. If the waveform isn't clipped
or only clipped on one side, the problem could be an open in the diode circuit or a bad diode.

1st IF Amplifier Section

This is almost an exact duplicate of the RF Amplifier section. For the 1st IF Amplifier section you will
need the following components.

Quantity Value Description Color Code

2 10 ohm Resistor brn-blk-blk
2 100 ohm Resistor brn-blk-brn
4 220 ohm Resistor red-red-brn
2 1k Resistor brn-blk-red
2 2.2k Resistor red-red-red
8 .1uf Capacitor
2 1N4148 Diode
2 2N3904 Transistor
1 2-pin header for AGC

1st IF Amplifier Components

31
Using the parts placement diagram below assemble the 1st IF amplifier section.

First IF Amplifier Section Component Placement

Note: The AGC connector will be used when we assemble and integrate the AGC with the Exciter
board.

After assembly, apply turn on your power supply and verify that the voltage at the Exciter board's V
connection (from the PA board) is 13-14 VDC. The measured current should read approximately 83
milliamps in receive mode.

milliamps on Receive

Measure the Q2 voltages and compare to the chart below.

Engage your SPST switch that is acting as the PTT switch so that 13.25 volts is applied to the Transmit
voltage connection. The measured current should read approximately 114 milliamps in transmit
mode.

milliamps on Transmit

Measure the Q12 voltages and compare to the chart below.

Receive - Q2 voltages Transmit - Q12 voltages

Emitter 1.988 Emitter 1.97
Base 2..708 Base 2.696
Collector 8.74 Collector 8.76

Transistor voltages with 13.25 volts applied

Q2 and Q12 circuits are identical so the differences in measured voltages are due to component
tolerances.

32
2nd IF Amplifier

We will need the following components for the 2nd IF Amplifier.

Quantity Value Description Color Code

1 4.7 ohm Resistor yel-vio-gld
1 22 ohm Resistor red-red-blk
2 100 ohm Resistor brn-blk-brn
4 220 ohm Resistor red-red-brn
2 470 ohm Resistor yel-vio-brn
2 1k Resistor brn-blk-red
1 2.2k Resistor red-red-red
1 10k Resistor brn-blk-org
1 47k Resistor yel-vio-org
8 .1uf Capacitor
2 1N4148 Diode
3 2N3904 Transistor

2nd IF Amplifier Components

Using the parts placement diagram below assemble the 2nd IF amplifier section.

Note: The 4.7 ohm resistor in the drawing below is correct. The silkscreen on the board may show
10e. Use a 4.7 ohm here, but both values will work fine.

2nd IF Amp Component Placement

33
Turn on your power supply and verify that the voltage at the Exciter board's V connection (from the
PA board) is 13-14 VDC. The measured current should be approximately 100 milliamps in receive
mode.

milliamps on Receive

Measure and compare the voltages in the chart below for Q3 and Q3A.

Receive - Q3 voltages Receive - Q3a voltages

Emitter 0 Emitter 5.35
Base 0.71 Base 6.07
Collector 6.08 Collector 10.78

Receive transistor voltages with 13.25 volts applied

Engage your SPST switch that is acting as the PTT switch so that 13.25 volts is applied to the Transmit
voltage connection. The measured current should be approximately 119 milliamps.

milliamps on Transmit

Measure and verify the voltages in the chart for Q11.

Transmit - Q11 voltages

Emitter 2.405
Base 3.118
Collector 9.9

Transmit transistor voltages with 13.25 volts applied

34
BFO Section

We will need the following components for the BFO section.

Quantity Value Description Color Code

1 100 ohm Resistor brn-blk-brn
3 1k Resistor brn-blk-red
1 120k Resistor brn-red-org
1 10pf Capacitor, NPO
1 15pf Capacitor, NPO Not installed in Step 1
2 22pf Variable capacitor Not installed in Step 1
2 220pf Capacitor, NPO
1 .001uf Capacitor
2 .1uf Capacitor
1 50uf Capacitor
1 10 MHz Crystal
Inductor, wound on
supplied dumbell core,
1 10uh see text Not installed in Step 1
1 100 ohm Trimpot Be sure to check value!
FT37-43 core with 8 Trifilar Transformer for
1 turns trifilar #34 T2
2 1N4148 Diode
2 2N3904 Transistor
1 100uH RFC RF Choke
For temporary crystal
4 Socket pins installation, see text Not provided in kit

BFO Section Components

We wound T2 earlier in the mixer section. If you didn't at that time, refer back to the Mixer section for
directions.

T2 Wound on FT37-6 Core, 8 Turns #34 Gauge Trifilar Magnet Wire

35
 Simplified Winding Connection Diagram, Cross Section Side View of Core

Install T1 as shown below. The numbers correspond to those shown in the Simplified Winding
Connection Diagram above.

Installation of the Trifilar Transformer in BFO Circuit

36
We are going to build the BFO in two steps. In the first step we will configure the BFO circuit to allow
us to accurately measure the frequency of each of the crystals supplied in the kit (or more if you have
them). The data from these measurements will be used to select the crystals for the crystal filter that
we'll build next. Once we have the data we'll reconfigure the BFO section as the BFO. The reason
that we have to do this in two steps is because components in the complete BFO section purposely
shift the crystal's output frequency, specifically to lower the frequency by several kilohertz. This is
essential to the operation of the rig. This shift in BFO frequency downward allows the crystal filter
that is downstream from the BFO to attenuate what little BFO signal remains after passing through the
balanced modulator, as well as attenuate the lower sideband when the BFO signal is modulated with
audio frequencies. It is therefore equally important that we characterize the crystal filter skirts so we
are sure where to set the BFO frequency to achieve the desired attenuation. We'll do that when we
build the crystal filter section.

BFO Section, Step 1: Building the Crystal Characterization Circuit

Using the parts placement diagram below assemble the BFO section. If you can obtain socket pins for
the crystal it will make swapping crystals in and out of the circuit because we will use the circuit to
help measure and match the crystals' frequencies before we build the crystal filter.

As noted in the drawing below, do not populate L5, the 22pf variable cap or the 15pf cap. Install a
jumper for L5 and the 22pf variable cap, and socket pins (if you have them) at the crystal location.
The PCB is very sturdy and can take repeated soldering/desoldering operations, so you probably won't
damage the PCB traces by swapping crystals onto the board if you don't have socket pins. Solder
wick is extremely helpful with this.

BFO and Balanced Modulator Component Placement

37
 Diode Orientation for Balanced Modulator Section

The 100 Ohm trimpot requires a bit of fussing with the leads to get it to fit. This arrangement works:

100 Ohm Trimpot Lead Bends to Fit PCB

Note the orientation of the lead bends to the notches in the body of the trimpot.

After assembly, Turn on your power supply and verify that the voltage at the Exciter board's V
connection (from the PA board) is 13-14 VDC. The BFO runs all of the time.

The measured current should read approximately 113 milliamps.

milliamps

38
Measure Q8 and Q9 voltages and compare to the chart below.

Q8 voltages Q9 voltages
Emitter 6.32 Emitter 5.81
Base 6.41 Base 6.3
Collector 11.99 Collector 11.99

Transistor voltages with 13.25 volts applied

We will now measure each of the five supplied crystals' frequencies. Connect a scope or a counter as
shown below to measure the crystal frequency.

Measuring Points in BFO Circuit

We can use the FLL Counter to measure precisely the crystal frequency versus using the scope.
Disconnect the FLL Counter from the Exciter board (the counter input and the control connectors).
Make a set of clip leads that will connect the FLL Counter input to the test points on the Exciter board.

Tack solder or plug a crystal into place on the exciter board and apply power. Again, power is always
applied to the BFO. Record the measurement shown on the FLL Counter display. Be sure to program
the FLL Counter so that it thinks the IF Frequency is zero Hz, that way the counter will display the
actual crystal frequency. Of course if you have a frequency counter in your test equipment arsenal
you can use that.

39
 BFO Circuit Setup for Measuring Crystal Frequency

Using the FLL Counter to measure the crystal frequency you should see something like this:

Using FLL Counter to Measure Frequency

40
If you connect a scope instead of the counter you should see the waveform below.

BFO Output at Junction of T2 Primary and 0.1uF Cap, Crystal Characterization

My particular kit's crystals measured:

Crystal # FLL Counter, Hz

1 9,998,930
2 9,996,820
3 9,996,860
4 9,998,960
5 9,996,870

Sample Crystal Frequency Data

Note: The FLL Counter measures to 10Hz resolution. In the above data I "fudged" the last digit and
called it a zero.

A reasonable choice for the crystal filter crystals might be crystals 1, 2, 3 and 5 because there's the
least amount of spread (but not by very much), and crystal 4 for the BFO.

Measure and record your crystal frequencies:

Crystal # FLL Counter, Hz

1
2
3
4
5

Measured Crystal Frequency Data

41
Crystal Filter

We will need the following components for the crystal filter.

Quantity Value Description Notes

2 100pf Capacitor
1 220pf Capacitor
4 10 MHz Crystal Matched as close as possible

Crystal Filter Components

Install the four remaining crystals that you chose based on your frequency measurements from when
you built the BFO section. Assemble the crystal filter using the photo below. Install a ground wire
that connects all four crystal bodies. The hole for the ground wire is just above the leftmost crystal.

Crystal Filter Components Installed

Now we need to characterize the skirts of the crystal filter and set the BFO frequency. Since the
crystal filter is only supposed to allow the upper sideband signal through, the BFO frequency must be
a tad lower than the crystal frequency. Experience has shown a good setting of the BFO frequency is
the frequency that the crystal filter response is -20dB from its center frequency, on the low side. Here
is a simplified plot of the frequency response of the filter:

42
 Idealized Crystal Filter Plot

Ideally, in order to do this we need to sweep the crystal filter with an RF generator signal around its
center frequency and determine what the frequency of the filter is when the filter attenuates the signal
by 20dB. If you don't have the equipment to do this you can estimate the BFO frequency and then do
a find adjust during listening tests in receive mode. To estimate the BFO frequency compute the
average crystal frequency you measured for the four crystals that are installed in the Crystal Filter
section, and subtract 1 kHz. Set the BFO for that frequency in the next step.

If you do have the necessary test equipment the schematic below shows how determining the BFO
frequency is done:

43
 Test Setup for Characterizing the Crystal Filter

We need the RF generator, a scope and counter. We can use the FLL Counter to keep track of the
frequency and the scope to measure the amplitude of the crystal filter response.

Lift the leads of the indicated caps and connect the RF Generator and scope probe as shown above.
Set the RF Generator signal to no more than 100mV pk-pk at around 10MHz. Carefully sweep the RF
Generator signal around 10MHz until a signal is detected at the output, and then adjust the frequency
for maximum signal amplitude. Measure this pk-pk voltage. This is your 0dB value. Note the
frequency on the FLL Counter display. Then compute 20dB down from that value (1/10 of the pk-pk
voltage), and adjust the RF Generator frequency lower until the signal amplitude on the scope equals
that value, and record the frequency on the FLL Counter display. That's the frequency you will want
to set the BFO to. If you want, run the RF Generator higher than the center frequency until the output
rises and then drops again, noting the frequency at which the signal is at 20dB down from the center
frequency amplitude.

The crystal filter characteristics for my board were:

Low Side Center High Side

Frequency 9,995,900 9,997,090 9,999,410
Amplitude -20dB 0dB -20dB

Sample Crystal Filter Characteristics

Note: The FLL Counter measures to 10Hz resolution. In the above data I "fudged" the last digit and
called it a zero.

My BFO frequency, when adjusted properly for the filter on my board, was 9,995,900 Hz.

Again, it is the -20dB down frequency on the low side of the center frequency that you will set your
BFO frequency to. Record your crystal filter characterization data here:

44
 Low Side Center High Side
Frequency
Amplitude -20dB 0dB -20dB

Measured Crystal Filter Characteristics

BFO Section, Step 2: Completing the BFO

Now we need to go back and install the components into the BFO to complete that section. We may
have to fiddle with L5 and some capacitor values later to make sure the BFO frequency and the crystal
filter work together to allow only the modulated upper sideband to pass on to the mixer.

After installing the desired crystal, a ground wire is then soldered onto the body of the crystal, which
passes through the circuit board through a hole to the PCB's ground trace. The hole is just to the
right of the crystal, but it is not marked. See the photo below.

BFO Section Now Complete

Remove the jumpers you installed at the 22pF, 15pF and L5 locations. Install the 22pF variable cap
and the 15pF cap. Wind 32 turns of the supplied 34 gauge magnet wire onto the dumbell core. Plan
to take turns off the core to tune the BFO to the desired frequency, so tack solder the coil to the
Exciter board temporarily. Set the 22pF variable cap to mid-capacitance, apply power to the Exciter
board and use the FLL Counter to measure the BFO frequency. Adjust turns on L5 to achieve the
desired frequency and use the variable cap for fine adjustment. When satisfied with the coil
adjustment solder the coil leads to the core leads. The completed inductor should look like this:

Inductor L5

45
Install L5 permanently on the Exciter board. Record your BFO frequency:

BFO Frequency, Hz

BFO Frequency

The signal at the output of the BFO can be measured at the same point that was used during the
crystal frequency measurements. The signal now with the BFO complete and adjusted to the correct
frequency should look like this:

BFO Output at input to T2 primary

Be sure to set the IF frequency on the FLL Counter to the BFO frequency you just measured.

RF Driver

We will need the following components for the RF Driver.

Quantity Value Description Color Code

1 10 ohm Resistor brn-blk-blk
2 100 ohm Resistor brn-blk-brn
1 1k Resistor brn-blk-red
1 2.2k Resistor red-red-red
4 .1uf Capacitor
1 2N3904 Transistor
FT37-43 core with 8
1 turns bifilar #34 Bifilar Transformer T3
1 2-pin header Marked "To PA"

RF Driver Components

46
Assemble the components as shown below.

RF Driver Component Placement

The transformer is made using an FT37-43 core.

Wind 8 turns of the #34 gauge bifilar wire you prepared when building the PA board transformer on
the core. This will take about 6" of the prepared wire.

Bifilar Transformer T3 Prior to Creating Center Tap

47
 Simplified Winding Connection Diagram, Cross Section Side View of Core

If your wire is not heat strippable, carefully strip off the insulation on all winding leads with a hobby
knife. Flow solder into the twisted connection. Tin the other leads. Install the transformer into the
RF Driver circuit as shown in the RF Driver Component Placement diagram above. The numbers
correspond to those shown in the Simplified Winding Connection diagram above.

After assembly, turn on your power supply and verify that the voltage at the Exciter board's V
connection (from the PA board) is 13-14 VDC. Engage your SPST switch that is acting as the PTT
switch so that 13.25 volts is applied to the Transmit voltage connection.

The measured current should read approximately 120 milliamps in transmit mode.

milliamps on Transmit

Measure the Q14 voltages and compare to the chart below.

Transmit - Q14 voltages

Emitter 2.47
Base 3.19
Collector 10.58

Transistor voltages with 13.25 volts applied

48
Audio Section

We will need the following components for the Audio Section.

Quantity Value Description Color Code

1 10 ohm Resistor brn-blk-blk
1 100 ohm Resistor brn-blk-brn
1 180 ohm Resistor brn-gry-brn
2 220 ohm Resistor red-red-brn
4 1k Resistor brn-blk-red
2 2.2k Resistor red-red-red
2 4.7k Resistor yel-vio-red
2 10k Resistor brn-blk-org
1 120k Resistor brn-red-yel
1 680k Resistor blu-gry-brn
1 100pf Capacitor
Blue disc cap, PCB silksreen
2 4700pf Capacitor label is "4K7"
1 .001uf Capacitor Blue disc cap
1 .01uf Capacitor
2 .1uf Capacitor
7 1uf Capacitor, electrolytic
1 10uf Capacitor, electrolytic Optional, see text
3 47uf Capacitor, electrolytic
2 220uf Capacitor, electrolytic
1 LM386 Audio amp IC
1 8-pin IC socket For LM386
1 1N4007 Diode
4 2N3904 Transistor
2 2-pin header For Speaker, Mic Input
For Mic Gain and
2 3-pin rt angle header Volume Control Mount on rear of PCB

Audio Section Components

Using the parts placement diagram below assemble the audio amplifier section.

Note: Solder the 3-pin right angle headers to the underside of the board. Ensure the headers are
flush with the bottom of the board as this will be important when the board is installed in the chassis.

Tip: Review the included photographs for orientation of the headers.

49
 Audio Section Component Placement

There is a modification that has to be made to correct an error in the Ver3b PCB. Do not
install Q16 until you have read this information. Before installing Q16, bend the collector up so
it is not soldered into the PCB, and install the transistor. A jumper needs to be installed between the
collector of Q16 and pin 3 of the LM386. An easy way to do this is to jumper from the Q16 collector
over to the already installed short jumper as seen in the photo below:

Modifications Required for the Audio Section

50
Also, the silkscreen indicates a 10k resistor that goes to the base of Q16, but install a 1k resistor
there.

Note: A 10uF electrolytic capacitor can be installed at the location noted in the Audio Section
Component Placement diagram if you are using the speaker mounted to the chassis. If using a mic
with an integrated speaker this cap is not required.

After assembly, turn on your power supply and verify that the voltage at the Exciter board's V
connection (from the PA board) is 13-14 VDC. Do not connect the volume control pot or the speaker.
The measured current should read approximately 114 milliamps.

milliamps on Receive

Measure the Q4 voltages and compare to the chart below.

Receive - Q4 voltages
Emitter 0
Base 0.709
Collector 2.234

Transistor Voltages with 13.25 Volts Applied

Engage your SPST switch that is acting as the PTT switch so that 13.25 volts is applied to the Transmit
voltage connection.

The measured current should read approximately 150 milliamps in transmit mode.

milliamps on Transmit

Measure the Q10, Q15 and Q16 voltages and compare to the chart below.

Transmit - Q10 voltages Transmit - Q15 voltages Transmit - Q16 voltages

Emitter 3.5 Emitter 0.17 Emitter 0
Base 4.18 Base 0.84 Base 0.84
Collector 9.16 Collector 4.09 Collector *

Transistor Voltages with 13.25 Volts Applied

*Q16 acts like a switch to mute the speaker (via the LM386) when the PTT switch is activated,
preventing any popping noise from emanating from the speaker, a welcome modification. The
collector of Q16 has the audio signal on it, which is not present during these tests. Just make sure the
base voltage will turn the transistor on.

We'll check the operation of the Audio section with the speaker and the volume control pot when we
install the components into the chassis.

51
Alignment

Alignment of the Exciter board is a series of steps that make sure all the sections work together
properly. You've already completed the first three steps, setting and verifying the VFO frequency
range, characterization of the crystal filter and the setting of the BFO frequency, so you can check
those steps off right now. The entire process is shown below:

1 Check that the VFO gives the proper range of frequency for the desired band tuning range
2 Characterize the crystal filter center frequency and -20dB skirts
3 Adjust the BFO frequency so it is at the lower skirt of the crystal filter bandpass
4 Adjust the balanced modulator for minimum BFO signal at balanced modulator output
5 Verify only the USB signal is present after the crystal filter using an audio signal input
6 Verify mixer products, should be BFO +/- VFO
7 Tune the bandpass filter to peak over the desired tuning range
8 Sweep audio frequencies into mike input and verify reasonable audio bandwidth at output of bandpass filter
9 Verify signal modulation after bandpass filter is at VFO+BFO and is large enough to drive the PA section properly

Some of these steps require a spectrum analyzer but we can make do without one.

Balanced Modulator Adjustment

The balanced modulator portion of the circuit suppresses the BFO signal after the audio signal has
been mixed with it. The balanced modulator passes the modulated BFO signal (BFO +/- audio) but
suppresses the BFO carrier. Monitor the signal at the 22 Ohm resistor, just after the 100 Ohm pot,
and adjust the pot and the 22pf variable cap for a minimum of signal. The adjustment is subtle, just
try get the scope signal to be as small as possible.

Adjusting the Balanced Modulator

When the Balanced Modulator is balanced (pot and variable cap make the signal the smallest) the
signal should look like this:

52
 Balanced Modulator Output When Balanced

The signal at the 22 Ohm resistor should look like this when the Balanced Modulator is unbalanced
(pot and variable cap make the signal the largest):

Balanced Modulator Output When Unbalanced

Not much difference, but the Balanced Modulator circuit is definitely doing its job.

Now get out your function generator and set it up for a 1kHz, 100mV pk-pk sinusoid. We'll inject that
signal into the Mic input connector, but we have to modify the circuit a bit. We have to remove the 1k
resistor that ties the Mic input to +12VDC; that is required when using an electret condenser mike,
but not when we use a dynamic mike or, in this test case, a function generator. Also, the 10k Mic
Gain front panel pot (included in the full kit) needs to be connected to the circuit as shown below.
Monitor the audio signal and adjust for about a 400mV pk-pk signal by adjusting the 10k Mic Gain pot,
making sure the signal is not distorted.

53
 Injecting Audio Signal at Mic Input

The audio signal being injected into the Balanced Modulator should look like this:

Audio Section Output to Balanced Modulator (see text)

Examine the signal at the output of the balanced modulator with the 1kHz audio signal injected at the
Mic input. Engage your PTT switch to energize the transmit circuits. The signal should look something
like this, but will depend on your scope triggering:

54
 Balanced Modulator Output with 1kHz Audio Signal Injected at Mic Input

This is the BFO +/- 1kHz audio. This signal then goes to the Crystal Filter where everything but the
BFO + 1kHz audio frequency is filtered out. Monitor the signal output of the First IF Amp, the T1A
primary.

Monitor Point for Crystal Filter Output at First IF Amp

The resulting signal after the Crystal Filter and the First IF Amp should look like this. This is the BFO
+ 1kHz audio modulated signal.

55
If you have a Spectrum Analyzer that has enough resolution you should be able to see that this signal
indeed is only the Upper Sideband. This signal is then mixed with the VFO signal to form the VFO +/-
BFO + 1kHz audio products. We only want to transmit the VFO + BFO + audio signal, so the Band
Pass Filter is adjusted to do that. Because the mixer products are quite a bit apart in frequency we
don't need such a narrow filter like the Crystal Filter circuit, it's done with a multiple pole LC circuit.
The next step in the alignment process is to adjust the Band Pass Filter transformers.

Monitor Point and Adjustments for Band Pass Filter

Monitor the output of the RF Driver that drives the signal to the PA, which will be built next, with the
1kHz audio signal injected at the Mic Input as before. Switch power to the T pin, or engage your PTT
switch to energize the circuits. The signal at the PA connector should look like this:

56
 Signal at PA Connector with 1kHz Audio Applied to Mic Input

The signal will be the VFO + BFO + 1kHz audio and is a nice healthy 7 volts pk-pk. Confirm that the
signal goes away when you turn off the 1kHz audio signal (turn off your function generator's output)
in transmit mode. With no audio the signal at the PA connector should look like this:

At this point you've completed all the alignment steps outlined above and you are ready to move on to
integrating the PA board you completed with the Exciter board.

57
BitX20 Ver3b Exciter Board

58
BitX20 Ver3b Exciter Board

59