GenesisRadio G3020 Xcvr (BETA) 10_TX Driver and PA

Install Driver Transistor and Heat Sink

Install the 2N3866 transistor and its heatsink. Refer to the instructions in Phase 6 for details on mounting and installing the 2N3866.

Check	Designation	Component	Marking	Category	Orientation	Notes
❏	misc10-2	TO-39 heatsink		Misc
❏	Q10-2	2N3866 NPN Transistor		TO-39

Wind and Install the Dual Binocular Transformer

Glue together the two binary cores as indicated in the graphic, below:

Take care when gluing the two cores together to carefully set and align them so they are aligned with one another, as in the image. There is a tendency, especially when using "Super Glue" to let them slide out of aligment just as the glue sets, making recovery and realignment quite difficult.

Twisted Wire

Prepare a 40 cm (~16") long piece of enameled copper wire and fold it over so that it is two 20 cm wires joined at the one end

Twist the wires together so that you get approximately three twists per 10 mm (3 twists per every 0.4 inches) of length

Wind the Wire through the Core

Click Picture to Enlarge

Thread the twisted wires (folded end first) through the glued cores, starting in hole 1, coming out the other end and looping back through the top core to exit at hole 3. Continue from hole 3 into hole 2, coming out the other end and looping back into the upper core so as to exit at hole 4.

When finished winding, cut the folded end of the twisted wire off, such that you noe have four wire ends.

The pair at hole 1 represents the primary leads; the pair at hole 4 represents the secondary leads of the wound transformer.

Using an ohm meter, identify the ends of each wire as indicated on the graphic above. You may want to use a small piece of colored hookup wire insulation to identify the "a-a1" pair (or, if you prefer, the "b-b1 pair") wire's ends.

Mount the Transformer

You do not need to worry how to figure out the phasing; if you match the designated leads (a1, b1, a, b) with the holes as marked in the graphic below, you will have correct phasing.

Insert transformer's leads into the PCB holes, as indicated above. Form the leads and pull them tight. Then cut off the excess (on the underside of the board) so that approximately 5mm (1/8") of wire is protruding out on the underside of the board.

Remove the transformer from the PCB, scrape the enamel coating from the 4 leads but DO NOT TIN them as yet (tinning the leads could cause them to be too "fat" to go back into the holes).

Insert the 4 transformer leads back into the PCB and solder them.

Install Passive Components

Install resistors, capacitors, chokes

Some PCBs for the G3020 have a silkscreen image suggesting that the component to be installed just above the 1 ohm ("1R") resistor is a 470 nH inductor. The silkscreen is incorrect. It should be a 330 ohm resistor, NOT an inductor. See the top of the board graphic - it is correct.

Check	Designation	Component	Marking	Category	Orientation	Notes
❏	C10-8	10 nF (.01uF)	103	Ceramic		(added)
❏	R10-1	1R 1/4W 1% (1R)	brn-blk-blk-silver-brn	1/4W
❏	R10-2	10 ohm 1/4W 1%	br-blk-blk-gld-br	1/4W
❏	R10-3	10 ohm 1/4W 1%	br-blk-blk-gld-br	1/4W
❏	R10-4	10 ohm 1/4W 1%	br-blk-blk-gld-br	1/4W
❏	R10-5	68.0 1/4W 1%	blu-gry-blk-gld-brn	1/4W
❏	R10-6	100 1/4W 1%	br-blk-blk-blk-br	1/4W
❏	R10-7	330 1/4W 1%	ora-ora-blk-blk-brn	1/4W
❏	R10-8	330 1/4W 1%	ora-ora-blk-blk-brn	1/4W
❏	R10-9	330 1/4W 1%	ora-ora-blk-blk-brn	1/4W
❏	R10-10	390 1/4W 1%	ora-whi-blk-blk-brn	1/4W
❏	R10-11	470 1/4W 1%	yel-vio-blk-blk-brn	1/4W		Note: This is a 470R, NOT a 4k7 or 47k.
❏	R10-12	1 k 1/4W 1%	br-blk-blk-br-br	1/4W		(reloc)
❏	C10-1	100 nF	104	Ceramic
❏	C10-2	100 nF	104	Ceramic
❏	C10-3	100 nF	104	Ceramic
❏	C10-4	100 nF	104	Ceramic
❏	C10-5	100 nF	104	Ceramic		(reloc)
❏	C10-6	100 nF	104	Ceramic		(reloc)
❏	C10-7	100 nF	104	Ceramic		(reloc)
❏	R10-12	100 nF	104	Ceramic		(reloc)
❏	L10-3	47 uH molded inductor 10%	yel-vio-blk-slv	Choke

Install the 2 Jump Wires

Install PA FET and Heat Sink

Be sure the transistor is oriented with its flat "Drain Flange" (see BOM for the final transistor) facing the bottom of the board.

Check	Designation	Component	Marking	Category	Orientation	Notes
❏	Q10-1	Power MOSFET IRF510	IRF510	TO-220
❏	hdw10-1	M3 screw and nut set		HDW
❏	misc10-1	TO-220 1" Heatsink		Misc

Install Remaining Wires

Install the remaining permanent wires to the board. Some have been already installed in previous phases. At this point, if you have not removed any temporary wires/switches, you should do so now. For your help in this effort, all permanent (non-switch associated) wires are itemized in the following table:

Click to see a high resolution picture of the wires.

Install Remaining Switches

If, at this point, you have not removed any temporary switches, you should do so and then ensure you have all of the permanent switches.

Some builders may have postponed the actual wiring and installation of switches in earlier stages, in order to make handling of the board less complicated. If this is the case, those switches must be installed at this point and it would be a good idea to review any tests associated with the switches with a view toware repeating the tests.

Note that there were two options to handling the band-switching of the oscillator's crystals: the original design, using the panel, LEDs, and DPDT switches; and the use of the Rotary Switch with no LEDs. It is your decision.

Refer to the Final Diagram for the final positioning and wiring of all of the Switches

Watch out for the pre-amp and attenuator switches in the Final Diagram. In the lower right hand corner there are they are labeled PREAMP and ATTN. According to the wiring of these two switches in the diagram, the names on the two switches have been reversed. The upper switch should be labeled ATTN and the lower switch should be labeled PREAMP.

The table below provides information on the switches, their function, and the stage withn which they were described/defined/installed: