GenesisRadio G40 40m Xcvr 10_PA Driver

Install All Components, Except FET and Transformer

Check	Designation	Component	Marking	Category	Orientation	Notes
❏	E231	10 nF (.01uF)	103	Ceramic
❏	E201	100 nF	104	ceramic
❏	E204	100 nF	104	ceramic
❏	E225	100 nF	104	ceramic
❏	E232	100 nF	104	ceramic
❏	E237	100 nF	104	ceramic
❏	E333	100 nF	104	ceramic
❏	E334	100 nF	104	ceramic
❏	R51	47 uH molded inductor	yel-vio-blk-gld	choke
❏	R64	1R 1/4W 1% (1R)	brn-blk-blk-silver-brn	1/4W
❏	R100	10 ohm 1/4W 1%	br-blk-blk-gld-br	1/4W
❏	R49	10 ohm 1/4W 1%	br-blk-blk-gld-br	1/4W
❏	R53	10 ohm 1/4W 1%	br-blk-blk-gld-br	1/4W
❏	R101	68 1/4W 1%	blu-gry-blk-gld-brn	1/4W
❏	R69	100 1/4W 1%	br-blk-blk-blk-br	1/4W
❏	R50	330 1/4W 1%	ora-ora-blk-blk-brn	1/4W
❏	R52	330 1/4W 1%	ora-ora-blk-blk-brn	1/4W
❏	R92	330 1/4W 1%	ora-ora-blk-blk-brn	1/4W		Phase 8: Marked on pcb as 470nH
❏	R46	390 1/4W 1%	ora-whi-blk-blk-brn	1/4W
❏	R48	470 1/4W 1%	yel-vio-blk-blk-brn	1/4W
❏	R68	1 k 1/4W 1%	br-blk-blk-br-br	1/4W
❏	E206	TO-39 heatsink		misc
❏	E304	2N3866 NPN Transistor		TO-39
❏	E82	3.5mm stereo jack - PCB mount		jack

Wind and Install the Dual Binocular Transformer

Glue the Cores

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

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 (~0.4") of length

Wind the Wire through the Cores

• (Refer to the numbered holes in the cores on the above graphic)
  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 now have four wire ends.
• The pair at hole 1 represents the primary leads (a and b); the pair at hole 4 represents the secondary leads (a1 and b1) 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" (or, if you prefer, the "b - b1") wire's ends.

Testpoint	Units	Nominal Value	Author's	Yours
a - a1	Ohm	0	0	_______
b - b1	Ohm	0	0	_______

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.

Check	Designation	Component	Marking	Category	Orientation	Notes
❏	E198	BN43-202		binocular core
❏	E198a	BN43-202		binocular core
❏	MW	Magnet wire, enameled #20				Copper magnet wire for coils

Install FET and Heat Sink

Attach the IRF510 power MOSFET to its heat sink with the M3 screw and nut. Then solder the IRF510 leads and the two heat sink pins, such that the Transistor side of the heat sink is facing "north" and the blank side of the heat sink is facing "south".

Check	Designation	Component	Marking	Category	Orientation	Notes
❏	E196	Power MOSFET IRF510	IRF510	TO-220
❏	E219	TO-220 heatskink		misc
❏	hdw1	M3 screw and nut set		HDW

Install two Jump Wires

Using two pieces of cut-off component lead wires, solder jumper wires as indicated below

Install Remaining Permanent V_tx Wires

Install the permanent wires that provide V_tx routing (click here for a high-resolution view of the graphic).:

• C-C (endpoints marked "C")
• D-D (endpoints marked "D")
• G-G (endpoints marked "G")
• H-H (endpoints marked "H")
• I-I (endpoints marked "I")

Install Final Permanent Wire

Install wire J-J (endpoints marked "J")