DZ PSKUBE PSQ-100 Assembly Manual

Page

DZKit

ASSEMBLY MANUAL

PSKube

20 Watt PSK Transceiver

Model PSQ-100

Price: $10.00

DZ CompanY • LOVELAND, COLORADO

Page 2

DZ COMPANY CONTACT INFO

Orders, parts, phone assistance.....................................................................(970) 667-7382

Email orders............................................................................................... [email protected]

Email technical support ......................................................................... [email protected]

Online orders ................................................................. www.dzkit.com/catalog/index.htm

Mail:

DZKit

710 Grove Ct.

Loveland, CO 80537

During your first ninety (90) days of ownership, DZ Company will replace or repair free of charge—as soon as

practical—any parts which are defective, either in materials or workmanship. You can obtain parts directly from

DZ Company by writing us, emailing us or telephoning us. And we’ll pay shipping charges to get those parts to

you—anywhere in the world.

We warrant that during the first ninety (90) days of ownership, our products, when correctly assembled,

calibrated, adjusted and used in accordance with our printed instructions, will meet published specifications.

You will receive free consultation (except for the cost of your long distance phone call) on any problem you may

encounter in the assembly or use of your DZKit product. Just drop us a line, email us, give us a call, or visit our

website and click on “Support”. That will give you access to free on-line support and a discussion group. Sorry,

we cannot accept collect calls.

Our warranty, both expressed and implied, does not cover damage caused by the use of corrosive solder,

defective tools, incorrect assembly, misuse, fire, customer-made modifications, floods or acts of God, nor does it

include reimbursement for customer assembly or setup time. The warranty covers only DZKit products and is

not extended to non-DZ allied equipment or components used in conjunction with our products or uses of our

products for purposes other than as advertised.

If you are ever dissatisfied with our service—warranty or otherwise– or our products, please write or email the

president, Brian Wood, W0DZ, and he will make certain your problems receive prompt, personal attention.

DZ COMPANY

LOVELAND, CO 80537

YOUR DZKIT 90-DAY FULL WARRANTY

Page 3

Assembly

And

Operation

Of the

KIT

20 Watt PSK Transceiver

Model PSQ-100A and PSQ-100B

DZ COMPANY

LOVELAND,

COLORADO

TABLE OF CONTENTS

Introduction...................................... 4

Assembly Notes................................ 5

Step-By-Step Assembly.................... 8

PSQ-100-3,10 Computer, Disk.... 8

PSQ-100-11 RF Amplifier......... 14

PSQ-100-5 DC-DC Converter... 24

PSQ-100-4 Mounting Plate ....... 30

PSQ-100-1 Chassis.................... 32

PSQ-100-2 LCD........................ 44

Chassis Integration .................... 48

Power-up Tests ............................... 52

Final Integration ............................. 54

Operating the PSKube.................... 55

Appendix: Software Installation..... 60

In Case of Difficulty....................... 60

Specifications ................................. 64

Warranty................Inside Front Cover

DZ Co.

10-12-03 PSQ-100-9

Page 4

The PSKube is a revolution in portable trans-

ceivers. For the first time, it is possible to

connect a keyboard, mouse and antenna to a

transceiver that operates only in digital

modes. It accomplishes this by means of a

tiny but powerful personal computer that runs

a common operating system—Microsoft®

Windows® 98 Second Edition. The computer

in this radio is unlike the microprocessors in

other radios. It is a fully functional IBM-

compatible personal computer with disk in-

terface, on-board SoundBlaster-compatible

audio, networking, COM ports, VGA display,

PS/2 keyboard/mouse, USB, parallel port and

more. Thus, it is possible to use all the bene-

fits of a standard PC, such as easy software

updates over the LAN, connection to the

Internet, running of many different applica-

tion programs, easy customization of the

screen, and a lot more.

The PSKube can be built in several stages

and in several combinations. This manual is

thus a complete assembly and operating man-

ual for the most complicated of the

PSKubes—the PSQ-100B, which has an in-

ternal flat panel display, mounting plate for a

PSK transceiver made by Small Wonder

Labs, and an optional 20 Watt amplifier. Fi-

nally, the chassis can be used as a simple

holder for other projects.

INTRODUCTION

Microsoft and Windows are U.S. registered trademarks of Microsoft Corporation.

Page 5

This manual is organized in parts that relate

to the various products that can be ordered

separately to build a PSKube. Although

each part can stand on its own, if you are

building a complete PSKube, we recom-

mend that you start at the beginning and

work your way through the manual in order.

Each circuit part has its own component

number (R1, L4, Q3, etc.). R1 on one as-

sembly will not be the same as R1 on a dif-

ferent assembly, so be sure you are looking

at the right set of parts when comparing part

numbers with the printed parts list. Check

off each part at the beginning of each sec-

tion to make sure all the parts are there. If

you find any missing, give us a call or email

us and we will rush a replacement to you.

Most electronic kits that are returned for

service have poor soldering jobs. Please

take a moment to familiarize yourself with

proper soldering technique. And do not, un-

der ANY circumstances, use corrosive

(“acid-core”) solder! That will void your

warranty and render your kit inoperative.

Resistors are identified by their values in

Ohms, Kilohms (k) or Megohms (M) and

by the color code:

The first two bands represent the numeric

value and the third band represents the mul-

Resistor Color Code Chart

tiplier, which is a power of 10. Thus, a 56

Ohm resistor is Green-Blue-Black. A

10KOhm resistor is Brown-Black-Orange,

and so on. The fourth band is the toler-

ance—no band represents 20%, a silver

band is 10%, and a gold band is 5%. One

percent resistors use 4 bands for the value

using the same color scheme.

Capacitors are identified by their type—

disk, polystyrene, polypropylene, electro-

lytic, trimmer, etc.) and capacitance values

are in microfarads (uF) or picoFarads (pF).

Inductors are represented either by their in-

ductance in microHenries (uH) or by the

number of turns in the coil if you are doing

the winding.

When a solder connection is to be made, it

is designated (S-n), where n is the number

of wires or parts to be soldered. For exam-

ple, (S-1) means to solder one wire to the

noted part. If a connection is to be soldered

later, because other parts will later be

added, it is shown as NO SOLDER (NS).

ASSEMBLY NOTES

Black 0 Yellow 4 Gray 8

Brown 1 Green 5 White 9

Red 2 Blue 6 Silver /10

Orange 3 Violet 7 Gold /100

Most kit builders find it helpful to sepa-

rate the parts into categories for quick

identification. Muffin tins and egg car-

tons serve this purpose admirably.

Page 6

SOLDERING INSTRUCTIONS

Poor soldering accounts for almost 90% of all kit building problems. The photographs below

show examples of the most common types of bad solder connections and a good one. If you lo-

cate any of these bad solder connections in your kit, correct them as described. Study this sec-

tion carefully before you start building your kit.

Use a good quality, low wattage (25-100W)

soldering iron and non-corrosive, rosin core

solder to assemble your kit. Keep the sponge

damp and wipe the tip on the sponge after

each solder step.

Solder blob. In this example, solder flowed

onto a lead, but the heat was not maintained

long enough for it to flow onto the circuit

board pad. Solution: reheat the connection,

touching the iron to both the component lead

and the pad at the same time.

Solder bridge. Solder that stretches from

one trace to another creates a short circuit.

Solution: Hold the board upside down and

reheat the area. The excess solder will flow

down the soldering iron. Another solution is

to use a “solder sucker” or solder wick to

remove excess solder. Solder suckers work

well one or two times on a given connection.

If used too much, they can pull pads and

traces off of PC boards.

Good solder connections. A good solder

connection looks like this. Solder flows

evenly onto both the part and the PC board

or chassis component. It is shiny and even,

not lumpy and dull. Component leads that

are properly soldered can not be moved in

the hole.

Page 7

STATIC PRECAUTIONS

Many of the components in your kit can be

damaged by exposure to static electricity.

Please read this page to familiarize yourself

with the causes of and solutions to this prob-

lem.

When the climate is dry, you can generate

thousands of volts simply by walking across

a carpet. When you then touch a metal object

you can feel the effects of this as you draw a

spark! That same spark, often too small to see

or feel, can destroy sensitive electronic com-

ponents. You MUST take precautions when

working with electronics to prevent damage.

The best solution is to outfit your workbench

with anti-static devices — floormats,

grounded soldering irons, and workmats with

grounded wriststraps. If these are not practi-

cal for you, the very least you should do is to

discharge yourself to ground after you sit

down and before you touch any electronic

items, by touching a grounded object such as

the corner of a wall.

In a dry environment, simply standing up af-

ter sitting in a non-grounded chair can also

charge you with electricity. If you stand up to

stretch, for example, be sure to re-ground

yourself before getting back to work.

All electronic components are susceptible to

static, but semiconductors and assembled

boards containing semiconductors are the

most prone to damage. These include diodes

(including light-emitting diodes [LEDs]),

transistors and integrated circuits (ICs).

You are a walking lightning bolt! Be

careful!

Page 8

Computer - PSQ-100-3

PIC (√) QTY DESCRIPTION

A1 ( ) 1 Single Board Computer, cables,

software drivers

A1 ( ) 1 128MB SODIMM memory

A1 ( ) 1 PS/2 fold-up keyboard

A1 ( ) 1 PS/2 mouse

A1 ( ) 1 Dual pouch fabric bag for kbd, mouse

A2 ( ) 1 Metal mounting plate

Hardware Pack (Marked PSQ-100-3 HW Pack”)

B1 ( ) 4 #6 x 5/16" spacer

B2 ( ) 4 6-32 x 5/8" panhead machine screw

B3 ( ) 4 6-32 x 5/16" panhead machine screw

B4 ( ) 8 6-32 keps nut

Other

C1 ( ) 1 Bracket bag: Includes 2 support angle

brackets, 4 6-32 clip nuts, 4 6-32 x 5/16”

panhead machine screws and assembly

instructions

C2 ( )

1 DB-9 female to female adapter ("gender

changer")

PARTS LIST

COMPUTER (PSQ-100-3)

And

DISK DRIVE (PSQ-100-10)

IMPORTANT NOTE: The computer and disk drive must be assembled as one unit. If you have

not purchased the PSQ-100-10, make sure that you have an equivalent set of parts available.

This is necessary because the disk drive fastens to the underside of the computer mounting

plate, and thus the disk mounting screws are underneath the computer.

A1

A2

B1 B2 B3 B4

C1

C2

Page 9

Disk Drive - PSQ-100-10

PIC (√) QTY DESCRIPTION

A1 ( ) 1 2.5” Laptop Hard Drive

A2 ( ) 1 Windows 98SE OEM license

Hardware Pack

B1 ( ) 4 M3 x 5mm machine screw

B2 ( ) 4 M3 Flat washer

B1 B2

A1 A2

Page 10

STEP-BY-STEP ASSEMBLY

Refer to Pictorial 1.

() Locate the Bracket bag. Attach the captive

nuts to the sides as shown in the documenta-

tion that comes with the angle bracket kit.

() Attach the angle brackets to the mounting

plate with 4 6-32 x 5/16” screws and 4 keps

nuts.

() Position the assembly as shown, with the

brackets extending out past the end of the

plate, facing you. On the left side, cut the

bracket as shown using wire cutters. The

metal is very soft and will cut easily. This

notch provides clearance for the display.

() Remove the PC card from its antistatic

package. It is best if you have an antistatic

work area (grounded wrist strap, floor mat,

etc.). If not, be absolutely sure that you have

discharged any static buildup in your body by

touching a grounded metal object prior to

working with this sensitive board.

Note: The next step installs memory cards.

These modules can only fit into the sockets

one way.

() Install the SODIMM card so that its gold

pins point down into the SODIMM socket.

Slip the SODIMM into the socket at a 45 de-

gree angle and carefully fit the bottom of the

card against the connectors. Gently push the

SODIMM into a perpendicular position until

the clips on the ends of the SODIMM sockets

snap into place. Check to ensure that the

SODIMM is correctly seated and all

connector contacts touch. The SODIMM

should not move around in its socket.

() If you want to use a Compact Flash (Type

I) memory card as a secondary “disk” (not

provided), insert it into the holder at this

time. Note: while it is possible to boot an op-

erating system from this solid state memory,

it is not recommended. Tests have indicated

that the lifetime of such a memory is very

limited. This is because flash memories are

constrained by the type of construction to

have a limited number of read/write cycles,

and this lifetime is quickly reached with a

Microsoft Windows operating system due to

the constant reading and writing of large data

files. However, it will work fine as a backup

drive.

Detail 1

Page 11

Pictorial 1

Page 12

() Attach a 2.5” Hard Drive (such as the

PSQ-100-10) to the bottom side of the

mounting plate with the connector facing the

side where the angle brackets extend out

from the plate. Use 4 M3 flat-head screws

and washers. It is easiest to do this by placing

the disk on a flat surface, placing the washers

into position on the 4 mounting holes, and

then carefully laying the plate on top. Con-

nect the IDE cable to the disk drive, being

careful to align pin one as shown.

() Attach the Single Board Computer to the

top of the mounting plate using four 5/16”

spacers, 6-32 x 5/8” screws and KEPS nuts.

Orient the board so that the connectors face

the side of the plate where the angle brackets

are flush with the plate.

() Attach the IDE cable (flat ribbon cable)

from the disk drive to the PC, being careful to

observe the location of pin 1 (striped side of

cable, pin 1 marked on board with white tri-

angle). Fold the cable as shown. Note! If you

are installing software yourself, you can con-

nect a floppy drive to the floppy drive con-

nector (cable included), and you can replace

the IDE cable with one that has both a 44-pin

CD ROM connector AND a 2.5” hard drive

connector, such as the PSQ-100-8.

() Attach the RS-232C cable to the connector

labeled COM2. This cable divides into two

pieces. Cut off the section with only 4 wires.

Wrap electrical tape around the loose end and

make sure the individual wires do not touch

each other.

() Attach the audio cable to the audio con-

nector.

() Pull the audio jumper off its 3-pin connec-

tor and move it to the other side of the con-

nector as shown in Detail 2. This allows 12V

to go to the on-board amplifier and provides

better sound quality. DO NOT change this

jumper when power is on!

Detail 2. Audio Jumper

This completes assembly of the internal PC

and disk drive.

Page 13

Photo 1. Top of plate

Photo 2. Bottom of plate

Page 14

RF AMPLIFIER (PSQ-100-11)

PARTS LIST

PIC (√) QTY DESCRIPTION

Capacitors:

A1 ( ) 1 220 uF/25V electrolytic (C1)

A1 ( ) 2 10 uF/25V electrolytic (C2, C13)

A2 ( ) 7 0.1 uF disk ceramic

(C3, C8, C9, C10, C11, C14, C15)

A2 ( ) 1 47 pF disk ceramic (C16)

A2 ( ) 2 180 pF disk ceramic (C4, C7)

A2 ( ) 2 330 pF disk ceramic (C5, C6)

A2 ( ) 1 0.01 uF disk ceramic (C12)

Resistors (1/4 Watt, 5% except where noted):

B1 ( ) 2 27 ohm 1/2W (red-violet-black) (R6,R7)

B1 ( ) 1 330 ohm (orange-orange-brown) (R5)

B1 ( ) 1 470 ohm (yellow-violet-brown) (R1)

B1 ( ) 1 2.2K ohm (red-red-red) (R3)

B1 ( ) 1 10K ohm (brown-black-orange) (R4)

B1 ( ) 1 100K ohm (brown-black-yellow) (R2)

B2 ( ) 2 5K ohm 1/2W potentiometer (RV1, RV2)

Semiconductors:

C1 ( ) 1 1N5231B 5.1V 1/2W Zener diode (CR1)

C1 ( ) 2 1N4148 signal diode (CR2, CR3)

C1 ( ) 1 1N4002 diode (CR4)

C2 ( ) 2 IRF-510 Power MOSFET (Q1, Q2)

C3 ( ) 2 2N3904 NPN transistor (Q3, Q4)

C3 ( ) 1 2N3906 PNP transistor (Q5)

A1

A2

B1

C3

B2

C1

C2

1/4 Watt

1/2 Watt

Page 15

Other:

D1 ( ) 1 DPDT relay, 12V (K1)

D2 ( ) 1 PC-mount pushbutton switch (S1)

D3 ( ) 2 BNC PC-mount jack (J1, J2)

D4 ( ) 2 Heat sink

D5 ( ) 3 Yellow toroid core (L1, L2, L3)

D6 ( ) 1 2 hole small ferrite transformer core (T1)

D7 ( ) 1 2 hole large ferrite transformer core (T2)

D8 ( ) 2 4-40 x 5/16” panhead machine screw

D9 ( ) 2 4-40 keps nut

D10 ( ) 1 Tube of thermal heatsink compound

D11 ( ) 2 12V miniature fan

D12 ( ) 1 RF amplifier PC board

( ) 7’ #24 enameled magnet wire

( ) 2” Double-stick tape

D12

D6

D1

D3

D2

D11

D8

D5

D10

D7 D4

D9

Page 16

L1 and L3 (Toroids)

() Cut 8” of magnet wire (thin, enameled

wire) and thread it through the donut-shaped

toroid cores exactly 12 times as shown. Pull

each turn gently to make the wire snug but

not overly tight. Tin the ends by holding the

soldering iron on the ends of the leads while

applying a small bit of solder to melt away

the insulation. It doesn’t matter which side of

the core you start from and you can ignore

the color difference, if any, from one side to

the other.

Detail 1. L1, L3 toroid construction

L2 (Toroid)

() Cut 9.5” of magnet wire. Thread it

through the toroid exactly 13 times, using the

same procedure as in the previous step. Sepa-

rate this from the other two finished toroids

so that you don’t get them mistaken for each

other.

T1 (Small ferrite core with two holes)

() Cut 11” of magnet wire and thread it

through the smaller ferrite core 6 times. Pull

gently to make each turn snug but not overly

tight. Tin the ends as described above. This is

the primary side of the transformer. Mark it

with a magic marker or pencil so that you can

identify this side when you install it.

() Cut 9” of magnet wire and thread 5 turns

through the same holes so that the leads exit

the other side. Tin the ends. This is the secon-

dary side.

STEP-BY-STEP ASSEMBLY

Detail 3. Transformer T1 construction

Detail 2. L2 toroid construction

Page 17

T2 (Large ferrite core with two holes)

() Cut 9.5” of magnet wire. Wind one turn,

then bring the end out one inch and make a

loop. Twist the two sides of the loop together

to form a center-tap, then thread the rest of

the wire through the core 1 more time. Pull

gently to make each turn snug but not overly

tight. Tin the ends as described above. This is

the center-tapped primary side of the trans-

former.

() Cut 10” of magnet wire and thread 3 turns

through the same holes so that the leads

exit the other side. Tin the ends. Mark the

leads with tape or other identification. This

is the secondary side.

L4, L5 (Air-wound coils)

() Cut two 10” lengths of magnet wire. Wrap

each piece tightly around a pencil or other

1/4” diameter cylindrical object 9 times, then

slide the coil off the pencil and gently push

the coil together to form a cylinder about 1/2”

long. Bend the leads at right angles to the

body of the coils. Tin the ends as described

above.

Cut at the X and heat

each lead to remove

enamel insulation, then

twist together.

Detail 4. Transformer T2 construction

Detail 5. Coils L4, L5 construction

Page 18

Solder all parts as they are installed

and then cut leads as close as practical

to the solder.

() Q1, Q2: Bend MOSFET leads

such that they and the mounting

hole line up. Dab heatsink grease

on underside of MOSFET. Insert a

4-40 x 5/16” mounting screw from

the top through the transistor and

then the heatsink. Insert the MOS-

FET and heatsink into the board

and secure the screw with a 4-40

keps nut. Tighten the nut.

( ) C15: 47 pF disk ceramic

( ) C4: 180 pF disk ceramic

( ) L1: 12-turn toroid

( ) C5: 330 pF disk ceramic

( ) L2: 13-turn toroid

( ) C6: 330 pF disk ceramic

( ) L3: 12-turn toroid

( ) C7: 180 pF disk ceramic

( ) CR1: 5.1V Zener diode

( ) J1: BNC connector

( ) K1: Relay

( ) CR4: 1N4002 diode

( ) J2: BNC connector

Page 19

( ) S1: Switch

( ) C1: 220 uF electrolytic

See polarity detail above.

( ) C3: 0.1 uF disk ceramic

( ) C13: 10 uF electrolytic

See polarity detail above.

( ) C14: 0.1 uF disk ceramic

( ) C8, C9, C10, C11: 0.1 uF

disk ceramic

( ) C12: 0.01 uF disk ce-

ramic

( ) RV1, RV2: Potentiome-

ters

( ) C2: 10 uF electrolytic.

See polarity detail above.

Detail 6. Electrolytic

capacitor polarity

Page 20

( ) L4, L5: 9-turn air-wound

coil

( ) Q3, Q4: 2N3904 NPN

transistor

( ) CR2, CR3: 1N4148 diode

(match polarity band)

( ) Q5: 2N3906 PNP transis-

tor

( ) R1: 470 Ohm (yellow-

violet-brown)

( ) R2: 100K (brown-black-

yellow)

( ) R3: 2.2K (red-red-red)

( ) R4: 10K (brown-black-

orange)

( ) R5: 330 Ohm (orange-

orange-brown)

() T2: Large trans-

former

() R6, R7: 27 Ohm

1/2W (red-violet-

black)

() T1: Small trans-

former. The primary

side (previously

marked) goes on the

side closest to connec-

tors J1, J2.

Keep your soldering tip clean by wiping it

off against a wet sponge periodically.

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DZ PSKUBE PSQ-100 Assembly Manual

DZ PSKUBE PSQ-100 Assembly Manual

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