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Universal 1Watter QRPp VCXO Transceiver               This document describes the building of 1Watters for bands 10, 12, 20, 30, 40 and 80 meters * all kits sold out except 160 & 30 meters* with serial numbers greater than 730 For earlier versions of the 1Watters, select band. 80 40 30 20 10 Last Updated Tue, 13 Jul 2021 17:12:04 -0400 Always check the Addendum Section for updates               Build this 1Watter Universal QRPp VCXO Tranceiver for $49 The 1Watter is a high quality inexpensive transceiver designed for the QRPp enthusiast Guaranteed 1 full Watt output on any band 160-10 Meters using 12 VDC Designed for home and portable operation. Full QSK, dual conversion design with great selectivity Very low noise measured at -137 dBm MDS The VCXO covers both sides of the standard QRP CW calling frequencies The PCB size is only 2.5" (63,5 mm) by 3.8" (96,5 mm) Includes keyer chip V4 with true "natural" sidetone Approximate VCXO Frequency Range by band 80 Meters - 3,557 to 3,562 kHz 40 Meters - 7,020 to 7,039 kHz 30 Meters - 10,101 to 10,119 kHz 20 Meters -  14,056 to 14,061 kHz 12 Meters -  24,892 to 25,915 kHz 10 Meters -  28,052 to 28,061 kHz I would like to thank Chuck Adams, K7QO for suggesting the new kit and appreciate his help testing it to remove all the bugs and bad smoke. He has some great pictures on his website at http://www.k7qo.net/onewatter.html and a 10 part youtube video series 1Watter Transceiver Build, Phase 1 by K7QO My personal operating experiences including QRPp WAS, QRPp DXCC and Pictures, Data and Links are at http://1watters.com Full Size Schematic Building Instructions:     DO NOT REMOVE ANY PARTS FROM THE PLASTIC BAGS UNTIL INSTRUCTED TO DO SO 1. Be careful if/when you inventory the parts; they are small and easy to lose. Parts Lists for each band                 80 40 30 20 12 10     Do not mix up the toroids between the plastic bags.     Keep all toroids in their plastic bags until called for installation.     Do not mix up the red 1N4148 signal diodes with the red 1N5240B zener diode.     If you are missing any parts, contact me immediately.  I will ship the parts the same day.     If you find extra parts in the kit, check the Addendum else throw them in your junk box.     This kit includes all parts to create a fully functioning transceiver.     Included parts are: 2 phone jacks, a bnc jack, a push-button, volume control pot, magnet wire and heat sink.     This kit uses several all black ferrite toroids. One (1) FT37-43 and multiple FT37-61 toroids; they look the same.     The FT37-43 is included in the bag with the green 100n capacitors.     Mark the bag with the green caps as "-43" and the bag with the resistors as "-61"     This will help with identification later on when installing inductors and transformers.     Install the parts in the order per this document to prevent mechanical installation problems later.     Each 1Watter is provided with a Serial Number, which is attached to the bag holding the PCB and magnet wire     Attach the label to the rear of your 1Watter enclosure or wherever suitable     The Serial Number may later be used for tracking 1Watter QSO contests.     This kit requires the following items to complete the kit:     No. 22 or 24 gauge hook-up wire to connect the PCB to the controls and enclosure.     Rosin Solder 60/40 (OK) or 63/37 (Best) and a fine tip solder pencil.     Tool for adjusting trimmer capacitors - suggest search for GC-8608     optional freq counter - search ebay 261731946045         Manual for the Frequency Counter     optional keyer speed adjust potentiometer - recommend 10K linear.     optional power on/off switch.     optional case - Suggested 1Watter Cases     optional Universal Interconnect Kit #2. Kit includes 30 female pins, 40 male pins and 10 3-pin (1x3) housings. 2. Install all 100n (0.1uF) green capacitors ____C6,7,8,9,10,11,13,14,19,27,33,36,37,38,41,44,46,47,48,53 3. Install all 1/8 Watt Resistors.     You may need a magnifying device to verify the resistor color codes.     Bend the resistor leads a sharp 90 degrees from the body of the resistors.     R20, the volume control will be connected later.     Save 5 cut resistor leads to ground the crystal cases later. ____R1,2:   51   Green-Brown-Black-Gold ____R3,9,21,22,29:   470   Yellow-Violet-Brown-Gold ____R4:   2K2   Red-Red-Red-Gold ____R5:   500   Horizontal mounted black trim pot (in hardware bag) ____R6 will be a 4K7 or 100K resistor - see parts list or schematic table         100K - Brown-Black-Yellow-Gold or 4K7 - Yellow-Violet-Red-Gold ____R7,8,17,18,19,26:   4K7   Yellow-Violet-Red-Gold ____R10:   1K   Brown-Black-Red-Gold ____R11:   1K5   Brown-Green-Red-Gold ____R12:   1K2   Brown-Red-Red-Gold ____R13:   1M   Brown-Black-Green-Gold ____R14:   4R7   Yellow-Violet-Gold-Gold ____R15:   100K   Brown-Black-Yellow-Gold ____R16:   10K   Brown-Black-Orange-Gold ____R23,24 are installed to enable the "natural" sidetone of the 1Watter - recommended option ____R23,24:   4M7   Yellow-Violet-Green-Gold ____R25 is only installed if you do not install the keyer speed potentiometer ____R27:   16K   Brown-Blue-Orange-Gold (installed for 40 meters only) ____R28 is not installed         If you do not install a speed pot then you must install R25         Install vertically R25, 470 ohms, into the center and right two holes of J9.         470   Yellow-Violet-Brown-Gold 4. Install all Diodes - observe polarity. ____D1,2,4,6,7: 1N4148 red glass diodes ____D3: 1N5256B silver 30 V Zener ____D5: MV209 varactor - leave 1/8 inch (3 mm) space between the PCB and diode body ____D8: 1N5817 black diode ____D9,10: NPC-127 blue 5.6 V Zener ____D11: 1N5240B red 10 V Zener 5. Install all IC sockets - observe polarity. ____U2,4,5,6,9: Match the notch on the IC socket with the pattern on the PCB 6. Install all remaining capacitors in the order shown. ____C5 40p trimmer cap - flat side into square hole ____C23,24,26: 50p or 60p brown or Yellow trimmer caps - flat side into square hole ____C1,2,3,4: These caps are detailed in the parts list and listed below ____C1,2,3,4: If the caps are polystyrene, bend one lead 180 degrees and install vertically ____C15: This cap is defined in the parts list and listed below ____C16: This cap is defined in the parts list and listed below ____C17,39: 47n labeled 473 small yellow axial cap ____C18: This cap is defined in the parts list and listed below ____C20: This cap is defined in the parts list and listed below ____C21: This cap is defined in the parts list and listed below ____C22: This cap is defined in the parts list and listed below ____C25: This cap is defined in the parts list and listed below ____C28: This cap is defined in the parts list and listed below ____C29,30,31,32: These caps is defined in the parts list and listed below ____C34: This cap is defined in the parts list and listed below ____C35: This cap is defined in the parts list and listed below ____C12,40: 10uF black electrolytic - observe polarity ____C42,49: 47uF blue electrolytic - observe polarity ____C43: 33uF black electrolytic - observe polarity ____C45: 33p labeled 33J NPO dark tan disk cap ____C50: This cap is defined in the parts list and listed below ____C51: This cap is defined in the parts list and listed below ____C52: 2u2 yellow mono cap marked 225 ____Cs: empty - see Mods section ____Cx: empty - see Mods section   C1 C2 C3 C4 C15 C16 C18 C20 C21 C22 C25 C28 C29-32 C34 C35 C50 C51 160 1800 1800 1800 1800 470 470 4P7 120 330 100 180 43 680 180 180 120 100 80 1000 1800 ---- 820 47 220 2P2 150 390 220 220 12 680 180 220 180 56 40 470 470 470 470 68 100 1P0 68 100 100 68 3P0 680 270 220 100 --- 30 330 330 330 330 100 100 1P0 --- 100 100 56 4P7 680 180 180 --- --- 20 220 470 ---- 220 100 470 3P0 22 100 100 56 22 470 100 100 --- --- 17 180 390 ---- 180 100 100 1P0 --- 220 220 47 4P7 470 100 43 --- --- 15 150 330 --- 150 47 100 1P0 47 220 220 47 3P0 680 120 68 --- --- 12 120 270 --- 120 27 51 1P0 --- 220 220 33 3P0 470 150 51 --- --- 10 120 120 120 120 47 56 1P0 43 220 220 43 3P0 680 120 68 --- --- 7. Install all Voltage Regulators and Transistors    Do not install Q1 at this time. ____U3,7: 78L08 voltage regulator; note orientation on the PCB ____U8: 78L05 voltage regulator; note orientation on the PCB    Temporarily connect a +12V source in series with a 100-200 ohm current    limiting resistor to J3-2 pad and power supply ground to J3-3 pad (ground)    Measure the tune voltage (10V), at J1 to make sure it is correct.    Temporarily put a clipped resistor lead from emitter to collector of transistor Q10    Measure the output voltage of U3 (8V) to make sure it is correct.    Remove the clipped resistor lead and remove the power source and continue with parts installation. ____Q2: PN2222 ____Q3,6,7: 2N3904 ____Q4: MPSH10 ____Q5: J310 ____Q8,9: J113 ____Q10: 2N3906 ____Q11: 2N7000 - CAUTION...static sensitive 8. Install all five 8-pin DIP ICs. ____U2: NE602A balanced mixer; the dot positioned towards C18 ____U4: NE602A balanced mixer; the dot positioned towards C26 ____U5: NE602A balanced mixer; the dot positioned towards C28 ____U6: LM386N-4 audio amplifier; the dot positioned towards C37 ____U9: ATtiny45 Keyer with Sidetone; the dot positioned towards C46 9. Wind and install all Toroid Inductors.  Wind all wires on the toroids clockwise. 9.1 ____L1,2: Install inductors L1 & L2 from the below table.   Inductors L1 & L2 Instructions 160 T37-1 Cut two pieces 16" of #26 wire and tightly wind 23 turns 80 T37-1 Cut two pieces 13" of #26 wire and tightly wind 17 turns 40 T37-2 Cut two pieces 13" of #26 wire and tightly wind 17 turns 30 T37-2 Cut two pieces 11" of #26 wire and tightly wind 14 turns 20 T37-7 Cut two pieces 11" of #26 wire and tightly wind 13 turns 17 T37-6 Cut two pieces 10" of #26 wire and tightly wind 12 turns 15 T37-6 Cut two pieces 10" of #26 wire and tightly wind 11 turns 12 T37-10 Cut two pieces 10" of #26 wire and tightly wind 11 turns 10 T37-10 Cut two pieces 9" of #26 wire and tightly wind 10 turns    Trim the wires of L1 and L2 to a half inch each. 160m shown    Strip & Tin the insulation to the base of the toroid using a hot solder pencil.    Spread the turns over most of the toroid 160m shown    Install L1 & L2 into the PCB, pull the leads tight using needle nose pliers, solder and trim    You should be able to straighten the toroid to match the outline on the PCB 9.2 ____T4: Install transformer from the below table.   Transformer T4 Instructions 160 FT37-61 Cut 20" of #30 red wire and tightly wind 31 turns; cut 6" of #27 green wire and wind 4 turns 80 T37-1 Cut 20" of #30 red wire and tightly wind 31 turns; cut 6" of #27 green wire and wind 4 turns 40 T37-2 Cut 19" of #30 red wire and tightly wind 30 turns; cut 6" of #27 green wire and wind 4 turns 30 T37-2 Cut 20" of #30 red wire and tightly wind 32 turns; cut 6" of #27 green wire and wind 4 turns 20 T37-7 Cut 18" of #30 red wire and tightly wind 28 turns; cut 6" of #27 green wire and wind 4 turns 17 T37-6 Cut 15" of #30 red wire and tightly wind 21 turns; cut 6" of #27 green wire and wind 3 turns 15 T37-6 Cut 16" of #30 red wire and tightly wind 24 turns; cut 6" of #27 green wire and wind 3 turns 12 T37-10 Cut 18" of #30 red wire and tightly wind 28 turns; cut 6" of #27 green wire and wind 3 turns 10 T37-10 Cut 15" of #30 red wire and tightly wind 21 turns; cut 6" of #27 green wire and wind 3 turns    Trim the #30 red wires to one inch.    Trim the #27 green wires to half inch. 160m shown    Strip & Tin the insulation to the base of the toroid using a hot solder pencil.    Spread the turns over most of the toroid    Install T4 with the #30 wires into the outside (upper and lower) holes on the PCB    and the 3 or 4 turns #27 wire thru the center holes for T4    You should be able to straighten the toroid to match the outline on the PCB 9.3 ____T2: Install transformer from the below table.   Transformer T2 Instructions 160 FT37-61 Cut 13" of #30 red wire and tightly wind 18 turns; cut 5" of #27 green wire and wind 2 turns 80 T37-1 Cut 19" of #30 red wire and tightly wind 30 turns; cut 4" of #27 green wire and wind 1 turn 40 FT37-61 Cut 8" of #26 red wire and tightly wind 7 turns; cut 4" of #27 green wire and wind 1 turn 30 T37-2 Cut 20" of #30 red wire and tightly wind 32 turns; cut 5" of #27 green wire and wind 2 turns 20 T37-7 Cut 14" of #30 red wire and tightly wind 20 turns; cut 4" of #27 green wire and wind 1 turn 17 T37-6 Cut 16" of #30 red wire and tightly wind 24 turns; cut 4" of #27 green wire and wind 1 turn 15 T37-6 Cut 12" of #30 red wire and tightly wind 15 turns; cut 4" of #27 green wire and wind 1 turn 12 T37-10 Cut 11" of #26 red wire and tightly wind 13 turns; cut 4" of #27 green wire and wind 1 turn 10 T37-10 Cut 12" of #30 red wire and tightly wind 15 turns; cut 4" of #27 green wire and wind 1 turn    Trim the #30 red wires to one inch.    Strip & Tin the insulation to the base of the toroid using a hot solder pencil.    If the green #27 wire is 1 turn...Tin the wire close to the toroid.    If the green #27 wire is 2 turns...Tin & Strip the insulation to the base of the toroid. 40m shown    Spread the turns over most of the toroid    Install T2 with the red wires into the outside (upper and lower) holes on the PCB    and the green wires thru the center holes for T2    pull the leads tight using needle nose pliers, solder and trim    You should be able to straighten the toroid to match the outline on the PCB 9.4 ____T3: Install transformer from the below table.   Transformer T3 Instructions 160 FT37-61 Cut 19" of #30 red wire and tightly wind 30 turns; cut 5" of #27 green wire and wind 2 turns 80 T37-1 Cut 19" of #30 red wire and tightly wind 30 turns; cut 4" of #27 green wire and wind 1 turn 40 T37-2 Cut 19" of #30 red wire and tightly wind 32 turns; cut 4" of #27 green wire and wind 2 turns 30 T37-2 Cut 17" of #30 red wire and tightly wind 25 turns; cut 5" of #27 green wire and wind 2 turns 20 T37-7 Cut 14" of #30 red wire and tightly wind 20 turns; cut 4" of #27 green wire and wind 1 turn 17 T37-6 Cut 13" of #30 red wire and tightly wind 18 turns; cut 4" of #27 green wire and wind 1 turn 15 T37-6 Cut 12" of #30 red wire and tightly wind 15 turns; cut 4" of #27 green wire and wind 1 turn 12 T37-10 Cut 12" of #26 red wire and tightly wind 15 turns; cut 4" of #27 green wire and wind 1 turn 10 T37-10 Cut 12" of #30 red wire and tightly wind 15 turns; cut 4" of #27 green wire and wind 1 turn    Trim the red wires to one inch.    Strip & Tin the insulation to the base of the toroid using a hot solder pencil.    If the green #27 wire is 1 turn...tin the middle inch of the wire    If the green #27 wire is 2 turns...Strip & Tin the insulation to the base of the toroid.    Spread the turns over most of the toroid    Install T3 with the red wires into the outside (upper and lower) holes on the PCB    and the green wires thru the center holes for T3    pull the leads tight using needle nose pliers, solder and trim    You should be able to straighten the toroid to match the outline on the PCB 9.5 Install inductor L4 using the below table. ____L4: Wind xx turns of #27 green wire on an FT37-43 black ferrite toroid, tightly spaced.    The FT37-43 black ferrite toroid is packed in the bag with the green caps Band Inductor L4 Instructions 160 Cut 13" of #27 green wire and tightly wind 18 turns 80 Cut 11" of #27 green wire and tightly wind 14 turns 40-10 Cut 9" of #27 green wire and tightly wind 10 turns    Trim the wires of L4 to a half inch each.    Strip & Tin the insulation to the base of the toroid using a hot solder pencil.    Spread the turns over most of the toroid    Install L4 into the PCB, pull the leads tight using needle nose pliers, solder and trim    You should be able to straighten the toroid to match the outline on the PCB 9.6 Install transformer T1 ____T1: Using an FT37-61 black ferrite toroid, follow instructions in table below.   Transformer T1 Instructions 160 Cut 14" of #26 red wire and tightly wind 20 turns; cut 6" of #27 green wire and wind 4 turns 80 Cut 12" of #26 red wire and tightly wind 15 turns; cut 6" of #27 green wire and wind 3 turns 40-10 Cut 9" of #26 red wire and tightly wind 10 turns; cut 5" of #27 green wire and wind 2 turns    Trim the #26 red wires to one inch.    Trim the #27 green wires to half inch.    Strip & Tin the insulation to the base of the toroid using a hot solder pencil.    Spread the turns over most of the toroid    Install T1 with the red wires into the outside (upper and lower) holes on the PCB    and the green wires thru the center holes for T1    You should be able to straighten the toroid to match the outline on the PCB 9.7 ____L3: Install inductor L3 from the below table.   Inductor L3 Instructions 160 FT37-61 Cut 22" of #30 red wire and tightly wind 34 turns 80 FT37-61 Cut 14" of #26 red wire and tightly wind 20 turns 40 FT37-61 Cut 14" of #26 red wire and tightly wind 20 turns 30 FT37-61 Cut 13" of #26 red wire and tightly wind 17 turns 20 FT37-61 Cut 10" of #26 red wire and tightly wind 12 turns 17 FT37-61 Cut 9" of #26 red wire and tightly wind 10 turns 15 T37-2 Cut 20" of #30 red wire and tightly wind 30 turns 12 T37-2 Cut 18" of #30 red wire and tightly wind 27 turns 10 T37-2 Cut 16" of #30 red wire and tightly wind 24 turns    Trim the wires of L3 to a half inch each.    Strip & Tin the insulation to the base of the toroid using a hot solder pencil.    Spread the turns over most of the toroid    Install L3 into the PCB, pull the leads tight using needle nose pliers, solder and trim    You should be able to straighten the toroid to match the outline on the PCB 9.8 ____L6: Install inductor L6 from the below table.   Inductor L6 Instructions 160 T37-2 Cut 16" of #30 red wire and tightly wind 23 turns 80 T37-2 Cut 11" of #26 red wire and tightly wind 13 turns 40 T37-2 Cut 13" of #26 red wire and tightly wind 18 turns 30 T37-2 Cut 16" of #30 red wire and tightly wind 24 turns 20 FT37-61 Cut 10" of #26 red wire and tightly wind 12 turns 17 FT37-61 Cut 13" of #26 red wire and tightly wind 17 turns 15 T37-2 Cut 13" of #30 red wire and tightly wind 18 turns 12 T37-2 Cut 20" of #30 red wire and tightly wind 31 turns 10 T37-2 Cut 13" of #30 red wire and tightly wind 18 turns    Trim the wires of L6 to a half inch each.    Strip & Tin the insulation to the base of the toroid using a hot solder pencil.    Spread the turns over most of the toroid    Install L6 into the PCB, pull the leads tight using needle nose pliers, solder and trim    You should be able to straighten the toroid to match the outline on the PCB 9.9 ____L5: Install inductor L5 from the below table.    This inductor determines the upper and lower frequencies of the 1Watter.   Inductor L5 Instructions 160 FT37-61 Cut 14" of #30 red wire and tightly wind 20 turns 80 FT37-61 Cut 11" of #26 red wire and tightly wind 13 turns 40 T37-2 Cut 18" of #27 green wire and tightly wind 27 turns 30 T37-2 Cut 21" of #30 red wire and tightly wind 33 turns 20 FT37-61 Cut 16" of #30 red wire and tightly wind 23 turns 17 T37-2 Cut 21" of #30 red wire and tightly wind 33 turns 15 T37-2 Cut 22" of #30 red wire and tightly wind 35 turns 12 T37-2 Cut 20" of #27 green wire and tightly wind 32 turns 10 T37-2 Cut 17" of #30 red wire and tightly wind 25 turns    Trim the wires of L5 to a half inch each.    Strip & Tin the insulation to the base of the toroid using a hot solder pencil.    Spread the turns over most of the toroid    Install L5 into the PCB, pull the leads tight using needle nose pliers, solder and trim    You should be able to straighten the toroid to match the outline on the PCB 9.10 Install transformer T5 Cut 10" of #34 red wire and 4" of #30 red wire. ____T5: Wind 8 turns of #34 red wire on an BN-43-2402 black ferrite binocular.    The BN-43-2402 black ferrite binocular is packed in the bag with the green caps    Trim the red wires of T5 to one inch each.    Wind 2 turns of #30 red wire on the BN-43-2402 black ferrite binocular.    Trim the #30 wires of T5 to one half inch each.    Strip & Tin the insulation on all 4 wires to the base of the binocular.    The #34 wire leads for the 8 Turn winding go to the two pads closest to the IC, Pins 1 and 2.    The #30 wire leads go to the two pads farthest away from the IC or toward the bottom of the PCB.    Install T5 into the PCB, pull the leads tight using needle nose pliers, solder and trim. 10. Install all Crystals.     There are 5 "IF" crystals included in the kit.     These crystals are graded for frequency and resistance.     If you find a crystal with a black dot, install it in X6.     If you find 2 crystals with black dots, install in X2 & X6.     The Filter Crystals X3,4,5 should not have a black dot.     When installing the crystals, tilt the crystals about 20 degrees while soldering     This will raise the crystal a small bit above the PCB after straightening     and will prevent trace shorts to the case of the crystal     Do not overheat the crystals. ____X1: see table ____X2,3,4,5,6: see table   160 80 40 30 20 17 15 12 10 X1 8.192 13.56 23.04 22.118 8.064 22.118 13.0 20.0 20.0 X2-6 10.0 10.0 16.0 12.0 6.0 4.032 8.064 4.915 8.064     When soldering the crystal cases to ground, do not overheat the crystals ____Solder one resistor lead across the top of crystals X3,4,5 ____Solder one resistor lead from the top of X4 to the ground below (top center) ____Solder one resistor lead from the top of X2 to the ground below (upper right) ____Solder one resistor lead from the top of X6 to the ground below (upper right) 11. Connections.    Suggested 1Watter Cases    Connect a user supplied pot (10K or 100K) to the "speed pot" connector J9.    Connect the speed pot control wiper to the center hole on J9.    If you do not install a speed pot then you must install R25    Install R25, 470 ohms, into the center and right two holes of J9.    Connect the 500 ohm volume pot (R20) using any insulated wire.    Connect the volume control high side to the center of J6 on the PCB.    Connect the volume control cold side to a ground on J6.    Connect the volume control center wiper to a 3.5 mm phono jack    Connect the 3.5 mm phono jack ground to the cold side of the volume control pot.    Connect a user supplied pot (5K or 10K or 100K or 1 Meg) to the "Tune" connector J1.    Connect the tune control wiper to the center hole on J1.    Connect the provided BNC connector to the "Ant" connection next to L1 on the PCB.    Connect paddles or a straight key to J5 via the other 3.5 mm phono connector    Connect the Push Button, one wire to the center of J4, the other wire to one of the ground connections    Before you apply power to the 1Watter, make sure your power polarity is correct    The 1Watter was designed to operate from a 12 volt Sealed Lead Acid Battery    Connect +12.6V volts (+/- 1 volt) to the holes in the upper right corner of the PCB. 12. Receiver Alignment.    Connect any antenna to the 1Watter or a wire at least 1 meter long.    Set the volume control to minimum and apply power to the 1Watter.    Increase the volume control setting until you hear noise/hiss from the speaker.    Adjust C5 and C26, back and forth for maximum noise coming from the speaker/headphones.    You may hear some CW signals by turning the Tune Pot. 13. Transmit Alignment using an Oscilloscope or a Calibrated Accurate Receiver    The band pass filter (X3,4,5) establishes the IF center frequency.    The transmit oscillator part of U2, X2 and L6 should match the IF frequency +/- 100 Hz.    Find a signal in the tuning range of the transceiver. As you tune across the signal,    the loudest audio frequencies should be about 600 Hz +/- 100 Hz    Next we will adjust for maximum carrier output.    You will need an HF receiver, oscilloscope or dummy load with power meter.    If you do not have either, we will align the transmitter after we install the final transistor.    The Voltage Controlled Crystal Oscillator and the Transmit Carrier Oscillator are mixed (U2)    to produce the 1Watter transceiver frequency of operation.    The mixer (U2) also produces other frequencies that must be rejected.    Preset the power control R5 to half way    Preset C23 and C24 at 50 percent maximum capacitance (see settings in addendum section)    C23 has broad tuning while C24 has very sharp tuning.    Preset the Tune Pot to half way or in the middle.    Place the Keyer into straight key mode    While listening to a receiver near the QRP calling frequency or watching a scope at the junction of R1/D4,    adjust C24 to max signal on the scope or receiver.    You should verify that the signal is the QRP frequency and not another mixer freq.    If using a receiver, you will need to hunt for the actual signal.    After finding the signal, readjust both C23 and C24 for maximum signal.    Make sure that you have aligned the filter to the correct frequency and not an alternate    frequency generated by the transmit mixer. 14. Install the RF Final Transistor Q1    Q1 is normally a 2N5109 but could be replaced with a 2SC5706 in the future.    Install a 2N5109 with the collector in the top hole, base in the right hole and emitter in the lower hole.    Install a 2SC5706 into the 3 center holes; metal tab towards the center of the PCB. ____Q1: 2N5109 - leave 1/8 inch (3 mm) space between the PCB and transistor case    These heat sink is factory fresh and offer a very tight fit,    so tight in fact that you will need to open up the diameter of the heat sink using    a blade screwdriver or other tool. If you open up the heat sink too far, you my easily    provide for a tighter fit by squeezing the heat sink until it provides a proper fit. ____Q1 heat sink: - slowly push the heat sink over the case of Q1 15. Sidetone volume setting.    The Command Sidetone Volume is fixed/set by R15, 1M & C45, 33p.    To lower the Command Sidetone volume, decrease the value of C45 or increase the value of R15    To raise the Command Sidetone volume, increase the value of C45 or decrease the value of R15    Replacements parts for R15 and C45 are not included in the kit.    The Natural Sidetone volume is set by R23 and R24 resistors near Q8 & Q9 16. Transmit Final Alignment using milliamp meter    Connect a 50 ohm dummy load to the output of the transceiver    Connect a Power Supply (12V) through amp meter    Place the keyer into straight key mode (see instructions below)    Key the transmitter and adjust R5 for exactly 250 milliamps.    If C23 & C24 were not aligned in a prior step then preset C23 and C24 to 50 pct capacitance    Ajusting C24 for maximum milliamps current. Adjust R5 to keep the current at 250 Ma.    repeat several times until you know that C23 & C24 are peaked and R5 is set for 250 Ma.    If you have a wattmeter, insert it between the dummy load and the tranceiver.    It should measure very near 1 watt output.    You may also adjust R5 for 20 volts P-P on a scope.    It is recommended that you do not adjust R5 for more than 1 watt to prevent instability.    It is possible to align your 1Watter output to something other than your desired frequency.    Verify that you have adjusted C23 and C24 to the QRP operating frequency by using a Receiver    or Oscilloscope or other instrument capable of verifying your output frequency.    This completes the 1Watter Tranceiver alignment.    The 1Watter Service Manual    The 1Watter Troubleshooting 17. Optional modifications to and experiments with the 1Watter 17.1 NE602A gain increase for U4 and U5    You may increase the gain by placing a 27K (not included) or higher value resistor (Rx on the PCB) across pins 1 and 8 of U5 17.2 Frequency Range Mods    You may change the frequency span of the 1Watter by changing the number of turns on L5    Too many turns and the oscillator stops working or becomes unstable.    Add capacitance at Cx, between the crystal X1 and L5 and ground. Try 3-10 pF for starters. 18. The 1Watter Keyer Instructions    This is a very basic Iambic-Mode-B Keyer using an ATmel AVR Microprocessor    On power-Up, the keyer defaults to 15 WPM and a sidetone of 625 Hz and annunciates "1W" [ .---- .-- ] via Int'L Morse Code.    Connecting a straight key with a Mono Plug automatically places the keyer into straight key mode.    Moving the "Speed Pot" changes the speed from 5 WPM up to 36 WPM (version 3 and higher only)    The internal timing oscillator in the Keyer Chip is an RC oscillator that runs at 9.6 MHz +/- 10 pct Factory Calibration.    Typical accuracy is +/- 5 percent; The accuracy can be impoved to +/- 2 percent if one takes the time to calibrate    the oscillator and reprogram the keyer chip. This procedure is too time consuming for 200 chips but may be OK for you.    The accuracy is typically +/- 5 pct so your sidetone may be off by +/- 5 pct and your keying WPM may also be off.    That means if you set the WPM speed to 20 WPM, you may actually have it set at 19 or 21 WPM; should not be a problem.    The keyer is placed into the "Command" mode by pressing and releasing the Cmd Button.    The keyer has the following commands available after pressing the Cmd Button: "A" (.-) Toggles transmit sidetone audio    The sidetone mode setting is saved on power-down.    If transmit sidetone flag was set, then clear flag and announce "Y"; Y=yes, we turn on transmit sidetone audio    If transmit sidetone flag was clear, then set flag and announce "N"; N=no, we turn off transmit sidetone audio    CMD Sidetone Audio is always active when a CMD is issued.    Enable this Mode when using the "natural" transmit sidetone. "B" (-...) Enter Beacon Mode (version 2 and higher only)    Hit CMD button and enter "B" to start Beacon Mode    Listen for a DIT to acknowledge ready to select message number    Enter message number...1, 2 or 3    Message repeats over and over    Hit paddles, dit or dah or straight key to turn off beacon mode "E" (.) or "T" (-) Toggles between normal keyer and straight key mode, acknowleged by annunciating    "S" (for Straight Key Mode) in code. The keyer mode is NOT saved on power-down.    Connecting a straight key with a Mono Plug automatically places the keyer into straight key mode. "M" (--) Enter Beacon Message(s) (version 2 and higher only)    Hit CMD button and enter "M" to enter message    Listen for a DIT to acknowledge ready to select message number    Enter message number...1, 2 or 3    Listen for a DIT to acknowledge ready to enter a character    Enter one character at a time, then wait for another "dit"    To enter a word space, do not enter anything in between annunciated "dits"    At the end of the message, do not forget to add empty character time.    This allows you to pause and listen between CQ calls. Recommend between 10 and 20 word spaces.    Terminate message entry mode by send "AR" or ".-.-." "R" (.-.) Toggles between normal and reverse paddles keys, acknowleged by annunciating "P" (for normal paddles)     or "X" (for reversed paddles) in code. The paddles (normal or reverse) are saved on power-down. "S" (...) Set keyer speed in WPM. Speed is entered as two numerical digits.    After sending the "S" command, the keyer sends a DIT (e) as a prompt for the first speed character (0-4)    After sending the first speed number, wait for another DIT (e) prompt and send the 2nd number (0-9)    Depending upon what you enter, you will hear a "?" for ERROR or an "R" for a "Roger" acknowlegement.    Valid keyer speeds are 1 to 45 WPM (good luck trying to send/use 1 WPM)    The keyer speed setting is saved on power-down. "F" (..-.) Sets the sidetone frequency.    After sending the "F" command, the keyer sends a DIT (e) as a prompt for the tone character (0-9)    Depending upon what you enter, you will hear a "?" for ERROR or an "R" for a "Roger" acknowlegement.    The sidetone frequency setting is saved on power-down.    The following table equates the sidetone number with the sidetone frequency:    0 = 1000 Hz    1 = 833 Hz    2 = 714 Hz    3 = 625 Hz    4 = 555 Hz    5 = 500 Hz    6 = 455 Hz    7 = 417 Hz    8 = 385 Hz    9 = 357 hz "V" (...-) Announces the keyer version number (version 0 and higher only)    This kit includes keyer version 4. "X" (-..-) Puts the keyer into transmit or tune mode    Hit paddles dit or dah or straight key to turn off tune mode Disable the keyer sidetone for the "natural" transmit sidetone. The keyer has Deadman Insurance. In the event that the keyer issues 64 successive DITs or 64 successive DAHs, the keyer will shut down and cease to operate. You must power down the keyer chip to restart normal operation. To Reset the Keyer to the Default mode, hold the Cmd button active until you hear "1W" Then immediately release the Command Button, else you will send another Command request. Source code and hex files for the keyer are available at http://kitsandparts.com/keyer Notes: Variable capacitor settings: Maximum Capacitance Midway Capacitance Minimum Capacitance If you need an alignment tool for the trimmers, look up "GC 8608" - available at newark.com and onlinecomponents.com We recommend the purchase of the optional Universal Interconnect Kit #2. The kit includes    30 female pins, 40 male pins and 10 3-pin (1x3) header housings.    A crimping tool is available from ebay.com for creating cables.    Search Ebay for SN-28B Pin Crimping Tool    or visit http://www.ebay.com/itm/321699003334    A How-To video https://www.youtube.com/watch?v=GkbOJSvhCgU Addendum Section: Oct 21 2016 2359 - Here are some data when sub'ing the MV209 varactor with 1SV322 & 1SV324 1W20 freq span using MV209 0V=14056.3 10V=14060.6 1W20 freq span using 1SV322 0V=14059 10V=14064 1W20 freq span using 1SV324 0V=14057.1 10V=14063.6 (my new freq coverage) 1W40 freq span using MV209 0V=7019.6 10V=7039.4 1W40 freq span using 1SV322 0V=7025.7 10V=7047.4 (my new freq coverage) 1W40 freq span using 1SV324 - not tested; I like the above too much. Sep 30 2018 1630 - If you have low drive level to the final and can not get full 1 watt output, you may try increasing the value of R10, a 1K resistor. Tracy W4EDJ reported that his 1W40 only had full output when he changed R10 from 1K to 4K7 End of Addendum Section:   top

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