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AUTO-SCAN FM RADIO KIT MODEL FM-88K ELENCO® 150 Carpenter Avenue Wheeling, IL 60090 (847) 541-3800 Website: www.elenco.com e-mail: [email protected] To see our complete line of Educational Products go to WWW.ELENCO.COM Assembly and Instruction Manual ELENCO ® Copyright © 2011 by ELENCO® All rights reserved. No part of this book shall be reproduced by any means; electronic, photocopying, or otherwise without written permission from the publisher. 753050 PARTS LIST GLOSSARY (Continued) If you are a student, and any parts are missing or damaged, please see instructor or bookstore. If you purchased this kit from a distributor, catalog, etc., please contact ELENCO® (address/phone/e-mail is at the back of this manual) for additional assistance, if needed. DO NOT contact your place of purchase as they will not be able to help you. RF Radio Frequency. Sensitivity The ability of a receiver to pick up low-amplitude signals. Speaker An electronic device that turn electric impulses into sound. Surface-mount Technology RESISTORS Symbol R5 R1 R3 R4 R2 R6/S3 Value Color Code 10Ω 5% 1/4W brown-black-black-gold 680Ω 5% 1/4W blue-gray-brown-gold 5.6kΩ 5% 1/4W green-blue-red-gold 10kΩ 5% 1/4W brown-black-orange-gold 18kΩ 5% 1/4W brown-gray-orange-gold Potentiometer 50kΩ & switch w/ nut & washer Part # 121000 136800 145600 151000 151800 192522 CAPACITORS Qty. r1 r1 r1 r1 r1 r1 r1 r1 r2 r1 r1 r6 r2 r1 r1 r2 Symbol C6 C7 C10 C5 C8 C4 C13 C23 C11, C12 C15 C19 C3, C9, C14, C16, C17, C* C21, C22 C20 C1 C2, C18 Value 33pF 82pF 180pF 220pF 330pF 470pF 680pF 1500pF 3300pF 0.033μF 0.047μF 0.1μF 10μF 22μF 100μF 220μF Description Discap (33) Discap (82) Discap (181 or 180) Discap (221 or 220) Discap (331 or 330) Discap (471 or 470) Discap (681 or 680) Discap (152) Discap (332) Discap (333) Discap (473) Discap (104) Electrolytic radial Electrolytic radial Electrolytic radial Electrolytic radial Part # 213317 218210 221810 222210 223317 224717 226880 231516 233310 243318 244780 251010 271044 272244 281044 282244 COILS Qty. r1 r1 Symbol L2 L1 Value Qty. r1 r1 r1 r1 r1 Symbol D1 D2 D3 U2 U1 Value BB909/BB910 1N4001 Description Coil 4-turn Coil 6-turn Part # 430150 430160 SEMICONDUCTORS LM-386 or identical TDA7088T or identical Description Varactor Semiconductor silicon diode Red LED 3mm Low voltage audio power amplifier FM receiver SM installed on PC board Part # 310909 314001 350003 330386 MISCELLANEOUS Qty. r1 r1 r2 r1 r1 r1 r1 r1 Description Antenna FM PC board w/ installed U1 (TDA7088T) Push button switch 12mm Battery holder Speaker 8Ω Cap push button switch yellow Cap push button switch red Knob pot / switch Qty. r1 r2 r1 r1 r1 r 3” r1 Part # 484005 517038 540005 590096 590102 622001 622007 622050 -1- Description Screw M1.8 x 7.5mm Antenna screw M2 x 5mm Nut M1.8 Socket IC 8-pin Speaker pad Wire 22 ga. solid Solder Lead-free Part # 641100 643148 644210 664008 780128 834012 9LF99 Trimmer A semiconductor component that can be used to amplify signals, or as electronic switches. Varactor A method of using special components that are soldered to the PC board’s surface. A diode optimized to vary its internal capacitance with a change in its reverse bias voltage. Voltage Electrical potential difference measured in volts. An adjustable fine-tuning resistor, capacitor, or inductor of small values. Voltage Regulator A circuit that holds the DC voltage. QUIZ INSTRUCTIONS: Complete the following examination, check your answers carefully. 6. The capacitance of the varactor is determined by . . . r A) the voltage level. r B) the amount of current in the circuit. r C) the signal strength of the RF carrier. r D) the amount of resistance in the circuit. 1. The number of cycles produced per second by a source of sound is called the . . . r A) amplitude. r B) vibration. r C) sound wave. r D) frequency. 7. The ability to select a specific band of frequencies, while rejecting others, is called . . . r A) selectivity. r B) sensitivity. r C) demodulation. r D) none of the above. 2. The frequency of the modulating signal determines the ... r A) number of times the frequency of the carrier changes per second. r B) maximum deviation of the FM carrier. r C) maximum frequency swing of the FM carrier. r D) amount of amplitude change of the FM carrier. 8. The process of mixing two signals to produce a third signal is called . . . r A) filtering. r B) detecting. r C) rectification. r D) heterodyning. 3. The FM broadcast band is . . . r A) 550 – 1,600kHz. r B) 10.7MHz. r C) 88 – 108MHz. r D) 98.7 – 118.7MHz. 9. The circuit designed to supply substantial power output into low impedance load is called . . . r A) power supply. r B) pre-amplifier. r C) power amplifier. r D) detector. 4. The AFC circuit is used to . . . r A) automatically hold the local oscillator on frequency. r B) maintain constant gain in the receiver to prevent such things as fading. r C) prevent amplitude variations of the FM carrier. r D) automatically control the audio frequencies in the receiver. 5. The device most often used for changing the local oscillator frequency with the AFC voltage is a . . . r A) feedthrough capacitor. r B) variable inductor. r C) varactor. r D) trimmer capacitor. 10. The gain of the LM-386 amplifier can be set in range from . . . r A) 1 to 20. r B) 20 to 200. r C) 0 to 200. r D) 50 to 100. Answers: 1. D, 2. A, 3. C, 4. A, 5. C, 6. A, 7. C, 8. D, 9. C, 10. B Qty. r1 r1 r1 r1 r1 r1 Transistor -14- PARTS IDENTIFICATION TROUBLESHOOTING Contact ELENCO if you have any problems. DO NOT contact your place of purchase as they will not be able to help you. ® r d) Have any solder bridges formed? A solder bridge may occur if you accidentally touch an adjacent foil by using too much solder or by dragging the soldering iron across adjacent foils. Break the bridge with your soldering iron. 1. One of the most frequently occurring problems is poor solder connections. r a) Tug slightly on all parts to make sure that they are indeed soldered. r b) All solder connections should be shiny. Resolder any that are not. Resistor LM-386 6-turn 3. Make sure that all of the parts are placed in their correct positions. Check if the IC, diode and lytic orientations are correct. LED Electrolytic Discap radial Diode -OR- AGC Automatic Gain Control. AF Audio Frequency AM Amplitude Modulation Amplifier Converts input signal to output. Anode The positive terminal of a diode. Detector Circuit Diode Receiver circuit that recovers the modulated portion of the signal impressed on the RF carrier wave. Frequency Modulation. Any device that either radiates a signal or pulls in a signal. Frequency Wave or pulse repetition rate. Baffle Used to ensure positive airflow. Gain Signal multiplication. Bandwidth The amount of frequency spectrum, in hertz, utilized by a filter or channel. IC Integrated Circuit. LED Light Emitting Diode. A semiconductor device that emits light when voltage and current are passed through it. PC Board Printed Circuit Board. Potentiometer Three-terminal variable resistor, volume control. Bypass Capacitor A capacitor used to shunt AC around a component. An electronic component that has ability to store a charge and block DC current. The negative terminal of a diode. Coil A component with inductive reactance. Current Transport of electrons throughout a conductor and measured in amps. Power Supply Resistor -13- 50kΩ Potentiometer and switch 4-turn FM antenna Speaker Battery holder Push button switch Cap push button switch Knob (pot / switch) Speaker pad An electronic circuit that produces the necessary power for another circuit. An electronic component that obstructs (resists) the flow of electricity. Varactor MISCELLANEOUS An electronic component that changes alternating current to direct current. FM Cathode SEMICONDUCTORS COILS IC Socket GLOSSARY Capacitor CAPACITORS 2. Use a fresh 9V battery. r c) Solder should flow into a smooth puddle rather than a round ball. Resolder any connection that has formed into a ball. Antenna RESISTORS PC board Screw M1.8 x 7.5mm Screw M2 x 5mm Nut M1.8 -2- TESTING - SECTION 2 You Will Need: • 9V Battery • 25 or 30 watt Soldering Iron • Small Phillips and Slotted Screwdrivers • Long Nose Plier • Side Cutters Voltage reference chart for U1 TDA 7088T (turn radio on and press reset). Test IDENTIFYING RESISTOR VALUES Verify that FM signals are present in your location by listening to another FM radio placed near the FM-88K. Use the following information as a guide in properly identifying the value of resistors. BAND 1 1st Digit Color Black Brown Red Orange Yellow Green Blue Violet Gray White Digit 0 1 2 3 4 5 6 7 8 9 BAND 2 2nd Digit Color Black Brown Red Orange Yellow Green Blue Violet Gray White Digit 0 1 2 3 4 5 6 7 8 9 Multiplier Color Black Brown Red Orange Yellow Green Blue Silver Gold Color Silver Gold Brown Red Orange Green Blue Violet Tolerance ±10% ±5% ±1% ±2% ±3% ±0.5% ±0.25% ±0.1% 2. Bend the antenna to vertical position and adjust for maximum length. BANDS 2 1 Multiplier Tolerance Capacitors will be identified by their capacitance value in pF (picofarads), nF (nanofarads), or μF (microfarads). Most capacitors will have their actual value printed on them. Some capacitors may have their value printed in the following manner. The maximum operating voltage may also be printed on the capacitor. Warning: If the capacitor is connected with incorrect polarity, it may heat up and either leak, or cause the capacitor to explode. Multiplier For the No. 0 1 2 3 Multiply By 1 10 100 1k Second Digit First Digit 4 5 8 10k 100k .01 100V Means Pico nano micro milli unit kilo mega 0.1 Tolerance* Maximum Working Voltage The value is 10 x 1,000 = 10,000pF or .01μF 100V Polarity Marking * The letter M indicates a tolerance of +20% The letter K indicates a tolerance of +10% The letter J indicates a tolerance of +5% Note: The letter “R” may be used at times to signify a decimal point; as in 3R3 = 3.3 METRIC UNITS AND CONVERSIONS Abbreviation p n μ m – k M 9 Multiplier 103K Multiply Unit By .000000000001 .000000001 .000001 .001 1 1,000 1,000,000 Or 10-12 10-9 10-6 10-3 100 103 106 -3- 3. Turn ON power switch (rotate clockwise until a “click” is heard). RED LED should light. Turn the VOLUME CONTROL potentiometer to middle position (comfortable level). 4. Press and release “RESET” ( R ) button. IDENTIFYING CAPACITOR VALUES Electrolytic capacitors have a positive and a negative electrode. The negative lead is indicated on the packaging by a stripe with minus signs and possibly arrowheads. Figure L 1. Install fresh 9V battery into holder. Resistance Tolerance Multiplier 1 10 100 1,000 10,000 100,000 1,000,000 0.01 0.1 If the radio is receiving station frequencies higher than 90MHz after pressing the “RESET” button, you will need to adjust coil L2 to a higher value (by making the gap between the coils smaller as shown in Figure L). Carefully press the coils of L2 together. Press and release the “SCAN” ( S ) button once or a couple of times; a station should be heard. Press and release “SCAN” button again; the radio should be automatically searching for other broadcast station. When you press the “SCAN” button in several times, there should be other broadcast stations coming before the HIGH-END frequency (FM106-108MHz). If test fails; If the radio is receiving station frequencies smaller than 87MHz after pressing the “RESET” button (to receive regular FM stations you need to press the “SCAN” button several times), then you will need to adjust the L2 coil to a smaller value (carefully slide a small screwdriver between coils to get the spacing shown in Figure M). Make sure that all of the parts are placed in their correct position. Check if the orientation of D1 is correct. Short pins 2 and 14 of U1 several times using a wire. If you don’t hear tapping from the speaker, check U1, capacitors C22 and C23, resistor R2, and potentiometer R6. Pin # Voltage Pin # Voltage 1 2 3 4 5 6 7 8 2.4 1.3 2.2 2.6 2.6 2.0 1.9 1.2 9 10 11 12 13 14 15 16 1.9 1.9 0.9 0.9 1.8 0 1.7 2.1 If sound is not clear; Install capacitor C* onto the copper side of the PC board as shown in Figure N. If you need more gain (up to 200), install capacitor C21 (10μF) as shown in Figure D. Figure M 1. 1,000 pico units = 1 nano unit 2. 1,000 nano units = 1 micro unit Alignment 3. 1,000 micro units = 1 milli unit 4. 1,000 milli units = 1 unit 5. 1,000 units = 1 kilo unit 6. 1,000 kilo units = 1 mega unit The first time “SCAN” button is pressed, the radio should start at the bottom end of the FM band (88-90 MHz). You may need to press the SCAN button a couple of times. If it doesn’t tune to the low end, you will need to adjust the coil. -12- Figure N DESCRIPTION AND FEATURES SECTION 2 ASSEMBLE COMPONENTS TO THE PC BOARD Place a check mark in the box provided next to each step to indicate that the step is completed. C5 - 220pF Discap (221 or 220) S1 - Push button switch S1 - Cap yellow (see Figure J) R4 - 10kΩ 5% 1/4W Res. (brown-black-orange-gold) The ELENCO® FM-88K Kit is a monophonic, two-IC, FM (frequency modulation) receiver designed to receive FM signals in the frequency range (88-108MHz). It uses electronic auto-scan to search for FM stations. This scan system is done with two button switches - one switch scans up, the other resets to the start of the tuning position. The unique design of this radio kit allows you to place the parts over the corresponding symbols in the schematic drawing on the surface of the printed circuit board. This technique maximizes the learning process, while keeping the chance of assembly error at a minimum. To simplify troubleshooting the FM radio, it is constructed in two sections (Audio and RF). There are two IC’s, one for the audio section, the other for the RF. The RF IC is surface mounted (SM-IC), pre-installed on the high quality printed circuit board. • • • • C7 - 82pF Discap (82) S2 - Push button switch S2 - Cap red (see Figure J) C8 - 330pF Discap (331 or 330) C14 - 0.1μF Discap (104) • Electronic auto-scan FM RADIO FM-88K is a receiver for searching FM stations • Operated by two push button switches • Frequency range: (88 – 108) MHz • High sensitivity C11 - 3300pF Discap (332) R3 - 5.6kΩ 5% 1/4W Res. (green-blue-red-gold) INTRODUCTION C22 - 10μF Electrolytic (see Figure D) The FM (Frequency Modulation) band covers 88 – 108 MHz. There are signals from many radio transmitters in the band inducing signal voltages in C6 - 33pF Discap (33) L1 - Coil 6-turn (see Figure K) C9 - 0.1μF Discap (104) Volume control of 8Ω speaker Telescopic antenna LED power ON indicator Power source 9V battery with ON/OFF power switch the area. Below is a block diagram of a basic SUPERHETERODYNE FM radio: C4 - 470pF Discap (471 or 470) C16 - 0.1μF Discap (104) Speaker C15 - 0.033μF Discap (333) RF AMPLIFIER L2 - Coil, 4-turn (see Figure I) MIXER IF AMPLIFIER OSCILLATOR AFC DETECTOR AUDIO AMPLIFIER r Install FM antenna C12 - 3300pF Discap (332) Mount the antenna to the PC board using two M2 x 5mm screws as shown. C10 - 180pF Discap (181 or 180) C23 - 1500pF Discap (152) FM antenna Note: Capacitors C21 and C* are not used. Figure I Figure J Figure K Using a spacer, create three 1/16” gaps in the 4-turn coil as shown. Mount the coil to the PC board as shown. Solder and cut off excess leads. Mount the push button switch flush to the PC board and solder into place. Attach the plastic button cap to the switch by snapping it into place. Mount the 6-turn coil to the PC board as shown. Solder and cut off excess leads. Button cap 1/16” gap Push button switch Legend side of PC board M2 x 5mm Screws -11- FM RF AMPLIFIER, MIXER, OSCILLATOR FM DETECTOR The RF amplifier selects and amplifies a desired station from many. It is adjustable so that the selection frequency can be altered, also known as tuning. The selected frequency and the output of an Oscillator are applied to the mixer, forming a frequency changer circuit. The RF amplifier and the oscillator are the only two resonant circuits that change when the radio is tuned for different stations. Since a radio station may exist 10.7MHz above the oscillator frequency, it is important that the RF stage rejects this station and selects only the station 10.7MHz below the oscillator frequency. The amplified IF signal is fed to the detector. This circuit recovers the audio signal and discards the IF carrier. Some of the audio is fed back to the oscillator as an Automatic Frequency Control (AFC) voltage. This ensures that the oscillator frequency is stable in spite of temperature, voltage, and other effects changes. If this occurs, the center frequency of 10.7MHz will not be maintained. AFC is used to maintain the 10.7MHz center frequency. When the local oscillator drifts, the radio detector will produce a DC (direct current) “correction” voltage. This signal is fed to a filter network that removes the audio so that pure DC voltage is produced and changes the frequency of oscillation of the local oscillator. The frequency of the undesired station 10.7MHz above the oscillator is called the Image Frequency. Since the FM receiver has an RF amplifier, the image frequency is reduced significantly. The output from the mixer is the Intermediate Frequency (IF), a fixed frequency of 10.7MHz. The IF signal is fed into the IF amplifier. The advantage of the IF amplifier is that its frequency and bandwidth are fixed, no matter what the frequency of the signals. The IF amplifier increases the amplitude, while also providing selectivity. Selectivity is the ability to “pick out” one station while rejecting all others. AUDIO AMPLIFIER The audio amplifier increases the audio power to a level sufficient to drive an 8Ω speaker. To do this, DC from the battery is converted by the amplifier to AC (alternating current) in the speaker. The ratio of the power delivered to the speaker and the power taken from the battery is the efficiency of the amplifier. In a class A amplifier (transistor on over entire cycle), the maximum Theoretical efficiency is 0.5 or 50%. In -4- TESTING - SECTION 1 a class B amplifier (transistor on for ½ cycle), the maximum theoretical efficiency is 0.785 or 78.5%. Since transistor characteristics are not ideal in a pure class B amplifier, the transistors will introduce crossover distortion. This is due to the non-linear transfer curve near zero current or cutoff. This type distortion is shown in Figure 1. In order to illuminate crossover distortion and maximize efficiency, the output transistors of the audio amplifier are biased on for slightly more than ½ of the cycle, known as class AB. In other words, the transistors are working as class A amplifiers for very small levels of power to the speaker, but they side toward class B operation at lager power levels. In this test, you will produce a clicking sound by shorting the bottom volume control pin to ground using your finger. You should hear a clicking sound every time the pins are shorted. If you hear no sound then; r Check that U2 and C18 are installed in the correct position as marked on the PC board. r 1. Install a new 9V battery into the battery holder. Turn the power switch on and turn the knob fully clockwise. The LED should light. r Check the potentiometer R6 and the speaker. Make sure the speaker’s wires are soldered correctly and not shorting together. If LED does not light; Make sure the diode D2 and LED D3, capacitor C2, and U2 are mounted in the correct position as marked on the PC board. Figure 1 CIRCUIT DESCRIPTION amplifier then follows, amplifying only one of those signals - the one whose frequency is equal to the IC - followed by the limiter, the demodulator, mute control circuit, and pre-audio amplifier. The FM-88K is an auto-scan radio containing two switches, scan “S” and reset “R”. Tuning is done by using a varactor diode (D1) instead of a tuning gang found in most radios. The varactor’s capacitance is changed by varying the DC voltage supplied to its anode over resistor R3. The model FM-88K is a monophonic FM receiver made on base TDA7088T IC, as shown in the schematic diagram (Figure 2). The circuit contains two ICs, speaker, two coils, and a few other components. The IC TDA7088T (U1) (depending on the manufacturer, may be type SC1088, SA1088, CD9088, D7088, or YD9088) is a surface mount, bipolar integrated circuit of a proper FM “superheterodyne” receiver. The IC contains a frequency-locked-loop (FLL). The station signals led from the telescopic antenna to the input circuit consists of L1, C5, C6 and C7. It is a parallel oscillatory circuit damper with resistor R4. Inside IC signals are led into the mixer, where they are given a new carrier intermediate frequency. The IF Voltage reference chart for U2 LM386 Check that resistor R1 is the correct value. Pin # Voltage Pin # Voltage Check if the battery is properly installed in the battery holder and that the power switch is operational. 1 2 3 4 1.3 0 0 0 5 6 7 8 4.5 9.0 4.5 1.3 Check capacitors C3 and C17. r 2. Touch the bottom and mounting pins with one finger as shown in Figure H. You may need to wet your finger. Voltage Regulator Circuit Check the following voltages. r 1. Voltage across D2 and D3 should be 2.6V r 2. Voltage across the LED D3 should be 1.9V. This is how the tuning is performed: When switch S1 “S” (Scan) is pressed and released, a positive voltage is applied to the input of the Tuning Search circuit pin 16. Capacitor C14 starts charging and the voltage on pin 16 increases. This voltage is Turn the power switch off and remove the battery from the holder. SCHEMATIC DIAGRAM FM-88K Figure H FM RADIO HIGHLIGHTS 1. The FM broadcast band covers the frequency range from 88MHz to 108MHz. 5. The number of times the carrier frequency changes in a period of time is exactly equal to the audio frequency. 2. FM signals are usually limited to line a sight. 6. The bandwidth assigned for FM is 200kHz. 3. Audio signals up to 15kHz are transmitted on the FM carrier. Figure 2 -5- 4. The amount that the RF carrier changes frequency is determined by the amplitude of the modulating signal. -10- ASSEMBLE COMPONENTS TO THE PC BOARD Place a check mark transferred through resistor R3 to the anode of the varactor diode D1 (BB910), causing its capacitance to decrease. Decreasing the capacitance of D1 increases the frequency of the local Oscillator (VCO). in the box provided next to each step to indicate that the step is completed. The Oscillator voltage and signals of all the other FM stations (Fs) from pin 11 are inputted into the Mixer. The output of the mixer is only FM signals whose frequencies are equal to the differences of the oscillator and the original station frequency. C1 - 100μF, Electrolytic (see Figure D) R2 - 18kΩ 5% 1/4W Res. (brown-gray-orange-gold) C13 - 680pF Discap (681 or 680) Equivalent Schematic and Connection Diagrams VS 6 15kΩ 7 BYPASS 15kΩ GAIN 8 Only a signal whose carrier frequency is equal to IF can reach the “Demodulator”. Selectivity (ability to “pick out” one station while rejecting all others) is accomplished by two active filters made from the capacitors connected to pins 6, 7, 8, 9 and 10). The oscillator frequency increases until the condition Fo – Fs = 70kHz is accomplished. When this happens, the charging of the capacitor is halted by the command that is sent into the “Tuning Search” circuit by two detectors (diode-blocks) located in the “Mute Control” circuit. D1 - BB909/BB910 Varactor (see Figure G) C17 - 0.1μF Discap (104) Figure G Your kit contains one of two types of varactor. Use the figure that corresponds to your varactor style for mounting instructions. Mount the varactor flush to the PC board with the printed band in the same direction as marked. Solder and cut off excess leads. Beveled edge 0.05” 0.3” -OR- r Install speaker Step 1 + Step 2 Step 3 Pad PC board marking Backing r Install battery holder Bend the leads of the battery holder as shown. Fasten the battery holder to the PC board with a M1.8 x 7.5mm screw and M1.8 nut. Solder the leads to the PC board pads as shown. Outer edge of PC board Backing Speaker M1.8 x 7.5mm Screw Step 1: If the speaker pad has center and outside pieces, then remove them. Peel the backing off of one side of the speaker pad and stick the pad onto the speaker. Battery holder Foil side of PC board Step 4 Step 2: Remove the other backing from the speaker pad. Step 3: Stick the speaker onto the solder side of the PC board. Solder Step 4: Solder two 1½” wires from the speaker to the pads +SP and –SP. -9- 1½” wires PC board (foil side) GAIN 1 15kΩ 5 VOUT 150Ω 1.35kΩ 2 3 – INPUT + INPUT 50kΩ 50kΩ 4 GND Dual-In-Line and Small Outline Packages GAIN In order to hold the frequency, the voltage on pin 16 must not change until the “Scan” switch is pushed again. That is the function of the AFC (Automatic Frequency Control) circuit; controlling the voltage on pin 16. Printed band M1.8 Nut Capacitor C20 is a bypass and necessary for an amplifier with a high gain IC. Capacitor C18 blocks the DC to the speaker while allowing the AC to pass. – INPUT + INPUT GND When the switch S2 “R” (Reset) is pushed, the capacitor C14 is discharged, the voltage on pin 16 drops down to zero, and the receiver is set to the low end of the reception bandwidth 88MHz. 1 8 2 7 3 6 4 5 GAIN BYPASS VS VOUT Top View Figure 3 Typical Applications Capacitor C23 and resistor R2 filter out the radio frequency component of the signal, leaving a clean audio signal. Capacitor C22 couples the audio signal to the input of the power amplifier. Since the maximum operating DC voltage of the U1 is 5V, the battery voltage must be regulated down. Components D2, D3, R1, C1, C17 and C* make up that circuit. Amplifier with Gain = 20 Minimum Parts VS 2 1 8 5 LM386 VIN 10kΩ 6 – 3 + 7 + .05μF 4 10Ω Figure 4a Our kit uses the standard design for the audio amplifier on base of the integrated circuit (U2) LM-386, or identical. In Figure 3, you can see equivalent schematic and connection diagrams. To make the LM-386 a more versatile amplifier, two pins (1 and 8) are provided for gain control. With pins 1 and 8 open, the 1.35kΩ resistor sets the gain at 20 (see Figure 4a). The gain will go up to 200 (see Figure 4b) if a capacitor (capacitor C21) is placed between pins 1 and 8. The gain can be set to any value from 20 to 200 if resistor is placed in series with the capacitor. The amplifier with a gain of 150 is shown in Figure 4c. The amount of gain control is varied by potentiometer R6, which also varies the audio level and, consequently, the volume. 2 6 – 1 LM386 VIN 10kΩ Amplifier with Gain = 200 10μF + VS 3 7 8 5 + + .05μF 4 BYPASS 10Ω Figure 4b Amplifier with Gain = 150 VS 2 3 1 7 -6- 8 5 + 4 Figure 4c + 10μF 6 – LM386 VIN 10kΩ 47Ω + 10Ω BYPASS .05μF CONSTRUCTION SECTION 1 • Turn off iron when not in use or reduce temperature setting when using a soldering station. Introduction The most important factor in assembling your FM-88K Auto-scan FM Radio Kit is good soldering techniques. Using the proper soldering iron is of prime importance. A small pencil type soldering iron of 25 - 40 watts is recommended. The tip of the iron must be kept clean at all times and well-tinned. • Tips should be cleaned frequently to remove oxidation before it becomes impossible to remove. Use Dry Tip Cleaner (Elenco® #SH-1025) or Tip Cleaner (Elenco® #TTC1). If you use a sponge to clean your tip, then use distilled water (tap water has impurities that accelerate corrosion). Solder ASSEMBLE COMPONENTS TO THE PC BOARD Place a check mark Safety Procedures For many years leaded solder was the most common type of solder used by the electronics industry, but it is now being replaced by lead-free solder for health reasons. This kit contains lead-free solder, which contains 99.3% tin, 0.7% copper, and has a rosin-flux core. • Always wear safety glasses or safety goggles to protect your eyes when working with tools or soldering iron, and during all phases of testing. • Be sure there is adequate ventilation when soldering. Lead-free solder is different from lead solder: It has a higher melting point than lead solder, so you need higher temperature for the solder to flow properly. Recommended tip temperature is approximately 700OF; higher temperatures improve solder flow but accelerate tip decay. An increase in soldering time may be required to achieve good results. Soldering iron tips wear out faster since lead-free solders are more corrosive and the higher soldering temperatures accelerate corrosion, so proper tip care is important. The solder joint finish will look slightly duller with lead-free solders. ' • Locate soldering iron in an area where you do not have to go around it or reach over it. Keep it in a safe area away from the reach of children. in the box provided next to each step to indicate that the step is completed. D3 - Red LED (see Figure A) Figure A Mount the LED flush to the PC board with the flat side in the same direction as marked. Flat D2 - 1N4001 Diode (see Figure B) R1 - 680Ω 5% 1/4W Res. (blue-gray-brown-gold) PC board marking • Do not hold solder in your mouth. Solder is a toxic substance. Wash hands thoroughly after handling solder. C2 - 220μF, Electrolytic (see Figure C) Assemble Components C3 - 0.1μF Discap (104) In all of the following assembly steps, the components must be installed on the top side of the PC board unless otherwise indicated. The top legend shows where each component goes. The leads pass through the corresponding holes in the board and are soldered on the foil side. Use only rosin core solder. Use these procedures to increase the life of your soldering iron tip when using lead-free solder: • Keep the iron tinned at all times. C20 - 22μF, Electrolytic (see Figure D) R5 - 10Ω 5% 1/4W Res. (brown-black-black-gold) DO NOT USE ACID CORE SOLDER! • Use the correct tip size for best heat transfer. The conical tip is the most commonly used. What Good Soldering Looks Like C19 - 0.047μF Discap (473) Types of Poor Soldering Connections U2 - 8-pin IC Socket U2 - LM-386 IC (see Figure E) A good solder connection should be bright, shiny, smooth, and uniformly flowed over all surfaces. Soldering Iron 1. Solder all components from the copper foil side only. Push the soldering iron tip against both the lead and the circuit board foil. Rosin Component Lead Foil 3. Allow the solder to flow around the connection. Then, remove the solder and the iron and let the connection cool. The solder should have flowed smoothly and not lump around the wire lead. R6/S3 - Potentiometer Nut & Washer Knob (see Figure F) Soldering iron positioned incorrectly. Circuit Board 2. Apply a small amount of solder to the iron tip. This allows the heat to leave the iron and onto the foil. Immediately apply solder to the opposite side of the connection, away from the iron. Allow the heated component and the circuit foil to melt the solder. C18 - 220μF, Electrolytic (see Figure D) 1. Insufficient heat - the solder will not flow onto the lead as shown. Soldering Iron 2. Insufficient solder - let the solder flow over the connection until it is covered. Use just enough solder to cover the connection. Solder Foil Solder Gap Component Lead Mount the diode flush to the PC board with the printed band in the same direction as marked. Printed band Solder 3. Excessive solder - could make connections that you did not intend to between adjacent foil areas or terminals. Soldering Iron Solder PC board marking Figure C 4. Here is what a good solder connection looks like. Figure F Polarity mark Electrolytics have a polarity marking indicating the (–) lead. The PC board is marked to show the lead position. Cut the tab off of the potentiometer as shown. Insert the potentiometer into the PC board holes, from the foil side, as shown. Place the washer over the shaft and tighten the nut. Solder the potentiometer into place and then insert the knob onto the shaft. Warning: If the capacitor is connected with incorrect (–) polarity, or if it is subjected to voltage exceeding its working voltage, it may heat up and either leak or cause the capacitor to explode. (+) Cut tab Knob Potentiometer Foil 4. Solder bridges - occur when solder runs between circuit paths and creates a short circuit. This is usually caused by using too much solder. To correct this, simply drag your soldering iron across the solder bridge as shown. Figure D Figure B Soldering Iron Mount capacitor C2 on the back of the PC board in the location shown. Make sure the lead with the polarity marking is in the correct hole as shown. Polarity mark (+) marking Foil Figure E Insert the IC socket into the PC board with the notch in the direction shown on the top legend. Solder the IC socket into place. Insert the IC into the socket with the notch in the same direction as the notch on the socket. Foil side of PC board Washer Legend side of PC board Notch Drag Solder -7- Nut -8- Shaft
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