HFpackerAmplifier

Project Manual

(Manual version: Sept. 2003)

Virgil Stamps K5OOR
and volunteers

HFpacker-Amp

Introduction
Welcome all builders to the homebrew Hfpacker-Amp Project.
This project and your efforts will provide you with a 2 watt input to
35 watt output linear amplifier for use with QRP SSB/CW
transmitters on the amateur bands 160 through 10 meters and
which can be powered from a 12 volt DC supply. The design is a
good balance between output power, physical size and battery
power consumption. The completed amplifier will reward the
builder with a clean, more powerful output signal for a QRP rig
when radio conditions become marginal.
This project is not a beginner's project and requires a medium skill
level to complete it successfully. Builders require soldering, hand
tool, basic electronics and component identification skills. This
project manual is not included with the project parts in order to
keep costs to a minimum. Instead it is available as a PDF
document file from http://www.hfprojects.com. The manual is
produced in landscape format to allow more readable text per
screen. This manual provides all you will need to successfully
complete the amplifier project, however, some additional PDF files
are provided at the above website for those interested in seeing
more pictures of the project at various stages of construction.
The genesis of this circuit is fully described in the 2001 ARRL
Handbook and in reprint articles from the ARRL. If you are an
ARRL member, you can view the amplifier articles on-line at:
http://www.arrl.org/members-only/tis/info/pdf/9903040.pdf and
http://www.arrl.org/members-only/tis/info/pdf/9903043.pdf. Full
design credit is given to Mike Kossor, WA2EBY. This amplifier
project comprises three printed circuit board modules: an RF
amplifier module containing the MOSFETs, a switch-mode power
supply module which converts 12VDC to 24VDC and a bandpass
HFpacker-Amp

filter module. The amplifier module is mounted to the inside

bottom of the chassis box and its MOSFETs are attached to a heat
sink. The power supply board is fastened above the amplifier
board, while the filter board is mounted vertically along one side
end of the chassis.

Circuit Details
The amplifier module is a push-pull design, biased for Class AB
linear operation and uses low-cost power MOSFETs in its output
stage. Maximum efficiency is at 10 MHz and develops over 70
watts input. QRP transmitter RF input is first sensed, which trips a
relay, feeding RF through an RF attenuator pad. The signal is then
applied to the primary of T3 via an input impedance-matching network consisting of L2. T3 is a 1:1 balun that splits the RF signal
into two outputs 180 degrees out of phase. One of these signals is
applied by C3 to Q1's gate. The other signal is routed via C8 to
Q2's gate. The drains of Q1 and Q2 are connected to the primary of
output transformer T1, where the two signals are recombined in
phase to produce a single output. T1 also provides impedance
transformation from the low output impedance of the MOSFETs to
the 50 antenna port. DC power is provided to the drains of Q1
and Q2 by phase-reversal choke, T2. This is a very effective
method to provide power to Q1 and Q2 while presenting a high
impedance to the RF signal over a broad range of frequencies. The
drain chokes for Q1 and Q2 are wound on the same core, and the
phase of one of the chokes is reversed. C7 increases the bandwidth
of impedance transformation provided by T1, especially at 21
MHz. The 5 V bias supply voltage is derived from a 78L05
regulator. Bypass capacitors C5, C6, C10 and C11 remove RF
voltages from the bias supply voltage. Gate bias for Q1 and Q2 is
controlled independently. VR1 adjusts Q1's gate-bias voltage via
R1 and L1. VR2 works similarly for Q2 via R5 and L3. At low
2

frequencies, the amplifier's input impedance is essentially equal to

the series value of R1 and R5. L1 and L3 improve the inputimpedance match at higher frequencies. The low value of series
resistance provided by R1 and R5 also reduces the Q.
The switch-mode power supply module plugs into the top of the
amplifier board and boosts the nominal 13.6VDC input to 24VDC
at 4-5 amperes during voice peaks. The power supply is normally
off unless commanded to be on by the TR Relay, which senses RF,
so that during receive or standby its standby current is very low.
There is a 10 mA current draw when power supply is off, 80.0 mA
current draw when power supply is on and 5A current draw when
the amplifier is keyed by a transceiver for power output of 35 watts.
The circuit is reverse polarity and overcurrent protected. In the
transmit mode, the power supply develops 24VDC at J3. The
voltage output measured at TP3 is controlled by U1, an LT1270
switching regulator. The output voltage is sensed back at pin 2
from the voltage divider R4 and R7. U2 is an IPS511 device which
provides short-circuit protection and zero volts out when the power
supply is off. An internal current limit of 5A is continually
monitored by U2. In the event of over-current, the output voltage
drops to zero. The U2 device purposely goes into a thermal
shutdown and has a temperature hysteresis time delay before
attempting to supply current again. A toggle switch connected to J5
can place the MOSFET amplifier in the tune and/or standby modes
when toggle switch is closed. A closed toggle switch position
inhibits DC output and the amplifier is thus off. With an open
toggle switch the Hfpacker-Amplifier is on.
The filter module board attaches to one internal side of the chassis
with a 6 position rotary switch. It has 6 low-pass filters covering
the amateur bands 160 through 10 meters for bandpass filtering.
These filters suppress harmonic output and comply with FCC
regulations. Frequency selection is made using SW4, a 2-pole, 6position rotary switch.

HFpacker-Amp

Specifications
Size

5.1 x 3 x 3.3 (LWD, including heat

sink)

Weight

less than lb.

Supply voltage

8.5 to 15 VDC (13.8V nominal);

reverse-polarity protection;
internal self-resetting fuse

Current drain,
Standby
Transmit
Filter Selection
Frequencies
Control
Input
Output
Power cable
Drive requirement
Power output
Duty cycle
Forced air
Intermittent
Spurious products
Harmonic content
Load tolerance
T-R delay
Control
Voltage Booster

less than 10 mA
8-9 A at 35-40 Watts
6-position rotary switch
160, 80, 40, 30-20, 17-15, 12-10 meters
Standby/Operate toggle switch
BNC 50 ohm
SO239 50 ohm
2-pin inline quick-disconnect
2.5 watts RF (with internal 4 dB pad)
35 watts RF 160 10 meters
Designed for intermittent SSB service
100%
50%
-40 dB or better @ 35 watts
-45 dB or better @ 35 watts
2:1 or better SWR recommended
approximately 10ms
RF sensing T-R relay
12 to 24 VDC buck-boost switching
regulator is activated to power the
MOSFET amplifier while transmitting.

Specifications above assume a 13.8 VDC supply and 50-ohm load

at the antenna.

Preparation
The most important preparation step before building is to
completely and thoroughly read this manual. This will familiarize
you with the project, its circuitry, building requirements and
components.
There are six steps in the Hfpacker-Amplifier assembly
process:
1. Chassis and Heat Sink preparation
2. RF amplifier board assembly
3. Power supply board assembly
4. Filter board assembly
5. Interconnect cables and Chassis assembly
6. Bias adjustment and Testing
After reading this document and prior to assembly you
should do an inventory of parts (Appendix A). In the unlikely event
that you appear to have missing parts, duplicates or wrong parts
please first double check for the parts in all bags, recheck the
inventory and if this fails please contact the project organizers. This
might also be the time to re-acquaint yourself with how to identify
resistors and capacitors by the standard codings (Appendix E), if
you have forgotten.

Construction Techniques
It is a fact that 90-95% of problems with completed
electronics/radio kits are due to either component misplacement or
soldering faults. We cannot stress highly enough the importance of
double checking component installation before soldering and then
good soldering technique in order to have a working amplifier at
the end of this project. Other builder faults are active component
damage due to over-heating and damage to circuit board pads and
tracks caused by poor desoldering, too high a wattage of soldering
HFpacker-Amp

iron or carelessness. It is very rare to have initially faulty

components or printed circuit boards (PCBs).

Good Soldering Technique

use a 12-25 watt soldering iron with a clean, non-corroded, welltinned, fine tip
keep the tip clean by frequently rubbing it along a wet sponge
keep the tip tinned
ensure all circuit board pads and component leads are clean (not
a problem with this project because boards and components are
new)
ensure the soldering iron tip is at its working temperature and is
in contact simultaneously with both surfaces to be soldered (the
pad and the component)
let the contact zones heat before applying only electronics grade
rosin cored solder (usually 3-6 seconds will do)
apply the solder to the two surfaces (not the iron tip) and only
enough solder to coat both surfaces
ensure that the joint does not move after you remove the
soldering iron tip and until the solder has solidified
the resultant good solder joint should be shiny, in perfect contact
with pad and wire and often has a concave upwards appearance
special care for toroid coils: the toroids and inductors you will
wind and solder in this project use enamel coated magnet wire.
You must remove this insulation coating at the ends of the wires
prior to soldering. Two techniques are: 1) use a small butane
cigarette lighter to burn off the insulation material or 2) take a
large drop of hot solder on your soldering iron tip and run the
wire end through the hot solder blob to remove the insulation
(this may not work with low wattage irons). Other methods such
as using sandpaper or a razor knife will work but you may
damage the wire or the toroid windings if you are not careful.

Suggested Tools
12-25 watt electronics soldering iron, electronics grade solder,
iron stand and sponge
desoldering braid and/or desoldering pump or bulb
fine needle nose pliers, small fine wire cutters, wire stripper
hobby drill and small drill bits,electric drill and drill bits, drill
punch or awl, reamer
drill bits: #60, #43, 1/16, 1/8, 3/16, 1/4, 5/16, 3/8, 5/8, 1 (last
two may be boring bits, punches or reamer)
4-40 NC size tap with tap handle
small screwdrivers including jewelers screwdrivers, small file
multi-meter, scissors, tape or glue stick, ruler, test leads
50 ohm 35 watt dummy load, 50 ohm resistors

Component Installation
For each component, our word Install always means:
1. Pick the correct part to start with in the assembly notes that
follow we often provide a part number only. You must match
this part number with the correct component using the parts lists
(Appendix A). Some parts may be in bags other than their own
module bags.
2. Insert the component into the correct PCB position. Refer to the
PCB component outline (silkscreen) and Appendix D for the
filter module.
3. Orient it correctly, following the PC board outline. This is vital
for active components, electrolytic and tantalum capacitors and
diodes. Also, it is good practice to mount resistors and
capacitors in identical orientations (for resistors normally read
color code left to right in same direction as the silkscreen on the
PC board). This makes component checks easier.
4. Install all low profile components first: usually resistors,
capacitors, diodes, then electrolytics and active components.
5. Resistors should be mounted about 1/8 above the board.
HFpacker-Amp

6. Mount all capacitors, relays and connectors as flush to the board

as possible.
7. Bend the wires of the components at the bottom side slightly
outwards in order to hold the component in place for soldering.
8. Solder as per techniques described above.
9. Trim excess wire leads.
10.Mark off each installation step in sequence as you complete it,
in the box provided (e.g.
).
11.Warnings and important points are posted with a

symbol.

Winding Toroids
To wind a toroidal inductor, pull the correct wire length
through the toroid core center, dividing the wire length in half.
Wrap half the turns with one wire end and then wrap the remaining
turns with the other end, in the direction shown in Figure 1. Each
pass through the center of the core counts as one turn (e.g., in
Figure 1 there are 3 turns). After winding, the turns should be
evenly spaced around most of the core, leaving a small (about 30)
gap between the first and last turns (i.e. about 85% of the
circumference of the toroidal core should contain evenly spaced
wire turns). You must then remove the insulation coating the ends
of the two toroid wire ends using techniques described above.

Figure 1

Care of the IRF-510 MOSFET's

MOSFETs are susceptible to electrostatic discharge damage
(ESD). It is important to use proper grounding techniques while
handling the amp circuit board and the MOSFETs in particular.
While working with MOSFETs you should wear a grounding strap
and have an antistatic mat at your feet. At the very least you should
frequently ground your hands to the nearest ground point. The
IRF510 is a good compromise MOSFET that will work up to 30

HFpacker-Amp

MHz but has poor thermal characteristics of 3.5C/Watt. When

used in intermittent SSB and CW service forced-air cooling is not
required. Tuning time with full power should be limited to less than
30 seconds with 1-2 minutes between cycles to prevent. Operating
at 24VDC does not press the MOSFET to their limits. The Sil-Pad
TO220 mounting kit has excellent thermal performance and
provides a greaseless thermal interface between the MOSFET and
the heatsink. Users report that this amplifier can be safely used for
contest CW operation without further cooling. For PSK/RTTY
forced air cooling is necessary or a reduction of power by reducing
the input drive.

Chassis and Heat Sink

Preparations
It is recommended that the builder start by preparing the chassis
and heat sink before assembly of the circuit board modules because
alignment of the MOSFETs requires that the chassis heat sink holes
and heat sink taps have been prepared beforehand. Also, seating of
the filter board requires that the chassis holes have been drilled.
Templates for drilling chassis holes and for drilling and tapping of
the heat sink are located in Appendix B. These are CAD drawings
which are exactly to scale in this document.

Test the threads with a 4-40 bolt or spacer. Be careful when

threading these into the heat sink. You do not want to break off any
threads.
File the edges of the holes lightly to remove burrs.

Chassis Holes Drilling

Cut out the chassis templates with scissors and paste or tape
them onto their appropriate positions on the aluminum chassis. See
example in Figure 2 and note below.

Print out the Appendix B template pages, ensuring that printer

settings are such that the pages are printed as shown (i.e. no fit to
page, nor scales other than 100%).
Check your printout scaling by measuring the templates with a
ruler and comparing those to the measurements shown on each
drawing.

Heat Sink Modification

Cut out the heat sink template with scissors and paste or tape it
to the back of the heat sink.
Start the holes with a hole punch, awl or pick and then drill the
six marked holes with a pilot (small sharp bit). A Dremel with a
#60 bit will do, or a regular hand drill with a 1/16 bit. A drill press
will enable better alignment, but is not necessary.
Enlarge the six holes with a #43 drill bit, just to the point where
the bit comes through the fins of the heat sink.
Tap thread the holes using a 4-40 thread hand tap. Tap at least
1/8 deep. If you feel resistance back off the tap to remove cuttings.
Oil on the tap and in the hole will help.
HFpacker-Amp

Figure 2. Using a template for drilling

It is vital that the builder position the end panel templates

correctly, in relation to the off-center large heat sink mount holes as
shown above. The orientation is shown in Figure 2 and Appendix
B templates and must be followed exactly.
Drill all the marked holes on the chassis templates with a pilot
7

(small sharp bit), after using a pick or drill punch to start the hole.
A Dremel with a #60 bit will do, or a regular hand drill with a
1/16 bit.
Drill the holes out to the size as listed on the drawings. If you do
not have 5/8 and 1 bits for the larger holes use a reamer, boring
bit or chassis punch.
File the edges of the holes lightly to remove burrs.

MOSFET Amplifier
Module Board Assembly
Install resistors R1 through R7.
__R1 __R5: 27 , W (red, viol, blk)
__R2: 24 , 1 W (red, yel, blk)
__R3 __ R4: 220 , 1W (red, red, brn)
__R6: 1.2K, W (brn, red, red)
__R7: 4.7K, W (ylw, viol, red)
Install ceramic disc capacitors C1, C3, C4, C5, C6, C8, C9, C10
and C11 (all 0.1 uF (104)).
__C1 __C3 __C4 __C5 __C6
__C8 __C9 __C10 __C11
Install C14 (0.01uF, 103).
Install C12 and C15 (.001uF, 102).
Install C7 (47pF).
Install C2, a radial electrolytic capacitor (10uF). This cap is
polarized. Insert + lead in the square pad at C2 outline on. The +
lead is longest.
Install dip molded capacitor C13 (2.2uF), also polarized.
Install diodes D1 and D3 (1N4148). The black ring on the diode
is the cathode. Form the diode leads with approximately 3/16-inch
lead on each side of the body. Use a pair of needle-nose pliers and
make a 90- degree bend. The white line on the PCB outline is the
cathode end. D3 needs to be mounted towards the edge of the board
to clear the connector jack J4, installed later.
HFpacker-Amp

Install diode D2 (1N4004). The cathode band on the diode

aligns with the white stripe of the component outline.
Install potentiometers VR1 and VR2. Rotate both
potentiometers until they are centered in the middle of their
operating range (in order to assist in correct placement). The pot
will stand up off the board resting on the shoulders of the leads.
Make sure it is flush on all three leads. Install VR1, VR2 to PC
board with blue arrow pointed directly towards the IRF-510
MOSFET silkscreen positions.
Using a small bladed screwdriver, now turn both pots fully
clockwise. This will be the starting position when adjusting the
MOSFET transistor bias later. Fully clockwise places the wiper of
the potentiometer at ground or zero bias voltage.
Install K1. Make certain the pins are straight. Two pins on the
end of the relay are spaced further apart from the other pins. Orient
the relay to align with the pattern on the board. Insert the relay and
ensure that all 8 leads are visible on the solder side. Solder one
corner pin making sure relay is flush to the board. Press down on
the relay while quickly re-heating the pin just soldered to ensure
relay is flush to the board. Solder the remaining pins.
Install U1 (7805). Spread the leads of the IC just slightly to
match the hole pattern on the board. Ensure the flat of the IC
matches the flat of the component outline. The body of U1 should
be spaced about 1/4 inch away from the board.
Install J6 (5-pin connector). Ensure connector is flush against
the board and perpendicular. Solder one pin. Inspect alignment. Reflow the soldered pin for final position. Solder the remaining pins.
Install J1 (3-pin connector), as above.
Install Q3 (2N5089). Spread the leads of the transistor just
slightly to match the hole pattern on the board. Ensure that the flat
of the transistor matches the flat of the component outline. Q3
should be spaced about 1/4 inch away from the board.
Install TP1, TP2, TP3. Orient the wire of the test points in the
same direction for consistency.
Install J2, J3, J4, J5. Orient the board with the relay viewed in
the lower right corner. The locking ramps of J3 (Ant) and J5
8

(Filter-B) are on the left, next to the relay. J2 (Filter-A) has its
locking ramp to the left, while J4 (Xcvr) has the locking ramp to
the right.
Install two 3/4 inch x .187 round spacers on the left side of the
board at the inside set of holes on the left edge of the circuit board.
Use two nylon washers and 4-40 x 3/16 inch screws attached from
the backside.
Install temporarily two inch hex male/female threaded
spacers. Use two 4-40 nuts on the backside to retain the spacers.
The nuts will later be replaced with threaded spacers attached to the
chassis when the amplifier is placed on the chassis.

T1 Transformer Construction
T1 has a primary and secondary winding on the BN-43 3312 balun
core (the large 2 hole ferrite core). Use the #20 AWG Teflon
covered wire to construct T1. See Figure 3 (left side) for a photo of
a completed T1.

Run the primary wire through first. Make sure to keep the wires
from crossing over and unnecessarily blocking the wiring tube.
When you complete running the primary winding you should have
two wire ends sticking out one end of the balun tube.

Mark the primary side by putting a dab of fingernail polish on

the core.
Run the secondary wires through. Be careful to organize the path
the wire takes so as to not block the wiring path. It may appear
difficult to pass the last wire through the tube but it can be done.
After you complete the windings, you will have primary wires on
one end and secondary wires on the other end.
Strip the wires within inch of the tube hole.
Place the primary wires on the right side of the rectangle near
capacitor C7 on the amplifier PCB. The secondary wires go to the
left side of the rectangle near J2.
Feed the primary wires into the board and pull them up tight into
the holes. You should not have any strands of wires showing when
you pull the wire tight into the hole. Solder the primary wires.
Feed the secondary wires into the board and pull them up tight
into the holes. A tiny bit of solder right at the very tip end of the
strands will hold them together as you push them through the holes.
Solder the secondary wires.
Position the transformer over the T1 outline. The transformer is
now suspended by the four wires and hovering possibly 1/8 inch
above the board. Press the transformer down to the board. The
leads will hold the transformer in this position.

T2 Transformer Construction
Figure 3. Photos of T1, T2 and T3

Prepare two wires. The first primary wire is 6 inches long.

The second secondary wire is 10 inches long. The primary will be
two loops while the secondary will be three full loops.
HFpacker-Amp

T2 uses two stacked FT-50-43 cores and has ten bifilar turns of #22
wire. See center of Figure 3.
Measure and cut two #22 wires, each 15 inches long. Twist
9

these two wires together, with about 4 twists per inch.

through the cores on the board. When oriented in this position, T2

will fit the component outline. See Figures 4 and 5.
With the PCB oriented such that T1 is in the left hand corner then
Lead 1 is upper right, with square pad, Lead 2 is lower right, Lead
3 is upper left and Lead 4 is lower left.
Put the 4 leads through the board and snug up T2 tight to the
board. Solder. Inspect your joints to make certain that solder flows
onto the wire and into the holes.

Figure 4. T2 and T3

Pass the twisted wire through the center of the two cores. Find
the center of the wire and bend around the cores in a U shape. Hold
one half wire set steady and wind the other wire half through the
center of the cores 5 times.
Pass the remaining wire end through the center 5 more times.
You now have a total of ten (10) turns through the center of the
cores.
Equally distribute the windings on the cores.
Unravel the twists on the wire ends.
Trim these ends so that only 3/8-inch leads remain.
Use a butane cigarette lighter, hot blob of solder, sandpaper,
emery board or small file to remove the enamel from the 4 wires.
Tin these leads.
Use an ohmmeter to determine the two windings. On the
schematic diagram (Appendix C) the first winding is labeled pins 1
and 2 (there should be zero ohms reading between pins 1 and 2).
The second winding is labeled pins 3 and 4 (zero ohms reading
between pins 3 and 4). Make certain the two windings are not
shorted. The circuit board has a square pad identifying lead 1 of the
transformer.
Lay the board flat in front of you with T1 at the top. TP1 should
be in your upper left corner.
Viewing the windings of T2 orient T2 so the wires run vertically
HFpacker-Amp

T3 Transformer Construction
T3 uses one FT-50-43 core and has ten (10) bifilar turns of #24
wire.
Measure and cut two #24 wires, each 11 inches long. Twist
these two wires together with about 4 twists per inch.
Wind 10 turns exactly as explained in the section above for
transformer T2.
Equally distribute the windings on the core. Unravel the twist on
the remaining ends of the wires. Trim these ends so that only 3/8inch leads remain.
Remove the enamel insulation (see Soldering Techniques)
from the 4 wire ends. Tin the leads thoroughly.
Use an ohmmeter to determine the two windings. The first
winding is labeled pins 1 and 2 (there should be a zero ohms
reading between pins 1 and 2). The second winding is labeled pins
3 and 4 (zero ohms reading between pins 3 and 4). Make certain the
two windings are not shorted. The circuit board has a square pad
identifying lead 1 of the transformer.
Lay the board flat in front of you with T1 at the top. TP1 should
be in your upper left corner. Viewing the windings of T3 now,
orient T3 so the wires run vertically through the cores on the board.
When oriented in this position, T3 will fit the component outline.
Orient the PCB oriented such that T1 is in the left hand corner:
10

lead 1 is lower left with the square pad, lead 2 is upper left, lead 3
is lower right and lead 4 is upper right.
Put the 4 leads through the board and snug up T3 tight to the

Inductors Assembly
NOTE : Frequent questions concerning 10 or 9 1/2 inductor
turns are answered in Figure 7. The next series of steps fabricate
L1, L2 and L3 using #24 enameled transformer wire. L1 and L3
have 9 turns of #24 close wound on a 0.25 inch ID. These two
inductors are identical in size and are formed by wrapping the turns
over the shaft of a inch drill bit.

Figure 5. T2 soldering positions on PCB.

Figure 7. Counting inductor turns.

Figure 6. T3 PCB position.

board. Solder. Inspect your joints to make certain that solder flows
onto the wire and into the holes. It will take a little more heat to
flow pin 3 since it is the ground plane.

HFpacker-Amp

Cut two 12 inch lengths of #24 AWG enameled magnet wire.

Wrap each wire around a drill bit shaft 10 times to make two
separate inductors. By wrapping the wire around the shaft 10 times
you will get 9 turns. The last turn arcs only turn before entering
the circuit board.
Trim the excess leads to 3/16 inch. Burn or scrape the insulation
off the ends of the wires, tin with solder and insert into the circuit
board. The wires poking through on the circuit side should be
adjusted to protrude only about 1/8 inch. Solder.
Align the inductors directly over the L1 and L3 outline on the
board using tweezers. The windings should remain close wound.
Cut a 4-inch length of #24 AWG enameled magnet wire. L2 has
11

3 turns of #24 close wound on a 0.19 inch ID. Form the inductor
by wrapping the turns over the body of a .187 aluminum spacer.
Wrap the wire around the spacer 4 times. Trim the excess leads to
3/16 inch. Burn or scrape the insulation off the ends of the wires,
tin with solder and insert into the circuit board. Solder.
Adjust the inductor position to be directly over the L2 outline on
the board. The windings should remain close wound.

The MOSFETs will be secured to the heat sink during final chassis
assembly.

Power Supply Module

Board Assembly

MOSFET Installation
Be aware that the sensitivity of a MOSFETs gate makes
them vulnerable to damage by ESD. If possible, use a soldering
iron with a grounded tip. It is recommended the builder wear a
wrist strap and use an anti-static mat. At the very least, you should
frequently ground your hands to the nearest ground point.
Attach four .187 x .25 inch male/female spacers temporarily on
the bottom side of the circuit board with four 4-40 nuts. The
male/female spacers are in the chassis parts bag.
Install the MOSFETs under the circuit board. Bend the leads 90
degrees up (away from the mounting surface of the MOSFET)
about 0.2 inch away from the body. Push the leads up through the
pads on the circuit board.
Locate the heat sink. You will use it temporarily to set the
spacing of the MOSFETs from the back side of the circuit board.
Ensure the MOSFET is flat against the heat sink with the circuit
board sitting on the spacers and flat on top of the heat sink. Note
also, that the thickness of the chassis (0.06 inch) needs to be
accounted for. Sandwich the chassis and heat sink together to get
the proper spacing.
Solder the leads from the component side of the board. Do not
bend the leads. Trim the leads flush with the board after soldering.
Center the hole in the tab of MOSFET with the access hole on
the circuit board. You can adjust the MOSFET position slightly by
placing the end of small file through the holes to leverage the
movement.
HFpacker-Amp

This power supply module is revision 2.0 and includes a revised

VOX circuit to eliminate voice clipping.
Install all resistors:
__R2: 1.0 W (brn, blk, gold)
__R3 __R9 __R12 __R15: 4.7K W (ylw, viol, red)
__R4 __R14: 22K W (red, red, orn)
__R5 __R8: 100K W (brn, blk, ylw)
__R6 __R7: 1.2K W (brn, red, red)
__R16: 2.7K W (red, viol, red)
Install capacitors __C6, __C7, __C8. Observe the lead with the
+ mark on C8. The + lead goes to the hole with the + symbol
(square pad).
Install Dl (RL251). The silver band of the diode aligns with the
white stripe of the component outline.
Install __D3, __D5 (1N4148). The black bands of the diodes
align with the white stripe of the component outline.
Install __D6, __D7 (1N753A). The color bands of these zener
diodes align with the white stripe of the component outline.
Install inductor L2 (brn, blk, gld). Install flush with board.
Install U1. This part requires that the leads be formed in a
specific way. It is advisable to work on a static free pad with a
ground strap to your wrist. You will note that the leads are pre-bent
in a stagger configuration for vertical mounting. However, we are
going to mount the device flush against the board. The first step is
to straighten the leads so they are all flat. Holding the tab in one
12

hand and with a pair on needlenose pliers in the other, squeeze the
five leads about inch from the body. All 5 leads should now be
flat. Hold U1 near its PCB outline position. Notice that leads 2 and
4 will have a shorter bend than leads 1, 3 and 5. A recessed dimple
marks pin 1 on the device that will go into the square pad hole.
Pins 2 and 4 are bent at a right-angle 1/8 inch from the body.
Temporarily place the part on the board with pins 2 and 4 through
the board. Observe where pins 1, 3 and 5 need to be bent to go
through their pads. Insert the 5 leads through the holes.

Figure 8. Mount position of U1.

Insert a TO-220 thermal conductor pad under U1 (these are

rectangle shaped pad material that has thermal conducting and
electrical insulating properties. They are gray or pink in color on a
peel-n-stick backing. Handle with needle-nose pliers to prevent
contamination of the pad). Align the pad with the mounting hole.
Place 4-40 screw from the backside through the board and through
the tab of the device. Place an internal tooth washer over the
threads. Fasten a 4-40 nut and tighten the component to the board.
Make certain while tightening that the body is flush against the
thermal pad and the board and that the leads are not under strain
when in final position. The leads should be parallel with the device
and then down through the board. It is only necessary to trim leads
2 and 4 on the backside so that all 5 lead tips stick slightly through
the board. An insulating shoulder washer is not needed for the
screw since the potential of the tab and the board is ground. Solder.
HFpacker-Amp

See U1 in Figure 8 (middle of photo

Install TP1, TP2, TP3, TP4. Orient the wire of the test points in
the same direction for consistency.
Install CB1 (Thermal Circuit Breaker- a yellow lozenge-like
component). Bend the leads at a right angle so the component will
lie flat on the board (see Figure 8, left side of photo). On the
backside, bend the leads in opposite directions to hold the
component in place.
Install TABS at J1, J2. Flush mount. Tack one lead. Make
certain the tab is perpendicular to the board. Repeat for the other
tab.
Install J5 (TUNE). This is a 2-pin friction lock header. Place the
friction lock to the outside. Solder one pin. Ensure header is flush
with board. Reheat connection if necessary.
Install J6 (TEST), as above.
Install Q2, Q3 (2N5089) transistors. Spread the leads of the
transistors just slightly to match the hole pattern on the board.
Make certain that the flat of the transistor matches the flat of the
component outline. Q2 and Q3 should be spaced about 1/4 inch
away from the board.
Install Q1 (2N3906) transistor, as above.
Install electrolytic capacitors:
__C2, __C3, __C5, __C9, __C24, __C25 .
The positive leads are longest. Insert these leads in square pads
marked (+).
Install C4 (330uF). The positive lead is longest. Insert in square
pad marked (+) and solder flush.
Install L1 (50uH). Flush mount to the board.
Install U2 (IPS511). This is a 5-lead TO220 device. Pin 1 goes
to the square pad. The leads are initially straight. You must slope
pins 2 and 4 forward so the device will match the component
footprint on the board. The device stands up off the board about 1/8
inch.
Install D2 (SR860) vertically and matching the component
footprint on board. Push the part in until it stands up off the board
about 1/8 inch.
Insert J3 and J4 on the back side of the circuit board. Before
13

mounting J3 carefully trim its leads by so they match 5 pin

header J5.
Install D4, the red LED. This LED is supplied with long
stranded wire leads for easier mounting of the LED to the chassis.
You will have to trim these leads to a convenient length.
Plug the power supply module on top of the amplifier module
and test for fit and alignment.
Visit: http://www.hfprojects.com and download
PictureGallery.pdf to see Header J3 and J4 and the power supply as
mounted above the amp module.

Filter Module Board Assembly

The assembly of the filter module PCB comprises 7 steps:
1. wind and prepare all the toroids
2. install the silver mica capacitors
3. install all the toroids
4. install the rotary switch
5. perform a continuity test
6. construct the coax cable interconnects
7. install the coax cable interconnects
It is important that the above steps be done in order. It is also
suggested that the builder refer to Appendix D for toroid and
capacitor placement positions, because the solder pads on this
board are very close together and components are soldered to both
sides of this PCB.

Toroids Construction
Wind L1: cut 15" piece of 24 ga. enameled wire, select BLUE
T50-1 core, wind 21 turns. Used on 160 meters.
Wind L2: cut 15" piece of 24 ga. enameled wire, select BLUE
HFpacker-Amp

T50-1 core, wind 21 turns. Used on 160 meters.

Wind L3: cut 9" piece of 24 ga. enameled wire, select RED T502 core, wind 9 turns. Used on 30-20 meters.
Wind L4: cut 8" piece of 24 ga. enameled wire, select RED T502 core, wind 8 turns. Used on 30-20 meters.
Wind L5: cut 7" piece of 24 ga. enameled wire, select RED T502 core, wind 7 turns. Used on 30-20 meters.
Wind L6: cut 15" piece of 24 ga. enameled wire, select RED
T50-2 core, wind 21 turns. Used on 80 meters.
Wind L7: cut 15" piece of 24 ga. enameled wire, select RED
T50-2 core,. wind 21 turns. Used on 80 meters.
Wind L8: cut 11" piece of 24 ga. enameled wire, select BLACK
T50-10 core, wind 11 turns. Used on 80 meters.
Wind L9: cut 10" piece of 24 ga. enameled wire, select BLACK
T50-10 core, wind 10 turns. Used on 17-15 meters.
Wind L10: cut 13" piece of 24 ga. enameled wire, select RED
T50-2 core, wind 16 turns, Used on 40 meters.
Wind L11: cut 13" piece of 24 ga. enameled wire, select RED
T50-2 core, wind 16 turns. Used on 40 meters.
Wind L12: cut 10" piece of 24 ga. enameled wire, select
BLACK T50-10 core, wind 9 turns. Used on 12-10 meters.
Wind L13: cut 9" piece of 24 ga. enameled wire, select BLACK
T50-10 core, wind 8 turns. Used on 12-10 meters
For all toroids:
Verify the # of turns are correct, equally spaced and occupy
about 85% of the core's circumference.
Cut the tail of the toroid leads to about 1/2 inch long.
Remove completely the enamel insulation from the leads to
within 1/8 inch of the core. Use a butane lighter to burn it off or a
blob of hot solder to aid in removal of the enamel, or scrape it off
carefully with a file or sandpaper.
Do not yet install these toroid inductors. Installation is after
installation of the capacitors on the bottom side of the circuit board.
14

__C11 1200 pF (1200)

__C21 470 pF (470)
__C22 820 pF (820)

Bottom-side Capacitor Assembly

All but three of the silver mica capacitors are installed on the
bottom side of the filter PCB. See Appendix D for a parts
placement diagram.
Capacitors are installed from top to bottom and from right to
left. Push the capacitor through and flush with the board. Bend the
leads at a very slight angle and cut the leads short. Solder one lead,
making sure capacitor is still flush with the board and then solder
the other lead. Trim the residual leads short as possible.
Install in order :
__C23 470 pF (470)
__C13 1200 pF (1200)
__C9 220 pF (220)
__C8 220 pF (220)
__C2 150 pF (150)
__C1 27 pF (27)
__C14 12 pF (12)
__C7 100 pF (100)
__C19 10 pF (10)
__C16 150 pF (150)
__C20 33 pF (33)
__C24 82 pF (82)
__C25 150 pF (150)
__C17 220 pF (220)
__C26 68 pF (68)
__C18 100 pF (100)
__C10 47 pF (47)
__C3 120 pF (120)
__C15 39 pF (39)
__C12 1800 pF (1800)
HFpacker-Amp

Top-side Toroid Assembly

Figure 9 is a photo of the toroids and some capacitors mounted on
the top layer of the filter module circuit board. Appendix D also
has a good parts placement diagram. The builder should refer to
both in order to assist in correct toroid installation. In order to
remove excess toroid leads in confined areas where wire cutters
cannot be positioned properly grasp the end of the soldered toroid
lead with long-nose pliers. Slowly bend the lead back and forth
until it breaks off.
Install toroids in the following order, proceed from left to right
and from top to bottom along the PCB:
__L3 (red, 9 turns)
__L4 (red, 8 turns)
__L8 (black, 11 turns)
__L2 (blue, 21 turns)
__L12 (black, 9 turns)
__L7 (red, 21 turns)
__L11 (red, 16 turns)
__L10 (red, 16 turns)
__L6 (red, 21 turns)
__L1 (blue, 21 turns)
__L13 (black, 8 turns)
__L9 (black, 10 turns)
__L5 (red, 7 turns)
Install the remaining silver mica capacitors on the top layer:
__C5 2700 pF (2700)
__C6 1500 pF (1500)
__C4 1500 pF (1500)

15

Rotary Switch Installation

Position the filter assembly board against the SW4 pins, as

square as possible using metal sides of chassis as a guide.
Solder the filter board to the contact pins of SW4.
Use a small round needle file on both SW4 chassis holes to
assist with squaring of the filter assembly board, if necessary.
Note in Figure 9 the two coax cables, which will be constructed
and mounted in the next section. It is now recommended that those
cables are attached to J1 and J2 on the back side of the filter board,
not the front side as shown in figure 9.

Figure 9. Installation of SW4.

Figures 9 and 10 assist with correct rotary switch (SW4)

installation. Note that along the top rim of the switch, close to the
shaft, is a small round circular protuberance, called a key (shown
and marked in read as key in Figure 9). This key must be on the
top-side of the PCB closest to the side with the 6 toroids, not the 7
toroids (Figure 9). The toroid (upper side) of this filter board will
face towards the metal chassis. One red toroid is seen directly
below the silver mica capacitor C4 (labeled as 1500 +/- 5% 500V
AE, Figure 9, upper left). This is the same upper left position
shown in Figure 10, illustrating how the filter board is to positioned
within the chassis.
Mount SW4 by itself, onto the chassis first.
Place thin cardboard pieces on both sides of toroids to evenly
space filter board away from metal chassis until the pins from SW4
barely protruded through the filter board.
HFpacker-Amp

Figure 10. Filter board and SW4 position on chassis.

Toroid Continuity/Short Tests

In this section we will use an ohmmeter to assure the builder
of toroid continuity and that there are no shorts to ground on the
toroids, which could destroy Q1 and Q2 amplifier MOSFETs when
the amplifier is powered up.
Connect multimeter between J1, pin 1 and J2, pin 1 on filter
16

board. Zero ohms must be read as SW4 (the rotary band switch) is
switched through all 6 positions.
If your meter does not read zero ohms, check the filter schematic
to see which toroids are installed in that particular switch position.
Re-flow the associated toroid solder joints, or remove and re-work
that toroid.
Connect multimeter between pins 1 and 2 of J1 on filter board.
There should be no reading, that is no shorts to ground as SW4 is
rotated through its 6 positions. Any shorts must be repaired.

Filter Module Coax Cable Interconnects

In this section we will construct two RG-174U coaxial cable
interconnects, which connect the filter board to the amplifier board.
Cut two 6-inch lengths of RG-174 coax. Strip inch insulation
back on each end, comb out the braid flat, trim the braid to 1/8 inch
long.
Cut 2 lengths of #24 AWG black hookup wire each 1 inch long.
Strip 1/8 inch insulation from the end of each wire. Tin all wire
ends. These small wires will be soldered onto the outer coax shield
braid and made into pigtails for easier connection to the crimp
terminals of the friction lock headers (Appendix B).
Solder one end of each of the above 1 inch lengths of #24
stranded black hookup wire to each coaxial cable braid end. Fold
the wire over and then double back in a U-shape and solder the
other end to the braid.
Cover with 3/8-inch length of 1/4 inch shrink tubing. Shrink the
tubing with a heat source.
Remove 1/8-inch insulation from the pigtailed black wire ends
and tin with solder.
The next steps are to attach the locking ramp housing (Molex
connectors) to one end of each coax cable. These will attach to the
RF amp board. Please refer to Appendix B View of Lock Ramp
HFpacker-Amp

Housing and View of Wire Attached to Crimp Terminal in

order understand how these Molex connectors work, before
proceeding.
Attach two crimp terminals to each of the center and braid
conductors on one end of each coax cable. Note the little barb on
the crimp terminal. This barb, when the connector is correctly
assembled, snaps into place within the housing. Tin the wire and
place it within the crimp connector trough area. Use needle nose
pliers to bend the metal tabs around the wire. Solder with minimal
solder. Form any remaining tabs around the wire and the insulation.
Insert the pin into the brown Molex housing with the barb visible in
the slot: the center conductor goes to pin 1 in each case. It should
click into place and you should then not be able to pull it out of the
housing.
Solder the free ends of each coaxial cable to the capacitor side
(back side) of filter board at J1 and J2. The center conductor is
soldered on the right side of J1 and J2 as you look at the back of
the board with the top of the board oriented correctly. You will
have to refer to the front-side J1 and J2 outlines as there are no
outlines on the back side of the filter board.
Although we are not at chassis assembly stage yet, observe how
the friction lock headers are installed on the MOSFET Amplifier
board. Orient board with relay in upper left when viewing the
component side. On J3 (Ant), J5 (Filter-B), and J2 (Filter-A) pin 1
is up. On J4 (XCVR), pin 1 is down.

Chassis Assembly
Install Filter Board, Switch, Coax Connectors
and Heat Sink
If not already installed, install the filter board to the chassis end
17

panel as per Figure 10. Dress its coax cable interconnects so as to

not interfere with other assemblies.
Attach two 6 inch lengths of black #24 AWG stranded hookup
wire to the SPST toggle switch. Twist the wires about 5 twists per
inch. Strip 1/8-inch insulation from each end and tin the wires
lightly.
Solder the wires to the terminals of the SPST toggle switch.
Install the SPST toggle switch in the 1/4 inch diameter hole.
Orient the switch so the bat handle moves horizontally on the
panel. The switch is in the closed position when the bat handle is
toward the center of the panel. Tighten the panel nut securely.
Connect the two switch wires to Molex crimp terminals and
insert into the Molex locking ramp housing. This cable will plug
into TUNE on the Power Supply Module. It does not matter which
wire is in the left or right locking ramp housing.
Install the BNC jack in the 3/8-inch hole on the chassis
connector panel. Tighten the nut securely.
Install the SO239 jack in the 5/8-inch hole and secure with two
4-40 screws, internal tooth lock washers and 4-40 nuts. Orient the
connector so the open side of the center pin is accessible for
soldering.
Place the heat sink on the outside of the bottom of the chassis.
Attach the heat sink to the bottom of the chassis with four
male/female threaded stand off terminals (.187 x .25 inch).
Make certain that the MOSFET mounting holes are free from
sharp edges that might puncture through the MOSFET insulators,
which will be installed next.

Mounting the MOSFETs and Amp Board

Take precautions against ESD.
Place a TO-220 thermal conductive insulation material pad on
the mounting surface of both MOSFETs. Align the pads such that
they cover the metal surface with the hole of the device and the
insulator centered.
HFpacker-Amp

Mount the MOSFETs to the heat sink through the chassis holes
with two 4-40 screws (do not use lock washers).
Make a final alignment of the MOSFET mounting hole over the
threaded hole of the heat sink.
If alignment is poor, re-solder the MOSFET leads on the amp
board to relieve any sideways pressure from mis-alignment.
Place a fiber shoulder washer on a 4-40 x 3/16-inch screw. The
shoulder is towards the end of the thread so that when it is inserted
into the mounting tab of the MOSFET device, the screw is
insulated from the MOSFET. A magnetic screwdriver makes it
easier to insert the screws. Tighten the MOSFETs to the heat sink.
Attach the MOSFET Amp board to the chassis 4-40 spacers
with two 3/16 inch 4-40 screws at one end and two 3/4 inch
threaded hex spacers at the end, near the relay.
Measure with an ohmmeter to ensure there is no short circuit
from the MOSFETs to the chassis:
1. Connect one ohmmeter lead to the chassis.
2. Connect other lead sequentially to all MOSFET solder
connections on the board. The reading should be infinite
resistance or very high megohms.
A low ohms reading indicates a short circuit from the board to
chassis. If you get a short, ensure that the MOSFET is properly
insulated from the chassis and heat sink.

Chassis Coax Cable Interconnects

In this section we construct two chassis coaxial cable interconnect
assemblies in exactly the same manner as we did in the Filter
Module Cable Assemblies above. Please refer to that section for
methodology. These two coax cables will be used to connect the
BNC RF in jack to J4 on the amp board and to connect the SO-239
RF out jack to J3 on the amp board.
Prepare two 5-inch lengths of RG-174 coax cable exactly as per
filter module cable assemblies section above
Note in Figure 11 how the J4 cable center conductor is towards
18

top side of the amp board while J3 center conductor is towards the
bottom side of the amp board. J4 goes to the BNC jack and J3 to
the SO-239 jack.

board. Insert the center conductor into the locking ramp housings to
mate with pin 1 on the board. Insert connector. Dress cable as
shown in Figure 11. Note location of the center conductor.
Plug coax cable interconnect Filter B, which is attached to J2
on the filter board into the Molex connector J5 on the amplifier
board. Insert the center conductor into the locking ramp housings to
mate with pin 1 on the board. Insert connector. Dress cable as
shown in Figure 11. Note location of the center conductor.
Uncertainties concerning coaxial cable installation and
orientation can be overcome by referring to Figure 11, the
schematic diagrams (Appendix C) and the PictureGallery.pdf file at
the website.

Install Power Supply Module and 12VDC

Power Cord
Figure 11. Placement of J2, J3, J4 and J5 coax
connectors.

Plug in a RG-174 cable assembly to J3 (ANT). The cable

assembly has crimp terminals and a locking ramp housing. Solder
the center conductor of the RG-174 cable to the center pin of the
SO-239 connector. The shield wire of this cable should have a ring
terminal attached. Put the ring terminal under the top mounting
screw of the SO-239 connector. Use a 4-40 screw, lock washer and
nut. Tighten securely. Use a 4-inch nylon cable tie to physically
secure the cable body to the ring terminal. This will provide strain
relief for the center conductor of the cable.
Plug in a RG-174 cable assembly to J4 (XCVR). The cable
assembly has crimp terminals and a locking ramp housing. Solder
the center conductor of the RG-174 cable to the center pin of the
BNC connector. Solder the shield wire of the RG-174 cable to the
other BNC terminal.
Plug coax cable interconnect Filter A, which is attached to J1
on the filter board into the Molex connector J2 on the amplifier
HFpacker-Amp

See Figure 12 for details.

Install the power supply module board on top of the amplifier
board using four 4-40 screws. Ensure that connectors power supply
and amplifier board connectors J3-J1 and J4-J6 mate correctly
under the board and that none of the coax cable assemblies are
pinched.
Insert a rubber grommet into the 5/16-inch hole on end panel.
Cut the black and red power cable in half.
Run the power cord through the grommet into the chassis
interior.
Strip 3/8-inch insulation from each wire end.
Crimp insulated crimp-on terminals on the two wires.
Plug terminals to the inch wide power input tabs on the power
supply module: the red wire goes on J1 (PWR+) and the black wire
goes on J2 (GND).
Put a service loop in the wire around C9. Use a 4-inch cable tie
to make a strain relief at the grommet (Figure 12).

19

and the power supply. Measure 24 volts (+/- 0.5V).

An unsuccessful test will require a thorough check of components,
component placement, connectors and solder joints on the power
supply module.

MOSFET Amplifier Bias Adjustment

Figure 12. Detatil of power cord and cables.

Testing and Alignment

For this exercise the builder will require the following:
a small flat bladed screwdriver for potentiometer adjustments
larger flat blade screw driver for case screws
multimeter to measure volts, ohms and amperes
dummy load to handle 35 watts
50 ohm terminators (50 ohm W resistors in parallel with the
BNC and SO239 jacks will suffice)
test leads
12VDC, 9A power source
cable to connect 12v power source to the power cable.

Power Supply Module Tests

Set the multimeter to measure DC voltage.
Monitor TP3 (+) and TP2 (-) with multimeter.
Jumper J6 (Test).
Connect the power cable to 12VDC while observing the meter
HFpacker-Amp

Ensure that the two potentiometers (VR1, VR2) are both in

the fully clockwise position. Failure to do so can lead to excess
current in the MOSFETs and their consequent failure.
Measure resistance between J1 pin 1 (+) to J1 pin 2 (-) on the
amp board. The reading should be very high or infinite.
Terminate both BNC input and S0239 output with 50 ohms
(50 , W resistors will suffice).
Plug the power supply module on to the MOSFET amplifier
board.
Make certain the cables to the filter board are not in the way or
pinched between the transformers below and the board above.
Ensure that J3 (male 3 pin header) and J4 (male 5 pin header) on
circuit side of power supply board are correctly plugged in to J1
(female 3 pin connector) and J6 (female 5 pin connector) on the
MOSFET amplifier board.
Tighten four (4) power supply hold down screws.
Put the multimeter in series with the power source and the
power cable in order to measure current. Plug in 12VDC power.
The T-R relay will click closed for about 1 second then it will open
again.
Measure in-line current of ____ mA. (11.48 mA reference
current). Unplug power.
Measure voltage from TP2 on the power supply module to the
VOUT pin of U1 on the MOSFET amplifier board. U1 is located
close to the 5-pin board-to-board connector. Capacitor C1 is just to
the right of U1. Plug-in power again. The reading should be 5VDC
(+/- 0.1 VDC). _____ VDC. Unplug power.
20

Put the meter in series with the power source and the power
cable to measure current. Connect the test clips from pin 1 to pin 2
of J6 (TEST) on the power supply module. This will activate the
power supply. Plug it in.
Allow 30 seconds for current stabilization. Record the quiescent
(idle) current. _____ mA, (60.2 mA reference quiescent current).
The T-R relay will click closed. Unplug power.
Measure voltage from TP2 ( - ) to TP3 ( + ). Voltage measures
about 24VDC. _____ VDC. Unplug power.
Put the meter in series from the power source to the power cable
to measure current.
Allow 30 seconds time for current stabilization.
Pass a small blade screwdriver through one of the BIAS access
holes after a stable reading has been obtained. Monitor the current
very carefully. Turn the potentiometer counterclockwise
slowly until you see the current begin to increase. Increase the
current for 10 mA additional current. Keep tweaking the reading
for the target current equaling quiescent + 10mA. For example, if
the reading is 60.2 mA, adjust BIAS pot for 70.2 mA.
Turn the other bias pot counterclockwise to increase the current
by 10mA. If the reading is 70.2 mA, adjust BIAS pot for 80.2 mA.
You are now finished setting the bias for both MOSFETs. The total
current should be 20mA above the quiescent (80.2 mA reference).
Do not attempt to run more bias current than 10 mA for each
MOSFET device.

Final Tests
Ensure that the QRP transmitter you will be using with the
Hfpacker-Amp has an RF power output of about 2.5 watts or less.
If more than 2.5 watts, the RF attenuation pad resistors (R2, R3,
R4) on the amplifier module board will have to be changed
accordingly. See the RF amplifier module schematic, Appendix C,
which has an input attenuator table.
Connect a 35 watt, 50 ohm dummy load to the SO-239 jack,
HFpacker-Amp

preferably also with an inline wattmeter. (A homebrew dummy

load can easily be constructed with appropriate high wattage
parallel resistors mounted in a small container with mineral oil, e.g.
4 200 , 10 W resistors in parallel).
Connect your QRP transmitter to the BNC jack.
Connect the amp power cable to a 11.5-14VDC, 9A power
source.
Place SW1 in the standby position.
Key your transmitter and check for approximately 35 watts
output on each band during voice peaks and for a clean sounding
signal on a nearby receiver.
No output power on any band suggests power supply or chassis
interconnect problems.
Significantly inconsistent watts out dependent upon the band
you choose suggests problems with the filter module.
Consistently poor output across all bands suggests problems
with the amplifier module.
Any problems encountered need to be traced back to their likely
module using standard troubleshooting techniques, along with
studying the schematics in Appendix C. Assistance is also available
at the user forums at http://www.hfprojects.com.

End Panels Silkscreen

As a final touch to this project the builder may choose to add
silkscreen end panels. They are provided in Appendix B. Further
ideas for enhancement of the chassis are provided in
PictureGallery.pdf at http://www.hfprojects.com and in the user
forums at the same website.

21

Appendix A Parts Lists

The parts for the Hfpacker-Amp come in sorted zip-lock bags labeled for each module they generally pertain to. Sometimes however,
to minimize the number of items in each bag and to reduce the labor of our volunteer sorters, certain parts may be placed in other bags.
Volunteers will attempt to ensure each bag contains only parts for that module. If you appear to be missing parts please double-check all
bags. A check box column is provided in the following Parts Lists in order to assist with inventory.

HFpacker-Amp

22

Appendix A
Designator
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
HFpacker-Amp

CHASSIS MODULE PARTS LIST

Description
Enclosure, Project Aluminum Box 5 1/4 x 3 x 2 1/8
Heat Sink, 4.6 x 2.4 inches
Spacer, Threaded Keystone male / female .187 x .250
Washer, Shoulder # 4
Pad, Thermal Conductor for TO-220
Connector, BNC (female) Panel Mount
Connector, SO239 (female) Panel Mount
Grommet, Rubber 1/4 inch ID
Disconnect, Polarized Quick -12", 2-pin 16 ga. wire
Terminal, "FLAG shaped" (female) .250 22-18 ga.
LED, Panel w/wires
Knob, 1.04D x 0.62H
Switch SPST Toggle
Cable Tie, Nylon 4 inch
Terminal, Ring #4
Crimp Terminal, Molex 538-08-50-0114
Locking Ramp Housing, 2P Molex 538-22-01-2027
Coax Cable, RG-174 566-8216-100
Heat Shrink tubing, 1/4"
Wire, Hookup #24 AWG stranded, black
Nut, 4-40 small pattern 2
Screw, 4-40 x 5/16th and/or 3/8 inch
Washer, 4-40 internal tooth LOCK2
Core, FB-24 77 Ferrite???
Crimp Terminal, Molex 538-08-50-0114
Locking Ramp Housing, 2P Molex 538-22-01-2027
Coax Cable, RG-174 566-8216-100
Wire, Hookup #24 AWG stranded, black
Nut, 4-40 small pattern
Screw, 4-40 x 3/8th inch (Binder Head)
Washer, 4-40 internal tooth LOCK
Nut, 4-40 small pattern (temp use)
Screw, 4-40 x 5/16 inch

Reference
Chassis
Chassis
Chassis
Chassis
Chassis and PS modules
Chassis
Chassis
Chassis
Chassis
Chassis
Chassis
Chassis
Chassis
Chassis
Chassis
Chassis
Chassis
Chassis
Chassis
Chassis
Chassis
Chassis
Chassis
Chassis
Filter module
Filter module
Filter module
Filter module
PS module
PS module
PS module
Amplifier module
Amplifier module

QTY.
1
1
4
2
3
1
1
1
1
2
1
1
1
2
2
6
3
12 in.
3 in.
12 in.
2
6
2
2
4
2
12 in.
12 in.
1
1
1
4
2
23

Appendix A
Designator
C1, C3, C4, C5, C6, C8, C9, C10, C11
C2
C7
C12, C15
C13
C14
D1, D3
D2
J1
J2, J3, J4, J5
J6
K1
L1, L3
L2
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
Q1, Q2
Q3
R1, R5
R2
R3, R4
R6
R7
T1
T2, T3
TP1, TP2, TP3
HFpacker-Amp

AMPLIFIER MODULE PARTS LIST

Description
Capacitor, 0.1uF, 100V, 10%
Capacitor, 10uF, 35V, radial
Capacitor, 47pF, 500V (470)
Capacitor, 0.001uF, 50V, 10%
Capacitor, 2.2uF, 25V
Capacitor, 0.01uF, 100V, 10%
Diode, 1N4148
Diode, 1N4004 1A 400V
Connector, 3 pin female, 0.2 PPSS-03-01-T-S
Header, friction lock 2 CKT male, 0.100
Connector, 5 pin female, SSW-105-02-S-S
Relay, DPDT, MR82-12USR
Coil (to be wound by builder), 9 1/2T #24AWG 0.25 ID ???
Coil (to be wound by builder), 3 1/2T #24AWG 0.19 ID ???
Printed circuit board for amp module
Spacer, aluminum RND threaded .187 x .750 in.
Washer, nylon or plastic #4
Standoff, HEX male/female threaded .750 x 4-40
Wire, #24 AWG magnet wire
Wire, #20 AWG teflon covered
Wire, #22 AWG magnet wire
Nut, 4-40 small pattern (temp use)
Screw, 4-40 x 5/16 inch
IRF-510 MOSFET (static sensitive!)
Transistor, 2N5089
Resistor, 27 , W (red, viol, blk)
Resistor, 24 , 1W (red, yel, blk)
Resistor, 220 , 1W (red, red, brn)
Resistor, 1.2K, W (brn, red, red)
Resistor, 4.7K, W (yel, viol, red)
Core, balun BN-43-3312 (2 holes)
Core, FT50-43 ferrite
Test Point, glass bead insulated (white)

(continued)
QTY.
9
1
1
2
1
1
2
1
1
4
1
1
2
1
1
2
2
2
60 in.
18 in.
36 in.
4
2
2
1
2
1
2
1
1
1
5
3
24

Appendix A
U1
VR1, VR2

HFpacker-Amp

AMPLIFIER MODULE PARTS LIST

Regulator, LM78L05ACZ, 5 volts
Resistor, variable potentiometer, 10K

(continued)
1
2

25

Appendix A
Designator
C2, C3, C5, C9
C4
C6, C7
C8
C24, C25
CB1
D1
D2
D3, D5
D4
D6, D7
J1, J2
J3
J4
J5, J6
L1
L2
Misc.
Misc.
Misc.
Misc.
Misc.
Q1
Q2, Q3
R2
R3, R9, R12, R15
R4, R14
R5, R8
R6, R7
R16
TP1,TP2,TP3,TP4
U1
U2
HFpacker-Amp

POWER SUPPLY MODULE PARTS LIST

Description
Capacitor, 100uF 50V, low ESR
Capacitor, 330uF 50V, low ESR
Capacitor, 0.1uF 100V
Capacitor, 1uF 25V
Capacitor, electrolytics, 10uF, 16V
Circuit breaker, 16V, 7A hold, 11.9A trip (yellow lozenge)
Diode, RL-250, 251 or 252
Diode, Schottky, Rectron SR860
Diode, signal, 1N4148
LED Diode, red, panel mount with wires
Diode, zener 6.2V, 1N753A
Terminal, tab shaped male, 0.25 (pc board mount)
Header, 3 pin male 0.2 pitch , Samtec
Header, 5 pin male 0.1 pitch , Samtec
Header, friction lock, 2 CKT male, 0.100, Molex
Inductor, 50 uH, radial high current, Dale/Vishay
Inductor, 1 uH, 4A (brown, black, gold)
Printed circuit board for power supply module
Nut, 4-40, small pattern
Screw, 4-40 x 3/16 (binder head)
Washer, 4-40 internal tooth lock
Thermal conductor pad for TO-220
Transistor, 2N3906
Transistor, 2N5089
Resistor, 1.0 , W, 5% (brn, blk, gld)
Resistor, 4.7K, W, 5% (ylw, viol, red)
Resistor, 22K, W, 5% (red, red, orn)
Resistor, 100K, W, 5% (brn, blk, ylw)
Resistor, 1.2K, W, 5% (brn, red, red)
Resistor, 2.7K, W, 5% (red, viol, red)
Test points, glass insulated (white)
IC, LT1270ACT, 10A power switch regulator, TO-220
IC, IPS511-ND, power MOSFET switch

QTY.
4
1
2
1
2
1
1
1
2
1
2
2
1
1
2
1
1
1
1
1
1
1
1
2
1
4
2
2
2
1
4
1
1
26

Appendix A
Designator
C1
C2, C16, C25
C3
C4, C6
C5
C7, C18
C8, C9, C17
C10
C11, C13
C12
C14
C15
C19
C20
C21, C23
C22
C24
C26
L1, L2
L3, L4, L5, L6, L7, L10, L11
L8, L9, L12, L13
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
SW4

HFpacker-Amp

FILTER MODULE PARTS LIST

Description
Capacitor, 27pF, 500V, silver mica
Capacitor, 150pF, 500V, silver mica
Capacitor, 120pF, 500V, silver mica
Capacitor, 1500pF, 500V, silver mica
Capacitor, 2700pF, 500V, silver mica
Capacitor, 100pF, 500V, silver mica
Capacitor, 220pF, 500V, silver mica
Capacitor, 47pF, 500V, silver mica
Capacitor, 1200pF, 500V, silver mica
Capacitor, 1800pF, 500V, silver mica
Capacitor, 12pF, 500V, silver mica
Capacitor, 39pF, 500V, silver mica
Capacitor, 10pF, 500V, silver mica
Capacitor, 33pF, 500V, silver mica
Capacitor, 470pF, 500V, silver mica
Capacitor, 820pF, 500V, silver mica
Capacitor, 82pF, 500V, silver mica
Capacitor, 68pF, 500V, silver mica
Toroid core, T50-1 (blue)
Toroid core, T50-2 (red)
Toroid core, T50-10 (black)
Printed circuit board for filter module
Wire, #24 AWG magnet wire
Crimp terminal, Molex 538-08-50-0114
Lock Ramp Housing, 2P, Molex 538-22-01-2027
Coax cable, RG-174
Heat shrink tubing, 1/4
Wire, #24 AWG, hookup, stranded, black
Switch, rotary, 6 position, 10WA175

QTY.
1
3
1
2
1
2
3
1
2
1
1
1
1
1
2
1
1
1
2
7
4
1
19.5'
4
2
12 in.
1.5
12
1

27

Appendix B Templates

HFpacker-Amp

28

HFpacker-Amp

29

HFpacker-Amp

30

HFpacker-Amp

31

View of Molex
Crimp Terminal
with wire attached

View of Molex
Lock Ramp
Housing with
terminal inside

HFpacker-Amp

32

Appendix C: Schematics

HFpacker-Amp

33

HFpacker-Amp

34

HFpacker-Amp

35

Appendix D: Filter PCB Component Placement

HFpacker-Amp

36

Appendix E: Resistor and Capacitor Identification

Identifying Capacitors
Small-value fixed capacitors (such as the silver mica
capacitors for the filter module) are usually marked
with one, two, or three digits and no decimal point. If
one or two digits are used, that is always the value in
picofarads (pF). If there are three digits, the third digit
is a multiplier. For example, a capacitor marked "330"
would be 33 pF (33 with a multiplier of 0). Similarly,
"151" would be 150 pF, and "102" would be 1000 pF
(or .001 F). Fixed capacitors with values of 1000 pF
or higher often use a decimal point in the value, such as
.001 or .02. This is the value in microfarads (F).

HFpacker-Amp

37