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Genesis G3020 Assembly Pictorial

Phase 7
Assembly of CW monitor

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Phase 7 - Assembly of CW monitor

10nF MLC capacitors are marked in red.




Phase 7 - Assembly of CW monitor


Phase 7 - Assembly of CW monitor

Plug CW hand key in the front panel KEY/PTT jack. Plug in stereo phones. Switch on S3. When pressing the key you should hear side tone. Adjust volume with 10K trimmer. Control test point : pin 2, 3 and 6 (LM741 on right side ONLY) +6.1V.


Phase 7 - Assembly of CW monitor

Position of jump wire W4.



Phase 8

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Phase 8

10nF MLC capacitors are marked in red.


Phase 8


Phase 8

PA keying unit - install highlighted components



PC RX/TX control testing should be performed in 2 steps.

Test Step 1

Using a DMM, measure the voltage at +VTX. It should be 0V. The voltage at +VRX should be +12-+13.8V.

  • Set switch SX1 ON. When switch SX1 is ON, +VTX will measure +12-13.8V and +VRXwill be 0V.


Test Step 2
  • Turn SX1 OFF.
  • Connect Genesis G40 to the serial PC port directly or via USB/ Serial adapter.
  • Settings in SDR software should be set according to theDB9 connector's Pins as shown below:
  • Turn on SX2 (temporarily installed in Test Step 1) and +VTX should be +12-+13.8V.

For more details on PC to G3020 connection and SDR settings
see http://genesisradio.com.au/G40/9assemblyG40.html



Phase 9

TX Sample and Hold Modulator

In this phase populate area on the top right and bottom right part of PCB.

Phase 9 - TX Sample and Hold Modulator

Phase is divided in two sub-phases, as shown below.

Phase 9A:


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Phase 9A



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Phase 9A


Phase 9B:


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Phase 9B


Phase 9B

Once the components have been installed, install the connecting wire W8 as shown in the connection diagram above.

Do not apply +V yet.


TX I/Q adjustment

TX I/Q Adjustment

Adjust serial resistance of 5K trimmer (Point A) and 1K resistor (Point B) to 3.3K when G3020 is turned off and G3020 isnít connected to sound card output!


TX I/Q Adjustment



Phase 10

TX driver and power FET assembly

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Phase 10 - TX driver and power FET assembly

  • Install All Components, Except FET and Transformer
  • Wind and Install the Dual Binocular Transformer
  • Install FET and Heat Sink
  • Install two Jump Wires

Wind and Install the Dual Binocular Transformer
Cores

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

Binary cores

Twisted Wire

Prepare a 40 cm (~16") long piece of enameled copper wire and fold it over so that it is two 20 cm wires joined at the one end

Twist the wires together so that you get approximately three twists per 10mm of length

For more details, see www.genesisradio.com.au/G40/8assemblyG40.html

Wind the Wire through the Core


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Phase 10 - TX driver and power FET assembly


Thread the twisted wires (folded end first) through the glued cores, starting in hole 1, coming out the other end and looping back through the top core to exit at hole 3. Continue from hole 3 into hole 2, coming out the other end and looping back into the upper core so as to exit at hole 4.

When finished winding, cut the folded end of the twisted wire off, such that you noe have four wire ends.

The pair at hole 1 represents the primary leads; the pair at hole 4 represents the secondary leads of the wound transformer.

Using an ohm meter, identify the ends of each wire as indicated on the graphic above. You may want to use a small piece of colored hookup wire insulation to identify the "a" (or, if you prefer, the "b") wire's ends.

Mount the Transformer

You do not need to worry how to figure out the phasing; if you match the designated leads (a1, b1, a, b) with the holes as marked in the graphic below, you will have correct phasing.

Wound cores


Wound cores


Transformer mounting

Insert transformer's leads into the PCB holes, as indicated above. Form the leads and pull them tight. Then cut off the excess (on the underside of the board) so that approximately 5mm (1/8") of wire is protruding out on the underside of the board.

Remove the transformer from the PCB, scrape the enamel coating from the 4 leads but DO NOT TIN them as yet (tinning the leads could cause them to be too "fat" to go back into the holes).

Insert the 4 transformer leads back into the PCB and solder them.





Final Assembly Diagram

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Final Assembly Diagram


Trimmer Adjustment

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Trimmer Adjustment

G3020 30m+20m/ 5W Transceiver KIT. Includes professionally manufactured double layer PCB and all components. Online assembly help file. Yahoo Group support.

Delivery status: IN STOCK

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