Manufacturing Process » History » Version 9
Dimitris Pipelias, 11/18/2025 11:35 AM
| 1 | 1 | Dimitris Pipelias | # Manufacturing Process |
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| 6 | ### 1. PCB Manufacturing / Soldering |
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| 7 | |||
| 8 | Description of the printed circuit board (PCB) manufacturing and soldering process. |
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| 9 | 1. PCB preparation |
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| 10 | 2. Component placement |
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| 11 | 3. Soldering process |
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| 12 | 4. Visual inspection |
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| 13 | 📌 Note: Insert photos here showing the PCB manufacturing steps. |
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| 14 | # |
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| 16 | ### 2. Components Assembly |
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| 17 | Description of the procedure for assembling the electronic components of the amplifier. |
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| 18 | 1. Module placement |
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| 19 | 2. Wiring |
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| 20 | 3. Securing components |
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| 21 | 4. Functional testing |
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| 22 | 📌 Note: Insert images here showing assembly steps. |
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| 23 | # |
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| 24 | 9 | Dimitris Pipelias | # |
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| 26 | 4 | Dimitris Pipelias | ## 3. Testing / Case Assembly |
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| 28 | 9 | Dimitris Pipelias | |
| 29 | 4 | Dimitris Pipelias | ### • Initial test |
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| 31 | 3 | Dimitris Pipelias |  |
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| 33 | 1. Visual inspection to ensure that all components on the board are correctly placed. |
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| 34 | 2. Check for a missing coil, as this is a common failure point (Fig. 1). |
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| 35 | 9 | Dimitris Pipelias | 3. Set the HDMOD-1 source (with RF output of 90dB) on channel 21 (MHz: fill in the exact frequency). |
| 36 | 1 | Dimitris Pipelias | 4. Connect the output to a 20dB attenuator. |
| 37 | 4 | Dimitris Pipelias | 5. Measure the PWR level at the output of the 20dB attenuator using the field meter. The desired power value to confirm correct operation of the source before connecting the amplifier is 69dBuV (Fig. 2). |
| 38 | 1 | Dimitris Pipelias | 📌 Note: 90dB (source) – 20dB (attenuator) + 36dB (DA102 amplifier) – 1dB (cable losses) = 69dB. |
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| 41 | 7 | Dimitris Pipelias |  |
| 42 | 1 | Dimitris Pipelias | |
| 43 | 8 | Dimitris Pipelias | 6. Place the amplifier between the source and the field meter, and power it with 12V DC, verifying a current consumption of approximately 270mA (Fig. 3). |
| 44 | 1 | Dimitris Pipelias | 7. Set the attenuation and equalizer switches to their maximum position (Fig. 4). |
| 45 | 8. Connect the output to a 30dB attenuator (required due to the DA102 36dB gain). |
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| 46 | 9. Measure the PWR level at the output of the 30dB attenuator using the field meter. The desired power value to confirm correct operation of the DA102 amplifier is 75dB (Fig. 5). |
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| 47 | 📌 Note: 90dB (source) – 20dB (first attenuator) + 36dB (DA102 amplifier) – 30dB (second attenuator) – 1dB (cable losses) = 75dBuV. |
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| 48 | # |
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| 49 | 5 | Dimitris Pipelias | # |
| 50 | 9 | Dimitris Pipelias | |
| 51 | 5 | Dimitris Pipelias | ### • Case Assembly |
| 52 | 9 | Dimitris Pipelias | |
| 53 | 6 | Dimitris Pipelias |  |
| 54 | 5 | Dimitris Pipelias | |
| 55 | 1. Visual inspection to ensure that all components on the board are correctly placed. |
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| 56 | 2. Check for a missing coil, as this is a common failure point (Fig. 1). |
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| 57 | 3. Set the HDMOD-1 source to an RF output of 90dB on channel 21 (MHz: fill in the exact frequency). |
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| 58 | 4. Connect the output to a 20dB attenuator. |
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| 59 | 1 | Dimitris Pipelias | |
| 60 | ### Step-by-Step Workflow |
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| 61 | 1. Materials and PCB reception |
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| 62 | 2. Incoming quality control |
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| 63 | 3. Soldering and visual inspection |
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| 64 | 4. Components assembly |
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| 65 | 5. Wiring |
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| 66 | 6. Housing installation |
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| 67 | 7. Final functional testing |
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| 68 | 8. Packaging |
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| 69 | 📌 Note: Insert diagrams or pictures illustrating the workflow. |