CONSTRUCTION, INSTALLATION, & OPERATION

EXPANDER 160 CRYSTAL OSCILLATOR & SWITCH ©

The EXPANDER 160 is a compact crystal oscillator unit which allows frequency, so series trimmers CT1–CT4 are provided for exact
remote controlled selection of up to four different crystals. This adjustment after installation. The trimmers have a range of 9-50 pF,
provides new injection signals for loop mixing in PLL synthesizer which is more than enough if proper crystals are specified when
circuits, or additional synthesizer frequencies in 23-channel CB ordering.
transceivers. The RF output is approximately 5 V peak-peak when
supplied at +8 VDC, and is buffered to minimize loading at its Jumpers J4-J7 are installed for the OSCILLATOR Mode, and are used
connection. Each crystal position includes a series trimmer capacitor to ground one side of the crystals. Sometimes a particular crystal can
for exact frequency adjustment. Crystal selection is made by diodes, be difficult to trim to the correct frequency. In such cases, you can
which eliminates the problem of stray wire capacitance often found in often replace the bare jumper wire with a small capacitor (5-68 pF)
mechanical switches. or RF choke (1-10 µH) to get the oscillator within the range of the
trimmers.
A unique system of wire jumpers allows the EXPANDER 160 to be
used solely as a crystal switch, with the oscillator circuit disconnected. Q1 is the oscillator. R2, R3, and R4 provide the DC operating biases,
This configuration is needed for all 23-channel crystal-synthesized and are chosen to oscillate with any crystal between 10-20 MHz at DC
radios, and all 40-channel PLL radios whose crystal frequency is supply voltages of about +5-12 VDC. C6 is the feedback capacitor
doubled or tripled before mixing with the VCO signal. In such radios, which causes oscillation. The values of C6 and C7 are chosen to
the existing crystal is removed from the radio’s chassis, and two oscillate with any fundamental crystal from approximately 8 MHz to
EXPANDER 160 wires are installed at the empty crystal location. 20 MHz, or any Third Overtone crystal type. (Typically these are in
The removed crystal is soldered into the EXPANDER 160 PC board, the 36 MHz range, and are actually cut near 12 MHz.) Q2 is a buffer
along with up to three new crystals. The module is now in series with stage which isolates the oscillator from possible loading effects in the
the radio’s crystal circuit. This allows up to four crystals (the original radio. C8 has purposely been kept small (22 pF) for this same reason.
plus your three) to be chosen instead of just the original. The radio’s
total operating range and bandwidth will depend upon the specific DC operating power comes from the radio. The source must be
chassis type. well regulated for maximum frequency stability. Most CB transceivers
all have at least one such source, usually +5-8 VDC, and this is used to
CIRCUIT DESCRIPTION power the EXPANDER 160. The DC source you choose must be
present for both RX and TX. Connect the RED wire to that, and the
See the Schematic Diagram on Page 9. The EXPANDER 160 consists BLACK wire to chassis common.
of a Colpitts oscillator, bipolar buffer stage, a diode switching array,
and various jumper wire options.
SWITCH MODE
One of four crystals is chosen when a DC voltage is applied through
your hard switch (toggle, rotary, slide, CB/PA, etc.) to one of the PC The EXPANDER 160 is connected as a straight electronic switch in
board holes numbered “1” through “4.” The “5” hole is the many PLL radios, and always in the older crystal-synthesized radios.
common hot side for the hard switch, and connects directly to the In this mode J8 is left out, which disconnects the active transistor
radio’s regulated +DC supply bus. With voltage applied, the stage. J4, J5, J6, and J7 are also removed, and J1, J2, and J3 are
appropriate diode (D1-D4) is turned on by the current flowing used instead. This ties the low side of all crystals together at hole “A,”
through it and R1/L5 to ground. R1 limits the current to a safe and all the high sides together at hole “B.” In most radios the crystals
value. L5 keeps all crystals above RF ground, since the crystal’s hot are not directly grounded, grounding instead through a Delta Tune
side is being switched. RF is decoupled from the DC power supply by or Clarifier VXO circuit on the crystal’s low side. Thus the jumpers
L1-L4 and C1-C4. allow the EXPANDER 160 to be used as a multiple series crystal
switch. Wires from holes “A” and “B” are installed in the appropriate
OSCILLATOR MODE holes formerly occupied by the original mixing crystal. Crystals are
chosen by diodes D1-D4, in exactly the same way as the
The Colpitts oscillator common to CB radios has a relatively high OSCILLATOR Mode.
shunt or parallel input capacitance. This can pull the crystal off

© Copyright 1983–2002 by L.M. Franklin. All rights reserved.

Published by:
CBC INTERNATIONAL • P.O. BOX 30655 • TUCSON AZ 85751 U.S.A.
TEL/FAX: 888-I-FIX-CBs (1-888-434-9227), (520) 298-7980
Internet: www.cbcintl.com • Email: info@cbcintl.com
 ASSEMBLY INSTRUCTIONS
PLEASE READ CAREFULLY BEFORE PROCEEDING!

NOTICE
This device will operate as advertised when properly constructed, installed, and adjusted. CBC INTERNATIONAL has no
control over the skill of the purchaser; therefore no warranty can be given. We will repair units built only from our own kits for
$25 prepaid with the returned unit. NO BASKET CASES PLEASE!
This device is intended for educational purposes, 10-Meter Amateur use, or 27 MHz receivers only. Supplier assumes no
liability for improper or illegal use.
Proper soldering is essential. Poor soldering is the biggest cause of problems. Finished joints should look shiny, never dull.
Use only a small iron (25-45 watt) with a very fine round or slot tip to avoid shorts.

Assembly consists of stuffing the parts into the proper PC board holes, as illustrated in the X-Ray View drawing, Page 10. Check against the
schematic circuit diagram if you’re in doubt about the correct holes. Push all parts down tight, wiggling back and forth if necessary as you press
down. (See photo, Page 11.) The diodes and resistors will bend naturally to the proper hole spacing.

NOTES
1. Unless you’re moving the EXPANDER 160 unit from one type of synthesizer circuit to another, you will save time and trouble by
installing the right jumper wires in the first place. Decide which installation type you need, then insert the proper jumpers when stuffing
and soldering all the other parts.
2. Observe correct diode polarity. The banded diode end is the cathode [—]. This is shown in the sketch above and in the X-Ray View.
Diodes also have [—] marks etched on the PCB.
3. Install transistors correctly. See sketch. Match the flat side of the transistor body with the flat side painted on the top of the PC board.
The emitter leads will be to your left.. If in doubt, check against the X-Ray View or the schematic. With the flat side facing you, the
leads will be (left to right) Emitter, Base, Collector.
4. Use cut off parts leads for the jumpers. Determine proper jumpers as described later.
5. Capacitor locations C6, C7, and C8 include extra holes to match different spacings if necessary.
6. Wires: Install the RED in [+], BLACK in [—], and short YELLOW in “RF” holes. An extra 12" wire is included for switch mode
option, as well as the 5-conductor ribbon cable for your switch. Match cable to your switch and crystals with the schematic diagram.

_________________________________________________________________________________________
EXPANDER 160 PAGE 2
CRYSTAL ORDERING
The same principle applies to 10-Meter Amateur
The following specifications should be observed when conversions. If you want the Channel 1 operating frequency
ordering crystals. to start, say, exactly 2 MHz higher (28.965 MHz), just add
2 MHz to a direct loop crystal, 1/3 of 2 MHz (667 KHz) to a
FREQUENCY: As desired. tripler crystal, or 1/2 of 2 MHz (1 MHz) to a doubler crystal.
ACCURACY: .005% or better. Refer to the later examples, which should clarify this idea.
HOLDER TYPE: HC18/U or HC49/U with solder
leads.
CRYSTAL CUT: Fundamental up to about
CRYSTAL SUPPLIERS
20 MHz. Crystals which are
being multiplied in the radio
CRYSTEK CORP.
should be specified as such. (For
2351/2371 Crystal Dr.
example, the 11.325 MHz
Ft. Myers FL 33907
crystal used in the
TEL: (800) 237-3061, (941) 936-2109
Cobra 148/2000GTL chassis is a
FAX: (941) 939-4226
tripler cut type.)
www.crystek.com
LOAD CAPACITANCE: 10 pF (series) preferred for easy
adjustment. The 32 pF used in
INTERNATIONAL CRYSTAL MFG.
many CB oscillators can be hard
10 N. Lee Av., P.O. Box 26330
to net by the trimmer alone.
Oklahoma City OK 73102
TEL: (800) 426-9825, (405) 236-3741
If you already have crystals with different specs, they can be
FAX: (405) 235-1904
tried first and will usually work. If you have the plug-in
www.icmfg.com
HC25/U types, these can also be used by drilling out the PC
board holes to fit their thicker pins. The PC foil pads have
JAN CRYSTALS
purposely been made extra large for this reason. The drill
2341 Crystal Dr.
size would be 0.052." Solder the pins directly to the PCB;
Ft. Myers FL 33907
using a crystal socket adds extra shunt capacitance.
TEL: (800) 526-9825, (941) 936-2397
FAX: (941) 936-3750
HOW TO FIGURE YOUR
NEW CRYSTAL FREQUENCIES
The effect of the EXPANDER 160 in a PLL circuit is always
PARTS SUPPLIERS
the same: the new injection signals simply drive the VCO up
CIRCUIT SPECIALISTS INC.
or down as required, until the input to the PLL’s
220 S. Country Club Dr. #2
Programmable Divider is correct and the loop locks. (This
Mesa AZ 85210
assumes the radio has not been modified by binary code
TEL: (800) 528-1417, (480) 464-2485
changes, or has otherwise been returned to its stock circuit
FAX: (480) 464-5824
configuration before installation.) Figuring new crystal
www.web-tronics.com
frequencies is therefore a matter of adding or subtracting the
desired amount of up or down shift, respectively, to the
DIGIKEY CORP.
output side of the PLL’s Mixer stage.
701 Brooks Av. South
P.O. Box 677
The 40-channel CB band has a total bandspread of 440 KHz
Thief River Falls MN 56701.
(27.405 MHz - 26.965 MHz = 440 KHz); the older
TEL: (800) 344-4539, (218) 681-6674
23-channel PLL radios have a bandspread of 290 KHz
FAX: (218) 681-3380
(27.255 MHz - 26.965 MHz = 290 KHz.) For continuous
www.digikey.com
expanded range, each new crystal must add or subtract
450 KHz or 300 KHz respectively, to the preceding crystal.
MOUSER ELECTRONICS
When the oscillator signal is used directly without
1000 N. Main St.
multiplication, add or subtract the 450/300 KHz directly to
Mansfield TX 76063
each succeeding crystal. If the crystal is one that’s being
TEL: (800) 346-6873, (817) 804-3888
doubled or tripled, add 1/2 or 1/3 of the 450/300 KHz
www.mouser.com
respectively, to each succeeding crystal.

_________________________________________________________________________________________
EXPANDER 160 PAGE 3
INSTALLATION TYPE 1 INSTALLATION — All 23-Channel AM or AM/SSB
NOTE: The radio’s tuned circuits may need realignment after Crystal-Synthesized Radios
installation of the EXPANDER 160. Much depends upon
See Figure 1. These radios all use banks of crystals that mix together,
the desired center operating frequency of the expanded
most often in the 6-4-4 or 6-4-2 configurations. For SSB types there
radio. Therefore a schematic diagram of the radio is
are a few extra crystals in the Carrier Oscillator and synthesizer stages
essential, as well as an accurate Frequency Counter.
to provide the SSB frequency offsets; these have no effect on the
Although specific installation points are described for some
location of the EXPANDER 160. The crystals to be added will go in
popular models, the work should be done by a qualified
the bank containing the six mixing crystals, regardless of whether the
electronic technician. The supplier assumes no liability for
radio is AM or AM/SSB. These six crystals always mix to control the
damage to any equipment resulting from improper
following six continuous channel groups:
installation.
Channels 1, 2, 3, 4
Channels 5, 6, 7, 8
GENERAL INSTALLATION BY CHASSIS TYPE
Channels 9, 10, 11, 12
Radios to be expanded can be classified into four general categories. Channels 13, 14, 15, 16
Channels 17, 18, 19, 20
TYPE 1: All 23-channel AM or AM/SSB having crystal synthesizers. Channels 21, 22, 23
TYPE 2: All AM or AM/SSB PLL types having a crystal oscillator For example, the most common AM schemes use a 37 MHz master
loop mixing stage which is doubled or tripled by subsequent oscillator plus separate 10 MHz oscillators for RX and TX
tuned circuits. (Figure 1A), or banks of 23 MHz, 14 MHz, and 11 MHz RX and TX
TYPE 3: All AM or AM/SSB PLL types having a fixed crystal oscillators (Figure 1B). Most older SSB radios generally use crystals
oscillator loop mixing stage operating directly at the crystal in the 7.8 MHz or 11 MHz range, in the 6-crystal mixing bank.
frequency.
TYPE 4: All AM or AM/SSB PLL types with a loop mixing signal Remove one of the six crystals from the radio and place it in the
generated indirectly from some other crystal-based circuit.
#1 crystal position of the EXPANDER 160 instead. To make it easy
Instead it comes from another area of the PLL circuit. An
remembering which Channel Selector positions provide which new
example would be the very common 15.36 MHz mixer
channels, you should remove either the lowest or the highest
signal generated from a tripled 5.12 MHz PLL IC pin.
frequency mixing crystal, depending upon whether you are expanding
the radio below Ch. 1 or above Ch. 23. Install your new crystals in the
For the TYPE 1 and TYPE 2 radios, the EXPANDER 160 will be
remaining three positions of the EXPANDER 160. Put them in the
used only in its SWITCH mode. For the TYPE 3 and TYPE 4 radios,
correct position order (#2, #3, #4) so that your chosen switch makes
the OSCILLATOR mode will be used. Each mode is determined by
the frequency bands continuous. Since you’re adding an extra three
specific jumper wires on the PC board; install the correct jumper wires
crystals, and each one will be mixed in the radio with four others, this
for the desired mode.
means you will get a total of twelve additional new channels.
Remember that any 40-channel radio modified by crystal mixing will
Cut a 12" piece of hookup wire (provided in our kits) in half. Place
still have exactly the same channel skips as the standard 40 channels.
the two pieces in the “A” and “B” holes of the EXPANDER 160.
Examples include the five in-between “A” channels, and the
Install wire jumpers to put the EXPANDER 160 in the SWITCH
non-continuous frequencies between Ch. 22 and Ch. 26. These skips
mode; i.e., remove J8, J4, J5, J6 and J7 and install jumpers in the J1,
are physically built into the sealed binary or BCD Channel Selector
J2, and J3 positions as shown on the X-Ray View and the PC board
switch, and can’t be changed.
legend. Install the two loose wire ends from holes “A” and “B” in the
two empty holes where you removed the mixing crystal, being sure to
Page 5 shows the general connection points for each type. Remember,
put the “A” wire in the low or ground side hole, and the “B” wire in
you must check the radio’s schematic for the exact location.
the hot or oscillator side hole of the radio.
IMPORTANT: Regardless of the installation type, the YELLOW
“RF” output wire (or “A” and “B” hole wires if
used) must be as short as possible. The YELLOW EXAMPLE A: Cobra 29 AM chassis. This uses the standard 23 MHz
kit wires have purposely been left at 6" lengths for and 14 MHz mixers, with the 11.730 MHz RX and 11.275 MHz TX
this reason. Find a mounting location where these oscillators. There are six 23 MHz crystals, and these are the ones to
wires can be connected into the radio’s PC board change. (Figure 1B.) Note that they change in 50 KHz steps: 23.290,
without needing any longer lengths. Stray 23.340, 23.390. 23.440, 23.490, 23.540. The next three for
capacitance from long wires can detune the circuit, continuous lower frequencies would be 23.240, 23.190, and
or even keep the crystals from oscillating. The 23.140 KHz.. This gives twelve continuous lower channels from
switch wires can be any length, and a 1-foot ribbon 26.955 MHz downward in the Ch. 1-4 positions, four channels for
cable is provided for this purpose. each of the three new crystals plus the original 23.290 MHz.

_________________________________________________________________________________________
EXPANDER 160 PAGE 4
EXAMPLE B: Cobra 134/138/139/Midland 13-895 AM/SSB chassis. TYPE 2 INSTALLATION — All PLL AM or AM/SSB with
This uses 8 MHz and 11 MHz mixing banks, with a 7.8 MHz Doubler or Tripler Oscillators
Carrier Oscillator. The 8 MHz are the ones to change, since there are
six of them. Once again, they change in 50 KHz steps: 8.1590, Refer again to the sketch above. In these radios, the crystal oscillator
8.2090, 8.2590, 8.3090, 8.3590, and 8.4090 MHz. The next three is doubled or tripled in frequency to get close to the output frequency
for continuous higher frequencies would be 8.4590, 8.5090, and of the VCO, which is typically operating in the 33-38 MHz range. The
8.5590 MHz. This gives you the next twelve channels (Ch.26-37) multiplier stage can not be bypassed for two reasons:
from 27.265 MHz to 27.375 MHz in the Ch. 1-4 positions, four
1. The SSB versions will have USB/LSB offset tuning
channels for each of the three new crystals plus the original 8.4090
adjustments following the multiplier stage.
MHz.
2. There is usually a Delta-Tune (AM-only rigs) or Clarifier
For 10-Meter use, add the desired Ch.1 up-shift to the highest radio
(AM/SSB rigs) circuit on the low side of the crystal, which
crystal, 8.4090 MHz. You’d then install up to ten new 8 MHz
must be retained for proper operation.
crystals, six in the radio, and four more in the EXPANDER 160.
NOTE: These old CBs will never cover both the 10M and 11M bands The EXPANDER 160 must be used in its SWITCH Mode for these
without retuning. You could get a straight 23 channels on types. Jumper for this configuration as previously described. Remove
10M by just replacing the existing six crystals, without using the radio’s loop mixing crystal, and install it in the EXPANDER 160
the EXPANDER 160. Using it, you’d get 23 channels plus along with your new crystals. Remember to use the correct crystal
12 channels more, for a total of 35 channels on 10M. positions that match your desired switching order. Install two short
This assumes you’re willing to buy a total of ten new crystals, hookup wires in the EXPANDER 160’s “A” and “B” holes. Place the
six to replace the radio’s originals, plus four to fit in the other wire ends in the corresponding high side (“B”) and low side
EXPANDER 160. Obviously, you could choose anything (“A”) holes where you removed the radio’s crystal. The net effect is
from 12 channels on up to 35, depending upon how much that you now have several loop mixing crystals in series between the
you’re willing to spend on new crystals.

_________________________________________________________________________________________
EXPANDER 160 PAGE 5
 Delta Tune or Clarifier (low crystal side) and the oscillator stage shown.) Bypassing that would kill the Clarifier! Check
(high crystal side) circuit points. the radio’s schematic to determine the right mode to use.
For the SSB radios in particular, it’s very important to adjust all EXAMPLE A: Any AM Courier model with the REC86345 PLL chip.
crystals for the proper frequency. Make all adjustments in the “AM” The mixer crystal is 36.380 MHz. Use the OSCILLATOR Mode. New
mode. There should be enough range with the trimmers for exact crystals might be 35.930 MHz for the lower 40, and 36.830 MHz for
netting, You should then check the USB/LSB offsets. These are the upper 40 channels. These are tripler cut (Third Overtone) type
usually ±1.5 to 2.5 KHz, as measured at the output of the tuned crystals.
circuit which does the multiplication. Adjust the offsets according to
the radio service manual, using the standard FCC band, Clarifier at its NOTE: Many other AM-only PLL radios also use the 36 MHz circuit.
midrange. When switching to the new crystals, the existing offset These include those with the SM5104, TC5080, µPD858,
adjustments should shift them by about the same amount. The and µPD861 chips, as well as all the Royce “sardine can”
Cybernet PLL02A SSB chassis uses trimmer capacitors for the offsets, type modular AM models. The same method works in all
while the Uniden SSB chassis types use coils to trim the offsets. these too.
EXAMPLE A: Cobra 140/142GTL Uniden chassis. This uses an
EXAMPLE B: Cobra 29/89XLR Uniden chassis with µPD858 PLL
11.1125 MHz tripler crystal. New crystals might be 10.9625 for the
chip. Either the SWITCH or OSCILLATOR modes could be used
lower 40, 11.2625 for the high 40, and 11.4125 MHz for the high-
here. However the SWITCH mode is easiest because there is no
high 40 channels. For 10 Meters, use 11.5575 MHz (28.300 to
coupling capacitor to remove; there is only a PC trace between the
28.740 MHz) or 11.4575 MHz (28.000 to 28.440 MHz) depending
oscillator’s peaking coil secondary and the input to the TR18 FET
upon your need for the USB or CW/USB parts of the band.
Mixer. Rather than having to cut this trace, simply switch in new
EXAMPLE B: Cobra 148/2000GTL, Uniden GRANT/MADISON crystals along with the existing 36.57 MHz crystal. New crystals
chassis. The existing crystal is a tripler, 11.325 MHz. New crystals would be 36.12 MHz for the lower 40, and 37.02 MHz for the upper
would be 11.175 for the lower 40, 11.475 for the high 40, and 40. These are also Third Overtone cuts.
11.625 MHz for the high-high 40 channels. For 10M, use 11.770 or
11.670 for USB or CW/USB respectively; coverage as shown above. EXAMPLE C: Realistic TRC459/TRC480. Because the LC7113 PLL
chip is now extinct and this chassis was very expensive, it’s worth
NOTE: The 11.325 MHz crystal used in some older Cobra chassis is
saving and expanding! The loop crystal is 17.8875 MHz. Use the
the oversize HC/33 type, not the standard HC/18 case. For CB
SWITCH Mode again, because the Clarifier is on the low side of this
expansion you’ll also have to replace that one, since the HC/33 won’t
crystal. New crystals might be 17.4375 MHz for the lower 40, and
fit in the EXPANDER 160 PC board. 18.3375 MHz for the upper 40 channels. For 10 Meters, use
EXAMPLE C: Cybernet PLL02A SSB chassis (Telsat SSB140, 18.4825 MHz (CW/USB) or 18.7825 MHz (USB only).
J.C. Penney 6247, etc.) The existing crystal is 10.0525 MHz and is
doubled. New crystals would be 9.94 MHz for the low 40, 10.165
MHz for the high 40, and 10.2775 MHz for the high-high 40. For TYPE 4 INSTALLATION — All AM or AM/SSB PLL Radios with
10M, use 10.38625 for USB or 10.31125 MHz for CW/USB. Indirect Frequency Mixing
EXAMPLE D: Early generation Cybernet PLL02A AM chassis with See Page 5 again. Almost all of these use a 15.36 MHz mixing signal
the 11.8066 MHz crystal. (Midland 13-857B, 13-882C, G.E. 3- which comes from the PLL chip itself. The chip has a 5.12 MHz
5810B, Kraco KCB2320B, etc.) This crystal is being tripled. New output pin, and this signal goes through a tripler coil to produce
crystals could be 11.6567 MHz for the low 40, and 11.9567 MHz for 15.36 MHz which is then capacitively coupled to the Mixer along with
the high 40 channels. the VCO signal in the 16-17 MHz range. Use the OSCILLATOR
Mode. Remove the coupling capacitor and put the YELLOW “RF”
TYPE 3 INSTALLATION — All AM or AM/SSB PLL Radios with wire of the EXPANDER 160 in the empty capacitor hole going to the
Direct Frequency Mixing Mixer side.
See the previous page. The oscillator output is coupled through a NOTE: Because there’s no actual crystal to directly generate the
small disc capacitor or tuning coil to the Mixer stage. You often have 15.36 MHz signal, you must order this crystal along with the
a choice of using the EXPANDER 160 in its SWITCH mode at point new ones so you can preserve the standard 40 FCC channels.
“A” like previous examples, or in its OSCILLATOR mode at point Otherwise some complicated switching would be needed to
“B.” We suggest the OSCILLATOR mode. Remove this coupling connect this signal and disconnect the EXPANDER 160
capacitor, and place the YELLOW “RF” wire of the EXPANDER 160 when you want to change bands. For 10M Amateur
in the empty capacitor hole (“B”) that goes to the Mixer side of the conversions, this crystal would not be needed.
circuit. Remove the original radio crystal, and solder it into the
EXPANDER 160 with the new mixing crystals. EXAMPLE A: Cobra 29GTL/29LTD chassis with µPD2816 PLL
chip. Use the OSCILLATOR Mode. Remove C87 (100 pF) in the PLL
NOTE: In some AM/SSB chassis the SWITCH mode must be used, area. Typical new crystals are 14.91 MHz for the low 40, 15.36 MHz
because the Clarifier circuit is part of the crystal’s low side. for the standard FCC 40, and 15.81 MHz for the high 40 channels.
(Same as the Type 2 sketch, minus the doubler or tripler

____________________________________________________________________________________________
EXPANDER 160 PAGE 6
EXAMPLE B: All late generation Cybernet PLL02A AM chassis with Special radio modifications are needed to make it work properly with
10.24 MHz and 10.695 MHz crystals. (HyGain 2702, Midland 77- the EXPANDER 160. The 5.12 MHz PLL tripler signal will be
857, G.E. 3-5804D, etc.) In this circuit, the 10.24 MHz crystal is used disconnected. Since you’re replacing it with an external 15.36 MHz
not only for the PLL Reference Oscillator, but it is also doubled to oscillator (plus your choice of others), the SSB offsets and Clarifier
20.48 MHz and used for loop mixing. Use the OSCILLATOR Mode. wouldn’t work afterwards. The following steps will solve this
Remove C17 (47 pF) from the chassis and install the YELLOW “RF” problem, and will also give you much more slide range too.
wire in the empty capacitor hole going to the IC2 Mixer. You will CRYSTALS TO USE:
need a 20.48 MHz crystal to preserve the standard 40 FCC channels, 14.460 MHz gives 26.065 to 26.505 MHz (LOW-LOW band)
as well as 20.03 MHz for the low 40 and 20.93 MHz for the upper 40 14.910 MHz gives 26.515 to 26.955 MHz (LOW band)
channels. 15.360 MHz gives 26.965 to 27.405 MHz (FCC band)
EXAMPLE C: Early NDI Chassis with MC14526/MC14568 PLL 15.810 MHz gives 27.415 to 27.855 MHz (HIGH band)
circuit. (SBE Sidebander IV, Sidebander V, Console V.) Connect for 16.260 MHz gives 27.865 to 28.305 MHz (HIGH-HIGH +10M CW)
the OSCILLATOR Mode. This chassis uses a 10.00 MHz crystal for 16.455 MHz gives 28.060 to 28.500 MHz (10M Novice band)
the PLL Reference Oscillator, which is also doubled to 20.00 MHz for You can pick a maximum of only 4 of the 6 possibilities!
loop mixing. Remove C918 (1.5 pF). Install the YELLOW “RF” wire
in the empty capacitor hole going to Mixer Q911. You’ll need a VCO BROADBAND
20.00 MHz crystal to replace the removed signal. New crystals could
be 19.55 MHz for the lower 40, and 20.45 MHz for the upper 40 1. Replace “A” (47 pF) with a .001 µF disc capacitor. This
channels. For 10M, use 20.595 MHz (CW/USB) or 20.895 MHz increases the control of the VCO varactor diode “F.”
(USB only). NOTE: The later NDI chassis with the NDC40013 PLL 2. Replace both resistors “B” with 180Ω. This increases the gain
chip works in exactly the same way. Those models include: Craig of the VCO transistor stage “F.”
L131, L231, Johnson Messenger 4730, Johnson Viking 4740, NDI
PC200, PC201, Pace 1000BC, 1000MC, SBE Console VI, Tram D64. CLARIFIER TX/RX SLIDER
EXAMPLE D: The Uniden µPD2824 SSB chassis. You must use the 1. Remove parts “C.” This eliminates the fixed TX-only control.
OSCILLATOR Mode. Currently includes the following models. 2. Replace “D” with a bare jumper wire; this adds an extra
PC833/PC965: Cobra 146GTL, Midland 6001(new), 7001 (new), +0.7 VDC to the total varactor control voltage.
Midland 79-260, Pearce-Simpson Super Cheetah (Australian), 3. Use your radio schematic to locate the Clarifier hot side. This is
President AR-144, AX-144, P300, Realistic TRC451, the end of the pot with the 8 VDC, RX-only normally on it. The
Sears 663.3810, Uniden PC244. newer chassis use ribbon cables, as the front panel is also a
PB062: Realistic TRC453, Uniden PC122 PC board. You’ll have to trace this conductor very carefully
PB105: Uniden Pro640e from the front panel to where it enters the main PC board. Lift
PB122: Realistic TRC465, Uniden Pro810e that PCB wire, and put one end of your own wire in that hole.
These popular models are still being sold. They require some extra 4. Run the other end of your wire over to “J.” This is the constant
modifications. The following special section is devoted just to them. +8 VDC. The radio will now slide on both RX and TX. Check
Use the Chart below to find the specific part number being discussed this out right now, before even installing the EXPANDER 160 .
in the text. Look under the columns “A” through “L” for the In the next step the 10.24 MHz PLL stage will be modified;
particular circuit function. Then substitute that part number as potential problems are much easier to isolate by logical testing of
you’re reading the text. The small parts are located in the wax VCO each step as you go.
mess
IMPORTANT! The SSB Clarifier control will be lost unless you REQUIRED RADIO MODIFICATIONS
make the following changes. This chassis was purposely designed to 1. Remove X1, the 10.240 (10.2417) MHz crystal. Solder one lead
use the 10.24 MHz PLL Reference Oscillator signal for the SSB offsets of a 4.7µF coil in the empty crystal hole that went to the [-] of
and the Clarifier too. (Precisely to discourage illegal Clarifier mods!) “H.” Leave the other end standing up vertically for the moment.

UNIDEN “A” “B” “C” “D” “E” “F” “G” “H” “I” “J” “K” “L”
Chassis VCO 10.24 MHz Clarifier 10.695 MHz Constant 10.240 MHz TX Tuning
Type Stage Oscillator Varactor Mode Offsets Regulated Mode Offsets Mixers & RF
Diode +8 VDC
PC833 C75 R98 D32 D31 C73 L14 TR22 D30 USB: L20/C102 Collector L16, L17, L18 MIX: L40, L39,
PC965 (47 pF) R99 R122 (5 pF) TR20 LSB: L21/C103 of TR35 (ignore all) L38, L37
PB015 TR19 D25 AM: L19/C101 (2SA473) OSC. = TR22 Final: L27
PB062 C72 R102 D25 D24 C66 L13 TR23 D23 USB: L19/C97 Pin 3, IC4 L17, L16, L15 MIX: L37, L36,
(47 pF) R103 R119 (5 pF) TR21 LSB: L20/C98 (HA17808) (ignore all) L35, L34
TR20 D19 AM: L18/C96 OSC. = TR23 Final: L26
PB105 C72 R102 D25 D24 C66 L13 Q23 D23 USB: L19/C97 Pin 3, IC4 L17, L16, L15 MIX: L37, L36,
PB122 (47 pF) R103 R119 (5 pF) Q21 LSB: L20/C98 (HA17808) (ignore all) L35, L34
Q20 D19 AM: L18/C96 OSC. = Q23 Final: L26

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EXPANDER 160 PAGE 7
2. Reinstall the crystal directly across the base of the oscillator “K” ADJUSTMENT & OPERATION, µPD2824 SSB MODELS
and ground. The simplest way is to first splice some short bare
wires to its leads so it will reach the proper PC foil pads. Then lay A Frequency Counter or second SSB radio is required. Ignore any
it down flat on the solder side of the PC board and solder to the alignment instructions for the “K” coils, now out of the circuit. Set
PC foil pads. Use electrical tape under it to prevent shorts. the Clarifier to the 12:00 knob position and adjust the AM “I” coils
and crystal trimmers for the center channel on each band. (26.955,
Alternately, you could also mount it vertically on the parts side of the 27.405, 27.855 or whatever in the Ch.40 position.) By using a
PCB. This means drilling two very small holes in the PC board. You second SSB receiver with known accuracy and its own Clarifier at
can use a #58 drill bit, or a #105 or #106 Dremel bit. Try to find a 12:00, you could then set the USB/LSB coils for the most natural
PCB spot where you only have to drill through the fiberglass. If you voice sounds, without even needing a Frequency Counter. Use the
must drill through a foil, pick a wide one, like the common ground. best combination of adjustments you can find, consistent with good
Then scrape out an extra 1/8" around each hole to prevent shorts Clarifier range and knob symmetry.
when you pass the spliced crystal leads through the drilled holes.
Recheck for any possible shorts from the crystal leads to the PCB foils. Adjust VCO coil “F” to cover the desired range. In most cases the
maximum range is 160 channels before the VCO quits. Adjust all “L”
RF coils for the most even RF power output across the desired range.
EXPANDER 160 PREPARATIONS
RX sensitivity is usually OK as is, with no further adjustment needed.
1. Jumper for the SWITCH mode, even though you will actually use
NOTES
the OSCILLATOR mode. Remove jumpers J4, J5, J6, and J7 and
1. Slide range varies from chassis to chassis and also depends upon
install jumpers J1, J2, J3, and J8. Install a wire in hole “A.”
crystal load capacitance. (Don’t exceed 20 pF when ordering.)
Ignore hole “B.”
You may get a case where there’s only about 2-3 KHz USB up-
2. Connect the loose end of the “A” hole wire to the top lead of the
slide with the Clarifier knob fully clockwise. To cure this, decrease
4.7 µH RF choke you installed in Step 1 of the preceding section.
the value of USB capacitor “I” by about 20-40 pF; this raises the
3. Remove capacitor “E” (5 pF) from the radio. Connect the
USB frequency and makes the Clarifier tune in more closely to the
YELLOW “RF” wire to the empty hole going to the base of
center position. If you need still more range, try screwing the slug
transistor “E.” Keep this wire very short; 3" should be plenty.
of the USB coil “I” all the way down to minimize its inductance.
This completes the installation. If you check the radio schematic and 2. You can sometimes boost the slide range by increasing your RF
the sketch below, you’ll see that you’re now using the existing choke value from 4.7 µH to 10 µH maximum. Don’t exceed this
Clarifier circuit to slide the cold end of the EXPANDER 160’s crystal amount!
bank. The radio’s 10.240 MHz PLL oscillator is still functional. But
now you’ve removed the “K” mode offsets and have added your own Before bolting the EXPANDER 160 to the radio frame, secure all
Clarifier tuning. The “I” offsets are the only frequency adjustments adjustments and critical VCO parts. You can use an ordinary candle,
you’ll need besides each crystal trimmer in the EXPANDER 160. dripping fresh wax around the VCO parts as well as the Clarifier
varactor diode. In a pinch you can use your wife’s fingernail polish,
You can power the EXPANDER 160 from the same source as the but it’s harder to remove if you must retune. This circuit area is
Clarifier (point “J”). Ground the BLACK wire by soldering to the extremely sensitive, and must be mechanically secure from vibration or
closest metal transformer can. Keep the YELLOW “RF” wire very you’ll drift all over the band!
short You can mount the unit along the PLL side of the radio frame Good DXing!
using a small L-bracket.
NOTE: For chassis not included here, send a large #10 stamped self-addressed envelope and the exact radio make and model number. We’ll try to
help.

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EXPANDER 160 PAGE 8
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EXPANDER 160 PAGE 9
 C1, C2, C3, C4, C9 = .01 mF C5 = .001 mF
R1, R5, R7 = lKΩ C6 = 150 pF
R2, R3 = 10KΩ C7 = 68 pF
R4 = 220Ω C8 = 22 pF
R6 = 2.2KΩ D1-D4 = lN914
L1 - L5 = 470 mH Q1, Q2 = 2N3904
CT1 - CT4 = 9-50 pF

For OSCILLATOR mode, install jumpers J4, J5, J6, J7, J8. For SWITCH Mode, install Jl, J2, J3, and connect hookup wire to “A” and “B.”

EXPANDER 160 PARTS LIST

5 each, .01 mF ceramic disc capacitor 2 each, 2N3904 transistor (2N2222A, ECG123A,
1 each, .001 mF Radio Shack #276-2009, 276-2016)
1 each, 150 pF 4 each, 1N914 fast-switching diode (1N4148, ECG519,
1 each, 68 pF SK3100, Radio Shack #276-1122)
1 each, 10 pF 5 each, 470 mH RF choke (Mouser/Circuit Specialists #43LS474)
3 each, 1KΩ 5% ¼-watt resistor (brown-black-red) 4 each, 9-50 pF, 5mm micro-miniature trimmer capacitor
2 each, 10KΩ 5% ¼-watt resistor (brown-black-orange) (Mouser/Circuit Specialists #24AA024 or ME242-8050)
1 each, 220 Ω 5% ¼-watt resistor (red-red-brown) 1 each, EXPANDER 160 Printed Circuit Board
1 each, 2.2KΩ 5% ¼-watt resistor (red-red-red) Misc: Crystals and switch per your requirements. (See text.)

A complete kit is available for $38 postpaid from:

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EXPANDER 160 PAGE 10
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EXPANDER 160 PAGE 11