Karl's procedures

The Author's one of those very organized builders of various projects, including electronic ones, such as radio communications for SRG. Once an idea is made, it's thought about it during other (boring) things, like driving on the hyway (summer-type conditions) or just relaxing around the house. A vacation would be thinking about it as well. But that's fun. The next practice is to draw a block and system diagram on what was thought up the device would do, and lots of "what-if" scenarios, for designing logic circuits. A project can take anywhere from a month to several years. For example:

An idea, perhaps even just "pipe dreaming".

Draw up a rough block diagram.

Research parts availability, sources and pricing.

Design and draw up a schematic diagram.

Write-up a theory of operation document and verify it agrees with the schematic and block diagrams. Make any changes or improvements at this time.

Design the rough artwork; boards "runs" layout.

Build the prototype and test it's operation in an actual situation. Make any changes or improvement at this time and update the schematic and theory of operation documentation at this time.

Find and hire a professional art worker and board builder; procure availability and pricing. If acceptable order the boards.

Upon receiving the boards, load them up and test them.

Install the final product in the equipment and test it's operation.

Install the equipment on site and turn up.

Monitor operation for a few days.

Ask alternate person(s) to monitor further.

"Read-in" those person(s) so they can make intelligent decisions and reporting.

After pre-determined period close the successful project.

Here's the test bench where the prototype and final projects are performed. On the right is the documentation creation to be printed out for a manual.

On the left side of the shop drafting and general operating happens when time permits. Just on the far edge of the picture is one of the equipment racks for the station; in this case, SRG 147.20 repeater. And yes, the floor is clean. A professional type setup.

When a new (or repaired) station is ready to go to a remote high site staging is performed for a few days or weeks to ensure the equipment is working properly. Here's shows an example of a (old) GE station being tested in the "lab" which is just a (multi-use) painting room. This is one of two "short" racks for those tasks. It' better than laying all of the stuff on the bench which takes up valuable space. Plus, the rack is on wheels so it can move it to the bay for other tests, and loading, etc.

Starting from the top is the Bp duplexer (needed in high RF areas) as apposed to a "BpBr" one which really is not very band-pass, because it's not a goes-in, goes-out on the coaxial jumpers. Next, is a little shelf that was used to used to lay a laptop PC. Next, is the controller, then the GE Mastr-II repeater with it's power supply. It's stock (non-SRG mods) That and some of the other components are rather heavy.

This is a typical "test station" for SRG equipment where two radios for different purposes, but for the same remote site is load tested for power out, heat dissipation and FCU cycle/operation.

During prototype building and general communications equipment maintenance the Author is evaluating several products for cleaning. Starting from the left is denatured alcohol, CRC cleaner 2000, CRC cleaner QD, Puretronics cleaner 3500, Deoxit D5, Deoxit F5, NXT (air) duster.

The denatured alcohol is a mix of ethanol and methanol according to the SDS so practice caution if handling it a lot without gloves.

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