LDG FT-Meter For Yaesu FT-857 and FT-897 Version 1.1

LDG Electronics

1445 Parran Road, PO Box 48 St. Leonard MD 20685-2903 USA Phone: 410-586-2177 Fax: 410-586-8475
ldg@ldgelectronics.com www.ldgelectronics.com

LDG FT-Meter

For Yaesu FT-857 and FT-897

Table of Contents

Introduction Jumpstart, or Real hams dont read manuals! Specifications Getting to know your FT-Meter Installation Setup Initial Calibration Receive parameter setup Transmit parameter setup Operation Application Notes Base Station Use Mobile Use Other Applications Care and Maintenance Technical Support Warranty and Service Feedback 11 11
Introduction Congratulations on selecting the LDG FT-Meter. The FT-Meter provides accurate and precise readings for a wide range of receive and transmit parameters. While most users will choose SMeter readings on receive and Power Output on transmit, several other useful readings are available. The FT-Meter simply plugs into the meter jack of your FT-857 or FT-897 transceiver. It is highly portable, in keeping with the popularity of these radios for use on Dxpeditions. LDG pioneered the automatic, wide-range switched-L tuner in 1995. From its laboratories near the Nation's Capitol, LDG continues to define the state of the art in this field with innovative automatic tuners and related products for every amateur need.
Jumpstart, or Real hams dont read manuals! Ok, but at least read this one section before you transmit: 1. Set up your transceiver for normal operations 2. Plug your FT-Meter into the meter jack using the right angle plug. This is on the bottom of the front panel, under the FUNC button on the FT-857, and just to the right of the main tuning knob on the FT-897. Plug the other end of the cable into the FT-Meter. 3. Connect a 12 volt power supply capable of delivering 100 mA to the 2.5 x 5.5 mm coaxial power jack (center positive) if desired. The 12 volt connection is for the light only; the meter will work fine without it. 4. Select the parameters you want to display on receive and transmit from the radio's extended setup menu (items 60 and 61, respectively) 5. Operate normally; the meter continuously displays the selected values.
Specifications S-meter, Discriminator or Voltage on receive Power output, SWR, Modulation, ALC or Voltage on transmit Externally powered cool blue backlighting On/Off switch for backlight. Size: 3.5 x 3 x 2 inches Sensitive 500 micro-amp meter movement Light requires 12 volts at 100 ma, 2.5 x 5.5 mm jack, center positive
Getting to know your FT-Meter Your FT-Meter is a quality, precision instrument that will give you many years of outstanding service; take a few minutes to get to know it.
The front panel presents the meter face with seven calibrated scales: S: Signal strength on receive, calibrated in "S" units and dB above S9 ALC: Automatic Level Control voltage on transmit (shares S Meter scale) PWR: Transmitter output power in Watts SWR: Standing Wave Ratio on transmit MOD: Percent modulation on transmit VOLT: Power supply voltage on receive or transmit DISC: Discriminator reading on receive You will select two of these scales for display, one for receive mode and one for transmit mode, from the radio's setup menu. You can change among them as often as you like. There are no controls on the FT-Meter; operation is fully automatic.

On the rear panel, the 2.5 x 5.5 mm jack coaxial DC power connector is on the left. The three foot stereo 1/8 input cable connects to the radio attaches on the right. This is a standard stereo cable, If you wanted to extend the distance away from the radio, a standard headphone extension cable would work fine. Near the top is the on off switch for the back light. The brightness control is in the middle and can be adjusted with a small screwdriver. The meter zero calibration can also be adjusted with a small screwdriver and is near the bottom of the back panel and will be described in the calibration section.
Installation The FT-Meter is intended for indoor use only; it is not water resistant. If you use it outdoors (packing up Mount Everest, for example) you must protect it from rain. Position your FT-Meter in a convenient spot on your operating position, anywhere within reach of its six-foot cable. Plug the cable into your transceiver as follows: The meter jack on the FT-857 is located on the bottom of the front panel, under the FUNC button on the left.
The meter jack on the FT-897 is similarly located on the bottom of the front panel, but a little right of center, just to the right of the main tuning knob.
Your FT-Meter requires 12 volts DC at 100 ma to operate the light. Connect a suitable power supply to the 2.5 x 5.5 mm coaxial DC input jack using the provided 2.5 x 5.5 mm jack coaxial power connector (center positive). If you don't want to use the meter light, simply leave the power jack unconnected; the meter itself is a passive device and will work fine without the 12 volt input.
Setup Your FT-Meter will display any two parameters you select, one on receive and one on transmit. You specify the parameters in the radio's extended setup menu. Press and hold the FUNC button on the radio to bring up the menu. Rotate the SELECT knob to menu item 1, labeled "EXT MENU" and turn the main tuning knob until the setting is "ON". This enables the extended menu items. Initial Calibration When off, the meter needle should rest on the bottom index mark of the SWR scale, labeled "1:1". If it doesn't, insert a small flat-blade screwdriver into the hole under the center of the meter face into the needle adjustment slot. Gently turn the screwdriver to center the needle on the mark. Rotate the SELECT knob to menu item 60, labeled "MTR ARX SEL". Turn the main tuning knob until the menu option reads "FS". This provides a full scale meter reading for calibration. Check that the meter settles at the top of the red portion of the S Meter scale, just to the right of the +60 mark. If the meter needs calibration, locate the FS adjustment on the back of the meter enclosure. Adjust it with a small flat-blade screwdriver until the meter is exactly at the top of the red arc. Your meter is now calibrated. The meter is calibrated at the factory, but shipping or other forces may require a recalibration. You should only have to do this once, when you first set up the meter. Receive parameter setup Leave the SELECT knob on menu item 60, labeled "MTR ARX SEL" to set the parameter that will be displayed during receive. Turning the main tuning knob, you can select from the following options: OFF: no meter display on receive VLT: power supply voltage CTR: discriminator center meter SIG: received signal strength ("S" meter) Select whichever parameter you want displayed on receive.

Transmit parameter setup Turn the SELECT knob to menu item 61, labeled "MTR ATX SEL". This sets the parameter that will be displayed during transmit. Turning the main tuning knob, you can select from the following options: OFF: no meter display on transmit VLT: power supply voltage SWR: standing wave ratio MOD: deviation level ALC: automatic level control voltage PWR: transmit power Select whichever parameter you want displayed on transmit. Turn the SELECT knob to menu item 1, and reset the extended menu option to "OFF" if desired. Press and hold the radio's FUNC button to exit the setup menu. You can repeat this process to select different parameters as often as you like. You can even change parameters while operating.
Operation To operate your FT-Meter you just, well, operate. The meter has no controls and requires no input from you. Simply use your transceiver normally, and your FT-Meter will continuously display the selected parameters. Application Notes Base Station Use Your FT-Meter can go practically anywhere on your operating desk. The three foot cable gives you a lot of latitude in where you place it. Some obvious choices are on top of the radio or beside your computer monitor. Mobile Use The FT-Meter is ideal for mobile operation. You can mount the meter on the dashboard with Velcro tape in any convenient location. The meter is much easier to read than the radio's display, especially if the radio is mounted at any distance from the driver's position. If you choose to connect the 12 vdc input to light up the meter, be sure to use a fused power line (not provided by LDG). LDG recommends a 1 amp "fast blow" fuse. Mobiling with the FT-Meter is great, but don't be distracted by its beautiful face; keep your eyes on the road! Other Applications LDG designed your FT-Meter specifically for the Yaesu FT-857 and FT-897 transceivers, and does not recommend using it in any other application. However, the meter is in fact simply a 500 micro-amp meter movement; the calibration potentiometer gives you a range of.5 - 2 ma. If you choose to use it in a different application, take care not to exceed the maximum current specification; the meter movement will be damaged or destroyed by current in excess of this specification.
Care and Maintenance Your FT-Meter tuner is essentially maintenance-free. The outer case may be cleaned as needed with a soft cloth slightly dampened in a mild household cleaning solution. Do not use solvents of any kind on the plastic meter face. As with any modern electronic device, your FT-Meter can be damaged by temperature extremes, water, impact or static discharge. Technical Support We are happy to help you with your product. Telephone technical support is available at 410-5862177 weekdays from 9 am to 5pm Eastern Time. Inquiries by Fax at 410-586-8475 are welcome, and prompt e-mail support is available at ldg@ldgelectronics.com. Warranty and Service Your product is warranted against defects in parts or workmanship for two years from purchase. The warranty does not cover damage due to abuse or exceeding specifications. This warranty applies to the original purchaser only; it is not transferable. A copy of the receipt showing the purchasers name and the date of purchase must accompany units returned for warranty service. All returns must be shipped to us pre-paid; we will not accept units with postage due. A return form is provided on our web site for your convenience. If you need to return your product to us for service, package it carefully, keeping in mind that we will re-use your packaging to return the unit to you. Download the return form from our web site (www.ldgelectronics.com), fill it out and return it with your tuner. A self-addressed returnshipping label, while not required, will help insure speedy and accurate delivery of your repaired unit. Include a full description of the problem, along with your name, address and a phone number or e-mail address where we can reach you with any questions. Repairs average about 3 to 6 weeks. We will be glad to service your LDG product after the warranty period has ended. We will notify you of repair charges by phone or e-mail, and bill you after repairs are completed. Visit LDGs web site for support, sales and for information on exciting new products from LDG. You can find us on the web at www.ldgelectronics.com.

Modification Sheet

Yaesu FT-897
last modified: 27. Dez. 2004

Directory

Introduction.... 2 Some background informations about the FT-897 mods.. 3 FT-897 FT-857... 3 AGC..... 3 Speechprocessor.... 3 ALC audio pumping.... 5 Exciter Stage Protection.... 6 Proper BIAS-adjustment.... 7 Replacing the stock MURATA filter.... 8 Using an Electret capsule.... 8 Battery modification from W4CNG.... 8 Service Menu Settings... 9 Freeband Mod.... 9 Programming Software.... 10 FT-897 wont Power ON.... 10 Modifications overview.... 12 TX.... 12 RX..... 13 Miscellaneous..... 13 Mods Summary View... 14 Mods Detail View.... 18 Disclaimer Disclaimer of liability... 24 Copyright.... 24
12/2004 Jochen Heilemann All rights reserved.
Jochen Heilemann, DG2IAQ P.O. Box 1106 D - 75218 Niefern-schelbronn

Germany

Phone: Fax: e-Mail:
+49 (0)340 +49 (0)341 dg2iaq@web.de

Introduction

I started on doing modifications of CB- and HAM-radios since 1980 at the age of 12 years. I mostly wasnt satisfied with the sound of the modulation or reception of my rigs. This is normally founded by restrictions of the local law or by rationalize productions. Only expensive high-class amateur radios have a good sound on their basic state. Therefore there must be some possibilities for improvements. So I learned the basics of RF electronics on myself and did a lot of modifications until today and I would like to spend my experiences to all other electronic interested people, CB- or HAM-radio stations. You have to recognize your local laws. Mostly modifications arent allowed by the local law or by the manufactures. So you do it on your own risk. Also the brand new HAM rigs are mostly build with a lot of teeny-weeny SMD parts. You have to use special equipment and you also must have a great expert knowledge. So some modifications arent for only hobby electronic technicians. So this and all of my Modification Sheet are for education purposes only !
Used pix are mostly done with my Fujifilm FinePix 6800 Zoom on resolution 3M/Fine, but they are reduced on their size due to minimize the total file size of this publication.
Some background informations about the FT-897 mods

FT-897 FT-857

Both transceivers are based on the same circuit diagrams but they have a different mechanical case. All my electronics modifications can be done on the FT-857 mobile transceiver too. But actually I hadnt the time to compare the numbers/names of the parts between those both TRX. So it could be that some parts have a different number/name on the FT-857 than described here for the FT-897. As many FT-897 just wait for this modification sheet I will check and compare this later and just spend my men-power in finishing this modification sheet first.
A lot of users have criticised the too fast SLOW AGC on SSB mode. For my opinion, thats true too. The circuit is similar to the FT-817 portable TRX on which I recognized the same problem some years before. But the fix is simple and easy by only adding an additional electrolyt capacitor (10F) parallel to the SLOW AGC capacitor C1503 (1F). As this stock capacitor can be found and handled very easily and without the need to remove any PCB this fix could be done from everyone and it only needs about 15 minutes including opening and closing of the TRX case. After that mod the SSB receiving sound is much, much better especially on strong signals. And the time constant is still fast enough not to loose weak signals between those big guns. I dont like those TRX which needs 3 sec. or more to come back. Oh, I just hear a lot of FT-897 owners breathing a sigh of relief. Hihi.

Speechprocessor

A story what I better would call.the mystery of the FT-897 speechprocessor. !! You ask me why !? Cause the stock FT-897 just has a speechprocessor-Button, but no build-in real speechprocessor ! Or let me better say the FT-897 has no build-in circuit which would act like a real speechprocessor. Youre confused ? Then you react like me as I first read some remarks about that fact on several ham discussion forums just a long time before I got my own FT-897. Prior to my own buying I had a QSO with a ham from Sweden (SM4YPG, Lars-Gunnar) on 20m and he used a FT-857. As I told him that he sounded distorted and harsh we did some on-air tests and comparisons on different menu settings. And the difference between speechprocessor ON and OFF wasnt really significant, even not on a speechprocessor level of 100. This was the final proof for me. A real speechprocessor consists of either an AF compressor, an AF clipper, an AF lowpass filter, or the combination of all these parts. The better and what I call real speechprocessors would be the RF speechprocessor which clip directly on the RF signal to prevent excessive distortions. And what on the FT-897 so called speechprocessor, when looking into the schematic !? Its only an additional simple AF amplifier (MAIN UNIT, IC Q1118, NUM2902V, pins 8 10) with an amplification factor of 100 (R1417/R1420), but the output level is reduced again with a resistor divider (R1435/R1437, 1:15) !! And what is the effect of this ? You get a real minimum additional amplification when activating this speechprocessor. The real amplification factor is set by the BIAS-line and the menu item no. 074
12/2004 Jochen Heilemann All rights reserved. Jochen Heilemann, DG2IAQ P.O. Box 1106 D - 75218 Niefern-schelbronn Phone: Fax: e-Mail: +49 (0)340 +49 (0)341 dg2iaq@web.de
(Proc. Level). But if the menu level no. 074 is set too high (up to 100) the audio sounded distorted cause the IC is overdriven. But it dont sounds much louder cause the output resistor divider destroys this higher AF level. I think the Yaesu engineers called this a speechprocessor cause when an IC audio amplifier is overdriven the signal clips as no more amplification is possible. This can be a kind of processing but the resulting distortions are ugly and not understandable. The sound is getting more and more hollow and the distortions reduce the total readability. But a real speechprocessor should HELP on weak signal operations, and should not additionally DESTROY them. So this overdrive way is one of the simplest but most bad possibilities which can be chosen for a speechprocessor.
R1420 680k C1412 R1417 6k8 R1435 22k C1475 Q1118

from Q1087

to Q1098 BIAS

R1437 1k5 1

The stock mystery speechprocessor To change this unusable speechprocessor into a good and working speechprocessor the trick is quiet simple. I removed R1437 to get a much higher output level. Now you would hear a difference between speechprocessor ON/OFF and the audio distortions are reduced significant cause you dont need as high menu levels on no. 074 than before. But now we would only have a switchable additional audio amplifier and nothing more. Does this make sense !? No ! So I had to limit the audio level to get a real speechprocessor. And I did this with two antiparallel lownoise diodes. As clipping on the audio side always produces some distortions and a high pitched sound characteristics (like loosing all basses) I added a capacitor to have an audio lowpass filter too.

D2 BAT85 D1 BAT85 C3

AF Clipping

Smooth Lowpass 1.5 kHz

150p R1420 680k C1412 R1417 6k8 R1435 22k C1475 Q1118
remove to raise audio level
The modified speechprocessor So the resulting sound with speechprocessor ON is great now ! And it has a real DX punch now !
The stock smooth AF highpass filter, consisting of C1412/R1417, reduces frequencies below 230 Hz and helps a little too. My AF lowpass filter with 1.5 kHz seems to be too low on the first view. But as we have a strong high pitched audio sound while being in the clipping area this reduction is necessary and the resulting sound of this both effects (working in opposite directions) is great as you can hear on my sample wav files I recorded. Im using a pair of BAT85 schottky diodes as they only have a forward voltage of 0,3V. So the clipping starts on the quieter voice parts too. But it should be possible to use 1N5711, HP2800-2810 or other lownoise diodes with 0,7V too. On menu item no. 074 Im using a Proc. Level of 35 now (with my audio modified MH-36 DTMF handmike) and the difference between ON/OFF is absolutely significant. Of course YOUR final value for no. 074 is depending on YOUR used microphone, its characteristics and its audio level. The DX can come !.

ALC audio pumping

Another big fault of the 857/897 design is the REV ALC which is documented on several ham radio forums too. The 897 reduces its output power when having a bad SWR. This is a real good and necessary option. But this detector works too fast and the SSB modulation is clipped or sometimes cut on its peaks. A QSO isnt possible in this state, as many users told. One possibility is to check and realign the REV ALC parameters as described in the servicemanual. Normally 100W on HF should be reduced to 50W on a SWR of 3:1. So some users only raised the digital values of the servicemenu to make the REV ALC acting later. This is done by servicemenu items 053 058. Heres an email from Mike (KM6AB) to me, as an additional statement to this fact:
Von: Mike Gesendet: Mittwoch, 17. November 2004 16:37 An: Jochen - DG2IAQ Betreff: Re: FT-897D - Reverse SWR alignment Hi Jochen, Hold down the A, B and C menu buttons during power up to get to the alignment menus. The main tuning knob will now change alignment parameters, be careful! Use the small menu/vfo/ch knob to find the parameter HF1-REV-ALC. This is the set point for SWR foldback on the lower HF bands and the main tuning knob will change the numbers in the upper right corner of the display. Factory settings are usually 40 to 50 and higher setting will make the radio ignore higher reflected power conditions. There is also an HF2 and HF3-REV-ALC for the higher HF bands I moved mine to 75 on all three menus and the radio now behaves fine with an LDG AT-897 autotuner into a G5RV on all bands from 80 through 10m. I would recommend trying the radio into the antenna you have (as long as the match is good) and move the numbers up until the radio stops breaking up on transmit. Do this mod at your own risk, you will be making the radio more susceptible to damage from an antenna mismatch. I have been very happy with my 897 after two trips back to Yaesu, but this is a very early model. I also replaced the stock mic cartridge with a Heil HC-5 element and it gets great audio comments and has a lot more audio punch, which helps with 20w battery operation. Good luck, Mike KM6AB

Menue No. 057 058

Description HF1-REV-ALC HF2-REV-ALC HF3-REV-ALC 50M-REV-ALC VHF-REV-ALC UHF-REV-ALC
Remarks CW CW CW CW CW CW 1.8 MHz 7 MHz 21 MHz 50 MHz 144 MHz 430 MHz

Value 61 61

Modified KM6AB 75

Realigned DG2IAQ 90 115

on a 150 ohms dummyload (= 3:1)
As Mike told this can solve the problem but can be dangerous too as you dont have this good protection on bad SWR than having before. So I tried another way and I had lengthen the time constant of the ALC circuit a little bit. This prevents from acting too fast, but still having the bad SWR protection as well as you can see on the table above. The mod is done simply by adding a capacitor parallel to the ALC time delay capacitor C1061.

Exciter Stage Protection

What a surprise !! The FT-857/897 uses the same critical FETs 2SK2975 for the exciter stage as the FT-817 uses on its PA module ! Have you ever heard of the BFC, the FT-817 Blown Finals Club !? Hihi. Oh yes, I think so So as I found out this fact on the FT-897 I decided to make a real necessary modification to prevent a damage of these FETs. Of course on the FT-897 these FETs never see a bad SWR as they work behind the PA module, but on the 817 these FETs werent destroyed only by bad SWR. The were also destroyed by overheat, overvoltage, voltage peaks, or combinations of this even when the FT-817 handbook tells about using this TRX on DC power supplies up to 15 volts. A real guarantor to destroy them ! The 2SK2975 have their full RF output still on less than 10 volts ! Each higher DC voltage would produce more heat but you wont get more RF out. On more than 12V you get into the critical area where the shown combinations above can produce higher RF voltages than the used DC voltage. But I dont want to bore you, you can read the whole stories on huge ham radio forums. Just search for the BFC and you will find tons of stuff Of course you can de-solder the 2SK2975 and re-solder their follower (Mitsubishi RD07MVS1) which is much more rough and can handle higher voltages. But I will only do that if my 2SK2975 would really die. The solution is simple here too. Just add a 10V fixed voltage regulator into the +DC line.

TP1017 / TP1018

13.8V to PreDrivers Q1006/Q1007

Jumper

L1890599 / C1021 / C1023

self-resetting 1.85A

10V to Driver FET's Q1001/Q1002 = 2SK2975
To be safe against damaged FETs and burned PCB lines as a result of a short I added a 1,85A selfresetting fuse into the 10V line too.

Proper BIAS-adjustment

Remark: The BIAS adjustment of VR1001/VR1002 must be done again after you build in the Driver Protection from the chapter before. The 857 of the Norway HAM I told you above sounded hard and breathing. It sounded like the operator didnt get enough air to speak or he had a cough and his lung works hard. I cant really describe this sound but it always sounded that he like to say more, but he hadnt air enough to bring it to end. Or as someone permanently tries to retard his voice. This is a result of wrong BIAS parameters. If the BIAS current is too low you would hear this effect and the modulation sounds as being retarded. The same was on my stock FT-897. The same I read on the ham radio forums as people told their BIAS currents werent properly aligned, sometimes they werent properly aligned from the factory ! Time for me to check and re-align my BIAS currents. Herere the results:

Adjust VR1004 VR1003 VR1001/1002 VR3002 VR3001
Description Pre-Driver 2SK2596 Driver 2SK2973 (2x) Exciter 2SK2975 (2x) HF/50MHz PA 2x 2SC5125 VHF/UHF PA 2SC3102
as told in the servicemanual 30 mA 20 mA 2x 100 mA (**) 300 mA 300 mA
DG2IAQ from factory 20 mA 56 mA 2x 42 mA 80 mA 270 mA
DG2IAQ re-aligned 40 mA 40 mA 2x 100 mA 400 mA 400 mA
(**) on the FT-817 the 2SK2975 are adjusted on a BIAS of 2x 38mA
Higher BIAS values give a more smooth, warm and full SSB audio so I raised all the BIASes a little bit with great results. I checked the datasheets of all the FETs or transistors and found sometimes even higher BIAS levels on their test circuits, so I dont expect any problems, overheat or damage with my higher BIAS levels above. Im still UNDER those test levels.
Replacing the stock MURATA filter
Im not a CW man (.I never learned it, cause I never liked that mode). But still to have the option to build in a CW filter later I de-soldered the stock MURATA filter and fit in an INRAD 706F (2.6kHz). On the option socket #1 Im using an INRAD 720F (2.0kHz). The FT-897 has a great TX-FILTER / RX-FILTER switching method. You can either use the one or the other filter independently targeted for TX and RX. This makes me able to transmit with a fixed 2.6kHz HIFI sound and on the RX side I can switch between the 2.6kHz and the 2.0kHz, depending on the crowded bands.
Using an Electret capsule
As the modified FT-897 has a great build-in speechprocessor now, I wasnt forced to use any external one. So the MH-31 stock microphone can easily be modified to get a strong and great audio without any of the strange sounds of the dynamic capsules. No additional mic amp, compressor, clipper and so on is needed.

+5V R1 4k7 CCC1 1n

R2 1k0 - 2k2

R3 680

MIC GND
C1 should be an SMD type and should be directly soldered on the backside of the electret capsule. This prevents any RFI. R2/R3 is a resistor attenuator as electret capsules have much more audio output level than dynamic capsules. Audio distortions and overdrive of the FT-897 mic amp would occur. The value of R2 varies on the used electret capsule, as some has more or less internal audio amplification (5.6mV or 7.9mV output). The resulting level should be some higher than with the dynamic capsule before, but still under the level where the distortions begin to start. A value of 1k5 would give a good never-to-think-about-any-more average.

Battery modification from W4CNG
I did the battery modification of W4CNG as described on http://www.eham.net/articles/4114.
Battery Modification for the FT-897 from Stephen Reynolds, W4CNG

Br1 50V / 25A

+ Charge
- Charge Bat1 12V / 2.3Ah

Bat2 12V / 2.3Ah

Service Menu Settings
I collected the factory settings of some FT-857/897 owners and calculated the average values of each setting. This gives a real good information for those users who have mis-aligned their TRX or would like to optimize some values. As YAESU told these values are INDIVIDUAL on each rig as they compensate production stray but as you can see the AVERAGE values work on ALL rigs and you cant damage anything with them. I read out the FACTORY DEFAULT values for each line too (by pressing the HOME button). But these values give only a good starting point for the service technicians but some interact the protections with that (REV ALC, overcurrent,). NEVER USE ONLY THESE FACTORY PRE-SETTINGS (HOME button on each item) !! Of course for this theyre NOT calculated into my average results.

Freeband Mod

Im a friend of enhancing all my rigs into freeband rigs (MARS/CAP). Thats not cause I want to use them on CB band or on Pirate frequencies, but I always would have the option to use them for emergency purposes. And if you really have emergency circumstances its too late to heat up the soldering iron. I want to be prepared sooner.
Jumper J1007 J1008 J1009 J1004 J1005 J1006 J1001 J1002 J1003 DG2IAQ original = B3 X MARS/ CAP X X X German version = B1 X X

X X X X

Don forget to do a MASTER RESET after that !!
You can find those information on several other sides on the net too. Please pay attention on the special sort order of the jumpers.

Programming Software

Im using FTBasicMMO from G4HFQ (www.g4hfq.co.uk). A great, simple and fast software which has me allowed to program my new FT-897 in less than 1 minute (!!) by using the exported CSV file of my FT-817. So I was able to take all of my defined memory settings of my FT-817 without the need to re-program any of them. I had all relay frequencies on VHF or UHF and all my HF memories as well. Now my FT-897 is a super-fast cloned big brother of my FT-817. Great !!!

FT-897 wont Power ON

The FT-897 can have three possible error sources when he dont power on immediately. One is documented by YAESU and they sent me their service sheet about that. 1.) R1595 (6.8 ohms SMD) This fault is documented by YAESU. Theres a small 6.8 ohms SMD resistor on the input of a 78L05 fixed voltage regulator. This resistor can fail and a break of the 13.8V DC input line would occur. Simply replace that 6.8 ohms resistor. I would recommend to use a real 1/8W resistor which should be more rough and which can handle higher temperatures under strong consumption. Never easily bridge that resistor !! I found out that there will be an ON-flash cause of the fast charging of some bigger electrolytes. These voltage peaks can destroy a FET !! This low resistant resistor is needed to have a little power-on delay and a smoother charging of those electrolytes.

2.) Q1031 (FET 2SJ355 SMD) This P-Channel MOS FET is in the same Power-ON State line as the resistor R1595 above. By pressing the ON/OFF button this FET let the +13.8V through and it feeds two fixed voltage regulators, which started the CPU and the rest of the transceiver electronics. Maybe it was a fault from me cause of my bridging of R1595 (see 1.) above). Or my Q1031 would have failed anyway. I dont know but I presumed it were the power-on voltage peaks which destroy this FET. I got a replacement via YAESU UK and the TRX works again. Of course Im using R1595 now again, hihi 3.) 13VUS line fault I had this error too and my FT-897 immediately stopped to power on. After a long time of excessive testing and disassembling I found out that I had a voltage drop of about 10V (!!) on the needed power-on status line. I had the full 13.8V on the PA UNIT, but going on the other side of the flat cable and measuring on the MAIN UNIT I only had 3V (!!). I had an equal fault on the same flat cable on my FT-817 so I expected a bad flat cable, maybe damaged by several turnings of the MAIN UNIT to test my mods. I ordered a new flat cable from YAESU UK and as it arrived no difference ! Finally I found out that there must be some bad soldering on the flat cable sockets or some of the filigree PCB lines were burned. So soldered a separate cable which is parallel to the +13VUS line and removes this voltage loss. No problems any more !! As I didnt want to reassemble the PA UNIT too, I decided to use 2 additional diodes to get the DC voltage from the (1) EXT and (2) ACCU connections on the upper side of the PA UNIT.
D1 +DC EXT. 1N4007 D2 +DC ACCU 1N4007

Voltage loss of 10V +3V

Q2 SJ 35 5

Flat Cable

+13.8V

R1157 47k

MAIN UNIT

PA UNIT

Modifications overview
1. 2. 3. 4. C1569 (0.1F) C1555 (1F) R1437 (1k5) R1420 (680k) 2.2F parallel 2.2F parallel removed adding 2x BAT85 schottky-diodes (antiparallel) + 150pF parallel 560pF 22nF parallel removed 10F parallel More basses Mic Amp More basses Mic Amp Higher audio output level of SpeechProcessor Adding clipping facility to SpeechProcessor. Prevents overdrive and hollow audio sound. Adding a smooth 1.5 kHz AF lowpass to reduce clipping distortions. More heights AM/SSB-lowpass filter More basses FM-lowpass filter More heights FM-lowpass filter Better ALC detection. Longer time delay prevents the BAD SWR audio fault. For this you dont have to change the REV ALC-parameters in the servicemenu. Prevents sensitive 2SK2975 FETs (the same as the PA in the FT-817) from overheating and damaging. You get out full RF output by only 10V maximum. They can be damaged by peaks when connected to the DC power supply of more than 12V. Get full TX range of 1.MHz MHz MHz Get better modulation on SSB. Some BIAS currents from factory are too low (distortions), others too high (overheat).

5. 6. 7. 8.

C1502 (1nF) C1492 (4.7nF) C1444 (10nF) C1051 (1 or 2.2F)
Exciter 2SK2975 (Q1001/1002)
Adding 10V fix voltage regulator in collector line

TX Wideband MARS / CAP

Solder only Jumpers J1007, J1008, J1009 and J1006
BIAS of PreDrivers, Drivers and PA FETs

check and re-align

12. 13. 14. C1503 (1F) C1383 (1.5nF) R1421 (82k or 100k) 10F parallel 1nF 470k parallel Raise delay time constant of AGC SLOW for much better SSB audio on strong stations More heights on AF audio lowpass Eliminating audio overload of audio IC and eliminate CW crackling noise too YAESU TroubleShooting Note TSN-0405 / 02. June 2004 HIFI Basses Audio Amp HIFI Basses Audio Amp HIFI Basses Audio Amp HIFI Basses Audio Amp Higher audio level on internal 8 ohms speaker

15. 16. 17. 18. 19.

C1519 (0.1F) C1540 (1F) C1542 (47F) C1550 (470F) R1577 (3.9)
2.2F parallel 10F parallel 470F / 16V 1000F / 16V bridged

Miscellaneous

20. MH-31 Removed 680 ohms resistor Replaced 0.33F by 0.1F 21. MH-36 DTMF Replaced 1k8 or 270 by 4k7 Bridged 2k2//0.1 (in serial) to electret capsule Removed 0.33F and added a bipolar 47F instead 22. Battery modification from Stephen Reynolds (W4CNG) MURATA filter 2.4 kHz Replacing by INRAD 706F and adding a 720F on filter option #1 Adding a separate cable to circumvent voltage loss of flat cable Replace The FT-897 wont power on if theres a voltage drop on the flat cable connections Higher AF output level.
Get back HIGH/LOW tones switch without the 680 ohms resistor. Much higher AF output level.
Adding basses and a natural human voice sound by removing the audio preemphasis.
More basses and more natural human voice sound. see http://www.eham.net/articles/4114

13VUS Line Fix

R1595 (6.8)
The FT-897 wont power on if R1595 is damaged.

Mods Summary View

For my mods you only have to disassemble and remove the MAIN UNIT. All other PCB can be left at their place. Remove all screws from the MAIN UNIT PCB. All cables can be connected and dont have to be removed too. For the down side of the PCB you can remove the PCB from case and turn it toward to you. Please take care not to damage the flat cable on the right side !

MAIN UNIT Upper Side

C1503 SSB AGC (RX)
MURATA Filter Replacement
R1421 CW crackle fix (RX) C1383 Audio Heights (RX)
C1542, C1550 HIFI Audio (RX)

Frequency Jumpers

10V regulator for Exciter Stage Protection (TX)

Flat Cable from PA UNIT +13VUS Line Fix

MAIN UNIT Lower Side

C1051 SSB ALC (TX) C1555, C1569 Basses Mic Amp (TX)

R1595 Not power on Fix

Q1031 (2SJ355) +13VUS Line Fix (RX)
C1519, C1540 HIFI Audio (RX)

C1444 FM Heights (TX)

R1577 Speaker Level (RX)
R1420, R1437 SpeechProcessor (TX) C1492 FM Basses (TX) C1502 AM/SSB Heights (TX)

PA UNIT Upper Side

+13.8V ext. DC +13VUS Line Fix
+ 13.8V Accumulators +13VUS Line Fix
Flat Cable to MAIN UNIT +13VUS Line Fix

Mods Detail View

Some picture were taken during the mods test period so it can happen that you dont see the final soldering on all of these pictures. But it suffers to show you the correct area on the PCBs.
C1569 (Basses Mic Amp TX) C1555 (Basses Mic Amp TX) Pluspoles of the tantalums each toward the middle SMD transistor.
C1502 (AM/SSB Heights TX) The original SMD capacitor was removed here and Im using the ceramic capacitor above instead.
Remove R1437 (SpeechProcessor TX)
R1420 (SpeechProcessor TX) The Clipper diodes and the lowpass capacitor are soldered on the connections of R1420
So the final SpeechProcessor looks like this. The 100pF were replaced by 150pF after taking that picture.

C1444 (FM Heights TX)

C1492 (FM Basses TX)

C1051 (SSB ALC TX)

Needed parts for 10V Exciter Stage Protection.
10V fixed regulator for Exciter Stage Protection You can solder that in a flying way. I soldered the middle PIN (ground) to the PCB ground which gives enough mechanical stability. By removing the BIAS jumper you have the needed both connections for +13.8V DC and the power supply line toward the Exciter Stage. The 1.85A self-resetting fuse was placed instead of this cable later.
C1503 (AGC time constant RX)
Q1031 Upper pin for 13VUS bridging cable (shown green) R1595 (power on fault) C1540 (HIFI audio RX) C1519 (HIFI audio RX)
C1550 (HIFI audio) C1542 (HIFI audio) The cap is desoldered on this picture.

Jumpers for MARS/CAP

Disclaimer Disclaimer of liability
This modifications mostly need to be done by a electronic specialist who had enough practise and who has knowledge in SMD soldering. You do the modifications on your own risk ! Radio modifications shown here are provided for properly licensed operators only! The user is solely responsible for making sure that any modifications made to the radio unit must meet all Federal and State Regulations or the Country of use! Liability of damages to any equipment is the sole responsibility of the user! Downloading , viewing, or using any information provided on these pages automatically accepts the user to the terms of this agreement! Modifications are provided for information purposes only! Although the greatest care has been taken while compiling these documents, we cannot guarantee that the instructions will work on every radio presented.

Copyright

The author intended not to use any copyrighted material for the publication or, if not possible, to indicate the copyright of the respective object. The copyright for any material created by the author is reserved. Any duplication or use of objects such as diagrams, sounds or texts in other electronic or printed publications is not permitted without the author's agreement. Some circuit details are password-protected because of legal reasons. Please contact me via e-mail.
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