ts440

The Kenwood TS-440SAT

Overview     The Kenwood TS-440 is one of the legends of ham radio. Over 600,000 of these radios were produced in the early eighties, giving it the largest production numbers of any HF ham radio. Though more recent radios have offered more features, DSP and other new technology, and easier integration with computers, the TS-440 may have reached a point where there is nothing more really needed. This is, for the present, the heart of my ham station. The Kenwood covers all of the HF bands (160 through 10 meters), traditionally referred to as the Short wave bands. The bands range, roughly, from 1.8mhz to 30mhz. The Kenwood can receive continuously on all frequencies, but will only transmit into the ham bands, as it comes from the factory. There is a switch which will automatically put the radio on ham bands only, for transceiver operations, or change it over for full coverage receive only. My particular radio has been modified to transmit continuously on all frequencies - by a former MARS user. I did not do this myself, but bought the radio in this condition. In order to stay legal, once I have been granted my general license, I will have to be careful about which frequencies I transmit on.
    The radio puts out 110 watts on AM, or 200 watts on SSB. It is also capable of FM operation, along with CW, and FSK. There are connections in the back for a computer, an unnamed accessory, a terminal (for FSK), and a remote. The unit has an antenna connector, and a built in antenna tuner. There is also a small, built in speaker, though I will probably get an external unit, or connect through my stereo. I was lucky, in that all of the usual add ons have been installed by a previous owner. This includes the FM module, all filters, and several internal modifications.
    The antenna tuner worked great with my Cliff Dweller antenna, and actually worked pretty well, when I had this unit connected to my 5/8 wave CB antenna. The unit must be set to operate through the tuner, and then the AT Tune switch is depressed. With the meter set to display SWR readings, and the antenna tuner engaged, the needle waves back and forth for a few moments, before settling down to the lower end of the meter. While the SWR is being adjusted, you can hear the little motors driving the variable resistors (or whatever the unit uses to match to the antenna). The AT Tune switch is then released, and the unit is all tuned, and ready to use. While the tuner is actively matching the antenna, the unit is unable to transmit. I plan to construct a multi wire dipole, and connect it with ladder line. this is widely considered to be the most efficient way to set up an antenna system for a multi band radio. I will post details to my antenna page as I make progress.
    I have installed the computer interface, and have picked up the cable, and adapter, to run the Kenwood from Porky. I am now searching for a good software package, and am trying to select between several. The best, offer full control of the radio, including splits, and crossband operation. They are also able to feed audio directly in, as well as processing audio taken directly out of the radio. This would allow me to use many of the fax, as well as the digital mode translation programs available. It would also allow me to do some packet radio, and data transmission, though data transmission over ham radio is very slow (9600 baud at maximum). One other thing I could do, is use the computer to send and receive Morse Code. There are a number of programs which allow the user to simply type in a message, which is then translated into Morse by the computer, and sent out through the radio. The same programs which do this, also translate incoming Morse Code messages into text, displayed on the computer monitor. This is yet another reason that the current code proficiency requirement is silly. I am presently learning visual basic, and hope to be able to write my own controller software. While I am at it, I will attempt to make use of the various signal processing software out there (including units providing spectrum analyzer functions) automatic.
    I have already listened (though have not transmitted) to broadcasts from China, Germany, Italy, and several in Spanish (Mexico, Spain, South America?). The unit requires over 30 amps, while transmitting, though it uses only a couple during reception. My old power supply was not up to the task, and the unit would dim, and hum, when I attempted to transmit, or to tune the antenna. A new power supply was ordered, providing over 40 amps, and everything is now working well.

I have only a vague idea of what to do with the assortment of buttons, dials, and other switches on the unit, but I expect that their uses will come to me in time. The rear of the unit is almost as complex, and capable as the front. There are the expected connections for antenna, power, external speaker, and ground, but there is also a collection of connectors for signal and control processing.

Specs The following specifications are taken directly from the Kenwood TS-440 owners manual:

Modes	LSB (A3J), USB (A3J), CW (A1), AM (A3), FM (F3), FSK (F1)
Antenna Impedance	With AT Unit	20 to 150 Ohms (Transmit Only)
	Without AT Unit	50 Ohms
Grounding		Negative
Power Requirements		12 to 16 Volts DC (13.8 VDC Reference)
Current Drain	Receive Mode with no input	1.9 amps
	Transmit Mode	20 amps
Operating temperature		-10 to +50 C (+14 to +122 F)
Dimensions	Wide High Deep	270mm (279mm) 96mm (108mm) 313mm (335mm)
Weight	With AT Unit	16.1 Pounds
	Without AT Unit	13.9 Pounds
Transmitter
Frequency range	160 Meter Band	1.8 to 2.0 MHZ
	80 Meter Band	3.5 to 4.0 MHZ
	40 Meter Band	7.0 to 7.3 MHZ
	30 Meter Band	10.1 to 10.15 MHZ
	20 Meter Band	14.00 to 14.35 MHZ
	17 Meter Band	18.068 to 18.168 MHZ
	15 Meter Band	21.00 to 21.45 MHZ
	12 Meter Band	24.89 to 24.99 MHZ
	10 Meter Band	28.0 to 29.7 MHZ
Input Power	LSB, USB, CW, FM, FSK	200 Watts PEP
	AM	110 Watts PEP
Modulation	LSB, USB	Balanced Modulation
	FM	Reactance Modulation
	AM	Low Level Modulation
Spurious radiation (CW)		Less Than -40 db
Carrier Suppression		More Than 40 db (With 1.5 KHZ Reference)
Unwanted Sideband Suppression		More Than 50 db (With 1.5 KHZ Reference)
Third Order Distortion		More than 26 db below one of two tones
Maximum Frequency Deviation (FM)		5 KHZ
Frequency Response (-6 db)		400 to 2600 HZ
Microphone Impedance		500 Ohms to 50k
Receiver
Circuitry		Triple Conversion Superheterodyne
Frequency range		100KHZ to 30 MHZ
Intermediate Frequency		1st: 45.05 MHZ, 2nd: 8.83 MHZ, 3rd: 455 KHZ
Sensitivity	LSB, USB, CW, FSK (At 10 db S/N)	100 to 150 KHZ	Less Than 2.5 uV
		150 to 500 KHZ	Less Than 1 uV
		500 KHZ to 1.6 MHZ	Less Than 4 uV
		1.6 to 30 MHZ	Less Than 0.25 uV
	AM (At 10 db S/N)	100 to 150 KHZ	Less Than 25 uV
		150 to 500 KHZ	Less Than 13 uV
		500 KHZ to 1.6 MHZ	Less Than 40 uV
		1.6 to 30 MHZ	Less Than 2.5 uV
	FM (At 12 db SINAD)	1.6 to 30 MHZ	Less Than 0.7 uV
Selectivity	LSB, USB, CW, FSK	-6 db	2.2 KHZ
		-60db	4.4 KHZ
	AM	-6 db	6 KHZ
		-50 db	18 KHZ
	FM	-6 db	12 KHZ
		-50 db	25 KHZ
Image Ratio	100 KHZ to 1.6 MHZ	More Than 50 db
	1.6 MHZ to 30 MHZ	More Than 70 db
IF Rejection	100 KHZ to 1.6 MHZ	More Than 50 db
	1.6 MHZ to 30 MHZ	More Than 70 db
IF SHIFT Variable range		More than 0.9 KHZ
RIT/XIT Varaible Range		More than 1 KHZ
Notch Filter Attenuation		More Than 20 db (at 1.5 KHZ)
Squelch Sensitivity	LSB, USB, CW, FSK	100 to 150 KHZ	Less Than 20 uV
		150 to 500 KHZ	Less Than 10 uV
		500 KHZ to 1.6 MHZ	Less Than 20uV
		1.6 to 30 MHZ	Less Than 2 uV
	FM	1.6 to 30 MHZ	Less Than .32 uV
Output		1.5 Watts at 8 Ohms (10% Distortion)
Output Load Impedance		4 to 16 Ohms
Frequency Accuracy		Less than .00001 error
Frequency Stability		Less than .00001 error

Mods While I do not desire to have this become one of the myriad of sites dedicated to radio modification (legal and illegal), there are a couple of significant modifications which have been performed on this particular unit. Though simple enough to perform, these mods have greatly increased the capability of the radio.

Display has been set to indicate frequency down to 10 Hz
Continuous coverage transmit, from 100Khz to 30 Mhz
Computer control, and connection to Porky
Computer signal interface, allowing computer processing of transmitted, and received signals.

A number of features may be changed/added, by clipping or inserting diodes on the You may have seen these on other places on the net, but I include them here for reference:
Diode options: There are a bunch of configuration options controlled by clipping or inserting diodes on the back of the control board. You get to it by taking the top and bottom covers off (a bunch of silver screws), loosening the front panel (4 flat-head silver screws, NOT the black ones). Then you have:

diode	controls	in	out (cut)
D65	mode confirmation	Morse	single beep
D66	display resolution	100 Hz	10 Hz
D67	memory protect	none	on
D73	CW shift	800 Hz	400 Hz
D78	WARC 24MHx band tx	disabled	enabled
D79	WARC 18MHz band tx	disabled	enabled
D80	General Coverage tx	disabled	enabled

Computer Interfacing     Like most modern ham radios, the TS-440 has some digital components, and a digital display. It is also able to interface with a computer. Introduced in the mid eighties, this is one one of the earliest radios to be so enhanced. Though these radios were designed for computer assisted operations, accomplishing this is not simply a matter of plugging a cable into the computer. In order to completely integrate a computer, and a ham radio, you need to have a control interface, and a signal interface. Control Interface     A control interface can be added quite easily, either by purchasing self contained kits by Kenwood, or other manufacturers, or by getting the parts yourself. However you go about accomplishing this, you will need to make a modification to the inside of the radio, unless this has already been done by a previous owner, and then add an adapter box to the outside. This combination will allow you to hook the radio up through your computer's RS232 serial port. Once connected, there is a fairly wide range of software out there for controlling, logging, and automating your radio.
    The internal modifications consist of the installation of a pair of chips. These are shown in the schematics as IC 54 and IC 55, and install easily into sockets already present in the radio, on the back of the control unit circuit board. These chips can be bought, with instructions, from Kenwood as the IC-10 Interface Kit, or as kits by aftermarket retailers; they can also be bought via mail order, or at any good electronics store:
     IC 54 is a uPD-8251-AC   Serial Communications Interface.
                Commonly called an 8251A
     IC 55 is a TC-4040-BP    12 Stage CMOS Divider.
                Commonly called a 4040
Installation of these chips enables an ASCII interface (TTL levels). This interface is accessible through the 6-pin DIN connector ACC-1 on the rear of the unit. Though this may be connected directly to certain computers, or through certain interface cards, most users will need the addition of an outboard converter box to connect to the more common RS232C port. With the IC-10 interface, or equivalent, installed, the output at ACC-1 is as follows:
    Signals are    TTL levels (NOT RS-232)
    Baud rate is    4800 (1200 Opt.)
    Format is    ASCII Serial; 1 Start, 8 Data, 2 Stops
The Baud rate may be changed to 1200 Baud by removing jumper W50 and installing a jumper from the left pad to the center pad as viewed from the front of the radio. This will become obvious once you have the radio opened up. Many other Baud rates are possible, just look at the schematic.
      The outboard converter box changes the signal from TTL to the more common RS232C serial form, adapting the voltage, and acting as a noise suppresser. It also adapts the six pin DIN connector to the more common D connector used by the RS232 port. Kenwood calls it's model of outboard converter the IF-232C. The outboard converter is plugged into ACC-1 on the back of the radio, presuming that the IC-10 or equivalent has already been installed. The computer may then be plugged in, via an RS232C port, to the converter box, and suitable software installed. The radio may now be completely controlled via computer. Signal Interface     Though control interfaces are common enough, even on radios ten years old or more, signal interfaces are harder to come by. Most radios, even those with integral control interfaces and extensive software suites, are not directly or easily adapted to run a signal interface. A signal interface is simply a way to run your radio's output into your computer, rather than directly through a speaker, and take an input directly from a computer, rather than only through a mike. Once this is done, a whole new world of possibilities opens up. It is not so much that it is impossible to install a signal interface, but rather, all of the current methods are a bit cumbersome. Most involve a hodge podge of cords, cables and converters, running from the computers sound card to the input, and output jacks of the radio. There would then be another set running from the serial port to the PTT circuit, unless there is already a control interface installed to perform this function.
    Digital technology has moved so fast, over the last couple of decades, that radio manufacturers can be forgiven for failing to recognize the coming advances, and the potential of running signals through a computer. Up until the last ten years or so, the average home computer was just not powerful enough to do much, in regards to processing audio signals, or extracting digital information from them. The early units also tended to be expensive, and to need expensive interface cards. Sound cards, as we know them today, were almost unheard of before the mid nineties. The early sound cards were also difficult to install, temperamental, and could be hard to add outside devices to. I know this from personal experience, because, in the early nineties I attempted to get digital audio into my old Windows 3.1 computer, a frustrating and fruitless effort.
    Once a signal interface is installed, the ham operator will have full access to:

RTTY
Packet
Fax
SSTV
FSK
Direct digital (computer to computer)

I am certain that there are others but, for now, I am still rather new to ham radio, and do not know them all. In the past, special terminals were used for RTTy and FSK. Special converters and cameras were needed for SSTV. Outboard converter boxes, or interface units were needed for Fax, or packet. Direct digital was experimental at best.
The genuine Kenwood parts are getting scarce, for those who have no desire to roll their own. This is having the predictable result of causing the prices to rise. In my own case, I actually did buy the Kenwood IF-232C outboard interface adapter. I did, however get the internal chips from an electronics house, for a few dollars, and they worked just fine. I bought, rather than built the IF-232C, because I did not wish to deal with the problems of shielding, and because it seemed that little money could be saved. For those who can not find the genuine Kenwood unit, or can only find one by paying dearly for it, there are after market companies (in the links below) which sell similar units for less money. Some of these companies also sell signal interface units.

A number of software packages are available, and I go into a bit more detail on my page about Porky the computer. However, once you have gotten your signal interface, and your control interface set up, you might want to try the DXLAB series of freeware. This is a series of applications which are able to run your computer, log your contacts, calculate usable frequencies for specific locations, and determine propagation affects of sunspots. These programs can also generate great looking maps, and display your contacts on them, decode, and encode RTTY, and PSK, and who knows what else. The whole suite can be found at: http://www.qsl.net/dxlab

TS-440 Links Some TS-440 specific links, and related subjects.

Computer interface	Eham review of TS 440	Raymond Sario LCU-3 cable	signal interface
Hosenose interfaces	Donners signal interface	Manual