Tuesday, February 20, 2018

Better frequency stability for the QRP Labs "ProgRock" synthesizer


It turns out that the newer (version 4) of the QRP ProgRock board has pads for a TCXO.  See below for a link to the web page.

The ProgRock:

The "ProgRock" synthesizer from QRP Labs link is an inexpensive device based on the Si5131 "any frequency" synthesizer that may be used to produce up to three frequencies simultaneously - typically from around 8 kHz to around 200 MHz (with some limitations) but it often be coaxed to go down about 3.5 kHz as high as 290 MHz.
Figure 1:
The "synthesizer" portion of an unmodified ProgRock.  The 27 MHz crystal,
in the upper right quadrant, is a typical "computer grade" device, but is
typically stable to only a few 10s of PPM over a a wide temperature range - OK
for many applications, but not where you want really good frequency stability.
Click on the image for a larger version.

Typically programmable using a pushbutton and a DIP switch, newer versions of firmware may be programmed via a serial port as well.  These devices also have an input from a 1PPS (1 pulse per second) source, such as a GPS receiver, to allow precise setting/control of the frequency.

Unlike a VFO, the ProgRock produces only a set of fixed, pre-programmed frequencies:  Up to 8 "banks" of frequencies may be selected via three digital select lines.

What sort of things might this be used for?

  • Arbitrary frequency sources for the workbench.
  • Providing clocks for digital circuits.
  • The local oscillator of a fixed-frequency receiver or transmitter.
  • An internal local oscillator for a radio - such as a a frequency converter or BFO.

For casual use the supplied crystal - a typical computer-grade unit - is adequate, but if you need the frequency to be held to fairly tight tolerance - say, a couple of parts-per-million - over a wide temperature range you will probably want something else.  QRP Labs does sell an "OCXO" version of the synthesizer which works well, but it is more complicated to build and adjust, it consumes several watts of power and produces extra heat.

You might ask:  "Why not just use the 1PPS input for frequency control?"

Figure 2:
The bottom side of the board after modification.  The tiny TCXO module
is affixed to the board and then connected to the circuit using flying leads.
In the picture above, pin "1" is in the lower right corner of the device - the
only one without a solder connection.  On the "label" side of the chip
pin 1 is identified by a very tiny dot.  Pin 2 ground (lower left, blue flying
lead) can be identified with an ohmmeter as it is also connected to the case.
Click on the image for a larger version.
While these devices can be "nailed down" to a precise frequency with the application of a 1pps input from a GPS receiver or other high-stability source, there is a problem with this option:  It tends to cause a "step" change in frequency on the order of 1-2 Hz.

Such step changes would probably go unnoticed on SSB or CW, but with certain narrow-band digital modes there might be a problem.  While modes like WSPR or JT-65 can deal with frequency drift, this would normally occur very gradually over the period of several symbols giving the decoder enough time to track, but if the frequency shift were very sudden, a few symbols would probably be lost.  While the occasional loss of data is normal, any loss caused intrinsic to the receive system - perhaps due to frequency steps of the local oscillator - would degrade the remaining error-correcting capability overall.

In other words:  If phase or very fine frequency changes will affect your communications, you might not want to use the 1PPS input.

Using a TCXO:

Another option is to replace the crystal with a TCXO (Temperature Controlled Crystal Oscillator).  These small, self-contained oscillators have on-board circuitry that counteracts the temperature-related drift, holding the frequency relatively constant over their design range.

A suitable device is a part made by Taitien and is readily available, being DigiKey part number 1664-1269-1-ND (Mfg. P/N TXETBLSANF-27.000000).  This device is tiny - only 3.2x2.5mm square so soldering to it is a bit of a challenge - but still manageable with a fine-tipped iron and some magnification.

As pointed out in the QRL-Labs documentation, some TCXOs may have "stepped" frequency adjustments as part of their temperature compensation due to a built-in temperature sensor and D/A converter referencing a look-up table to keep the temperature stable.  If sufficiently large (e.g. results in more than a few 10ths of Hz "step") this discontinuity can disrupt/degrade modes such as WSPR that operate over very narrow bandwidths. If a TXCO does this, the synthesizer being controlled by it will also exhibit the same frequency steps, proportional to the output frequency.

The Taitien TCXO units noted above were observed at 432 MHz (the 16th harmonic of the 27 MHz TCXO) to magnify possible frequency steps if such "step" behavior were occurring, it was smaller than 0.34 Hz at 432 MHz (e.g. 0.02Hz at 27 MHz.)

The power requirements of this device are very low - only 1-2mA, far less than the 100-200mA of a warming crystal oven - and it may be powered directly from the existing 3.3 volt supply of the synthesizer board.  This TCXO produces about a volt pk-peak output which is in line with what the data sheets for the Si5351A suggest for a capacitively-coupled external signal being fed into the crystal input.

Wiring the TCXO:

Comment:  In theory, it would be possible to add some pads and accommodation for a capacitor to the ProgRock board design to allow the direct installation of a TCXO module such as the one described.

I first removed the crystal and cleaned the holes of solder.  The TCXO module was then glued using cyanoacrylate adhesive (a.k.a. "Super Glue") "belly up" to the circuit board (after it was cleaned with denatured alcohol) at a location on the bottom side of the board between the synthesizer chip and the crystal position as shown with pin "1" in the lower right corner.  With the oscillator firmly in place, a small piece of 30 AWG wire was used to solder pin "4" (V+ - upper-right) to the nearby connection of C3, one of the V+ lines for the synthesizer chip.  Connected to the opposite corner (pin 2, lower left) another short piece of 30 AWG wire is connected to the other side of capacitor C3 to provide the ground.

A small, 1000pF disc ceramic capacitor was inserted into the bottom side of the board to connect to the crystal terminal closest C3 and the "CLK 0" terminal with the other lead carefully formed and bent to be soldered to the upper-left pin, #3 - the output terminal of the TCXO.  Once the capacitor is soldered into place it is a good idea to re-heat the capacitor's other lead (the one soldered into the board) to relieve any mechanical stress that might have occurred from bending the lead to fit to the connection.

Before soldering to the TCXO - but after it has been glued to the board - it is recommended that a small amount of liquid flux be applied to the connections and that they be tinned using a hot iron with a very fine tip:  The ceramic package tends to draw away heat quickly, making it a bit difficult to solder and tinning it before-hand assures that a solid connection has been made and if the unused pin is not tinned, it's an easy way to identify the pins of the device while it is inverted.

Assuming that the connections are good and that the pins were properly identified the synthesize may be plugged into a ProgRock as normal.  If all went well, the output frequency will be pretty close to what it was before - but slightly low in frequency.  While the nominal crystal frequency is 27.000 MHz, in this circuit the frequency is usually 2-5 kHz high, so the "default" clock frequency of the ProgRock is set to 27.003 kHz, but with the TCXO being within 1PPM of its intended frequency, register 02 of the ProgRock will have to be set to the new frequency.

Once everything was checked out I put a few more dabs of adhesive on the capacitor and flying leads to make sure everything was held into place.

How well does it work?

I put together two of these TCXO-based ProgRocks and when compared to a GPS-referenced source, I found one to be 1 Hz high (e.g. 27.000001 MHz) and the other to be about 13 Hz low (26.999987 MHz) - both well within the 1PPM specification.  These frequencies were programmed into register 02 and CLK0 was set to precisely 10 MHz and I found the output to be within 1 Hz of the intended frequency.  I then heated and cooled the units and observed that the frequency stayed well within the 1PPM spec, indicating that all was as it should be.

Example applications:

Stable receiver local oscillator:

Figure 3:
An application of the ProgRock where two of the outputs are being used as
the local oscillators of two "SoftRock Lite II" receivers configured to cover
different portions of the 40 meter band.  Fitted with a TCXO, these
frequencies will be held to within 1ppm over any reasonable temperature
Click on the image for a larger version.
An immediate need for a stable frequency source came about recently while I was putting together a module that is designed to cover the entire 40 meter amateur band in two segments using two "SoftRock Lite II" SDR receiver modules.  Normally these ship with crystal oscillators, but the use of a single ProgRock module allowed a pair of these receivers to collectively cover the entire 40 meter band with very good frequency stability - important if digital modes such as WSPR are to be considered.

Figure 3 shows the result.  Both receiver modules and the ProgRock were mounted in the lid of a Hammond 1590D die-cast enclosure and a simple 2-way splitter using a BN-43-2404 binocular core was constructed.  The end result - when coupled with good-quality 192 kHz sound cards - is a high-performance, stable receive system capable of covering the entire U.S. 40 meter amateur band - with a bit of overlap in the middle and extra coverage on the edges.

Replacement of a crystal oscillator on a phase-modulated transceiver:

These days it is increasingly difficult to source custom quartz crystals for older "rockbound" commercial radio gear.  An example of this is the GE MastrII line of VHF (and UHF) transceivers that require a crystal for each transmit or receive frequency.  Even though this equipment is now quite old, it is still useful as it is quite rugged and has excellent filtering and when properly prepared, it has been proven to very reliable.

These radios use crystals in the 12-13 MHz area for transmit and 16-17 MHz area for receive so a ProgRock can be easily programmed to be used in lieu of a crystal with a slight modification of a GE "ICOM" channel element.  Because the MastrII transmitters use phase modulation, the signal source is never modulated - and this is an advantage if you happen to need to set several overlapping transmitters to the same frequency and you need their modulation to "track" precisely.  By using a TCXO (or QRP Labs' OCXO) rather than the 1PPS to maintain frequency stability the possibility of occasional "clicks" in the audio due to frequency correction steps is eliminated.

With any synthesizer the concern is that it will produce spurious signals and/or additional phase noise that will degrade the transmit/receive performance, but preliminary testing has shown that even when multiplied to 70cm, the resulting spectra is quite clean - probably good enough to be used on a repeater.  If one does do this, there are a few things that should probably be kept in mind:
  • Even though the ProgRock can output two frequencies at once, there is a small amount of crosstalk between them and when multiplied to the ultimate VHF/UHF frequency, these low-level spurs could end up on the output.  For this reason it would probably be a good idea to use two separate ProgRocks, located apart from each other, in a full-duplex radio.  For half-duplex a single ProgRock could be used with the RX and TX frequencies being toggled by selecting a pre-programmed "bank".
  • Its worth noting that in many of these radios the LO frequency of the receive frequency is immediately multiplied by the next change.  Testing was done showing that the ProgRock could be set to the output frequency of this multiplier stage.  This cannot be done for the transmitter as the oscillator's output is immediately phase-modulated at its operating frequency.
  • It would probably be a good idea to place some high-Q band-pass filtering tuned to the LO frequency to minimize any low-level spurs that might be present on the synthesizer.  Initial testing didn't show any obvious problems, but using such a filter would be a sensible precaution.
  • A very small amount of added "hiss" - probably from low-level phase modulation - was observed at UHF harmonics.  In normal use, this would probably have not been noticeable unless one did an "A/B" test.


This page stolen from ka7oei.blogspot.com

Thursday, February 15, 2018

Managing HF signal dynamics on an RTL-SDR receiver

Note:  This article was inadvertently posted for a few days, before it had been finished.  This is the "completed" version of that article.

The "RTL-SDR":

The so-called "RTL-SDR" dongles are devices that have become quite popular owing to their low cost and their ability to cover a wide frequency range - typically from a few hundred kHz to nearly 1GHz, depending on the device.  There are two separate signal paths on these devices:
  • Via the Raphael R820 chip.  This has an onboard synthesizer, mixer and band-pass filters and it converts signals in the (approximately) 24-1300 MHz range to a lower frequency.  This is the "normal" signal path used in these RTL-SDR dongles.
  • Right into the RTL2832 chip.  This (typically unused) input may be made available via another connector, or via a frequency-splitting filter network as is done on the "RTL-SDR Blog" dongles.  This input can work from a few 100 kHz to 10s of MHz.
 It is the RTL2832 that has the A/D converter - which is just 8 bits and that is a main limit of these devices when used in environments with both strong and weak signals.
Receiving HF with an RTL-SDR dongle:

If we want to receive the HF spectrum - which we'll call 500kHz-30 MHz (we'll include MF here...) we have to work around some issues.  The most obvious is that the R820 chip can typically tune down to something in the 20 MHz range (it can sometimes be coaxed to go even lower) but it certainly cannot be relied on to work well down in the 1-5 MHz range.

The "direct" input has the advantage that is uses an 8-bit A/D that is sampling at 28.8 MHz followed by some DSP logic that allows signals in that stream to be internally converted to "baseband" samples - but the nature this chip poses a few problems.  To receive the entire HF spectrum, we have two methods that may be used, but each of these has their own sets of quirks, advantages and disadvantages:

The "direct" method:
  • It is very simple to implement in that it uses would would normally be an unused input.  Many dongles already include this modification - but if not, it may be easily added (instructions may be found on the web.)
  • The frequency stability can be better than the "upconversion" method since it is always lower - and there is only one oscillator that must be kept stable.
  • This has the disadvantage that the sample rate is about 28.8 MHz meaning that signals above 14.4 MHz will be aliased.  For example, a signal at 21.25 MHz will also appear at (28.8 - 14.4 = ) 7.55 MHz.  This can usually be mitigated by the addition of band-pass filtering around the frequencies of interest if "fixed frequency" operation is expected.
  • The "direct" input is typically quite "deaf", often requiring a bit of amplification if it is to be used for microvolt-level signals.  In testing, it took about 7 microvolts (-90dBm) for a CW signal to become audible, about 15 microvolts (-84dBm) for an SSB signal to be readable and around 25 microvolts (-79 dBm) for an AM signal to become listenable.  In other words, the sensitivity of this unit is 20-30dB worse than a modern receiver in "direct" input mode!
The "up-converter" method: 
  • In this method there are two oscillators that can contribute to drift:  The (typically) 100 or 125  MHz oscillator used for the up-conversion and the clock reference in the receiver itself.  Because both of these oscillators are operating at a rather high frequency - and because there are two of them - drift can be exacerbated.
  • The "image" problem associated with "direct" method is largely avoided.
  • The mixers used for frequency conversion can, in some cases, be overloaded by strong signals meaning that signals may be degraded before they get to the receiver.
No matter the configuration, there is one limitation intrinsic to these "RTL" devices:  Those 8 bits of A/D conversion.

The "dynamic range" problem:

With 8 bits one can only attain an overall dynamic range of about 48dB (the actual amount is actually harder to calculate owing to oversampling, thermal and circuit noise, external noise, etc.)  The problem arises from the fact that a "weak" signal at, say, 160 meters may be on the order of 1 microvolt (-107dBm) but a nearby AM broadcast transmitter may be presenting a signal that could be 500 microvolts (-53dBm) or even much more!  In our example, we can see that this could pose a signal difference of 54dB - above the range that can be represented using an 8 bit converter.  In other words, assuming a 48dB dynamic range of our A/D converter, if we adjusted our levels so that a 1 microvolt signal (-107dBm) just barely registered on the A/D, any signal(s) that were 48dB above this (-59dBm) would "max out" our converter - again, ignoring oversampling, etc.

In other words, if we were to carefully adjust our signal level to our RTL-SDR (using an attenuator) such that we were just below the signal level that "maxed out" our A/D converter, our weak signal would be below the signal level represented by the lowest bit and it would (probably) be lost in the noise.  Conversely, if we tried to bring the weak signal up to the point where it was out of the quantization noise of the A/D converter, we'd be overloading our A/D, causing distortion and making it work very badly.

The importance of band-pass filters:

Whether or not you are using the RTL-SDR dongle in the "direct" mode, it would be a very good idea to limit the signals arriving at its input to only those of interest as much as possible.  This need contradicts the desire of many users of this device to cover from "DC to Daylight" - but if one attempts to put such a large frequency range into the antenna, performance will suffer:  If the unit don't just overload, there will likely be issues with trying to receive weak signals in the presence of strong ones - and with just 8 bits of A/D conversion, if that difference is greater than 40dB, you may see significant degradation.

When used in the "normal" mode where the R820 chip is acting as frequency converter, the A/D converter in the RTL2832 chip sees a somewhat limited spectrum owing to filtering in the R820 chip - but despite this filtering there is still the problem of "weak versus strong" signals that are within this passband - not to mention the fact that it just doesn't take a lot of signal to overload the R820 outright.

If you are using "Direct sampling" mode on HF, the program is more severe:  The entire HF spectrum being applied at the RF input is being digitized by a measly 8 bits which means that even if you are running the RTL2832 in the 2048ksps mode where you can "see" 2 MHz of spectrum, signals from the rest of the spectrum are still being digitized by that 8 bit converter.  If you consider that the signal-handling capability of the 8 bit A/D to be a limit to the total RF power being applied, you may be "wasting" much of this A/D capability at frequencies that are of no interest to you at all!

Images in the "direct" mode:

A worst-case example:  20 meters

If you are running "direct" mode, the problem is worse, still:  As noted above, the sampling rate of the A/D converter is 28.8 MHz, which means that signals above the Nyquist limit at half this frequency - 14.4 MHz - will "reappear" elsewhere.  For example, if you were listening at 14.300 MHz on the 30 meter band - which is 100 kHz below the 14.4 Nyquist limit - you would also hear signals at 14.500, which is 100 kHz above the Nyquist limit.  Similarly, if you were tuned to an AM broadcast station at 1.0 MHz - 13.4 MHz below the Nyquist limit - you would hear signals that were at 27.8 MHz - 13.4 MHz above the Nyquist limit.

In the second case, it's pretty easy to filter out the 27.8 MHz signals:  A simple low-pass filter will do, but in the first case - using the RTL-SDR Dongle at 20 meters - things are quit different as it is difficult to build a filter that will pass signals at 14.35 MHz with little attenuation but block signals at 14.45 MHz - the "image" of 14.35 MHz - sufficiently.  What this means is that are several MHz away from this 14.4 MHz limit, you can probably get away with filtering in the "direct" mode - but the closer you get (say, 13-16 MHz) the more difficult it will be to remove the image.

The typical work-around for this is to convert the HF range to a higher frequency - typically by mixing it with a local 125 MHz oscillator, so instead of 20 meters being tuned in at 14.0-14.35 MHz in direct mode, it would be at 139.0-139.35 MHz.  This works pretty well, although oscillator stability - both in the RTL-SDR dongles synthesizer and in that added 125 MHz oscillator - is much more of a concern as the frequency at this 139 MHz frequency could drift hundreds between the two oscillators whereas in direct mode - with only one oscillator - the absolute frequency is much lower (about 1/10th) along with the amount of drift.

Even with the "upconverting" technique, you are not excused from needing to have front-end filtering:  The limits of the 8 bits of A/D conversion and those of the circuitry still apply!

Another approach for 20 meter coverage:

Taking our 20 meter example, while we could upconvert - which would be the easiest approach if  you happened to by an RTL-SDR with an upconverter - another approach would be to convert the frequency band from 14.0-14.35 MHz down to, say, 4.0-4.35 MHz by using a mixer and a 10 MHz oscillator:  This lower frequency would imply higher stability and the filtering requirements would be greatly relaxed as compared to up-converting by 100 or 125 MHz:  An example of such a circuit may be seen below in Figure 1.
Figure 1:
20 meter converter for an RTL-SDR Dongle used in "direct" mode.  This mixes the incoming (filtered) 20 meter signals with 10 MHz to produce a 4.0-4.35 MHz output.  Originally, I'd planned to use an inexpensive 10 MHz TCXO, but it was unavailable at the time of construction.  In the upper-right corner is an representation of the circuit layout.
Click on the image for a larger version.
In the diagram above we see the signals coming in and being applied to a 2-pole bandpass filter for 20 meters.  I "borrowed" this design from QRL Labs' bandpass filter (link) - so if you don't wish to build your own, you may order a kit of parts for the band of your choice from them.

This filter is not nearly "sharp" enough to pass the top end of the 20 meter band (14.35 MHz) and sufficiently block its nearest image frequency (14.45 MHz) if we were to use "direct" mode with the 14.4 MHz Nyquist limit so we down-convert the 20 meter band from 14.0-14.35 to 4.0-4.535 MHz, instead - well away from from the image response.  The bandpass filter limits the number of signals that get converted and provide enough filtering to minimize an image response that could occur due to the converter itself - that of the sum frequency (e.g. 24.0-24.35 MHz).  Transistor Q1 boosts the HF signal somewhat to overcome the loss of the filter and of the mixer and low-pass filter following it.

The local oscillator that I used was a 10 MHz OCXO (Oven-controlled Crystal Oscillator) that I had kicking around and its output was at TTL levels - a 5 volt square wave, so R5 was placed in series to knock this down to about 1 volt peak-peak at the "LO" input of U1, a diode-ring mixer.  I had originally intended to use an inexpensive 10 MHz TCXO (Temperature-controlled crystal oscillator - Digi-Key PN:  1664-1262-1-ND) but this turned out to be unavailable at the time I constructed it:  Had this part been on-hand I would have included a 3.3 volt regulator for the TCXO and would have omitted R5.  In a pinch, a "crystal can" 10 MHz computer-grade oscillator could have been used, but these - unlike the TCXO that I would have used - are not particularly accurate in frequency or stable with temperature (e.g. they would be within "only" 100ppm or so - which could be about 1 kHz at 10 MHz.)

The output of the mixer is passed to a low-pass filter to remove the "other" image resulting from the mixing product (24.0-24.35 MHz) as well as "bleedthrough" of the 10 MHz local oscillator - the presence of which could degrade the performance of the RTL-SDR.

This entire device was constructed "Manhattan Style" on a piece of copper-clad circuit board using "Me Squares" (from QRP-ME - link) which was mounted in the lid of a die-cast aluminum enclosure.

Is "Direct mode" worth the trouble?

Why use the "direct" mode at all?  When the frequency is converted, drift can be a concern, and this is significantly reduced  in "direct" mode - and it is quite simple to implement in hardware:  Many dongles - like the "RTL-SDR Blog" dongle have a diplexing filter (and amplification on the "direct" branch) that make it easy to use - provided that one be aware of the limitations!

In cases where the frequency is quite low - say, below 12 MHz - it is pretty easy to apply band-pass filters that will remove the image response above 14.4 MHz.  Above the Nyquist frequency we can actually use this effect to our advantage and directly tune in the 17 and 15 meter bands, using band-pass filters to limit the input to only those frequency ranges.  We again hit another Nyquist response at 28.8 MHz, but by then the low-pass filter built into the dongle is starting to take effect.

Whether or not you use direct mode, you will want to apply a bandpass filter to the input to limit the signals to those of interest - that is, if you really want to minimize the possibility of overload.

In short:  Is the "direct" worth the trouble?  In those instances specified above, it can be, owing to its relative simplicity and improved frequency stability as compared to the "upconverter" method.

Extreme case:  Receiving both the AM broadcast band and 160 meters

To illustrate this problem, let us look at the signals present on an HF antenna located in the Salt Lake City area, below:
Figure 2:
Off-air signals of the AM broadcast band into a Carolina Windom designed for 80 meters and higher bands.  This spectrum analyzer plot's vertical axis is 10dB/division with the top bar being 10dBm.
The on-screen reading is for marker #4, which is a weak "local" station at -62dBm, but the strongest signal is marker #1 which is a bit stronger than 0dBm which means that this signal has a million times more power at the antenna input than the weaker one!
Click on the image for a larger version.
 In Figure 2, above, we see the plethora of signals that are intercepted by a typical HF antenna in a metropolitan area.  The strongest signal (marker #1) is at 1160 kHz (KSL) a local 50kW "clear channel" station which is producing a power level of about +3dBm which is nearly 1/3 volt of RF!  In contrast we can see another signal indicated by marker #4 which is another local, low-power station with a signal level that is about 60dB (a factor of 1000000!) weaker.

The "top" end of this plot (far right) includes the entirety of the 160 meter band and at this (rather noisy) site location we can see that the background noise is presenting us with a signal level of about -80dBm (about 22 microvolts) of noise.  In a truly "quiet" location, away from power lines and other urban QRN this noise floor would be 10-15dB lower during daylight hours, or in the area of -95dBm (about 4 microvolts.)

From this plot we can see several problems that arise if we want to use an RTL-SDR:
  • The strongest signal (marker #1 at 1160 kHz) is about enough to case the front-end static-protection diodes built into good-quality dongles to conduct and cause intermodulation distortion on their own.
  • The signal level differences between the strongest local signal (marker #1) and the weakest (marker #3) is nearly 40dB below that of the strongest signal - which is almost all of the range of our A/D converter.  There are "nearby" stations located farther away that are even worse off - such as the station located at marker 4 that is about 60dB down (1-millionth) of the signal level of our strongest.
  • If we wanted to listen to local AM broadcast signals and be able to receive signals on 160 meters we would need manage the fact that there is about 80 dB difference (a factor of 100 million) between the strongest signal and the noise floor!  What's worse is that this -80dBm (ish) noise floor at 160 meters isn't all that much higher than the noise floor of the RTL dongle itself.
To be sure, the magnitude of these disparate signals can be a challenge even for a modern communications receiver which, when connected to this same antenna, may well experience overload unless a significant amount of attenuation is added but coupled with the limited dynamic range of the RTL dongle, being able to receive both sets of signals poses a challenge.

"Squashing" the signal levels

Clearly, if we want this system to work in both environments we need to reduce the levels of the strong broadcast band signals while boosting the weak signals on the 160 meter band and the way to do this is with some filtering.  If we design a "band stop" filter that will attenuate only the broadcast band signals we can prevent the dongle from being overloaded as badly.

Let's design a hypothetical band-stop filter that will reduce signals in the broadcast band by 30dB (1000-fold) but leave those outside the band alone:  Will this help?

Taking the strongest signal (1160 kHz) and reducing it by 30dB means that instead of +3dBm it will now be -27dBm - better, but this is still about 53dB above our 160 meter noise floor.  What about the other signals on the band?  That signal at marker #4 (1230 kHz) will be reduced from -36dBm to about -66dBm - quite weak, but still audible, albeit a bit noisy.  What about those other stations that are weaker-still?  Those will get submerged reduced as well, getting down near the -79dBm "minimum signal level" for the RTL dongle.  Even by reducing this level, we still haven't done anything to bring up the 160 meter signals at all.

To make it work we will need to do more.  One way to do this is to apply selective (notch) filters to the strongest signals to reduce just those signals.  Looking at Figure 2, again, we can see that if we were to considerably reduce the strongest signals by 20-30dB, we'd "compress" the range between the strongest and weakest signals and allow us to be able to deal with them with our range-limited RTL dongle.  Figure 3, below, shows what the AM broadcast band looks like once we have done this:
Figure 3:  
The AM broadcast band - and the 160 meter band, with the YELLOW trace showing the signals before filtering and the CYAN trace after we have applied broadband attenuation to the AM broadcast band, selective attenuation to the strongest signals and some amplification overall.  As can be seen the range between the weakest and strongest signals is significantly reduced with the signal levels in the 160 meter band being increased enough to be above the dongle's noise floor.
Click on the image for a larger version.
In Figure 3 we can see the result of our work:
  • The strongest signals are reduced by about 20dB
  • The weaker signals are reduced a bit overall, but not as much as the strong ones owing to our attempts to selectively reduce only those that are strong.
  • The noise floor at 160 meters has been increased by 20dB.
  • The difference between the strongest broadcast band signals and the 160 meter noise floor is now around 40dB - within the (theoretical) usable range of the 8 bit converter in our RTL dongle.
In other words we have reduced the strongest signals by over 40dB, the weaker signals by 20dB and then brought everything back up by about 20dB.  Because our filter had little effect on the signals above and below the broadcast band, they came up by about 20dB as well.

How this may was done:

After using the Elsie program (there's a "free", somewhat cripped student version that's adequate for this task) and perusing my "Filter Design Handbook" by A.B. Williams I designed a "band stop" filter that was designed to cover the AM broadcast band - that is, provide at least 30dB of attenuation from about 540 to 1725 kHz.  Within this range, the attenuation can be much higher - greater than 60dB - but I was (theoretically) guaranteed that minimum 30dB - and I ended up with the circuit, below:
Figure 4:
Diagram that includes a splitter to provide an unfiltered signal path along with the BCB reject filter and post-filter amplifiers.  Adjustable notch filters to attenuate strong, local stations are also included.
Click on the image for a larger version.

Circuit description:

Because one may want an "unadulterated" signal path for other purposes, a two-way signal splitter (L1/L2) is included:  The added 3dB loss is irrelevant with a decent HF antenna and modern receivers in terms of ultimate system sensitivity.  One branch of the filter is passed through a resistive attenuator that helps set the source impedance to the band-reject filter and again, this added loss isn't much of a concern on a decent HF antenna.

The AM BCB filter was designed for a nominal center frequency of 950 kHz and each series and parallel L/C circuit is tuned at that frequency.  The capacitor and inductor values were juggled to attain the closest standard values (or permit parallel combinations of standard capacitors) - this variation from the "ideal" having negligible effect on performance.  The capacitors used are all 5% NP0 (a.k.a. C0G) types for stability and the inductors are wound on T50-1 toroids using 30 AWG wire:  The values of the inductors were checked and adjusted with a known-accurate L/C meter after winding and it was determined that the calculated number of turns typically yielded inductance that was 5-10% high - a direction preferable to the other as adjustment simply required the removal of a few turns. (Yes, I wound toroids - lots and lots of toroids!)

Across the output of the band-stop filter is a set of simple series L/C notch filters.  I happened to have on-hand some inductors that were adjustable from about 8uH to 15uH and number crunching indicated that with just three capacitor values, the entire AM broadcast band could (more or less) be covered with a bit of overlap.  The first three notch elements (those at the right side of the string) used just a single capacitor as it was anticipated that there would be at least one station in the low, middle and upper portion of the AM broadcast band that would need to be reduced in strength.  The remaining four notches use two capacitors with computer-type push-on jumpers that allow the smaller capacitor to be selected for the upper portion of the broadcast band, the larger for the middle and the two together for the lower portion - or complete removal of the jumpers would disable the notch altogether.

Ignored up to this point are R5 and R6 - the "bypass" adjustment that reinjects signals back into the filter's output.  It may seem strange to build a filter that removes signals in the AM broadcast band - only to put them back again - but it does make sense if you do want to be able to receive such signals, but be able to strictly control their levels at the receiver input terminals - more on this later.
Figure 5:
 The "as built" AM/BCB filter module depicted schematically in
Figure 4, above.  Along the left edge is the splitter and to the right
of it is the AM band-stop filter with the "bypass" control along the top.
In the lower-right is the 7-element tunable notch filter assembly.  The
remaining circuits are the amplifiers/splitters that are downstream from
the band-stop filter.
Click on the image for a larger version.

Following the filter is a broadband RF amplifier constructed using the venerable 2N5109 transistor - a rugged, low-distortion device that is readily available from many suppliers.  This amplifier provides a reasonably low noise figure (in the 2.5dB range) along with about 12-14dB of gain, overcoming the losses of the front-end splitter, attenuator and filter with a bit of room to spare.  Theoretically, the system noise figure at this point will be on the order of 9 dB, but considering the nature of the HF spectrum and the fact that even at 28 MHz an "acceptable" system noise figure is around 15dB, we aren't really suffering due to the losses in this signal branch.

Following this amplifier is another 2-way splitter - and another amplifier with splitter:  This second amplifier with splitter - which is probably a bit of overkill - is useful for some types of wideband SDR devices, such as the RTL-SDR dongles:  When these are coupled with filtering and an adjustable attenuator, a bit of "excess" gain is handy to be able to throw away when setting the RF levels into them.

A balancing act:

As mentioned above, there is a "bypass" adjust that is used to allow the reinjection of AM broadcast signals back into the signal path and with the components show the usable range is from about -35 to -15 dB.  As it turns out, only a few of the signals that one is likely to intercept will be strong enough to cause problems while the rest are quite low.  At night the cumulative signal power of the myriad stations arriving by "skip" can cause a receiver like an RTL-SDR to become overloaded, but by having 10-20dB of added attenuation we can keep this total signal power down to a more reasonable level.

As can be seen on the YELLOW trace of Figure 3, above, there are a few stations that stick way above the general level of the other stations and the trick is to knock these down so that they are still "strong enough", but not so strong that the receive system is overloaded.  By using the notch filters, the strongest of the stations can be reduced by 20-30dB, putting their signal levels on par with the rest as is demonstrated by the CYAN trace if Figure 3.

There is a side-effect of such a simple notch circuit - that being that the signal a few 10s of kHz above the notch frequency can be boosted by 10dB or so.  Unless that signal is quite strong, this is of little importance - but if is a problem one can carefully park the notch between the two signals, attenuating the strong, lower signal adequately while moving the "peak" above the upper signal.

At this point the real balancing act occurs.  In the case of this filter assembly, the receiver itself was an RTL-SDR dongle that was intended to cover from about 460kHz to 2500 kHz which encompasses the entire AM broadcast band plus the 630 and 160 meter amateur bands.  This proved to be a bit of a challenge as the signals in the two amateur bands could be as low as a few microvolts while those in the AM broadcast band were noted to be in the hundreds of millivolts - a span of around 90dB, which would be a challenge even for a 16 bit A/D converter, not to mention the measly 8 bits of an RTL-SDR.

By knocking the strongest AM broadcast band signals by 25dB with a notch and another 20dB with the band-stop filter we can get reasonably close to our goal.  Even with the overall AM broadcast band attenuated by 20dB, a reasonably sensitive and properly adjusted receive system can still receive some of the weaker stations during the daytime and still yield a band full of signals at night!

The other part of the balancing act is to set the signal level at the input of our receiver - an RTL-SDR dongle:  We have "excess" signal coming from our filter/amplifier network which means that we can knock it down again with an attenuator - which for an RTL-SDR could simply be a 100-200 ohm potentiometer paralleled with a fixed resistor (to achieve something in the 50-75 ohm area - the actual impedance isn't really important) with the "wiper" side feeding into the receiver.  At this point one would increase the attenuation just to the point below where the RTL-SDR's A/D converter started to clip significantly - and this sort of adjustment would have to be done under various conditions.  In my case, it was checked during the daylight hours when a number of the local stations were running their full 50kW and again at night when these stations were running lower power - but there were many other stations of low-moderate strength being propagated via skip.

Also included in this balancing act is the adjustment of the "bypass" control:  Too little bypass, the weaker AM signals cannot be heard, but too much and the receiver will overload.  It need not be said that this set of adjustments is trial-and-error, but it is quite possible.

Real-world result:

Contained in Figure 6, below, is a trace captured from exactly the system described above as used on the Northern Utah WebSDR - link where you may see this filter in action, with the visible signals varying wildly depending on whether it is local day or night.  This receive system is connected to a large antenna (which is designed to work only down to 3 MHz, but still intercepts signals below this range quite will) and it passes through the splitter/filter/amplifier system depicted in Figure 4.
Figure 6:
An actual, off-air "waterfall" capture (during the local nighttime) from an RTL-SDR system that covers from about 460 to 2500 kHz - a range that includes the AM broadcast band and the 630 and 160 meter amateur bands.  As can be seen,
the band is packed with signals - most of them via ionospheric "skip".  Outside the range of 530-1750 kHz the
background noise can be seen with several signals being visible on 160 meters.
Click on the image for a larger version.

If you look at the larger version of Figure 6 you can see that there are quite a few signals present - mostly local, and their relative strength is indicated by the "brightness" of the traces.  A closer look will reveal something more:  You may notice that between the range of 550 and 1750 kHz, the deep background is rather "smooth", but outside this range it has a bit of granularity to it.  This is due to the attenuation of the BCB reject filter causing the background noise level within the 550-1700 kHz range being below the sensitivity of the RTL-SDR dongle but outside this range, the sensitivity is just high enough that the background noise on these frequencies is visible, allowing even relatively weak signals on the 160 meter band to be received.

To achieve this result the RTL-SDR dongle is being run in "direct" mode and there is a 2.5 MHz low-pass filter and adjustable attenuator placed between it and the output of the BCB filter unit - the low-pass filter being used to remove the energy from those signals above the frequency range of interest.


As can be seen, it is possible to deal with wide signal ranges when using a receiving device that has intrinsically poor dynamic range - but it depends on several things:
  • The signal levels need to be fairly predictable.  In this case, the signal levels on the AM broadcast band are very consistent - at least during the majority of the "powerhouse" daytime-only 50kW stations are on the air.
  • Outside the filter's range the signals are typically much weaker owing to the fact that they are being propagated via shortwave from relatively low-power transmitters.
  • The ability to manage the signal levels overall:  The "compressing" of the range of the signal strength of the "local" AM stations with band-reject and notch filters helps out a lot!
Admittedly, this method is quite complicated, but it is do-able and in spite of its complexity, it allows very inexpensive hardware to be used to cover a fairly wide frequency range - in fact, if the goal was to use an RTL-SDR dongle to cover just the AM broadcast band and there were any nearby AM stations, you'd have to apply at least some of the above techniques to make it work well if your goal was to allow the reception of both local and distant stations.


This page stolen from ka7oei.blogspot.com

Thursday, February 8, 2018

Un-Bricking an RTL-SDR Dongle after an EEPROM write

Figure 1:
One of the better general-purpose "RTL-SDR" receiver dongles available,
with a TCXO for better frequency stability and built in filtering/amplification
on the "Direct Sampling" path to allow HF reception - among other
things!  The entire point of this exercise was to give the RTL-SDR
dongle a unique serial number, seen in the picture, so that it could be
uniquely identified if more than one were plugged into the same computer.
The dongle shown above is sold by "RTL-SDR.com".  It seems to be
no more or less susceptible to "bricking" than any other RTL-SDR dongle
using the same chipsets, so this fix may apply to other versions as well.
Click on the image for a larger version.
The other day I was using the "rtl_eeprom" utility to change the serial number of an RTL-SDR dongle (they all ship with serial number "00000001") to make it easier to identify it when it is online with other units - and I "bricked" it.

This seems to be a common occurrence - the causes (possibly) being:
  • Unplugging it too soon after programming it.  Perhaps one should give it a slow "10" count before unplugging it?
  • Changing more than one parameter at a time.
  • Changing something other than the serial number.
Figure 2:
The SOIC-8 to DIP header (no EEPROM) in the
programmer.  This particular carrier came from
"qrpme.com" although many different types
are available for cheap on EvilBay.  The
programmer in this case is the "MiniPro".
Click on the image for a larger version.
I probably was guilty of doing the first two.  The remedies suggested online seem to be limited variations on a theme, such as:
  • On the EEPROM chip, short the SCL and SDA pins (5 and 6) together while plugging it in - then removing the short and programming it.
  • Shorting the SDA pin (pin 5) of the EEPROM to ground (pin 4) while plugging it in - then removing the short and programming it.
Neither of the above worked for me as the device was steadfastly not being recognized on the machine that I was using.  Interestingly, it was still usable on another machine with the "SDR#" program - but it wasn't being properly identified by the operating system.

On a hunch I plugged in a "good" RTL SDR (one that I hadn't bricked) and downloaded the contents (using the "-r" option) and saved it with a .BIN extension as raw data using the same rtl_eeprom program.  In looking at this file with a HEX/ASCII editor (such as the one built into the "PonyProg" program) I could see the data (some ASCII text) which seemed to comprise a device ID and the serial number.

Using a hot-air rework station I removed the 24C02B EEPROM (256x8) chip from the dongle and soldered it to an 8-pin DIP-to-SOIC-8 header and put it into a programmer.  Interestingly, when I looked at the EEPROM's contents after having done this they were all zeroes - clearly something had gone wrong in the write process!

Importing the .BIN file into the programming software I changed the serial number to what I'd originally wanted it to be and programmed it, verifying that it "took".  I then unsoldered the EEPROM from the header and put it back in the RTL-SDR dongle, again with the hot air rework tool.

Success!  The dongle was working again - with the "new" serial number.

Figure 3:
The location of the EEPROM chip within this particular
RTL-SDR.  Using a hot-air rework tool it took only seconds
to remove the chip and plop it onto the header in Figure 2
so that it could be reprogrammed.  Many RTL-SDR
dongles have similar EEPROM chips, but if you happen to
brick yours when changing the EEPROM contents it will
be up to you to find it on the circuit board if you open it up.
Because fewer than 128 bytes are used, the EEPROM may be
of larger or smaller capacity than the 24C02 mentioned
on this page.
Click on the image for a larger version.
For your edification, the .HEX file is included below, with the serial number of "00001234" which visible when editing it in the programmer software.  In addition to this serial number, the IR receiver has been disabled, since it wasn't needed - and isn't used at all with these particular RTL-SDR dongles.  I won't include pictures and details on how to solder and unsolder or use an EEPROM programmer - or tell you which one to use (there are other sites for that) but I hope that it is useful nonetheless.  Having said that, the "PonyProg" programming software is popular and one can homebrew a quick programmer with it.

Anyway, it saved me $20 in not getting another dongle - not counting my time!

* * *

This is the contents of a .HEX file that can be programmed into the EEPROM on an RTL-SDR dongle to "un-brick" it.  As noted above, you will need to be able to program the chip - probably out of circuit - to effect the repair.

Simply copy and past the hex data below into a plain text file and rename it with a .HEX extension:


In the above file, the serial number is in plain ASCII as "00001234" starting at address 0x37 with the last character at 0x45, skipping every other byte with a null (0x00) between each character.  Again, I'd recommend using a .HEX editor with an ASCII pane such as the one in the "PonyProg" program to better-visualize its contents.  There are clearly fewer than 256 bytes used which means the smaller (128x8) 24C01 EEPROM chip could have been used, so be sure to check which device is being used before programming.


This page stolen from ka7oei.blogspot.com

Saturday, January 13, 2018

A simple crystal oven/heater that uses no power resistors

There are times where one needs to elevate a component to a consistent temperature to better-maintain its characteristics, the most common being the need to heat a quartz crystal to attain better temperature stability.

I had such a need when I was constructing my 24 GHz transverter - link - and needed to have the 99 MHz crystal oscillator (multiplied by 240 to yield 23.76 GHz for a 432 MHz IF at 24.192 GHz) that was locked to a high-stability 10 MHz reference.  This 99 MHz oscillator uses an overtone crystal oscillator, but these are notoriously difficult to electronically tune over much of a range so I needed to maintain the crystal and oscillator at a constant temperature to keep it "close enough" to frequency to be within its narrow tuning capability to allow it to be locked precisely at frequency.

To do this I needed to construct a "crystal oven" - a circuit/device that holds the critical components at a (fairly) constant temperature to accomplish this.

How it works:

Typically, one uses several power resistors to heat a crystal, but there are ways that this can be done using no power resistors at all:  Consider the circuit in Figure 1, below.

Figure 1:
Crystal oven using a power MOSFET as the heating element.
R320/Q306 form a constant-current limiter circuit so that the FET can never be fully "on", keeping its resistance higher so that it can function as a heater.  The FET itself, along with thermistor R316 are "thermally coupled" to the crystal being heated.  The (nominal) 0.6 volt turn-on threshold of Q306 and the value of R320 limit the maximum current to about 600mA, but this could be adjusted by selecting appropriate values for R320.
Click on the image for a larger version.
In this circuit Q305, a generic N-channel MOSFET power transistor, is used as the sole heating element:  Its tab could be soldered or bolted directly to the device that needed to be heated such as the crystal or soldered/bolted to a substrate to which the crystal and other components are mounted, etc.  Because the tab of  typical power FET is the drain lead, make sure that it has DC isolation from ground.

The heart of this circuit is the Q305/Q306/R320 combination.  Assuming that voltage has been applied to the gate of the FET via R319, when the current through R320 exceeds that which is required to effect an (approximately) 0.6 volt drop, Q306 turns on, pinching off the gate drive and regulating the current through R305 to that level.  With the components shown, the maximum amount of current that will flow is that which causes 0.6 volts to appear across R320, which, in this case is (0.6 volts * 1 ohm = 0.6 amps) 600 milliamps.  By limiting the current to a reasonable level the FET's "on" resistance is regulated, allowing it to act as a heater.  Without this current limiting U303 would simply turn FET Q305 "on" and its resistance would be a fraction of an ohm, effectively shorting out the power supply - but more likely it would dissipate a lot of power and blow up if there was sufficient power supply current.

Assuming that there are 9 volts available across Q305 (e.g. the 10 volt supply shown, the drop across R320 and a few other, miscellaneous losses) Q305 will produce about (9 volts * 0.6 amps) 5.4 watts of heat, conducted from its metal tab into whatever it is that is being heated.

To regulate the temperature a simple controller is built around an op amp - in this case, a generic 741 (U303) and a thermistor (R316):  Because of the typical 2-4 volt threshold voltage of typical power FETs, the fact that the output voltage of a common op amp like the 741 doesn't get very close to its negative rail isn't a problem - but this should be kept in mind if you happen to use a "logic threshold" FET that starts to turn on at about a volt.  R316 is "thermally coupled" to the device(s) being heated - but not coupled too closely to the heat-generating component, Q305 that there is constant over/undershoot when the heater is active.

The actual temperature at which the oven will stabilize is determined by matching the value of fixed resistor R315 that of thermistor R316 at the desired temperature - a resistance that can be determined from the thermistor's 'spec sheet or by experimentation.  The actual value of the thermistor at the operating temperature is not particularly important but it is recommended that it be in the range of 5k-100k for practical reasons.  The thermistor that I happened to use had a nominal resistance of 30k at 25C, decreasing to about 11k at 50C, the target temperature, so I used a value of 11k for R315.

When the oven is cold the resistance of thermistor R316 is going to be higher than that of fixed resistance R315 which causes the non-inverting (+) terminal of the op-amp to be higher than that of the inverting (-) terminal which is biased at mid-supply by two equal resistors.  When this happens the output of the op amp goes high, providing gate voltage to Q305 via resistor R319, allowing it to heat up.

Figure 2:
The oven and its controller.  The tab of Q305 is soldered directly to
a large, electrically-isolated island of circuit board material.  As can be
seen from the picture, the board to which the heater is mounted is actually
smaller than the surrounding enclosure, mechanically "floating" in the center
via four pieces of small-gauge wire that provide both a DC return and RF
ground connections as well as allowing a gap that is filled with an air
space and insulating foam.  The circuit is wired "dead bug" with the op
amp being "leads-up", just to the right of Q305.  At the bottom of the
picture is a 3-terminal 10 volt regulator (a 7810 - not shown in figure 1) that
provides a stable 10 volt source for both the oven and the crystal oscillator.
Click on the image for a larger version.
When the oven comes up to the design temperature (e.g. that which the resistance of thermistor R316 is the same as fixed resistor R315) the voltages at the inverting and non-inverting terminal of the op amp are equal and the voltage being output by the op amp drops, removing the bias voltage from the gate of Q305 and preventing the oven from heating further.  In reality, there isn't an "on/off" action by the oven, but a more gradual "power up/power down" caused by the inclusion of R317 between the output of the op amp and the noninverting (-) input of the op amp.

It's worth noting that using the turn-on voltage of a transistor as a current reference means that the actual current will vary depending on that transistor's temperature (e.g. that of Q306), but because Q306 is located within the oven chamber it, too, will be heated and the maximum "oven" current (e.g. that through Q305) will be quite stable.  What can affect the dynamics of this oven system is a variation in the voltage applied to Q305:  The higher the voltage, the more power (in watts) will be produced in heat.  While the oven controller will help to maintain temperature, if the power supply voltage is quite variable - as could happen when this oven is run from a "12 volt" battery (anywhere from 11.5-13.5 volts, depending on state-of-charge) the thermal input power can change and cause a slight instability in the closed-loop temperature control due to this change in available thermal power.  In this case - with the crystal being externally locked to frequency, anyway, this wasn't too important.

There are a few other component sprinkled about in the diagram as well:
  • C318 and R321 are used to prevent the Q305/Q306 circuit from oscillating.
  • R322 is an optional test point to measure the oven current.  FT304 is an (optional) feedthrough capacitor used to prevent RF ingress/egress along this monitor point.
  • C316 and C317 are power supply bypass capacitors - always a good practice to include.
  • R318 and LED D303 provide an optional "oven on" indication.  The cycling of this LED between full brightness and dim/off after being powered up indicates that the oven is heating/stabilizing.  If it cycles on and off continually this can indicate that there is too much thermal resistance between the heater (Q305) and the thermistor, causing the circuit to overshoot.
  • The values of R313 and R314 are not critical - but they should be equal.
  • The value of the thermistor is not critical, but it should probably be between 1k and 100k at the desired operating temperature.  Select R315 to have the same resistance as the thermistor at the desired oven operating temperature.
  • To provide a temperature adjustment, R315 may be made variable with a good-quality multi-turn potentiometer.  Alternatively, resistors R313/R314 can be replaced with a single 20k-50k multi-turn potentiometer.
What to use this for?
Figure 3:
The "oscillator side" of the circuit shown in Figure 2.  The oscillator is a 5th-
overtone "Butler" type build "dead bug" on a piece of double-sided
copper-clad epoxy board.  The crystal is located directly opposite the
location of Q305, the heater (e.g. the board is rotated 1/4 turn counter-
clockwise from Figure 2).
Click on the image for a larger version. 

I devised this circuit when constructing a homebrew 24 GHz amateur radio transverter (transmit/receive frequency converter) and needed a "fairly stable" source of a 99 MHz signal to be multiplied upwards and to be locked to an outboard, stable 10 MHz reference (e.g. high-stability crystal or rubidium source.)

Because this crystal oscillator was to be externally locked, it didn't need to be ultra-stable - just stable enough to keep its temperature close enough to the rather limited frequency-pulling range afforded by high-frequency overtone crystal oscillators.  With this relaxed requirement, the crystal could actually vary a few degrees about the set point with no ill effects whatsoever.


I didn't need to optimize this circuit for ultimate frequency stability as the 99 MHz oscillator is locked to an external 10 MHz reference:  All that is necessary is that the frequency be "close enough" - which is to say, within the rather narrow frequency tuning range afforded via the VCXO (Voltage Controlled Crystal Oscillator) circuit.

If this circuit is to be used for a "stand-alone" oscillator where the frequency is directly affected by the temperature, additional care will be required to appropriately thermally couple the thermistor and heater (Q305) - and possibly tweak the value of resistor R317 - to prevent the temperature from oscillating about its set point.

Finally, even though the temperature controller is entirely ratiometric - that is, power supply voltage variations will not affect the temperature set point to a significant degree -  remember that at higher voltages the power going into the heating element (e.g. the power FET Q305) will also increase.  This change in thermal input can cause the dynamics of the oven to change somewhat and slightly change the rate-of-change and potentially alter the stability of the feedback loop.  Because this oven was intended to keep an oscillator "close enough to" rather than "dead on" frequency this factor wasn't important.

Additional resources:
  • W6PQL Crystal Oven Controller - link - This discusses a more conventional "heater-resistor" circuit for maintain constant crystal/component temperature.
  • The OCXO/Si5351A synthesizer - link - QRP Labs sells a version of their Si5351A synthesizer board with a built-in crystal oven controller providing a stability of 1ppm or better.  The assembly manual for this kit (linked on the referred page) uses low-power FETs as heaters and a bipolar transistor as the temperature sensor.  This manual discusses the operation of the circuit and is an interesting read.


This page stolen from ka7oei.blogspot.com

Thursday, January 4, 2018

A quick fix for a Yaesu FT-757GXII blank display

A couple weeks ago I was contacted by an old friend of mine, having obtained his amateur license in mid-2017, who has a Yaesu FT-775GXII - a synthesized, all-mode HF transceiver from the the mid-late 1980s which had been working well until, one day, there was no display.  Clearly the main processor was fine as the front panel buttons would work, he could transmit and receive and he could even "see" and control the radio's frequency and mode on his computer via the serial CAT interface.
Figure 1:
The front panel of an FT-757GXII with a working display!

One clue was that when power cycled, the display would occasionally flash very briefly, a possible indication that something was almost doing what it was supposed to.  Via email (he lives across the country from me) I had him do some preliminary troubleshooting such as the checking of voltages - but based on the rather sparse information available in the service manual and the difficulty in accessing some of the test points:  Even a couple key capacitors in circuits that often cause problems with displays in some radios - namely the switching supplies that provide the odd voltages for the vacuum fluorescent display - were swapped out, but the display remained blank.

I offered to look at it, so he packaged it up and sent it to me.  When I put it on my workbench I started probing the various lines on the display processor with an oscilloscope:  I could see many of the signals that I was expecting - namely the 500 kHz signal from the display processor's clock, the data coming from the radio's main processor that changed as I pushed buttons and turned the main tuning knob and another signal that appeared to be an acknowledgment pulse from the display processor to the main processor.  What I seemed to be missing were half of the multiplexing signals that drove the display:  It appeared that I was seeing the "common" signal lines for the display, but the signals on the pins that appeared to carry information as to which display segment was to be illuminated were missing as if the display was supposed to be blank.  Without both sets of signals activated appropriately, a multiplexed display will remain forever dark.

I'd already consulted the internet and determined, based on postings in various forums, that at least for its predecessor, the 757GX, the failure of the display processor wasn't terribly uncommon - but not surprisingly this part was long gone from the spare parts inventories of Yaesu and other means of repair/replacement such as getting displays from scrapped radios or even the construction of an "alternate" display unit using a different processor and driver transistors was discussed.  What was interesting was that the "important" signals - namely those for data, acknowledgement, scanning and synchronization - seemed to be present, so the display processor clearly wasn't completely dead.
Figure 2:
Annotated picture showing the two buttons that, when both are set to their
"in" position will disconnect the radio's internal memory back-up battery.
If both buttons are in when the power is removed the processor will be
reset to its "factory" state.
Click on the image for a larger version.

At about that point the old adage drilled into me from the early days of computers and Windows came back to me - although it probably should have been one of the first steps to be taken when the display went blank:  "When in doubt, reboot!"  Perusing the user's manual I determined that a complete "memory reset" was done on the FT-757GXII by setting both the "Linear" and "Marker" switches on the back panel (see Figure 2) to the "in" position at the same time and turning off the radio for 30 seconds - and then turning it back on and restoring the two rear switches to their normal position:  It would appear that these two switches have a second, "non-intuitive" function that when used together, disconnects the internal battery.

The result?  The display came back to life!

What had apparently happened was that somehow, the data stream between the display and main processor wasn't what it should be and the main processor was apparently sending some sort of garbage that the display processor didn't understand - probably due to something in the main processor's static RAM.  It would appear that in the absence of sensible data, the display processor remains blank, relying on the main processor to send the various bits and bytes that display frequency, mode, etc. rather than reverting to some sort of static display.  Clearing the battery-backed RAM of the main processor and resetting it apparently cleared whatever junk had gotten into the memory that had caused it to work improperly.

I checked the back-up battery - an innocuous-looking 2-cell NiCd pack that was near the rear of the main synthesizer board - and it read 2.8 volts with the radio having been disconnected from power for over 24 hours indicating about 1.4 volts/cell, which was appropriate for a properly-charged NiCd.  Visually, this small battery pack looked OK in that there were no signs of corrosion, so it is probably OK, despite its age - longevity being one of the virtues of a properly cared-for, high-quality NiCd cell.

How did the main processor's memory get scrambled?  Who knows - it could have been an entirely random event, due to static from a finger touching the front panel, the back-up battery's voltage having sagged below the point of memory retention while the radio was turned off or the results of some sort of spike - perhaps lightning - intercepted by the antenna that found its way into other circuits.  This sort of "display failure" - apparently caused by the processor's memory being scrambled - doesn't seem to be too common, so my friend considers himself very lucky!

After restoring the radio's operation I did a few tests and found that everything seemed to be working as it should, so it will be packed up and returned to its (very fortunate!) owner very soon.


This page stolen from ka7oei.blogspot.com

Wednesday, December 20, 2017

Does the Tesla Powerwall 2 produce RFI (Radio Frequency Interference)?

Figure 1:
A typical Powerwall 2 installation.
Left to right:  Utility meter/original load center fed from an underground
power feed, the"new" load center to which the household circuits now
connect, the Powerwall "Gateway" (with two 4G antennas on top), AC
disconnect for the Powerwalls, sub-panel for the Powerwalls (containing
two circuit breakers), and finally the two Powerwalls.
This type of system is typically installed outside, near the utility's
connection to the house.
Click on the image for a larger version.
Now that I have an installed and operating Tesla Powerwall 2 system I've had the opportunity to answer a question that I've not seen answered elsewhere:  Does the Powerwall 2 cause radio interference?

Why I care:

Being an amateur radio operator that uses a wide range of frequencies across the electromagnetic spectrum (from below 137 kHz to at least 24 GHz) and often "listens" over wider ranges than that I'm always on the look-out for devices that unintentionally produce radio frequency energy which will be manifest as radio interference, reducing my ability to receive signals.

This sort of interference is increasingly commonplace, the incidence having accelerated with the prevalence of "switching" type "wall-warts" (a.k.a. "power cubes") that ubiquitously power nearly anything that is plugged into the wall.  As part of their power conversion, these small devices contain powerful oscillators - typically operating in the 20-100 kHz range - that have the potential to cause radio interference at frequencies far removed from that.

What this means is that the inclusion of even more of these devices in my household - including a Tesla Powerwall 2, which is a really big switching power converter - have the potential of adding to this sea of noise.

What is a Powerwall?

A Powerwall is the Tesla-specific name for what amounts to a "whole house UPS" (Uninterruptible Power System).  There are other manufacturers of similar systems and they have their own nomenclature, generically called an "AC Battery" because they internally perform the AC to DC conversion for charging and DC to AC inverting to provide external AC power.

As the name implies, if the mains power disappears this system can provide electricity to the entire house (or a portion of it) during the power outage.  As you might expect, very large, high duty-cycle loads such as whole-house air conditioning, electric water heaters, electric clothes dryers and electric furnaces are typically not backed up by a system like this as they would draw down the battery very quickly.

When integrated with a PV (solar electric) system it can be charged from solar energy and if the grid remains unavailable the house can run indefinitely, provided that the short-to-medium-term power budget is positive - that is, more solar power is produced than is being used and the battery is not discharged so much between charges (e.g. overnight, on cloudy days) that it reaches the point of cut-off.  My system has two Powerwall units which, working in tandem can provide at least 10kW of power with a storage capacity of a bit more than 26kWh - enough for about a day (without any solar input) with normal usage or several days (without solar input) if serious power conservation measures are taken.

In areas where there are significant electric rate (tariff) differences between "peak" and "off-peak" hours, this type of system can be used to "zero out" (or reduce) utility usage during peak hours and charge  during off-peak hours from the grid and/or with solar.  In my area, this is not relevant as the power rates remain constant throughout the day and it is configured to charge only from solar.

Having one of these systems is a bit like having a back-up generator - except that if the sun is shining, the "gas tank" can be refilled.  Practically speaking this system is unlikely to save me any money in the same way that a back-up generator probably wouldn't so I would consider it to be a sort of extravagance - like owning an RV, boat or some 4 wheelers - a bit like a somewhat expensive hobby, but more utilitarian.  Being an amateur radio operator I'm also interested in having back-up power in case there is some sort of event that causes the loss of the grid for a period of time, hence the concern about possible radio interference.

How it's connected:

Figure 2, below, shows how a typical "AC Battery" might be wired into a household power system and integrated with a PV inverter.
Figure 2:
A generic block diagram of an "AC Battery" type of back-up power system.
In "Tesla speak", the "Gateway" comprises the functions depicted in the box labeled "Supervisory Control" while the
Powerwall(s) themselves are depicted by the boxes labeled as "Battery-backed inverter/charger system(s)".  Both circuit
a manual disconnect and circuit breakers are required to give first responders an easy way to kill power to the entire house
should it be necessary - such as in the event of a fire or other disaster - as simply killing the mains circuit alone would
not do this!
Click on the image for a larger version.
Comment:  As the time of writing there are some parts of the world - mostly in Europe - where, due to regulations, "whole house back-up" during a grid failure is not available.  The radio interference potentials described below still apply in these cases.

As can be seen, in normal operation the AC battery system is in parallel with the house's power and the power grid.  When "charging" from the solar, it simply monitors the output power of the PV system and the power to/from the grid and adjusts its charge rate to match.  Likewise, in the "Self-Powered" mode (described below) when there is a grid connection it will charge/discharge at a rate that precisely matches the house's usage, effectively zeroing-out the power going to/from the grid or export power to the grid once the battery has been charged in the same way as a typical "net meter" installation.

If the mains power fails the "Grid Isolation Relay" opens, disconnecting the house from the grid, allowing power to the backed-up loads to be maintained without back-feeding the utility.  The process of detecting a power failure, disconnection from the grid and full restoration of the power seems to take between 200 and 750 milliseconds but the return to a grid connection after the power has returned and stabilized for a few minutes is nearly instantaneous.

Does the Tesla Powerwall 2 cause radio frequency interference:

Yes and no.

The "no" part:

On the HF bands I have determined that in my particular case (and prior to mitigation techniques described later) the interference potential on the HF bands to be minimal or negligible.  When the unit is operating (either charging or discharging) and I am using my normal HF antenna system I cannot detect any interference from it on the HF amateur radio bands of 80 through 10 meters (e.g. 3.5-30 MHz).  Additionally, I cannot detect any interference from the Powerwall 2 system on any VHF or UHF band, either.

If I walk up to the Powerwall 2 system with a portable shortwave radio while it is operating I can hear a bit of noise when I am within a foot or so (less than a meter) that is likely due to influence from short-range magnetic fields, but this noise energy doesn't seem to be being coupled to the connecting wires outside the unit.

The "Yes" parts:

160 meters:

Prior to noise mitigation techniques on the highest MF band, 160 meters (1.8-2.0 MHz), the story is a bit different:  When the unit is operating, I can just detect a bit of noise from the unit in the far background, just below the local noise floor - but whether or not I can hear this at all depends on which antenna I'm using for receive.  For example, on an active E-field whip I can just hear this noise, but it is not at all audible when using a wire antenna.

On lower frequencies:

Going down lower in frequency - into and below the AM Broadcast band (e.g. below 1.7 MHz) - the RF noise being produced by the Powerwall 2 (again, when it is charging or discharging) gradually increases, being fairly obvious by the time one gets to the bottom of the AM broadcast band (e.g. 530 kHz).  Below the AM broadcast band are two more bands - relatively recent additions to amateur radio in the U.S. - and both of these are bands on which I operate:  The 630 meter band (472-479 kHz) and the 2200 meter band (135.7-137.8 kHz).

At these frequencies the interference from the Powerwall 2 (when it is operating) ranges from "significant" at 630 meters to "considerable" at 2200 meters - but this is not surprising.  It would appear that the main power converter(s) inside the Powerwall(s) operate at 32 kHz - and the 2200 meter band is at only about 4 times this frequency.  Because the 2200 meter band's frequencies are comparatively close to the operating frequency of the inverter and its 4th harmonic at 128 kHz - and because RF interference filtering works better as frequency is increased while the harmonics of these converters (and their significant mains-frequency modulated sidebands!) also decrease in amplitude - the amount of energy at 2200 and 630 meters will naturally be higher than it would be on the HF bands.

In short:  If you do not plan to operate on the 160, 630 or 2200 meter bands, you will likely not experience any interference at all, even if no mitigation techniques are used.  I can only speak from experience with my system:  Other systems may be better or worse in terms of interference, depending on the situation.

An interference source that can be controlled:

If the RF interference from the Powerwall 2 were to be of great concern it's worth noting that the user has pretty good control of when this might happen as interference from the Powerwall 2 seems to occur only in two possible states:  When it is charging, or when it is discharging.  What this means is that even if you use the MF (160 or 630 meters) or LF (2200 meters) bands it will not cause interference when it is "idle."

A typical Powerwall 2 owner would operate it in one of two modes, selectable from a phone app:
  • Backup-only.  In this mode the Powerwall 2 operates only as a "whole house UPS" - that is, it is not producing power except when the utility mains is offline (e.g. a power failure or the user has disconnected it from the grid).  In this configuration and in a typical installation, charging of the Powerwall 2's battery is done only with energy from the PV system (solar + inverter) when it needs to do so - and this usually occurs only if the battery has been discharged below 95% or so.
  • Self-powered.  In this mode the Powerwall 2 monitors the net inflow and outflow of power from the house.  In this configuration the Powerwall will either output enough power to "zero out" the usage of the house so that there is, on average, no power going to/from the utility and/or it will take excess power from the PV system to charge its battery which will also "zero out" the power to/from the utility.  If the battery is fully-charged, excess power from the PV system will be fed back into the Grid, just as is done in a normal "Net Metering" situation.
Note:  At the time of this writing there is expected to be a "load leveling" mode offered in the near future where the Powerwall may be configured to charge/discharge at specific times to take advantages of time-based tariffs (e.g. lower-cost power during "off" hours).  This does not apply to me and such operation is beyond the scope of this article.

In the "Backup-only" mode the Powerwall 2 system is not usually operating (charging/discharging) and will thus not typically produce any noise on any amateur band - but in the "Self Powered" mode, the only time that interference would not be being produced would be when the Powerwall 2's battery is fully-charged and the excess PV power is being exported to the utility grid.

What this means is that if there is the possibility of interference, one would typically operate in the "Backup-only" mode where it is fairly rare for the unit to operate at all.  In my case, the charging portion of the inverter will operate only for a few hours in the morning as soon as the PV system starts to produce power, one or two days a week when it "tops off" the battery.

If, for some reason one wanted to completely eliminate the possibility of the unit going active - say, during some sort of contest - the Powerwalls could simply be turned off, but this would be done at the risk of losing the power back-up capability in the event of a grid failure

Mitigating interference from the Powerwall 2:

If we were dealing with a normal switching power supply the mitigation of interference would be quite straightforward:  Apply "brute force" L/C filters to all of the AC connections in and out of the device - a topic that has previously been discussed in great detail at this web site (see the links to related articles at the end of this blog posting.)

Applying filtering to a plug-in device that is capable of up to a kilowatt or two is one thing, but mitigating interference issues on a device that is permanently wired in to the house's electrical system and capable of many kilowatts is an entirely different matter!  For example, my Powerwall 2 system consists of a two battery/inverter modules that, together, are rated for 14 kW for short periods, or over 10 kW continuously, representing over 58 and 41 amps at 240 volts, respectively.

To afford a wide safety margin any added inductive filtering would need to be capable of handling at least 100 amps with any capacitors being conservatively rated for the voltage.  Finding and installing a commercially-available AC mains filter with such ratings could be difficult, expensive and awkward, probably requiring a separate enclosure - not to mention appropriate sign-off by inspectors.  What's more is the fact that on a battery-inverter system like this, two such filters would be required:  One on the AC mains feed-in from the utility to the Powerwall and another on the AC mains from it.

A more practical solution - and one that works effectively for 160 meters - is to install snap-on ferrite sleeves on these six conductors (e.g. the two "hot" phases and the neutral for each of the lines.)  It so-happens that readily-available devices that will fit over RG-8 coaxial cable will also fit nicely over power cable that is appropriately sized for 125 amp circuits.  (The dimensions of these devices is approximately 1.55" [39.4mm] long, 1.22" [31mm] diameter and are made to accommodate cables up to about 0.514" [13.05mm] - but could be modified to go over cables that are nearly 0.6" [15.24mm] diameter).

For exclusively HF, the so-called "Mix 31" ferrite material a reasonable choice, each device providing equivalent resistance as follows:
  • 1 MHz:  25Ω
  • 5 MHz:  71Ω
  • 10 MHz:  100Ω
  • 25 MHz:  156Ω
  • 100 MHz:  260Ω
  • 250 MHz:  260Ω
I used two of these devices on each of the leads (for a total of 12) which, at 160 meters, would provide an equivalent of about 60Ω of resistance.  Considering that there are 3 leads per feed, this parallel resistance is roughly equivalent to 20Ω per feed, so for 160 meters a bit more "help" may be required, so I also used some "Mix 75" ferrite devices of the same size.

Intended for lower-frequencies, the equivalent resistance of each of these devices is:
  • 200 kHz:  20Ω
  • 500 kHz:  58Ω
  • 1 MHz:  102Ω
  • 2 MHz:  70Ω
  • 5 MHz:  50Ω
Figure 3:
Beneath many of the boxes is a raceway/channel that contains some of the
conductors, including data lines and, as depicted above, the wires coming
from the utility mains, connecting to the Powerwall's gateway.  In
my installation there are no exposed conductors in this raceway and there
is plenty of room for the installation of the ferrites.  The marked ferrite
devices are the "Mix 75" while the unmarked are the "Mix 31."  While
it probably doesn't make a difference, I placed the Mix 75 ferrites on the
end of the leads closest to the Powerwall in the unlikely event that low-level
harmonics are generated in the Mix 75 ferrites that need to be attenuated
by the Mix 31 ferrites.  Placing large ferrites over all three conductors
at once for common-mode filtering would be preferred, but doing so
is not always practical as discussed below.
Click on the image for a larger version.
As can be seen, for covering 160 meters and higher frequencies a combination of both types of devices is suggested.  At 1.8 MHz, it is estimated that total equivalent resistance on each lead of the four devices (two Mix 31 and two Mix 75) will be on the order of 220Ω, or about 73Ω for each of the three sets of wires in parallel.  As can be seen from the pictures, I used two of these "Mix 75" devices on each of the leads.


At this point, there are a few "weasel words" that I must include:
  • While it is possible to put these ferrite devices (or anything at all!) inside the Tesla Powerwall's gateway box, doing so would probably require the "official" permission of Tesla's engineering department to avoid the possibility of voiding a warranty/service agreement.  Because of this, it is better to mount them on the conductors outside the gateway.  Filtering could also be installed at the disconnect and/or circuit breaker between the Gateway and the Powerwalls, but this, too, may require appropriate approval and sign-off by Tesla engineering to avoid warranty issues.
  • Placing any ferrite devices as described here outside the Gateway box will not affect its operation and would be less intrusive than, say, installing a whole-house surge protector as no physical connections are being made.  Because of the wide difference between the mains frequencies (50/60 Hz) and the lowest RF frequencies of interest (136 kHz-1.8 MHz) for which these devices are designed, these ferrites will have no measurable effect at mains frequencies.
  • The installation described below involves the exposure of high voltage, high-current circuits inside a breaker panel.  DO NOT even think of opening such a panel when it is "live", let alone installing any such devices inside it.
  • DO NOT even think of installing such devices in a panel - even if it is powered down - unless you have experience working with electrical circuits.  If you do not have such experience, refer to a licensed electrician to install such devices.
  • Where I live it is permitted for the homeowner to make modifications to the home's electrical system, but it is up to YOU to determine the safety and legality of any sort of modification of your electrical system and determine if you are competent to work with it.  Do not presume some/any of the described modifications to be legal or in compliance of safety regulations in your (or any) jurisdiction!
  • I cannot be responsible for injury or damage related to anything described on this page.  You have been warned!

First off, note that all of the units (the two Powerwalls, breaker panels, etc.) in my installation are connected together with metallic conduit and if properly installed this conduit will quite effectively bond all of the various boxes together electrically which means that it is likely to be quite effective in both preventing direct radiation of RF energy from the contained conductors as well as minimizing differential RF currents between the various boxes.  What this de-facto shielding will not do is stop RF from being conducted on the wires that leave this system - notably those that go into the house or to the power utility.  In my case, utility power is fed from underground which means that the most likely source of interference from the Powerwall is likely to be conducted into it from the main breaker panel and onto the house wiring.

Visible in Figure 1 (above) is a channel that runs underneath several of the boxes and in this channel are the conductors that, in my installation, go from the utility mains panel to the Powerwall's Gateway - and I installed one set of the ferrites (a total of 12 devices) in it as depicted in Figure 3.  Because there are no exposed electrical connections in this channel, these devices can be safely installed without turning off power.

Vibration prevention:

These ferrite devices are, by their nature, quite magnetic and as such the magnetic field associated with the AC current flowing through the wires over which they are slipped will cause mechanical movement.  When I installed the first of these devices I could hear them buzzing slightly, the apparent result of the two halves of the ferrite moving with respect to each other.

Figure 4:
 This is a view inside my main house's breaker panel with the "dead front"
cover removed.  In the upper-right corner is a 125 amp circuit breaker that is
the main feed-in from the Powerwall Gateway (the partially-visible box to the
right) which can carry the power from the utility and/or from the Powerwall.
The space for these ferrite devices is a bit crowded, but they do fit.
As noted in the warning, this panel has exposed, live connections and you
should not even think about working in it unless you have experience
in working on electrical systems and the power is turned completely off!
Click on the image for a larger version.
To prevent this movement - and the possible damage of these devices due to this constant motion over time - I spread an extremely thin layer of clear RTV (silicone) adhesive across the mating surfaces of the two halves to bond them gently together.  These devices have two mirrored halves of the ferrite that, when assembled, touch each other and are polished smooth, so one need only barely "wet" their surfaces with the slightest film - only the tiniest fraction of what would be used normally, an amount so small that it looks somewhat like an oil slick is sufficient for the polished surfaces.  Alternatively, a small drop of cyanoacrylate (e.g. "Super Glue") could be used, but unlike RTV, this would make removal difficult were it required in the future!  Adding anything between the two, polished halves of the ferrites will reduce their effectiveness somewhat so it is important that the two surfaces be as close to each other as is possible by using the smallest amount of RTV.

Installation in the main breaker panel:

In my installation there was another location at which these ferrites were to be installed:  On the power feed from the Powerwall to the household circuits where the majority of RF noise is likely to be conducted - but instead of being in a raceway where there are no "live", exposed connections, the only place that this wiring appears is in the main circuit-breaker panel.

Figure 4, above, shows the installation of the ferrites on the conductors within the breaker panel.  As can be seen, there are "live" exposed connections that pose a shock hazard which means that these devices can be safely installed only if the power is turned completely off.  As was done with the other devices, an extremely thin layer of RTV was put on the mating surfaces of the ferrites' halves to prevent their buzzing.

It would be preferable to be able to wind several turns of the large power cables through non-split ferrite cores to achieve much higher effective resistance at the frequencies of interest, but this is simply not possible in the available space with the existing wiring - particularly in the preferred common-mode fashion (e.g. all conductors going through the same core(s)).  Because the conductors were already in place and routed, it was deemed to be too awkward to disconnect one end of the (heavy!) cable to allow ferrite devices to be slid over it, so "split" devices were used instead.
If one is starting from "scratch" - or has the ability to add it later with some rewiring - enough extra cable length added to allow the winding of multi-turn chokes through large ferrite (toroidal) "non-split" cores inside a dedicated, metal junction box would be desirable.  Doing this can greatly increase the series inductance and provide a commensurate reduction of conducted RFI.
It would also be preferable to pass all of the power cables through the center of a single ferrite (of ferrites) as a single bundle to provide a "common mode" impedance path, but this is difficult to do as I have not found a source for split ferrites of 31 or 75 mix that would accommodate three cables that are about 0.5 inch (approx. 1cm) diameter.  The obvious alternative would be to pass the conductors through a stack of adequately large ferrite beads/cylinders or toroidal cores, but doing this would require that the conductors be disconnected from one end and temporarily pulled back.  If this were done at the time of the original installation, it would be the preference - particularly if several turns could be passed through some large cores - but this is much harder to do after the fact, particularly with the limited length of wire in an already-installed system.
Finally, while there is plenty of room in the raceway to accommodate the bulk of a number of these cores, there is much less available space within the cramped confines of the breaker panel to accommodate a large stack of ferrite rings/sleeves, particularly if one were to wind several turns of wires through them.  If you are contemplating a brand new installation, or if you are willing to pull wire out and do mechanical re-work, by all means put several turns of the three wires (both "hot" and the neutral leads) through common cores to maximize common-mode impedance.
Other RF interference paths:

In addition to the power connections to/from the Powerwalls, there are two other possible egress paths for radio frequency interference:
Figure 5:
Also contained in the raceway is the CAT 5/6 cable for the Ethernet
cable that provides the Powerwall with internet connectivity.  In my
installation there is also another data cable that goes to current/voltage
monitoring equipment where the PV (solar) equipment feeds into its
sub-panel.  Multiple turns and conductors of wire were fed through several
ferrite devices to choke any RF that might egress.  The upper device
consists of three square snap-on ferrite cores while the bottom device is the
ferrite core from the yoke of a scrapped CRT computer monitor.
Note shown are additional multi-turn chokes wound on ferrites at
the "other" end of these same cables.
Click on the image for a larger version.
  • The Ethernet connection from the Gateway.  It is common to "hard wire" a CAT5/6 cable from the Powerwall's Gateway to an Ethernet switch (behind a firewall) to provide internet connectivity.  While an Ethernet interface is, by its nature, galvanically isolated from its support circuitry, it does have some capacitive coupling.  It is possible to wirelessly (via either WiFi or via a 4G cellular network) connect the Powerwall to the Internet - which would avoid such cabling - so one would have to determine the nature of the specific installation.
  • Serial power cable to voltage/current monitoring.  A typical Powerwall 2 installation uses devices made by Neurio to monitor the voltage and current at both the connection to the power mains and at the PV (solar) electrical connection.  While a wireless connection between some of these devices is possible, there may be a 2-wire (half-duplex, RS-485 serial) connection between some of these devices and RF egress could occur on this cabling as well.
In my case I have both an Ethernet cable going to my firewall and a wired RS-485 connection to the Neurio monitoring the PV system.  To reduce the possibility of either of these lines conducting RF energy into a circuit that might radiate, the two cables were put together and wound through several ferrite devices as shown in Figure 5.  The upper devices are square, snap-on ferrite chokes while the lower device is the mass of ferrite from the CRT yoke of a discarded computer monitor.  The use of multiple devices and multiple turns greatly increases the effective inductance of this coil and its effectiveness overall.

While using ferrite devices on CAT5/6 cable will not normally affect the high-speed Ethernet signals within, CAT5/6 cable should not be coiled extremely tightly as doing so will distort the geometry of the twisted pairs and the integrity of the signals.  While this is unlikely to have much of an effect on 10 or 100 Megabit connections unless the cable is very tightly wound, it can degrade a "Gig-E" (1 gigabit) Ethernet connection (the Powerwall only uses a 100 Mbps connection) if the coil is smaller than 3-5 inches (about 8-12cm) in diameter or if the outer jacket of the Ethernet cable is "kinked".

The results:

While it may be a bit of overkill, the addition of the two types of snap-on ferrites (e.g. two of each type on each conductor for a total of 24 snap-on devices) has reduced the interference on 160 meters to the point of inaudibility and greatly reduced it on 630 meters.

On 2200 meters the interference is reduced, but still significant:  To completely quash interference at this frequency it would probably be necessary to, at the very least, install pulse-rated bypass capacitors (perhaps 1uF or greater) between each of the three conductors (ground, L1 and L2).  If I do this I'll do so using a low-current (15 amp) circuit breaker to provide the connection between L1 and L2 and the ground as a safe and simple way to make the connection.

If adding such capacitors were found to be insufficient to reduce the interference to inaudibility and working "around" the operation of the Powerwall were not practical (e.g. when it was not active) the next step would be a rather awkward and potentially expensive one:  The addition of the aforementioned extra junction box and re-running of the cables to allow the installation of multi-turn common-mode chokes.

What about RF interference to the Powerall? 

The Powerwall itself is a computer-based system with a number of analog monitoring points and as such, it is theoretically possible for external RF to cause it to malfunction if that energy somehow "glitches" one of its computers and/or causes one of its many sensors to read incorrectly.  To provide protection, the Powerwall is designed very conservatively and in the event of a serious discrepancy or fault, it will shut itself down.

The question should be asked:  Is it possible for external RF to cause such a shut-down?

The answer is:  Maybe.

About a week after my Powerwall was installed I happened to tune up on 40 meters using my 1.5kW amplifier.  While I was doing this, the power to my entire house "blinked" several times and went off, with the Powerwalls indicating some sort of error condition.  Unfortunately, the isolation relay had tripped and my house was disconnected from the mains and the Powerwalls did not reset themselves even after turning them "off" for over 15 minutes.  After a bit of hassle, I was able to get the Powerwalls reset - but the question remained:  What happened?  I opened a ticket with Tesla support and they came out to investigate a few days later.

It was determined that a possible cause of this "loss of power" event was arcing at one or more connecting clamps on the mains side of the isolation relay in the gateway that had not been properly tightened when it was installed.  The extra 2+ kW of load on the AC mains from the RF amplifier may have been enough to cause arcing in that loose connection and the Powerwall, detecting this as a potentially dangerous fault (as arcs can be!) killed all of the power for reasons of safety.

Since the clamps were tightened I have never been able to recreate this event, but being "gun shy" I immediately started installing the various ferrite devices on the power and data communications cables - not only to keep RF interference from the Powerwall from radiating, but also to prevent RF from getting in!

Parts sources: 

There are several sources of snap-on ferrite devices described on this page, including:
  • KF7P Metalwerx - link - Supplier of a variety of Ferrite devices and many other things.  At the present time he stocks the "Mix 31" devices, but does not stock "Mix 75" snap-on cores.
  • Mouser Electronics - link - The "Mix 31" snap-on cores - P/N:  623-0444164181  (Fair-Rite P/N:  0444164181);  "Mix 75" snap-on cores - Mouser P/N:  623-0475164181  (Fair-Rite P/N: 0475164181).  Mouser Electronics has other sizes and mixes of these various devices. 

Other solar power related posts at this site:
Other articles related to the mitigation of interference from switching power supplies:
Some of the above articles contain additional links to other web pages on related topics.


This page stolen from ka7oei.blogspot.com