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1296
MHz / 23cm Transverter Info
July
2009
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The time
has come for me to get 23cm gear going mainly for activities for
VHF/UHF Field Days and since I now have a bit more time on my hands,
I decided that the approach would be "hands-on" style.
By that statement, nothing would be bought outright ( i.e. a black
box device) and, wherever possible, made here in my workshop.
The first
step was to decide on a transverter design and a lot of time was
spent researching on the world wide web using the key words "23cm
transverter" and "1296 transverter". In brief, the
best / most relevant results were attributed to W1GHZ's
rover
designs for UHF/microwave. Would I build one from the ideas
presented there ? - or would I just take the easy path and buy something
similar ? The main thing about the rover design transverter was
that it was high-side injection and for the published crystal/oscillator
frequency, 1296.1 was going to be derived from an I.F. (intermediate
frequency) of 143.900 MHz - which wasn't going to work for me as
the proposed transceiver will NOT go below 144.000 Mhz. Maybe I
could have chased up a slightly lower crystal but then it wasn't
going to be s simple solution. I couldn't just use a standard low
side injection on the same W1GHZ 1296 PCB as the tuned L.O. ( local
oscillator) PCB filters were for 1440 MHz - rather than about 1150
MHz. No, that was not a good solution. Actually I found out later
that there was a solution by W1GHZ but by then it was too late -
my mind had been made up! His solution : NEW-
1296 MHz Transverter - Right Side Up (Low-side LO injection) Paper
- which I still didn't like because the 64MHz oscillator had no
frequency correction adjustment !
In short,
I decided that while I felt I was capable of laying out a suitable
PCB, my experience at 1.3GHz was in relatively short supply so I
considered that, initially at least, the probable "most-successful
track" was to buy a "kit of bits" from Minikits
in South Australia. Mark VK5EME despatched the ordered goods within
a day of ordering and so my 23cm journey / saga begins.....
The following
is a bit blog-ish but best describes the due process and findings.
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Step
one : 2nd July 2009 - Build up the Local Oscillator PCB
- the Minikits
EME-65B - the recently revised version.
This PCB
uses a couple of surface mount transistors but the rest of the components
are standard leaded styles ( eg conventional capacitors and resistors..).
I decided that I would use the 95.91666 MHz crystal so that my I.F.
would be 145 MHz rather than 144 MHz. The main reason was that since
I would be operating on, for example, 144.150 MHz USB during a field
day, the last thing I would need to do is to have to jump and find
the 2 metre radio's volume control when I fired up on 1296.150 USB.
By selecting the 95.9xx MHz option, the frequency on 2 metres would
be 145.150 MHz USB for an output frequency of 1296.150 USB. Hopefully,
the 1.0 MHz separation would be enough, when coupled with the few
milliwatts of power at that frequency, not to cause significant
interference to the 2 metre radio.
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The board
was built up and finally powered up. Hint : when mounting the 10
ohm resistor supplying the collector of the BFR93A via L4 (near
the LHS black electrolytic capacitor in the photo above), mount
it a little above the PCB for 2 reasons : (1) you need to be able
to measure the voltage across it as you tune the trimmers; and (2)
it does get warm under normal operation.
Checking
the crystal was oscillating and then monitoring the output at 575.500
MHz on my 1GHz spectrum analyser plus on wideband AM on my Icom
IC-R7100 receiver made it easy to find the nominally correct tuning
points - but more about this below.
Info from
Minikits about the tuning sequence was as follows :
The
free-running frequency of the coil L1 & C1 needs to be determined
first. Please follow the following alignment notes.
Disconnect the wire link near the crystal & connect the supplied
47 ohm resistor between the two BFR92A transistors emitter connections.
This effectively will allow the oscillator to free run at the resonant
frequency of L1/C1 without the crystal. Monitoring the signal on
a either a wavemeter or a scanner tuned to the crystal frequency,
e.g. 94MHz, 96MHz, or ( 67.333MHz with 432/28MHz Transverter ),
adjust the oscillator coil L1, ( Toko Coil ) until you hear the
signal. It will not be all that stable or easy to tune exactly,
but you should try & tune it within a few kHz.
You need to get this right first before connecting the crystal into
circuit. When you are happy that it is correct then reconnect the
crystal into the circuit.
Do alignment section 3 ( of the supplied kit notes) for maximum
output power.
Then you can get the frequency of the oscillator onto frequency
as in section 4 ( of the supplied kit notes).
L1 is not normally used to adjust the frequency of the oscillator
but can be used to trim it slightly if the crystal is only off a
few hundred Hz. The EME.DOC changes should only be tried without
crystal fitted So don't use L1 to move the frequncy very far else
the crystal will become rubbery. I recommend leaving L1 where it
free-runs on frequency & doing the above steps.
My initial
problems were that the tuning of the first trimmer (TC1), the collector
tuned circuit of the second BFR92A tuned to 200MHz, made the oscillator
"squegg" (low frequency oscillate). The squegging noise
was plainly evident in the R7100 receiver so I knew there were some
problems to be addressed. Tuning L1 caused the squegg-rate to vary
as did adjusting TC1. The oscillator was off frequency - about 10KHz
low at 575.5 MHz. A couple of spurious were noted on the spec analyser
at about +/- 15MHz on either side of the true LO output. Tuning
these two adjustments, but primarily L1, caused the frequency to
shift - something was not quite correct... The tuning slug of L1
was a fair way out of it's former and seeking info on the Minikits
web site for this project revealed a document that indicated for
an operating frequency around 96MHz, the capacitor across L1 should
be more like 15pF - rather than the original 22pF. I changed C1
to 15pF and the slug was now almost mid-way down the former - so
the best value was probably actually 18pF. Even so, I left it at
15pF. The oscillator still squegged as L1 and TC1 were tuned but
the output at 575.5 MHz rose and I was able to tune the rest of
the trimmer capacitors for maximum output. Having optimised the
rest of the trimmers, it was time to get down to find the cause
of the instability in the oscillator itself.
My experience
with well-designed crystal oscillators over the past 40 years is
that they usually oscillate at/around the marked crystal frequency
- or they don't oscillate at all. If an oscillator squeggs then
there is a fundamental design or construction flaw. If you tune
the "tank circuit" within range of resonance at the oscillator
frequency, it will "pull" the frequency low or high a
little - but squegging - not on !
The oscillator
style is a well-known Butler format, two transistors that use a
crystal between the emitters, the base of the first transistor at
RF ground. I could probably have reduced the 27pF coupling capacitor
between them to something lower, like 6.8pF, but I started using
another ceramic disc capacitor (with short pigtails/leads) and placing
it across various points on the PCB while watching the output on
the spectrum analyser and listening to the LO at 575.5 on the R7100.
There were two points that dramatically changed the spurious and
the squegging - the supposedly RF-earthed base connection of the
first BFR92A, and the top of its collector tuned circuit (i.e. 'cold
end' of L1 & C1). Both of these are bypassed by 1nF capacitors
to ground but maybe the particular style supplied are not quite
a low enough impedance at RF - I don't really know - however by
placing additional ceramic capacitor bypasses on the bottom of the
PCB, all of the spurious noted disappeared and so did the squegging
! Tuning L1 too far in stopped any oscillation, too far out - the
same. Around mid-way between the 'stop points', the oscillator started
each time power was applied, varied the output frequency by a KHz
or so, but the required signal purity (i.e. freedom from spurious)
was now there.
The capacitors
I used were simply picked up out of a "mixed pile" and
provided the capacitance was more than about 200pF, it should be
an adequate value to be a low impedance at 100+ MHz. The final values
were 470pF across the base to ground of the 1st BFR92A and 1000pF
across the "cold end" of the oscillator tank (L1/C1) to
ground - but they could just have easily been almost anything between
220pF and 47nF. The physical / electrical structure (ie. good ceramic
disc) was more important than final value.
I also have
to go on record that I consider that the supplied "tuning technique"
for L1 seems to be unusually complex. I am not saying it doesn't
work - or shouldn't be followed - just that it shouldn't be required
in a suitably-designed & fundamentally-stable oscillator.
See also
a document by as suggested by Kevin Murphy ZL1UJG about using this
oscillator kit in building a 1296 MHz beacon
Make sure
you read the KIT FAULTS & MODIFICATIONS part on the EME65B
page...

The two extra
disc capacitors on the bottom of the PCB.
Realistically I should have removed the original "as-supplied"
capacitors and fitted these in the original holes but that doesn't
make the "proving it's stable" process any easier.
Maybe I will do that before I finally mount the LO PCB into the
box !
That solved
one problem but not the other : the LO was still low of 575.500
by nearly 10KHz. The supplied info suggests that you use a series
capacitor in lieu of wire link "Option 2" for low of frequency,
a series inductor for high of frequency. Obviously I needed a series
capacitor to bring it up. I tried a 22pF disc in series and the
frequency rose by all of a KHz or so. I was going to need a lot
less series C. My parts box revealed some new miniature ceramic
5-30pF trimmers and checking it against the PCB hole spacing for
the Option 2 link, it would fit if I enlarged the hole diameters.
See photo below for how it was accomplished.
Adjusting
the trimmer while noting the LO frequency on the counter shifted
it to about 575.500 +2.8KHz before it ran out of range. Looking
good. Over a period of adjustments, it became obvious that the best
adjustment process was to adjust the extra trimmer capacitor to
approximate frequency and then fine tune with L1 for absolute.
From
the photo below, you will notice that I have fitted the 50 degree
PTC thermistor to the TS07S (50 degree rated) crystal and then used
the supplied thick heatshrink to encapsulate the assembly. My initial
observations indicate that the output frequency is drifting - but
given the warning from Mark at Minikits that the unit needs to be
run continuously for at least a week to "age" the crystal,
I won't worry about that "fine frequency stability" yet.

P.S.
: info from Mark on 5 July :
"OK
on the oscillator. We have been working with a number of Hams in
other countries for over 12 months to redesign the EME65 Kit. It
has needed an update for some time & I am now at the stage of
finishing the circuit board artwork ready for a prototype panel
to be made soon & sent off to the Hams involved for testing.
The EME65 Kit is very old & goes way back to the early 1990s
but has had very minor changes along the way, as it basically worked
well & was reasonably successful to build. The crystals are
causing many of the issues in recent times as HY-Q products are
a bit variable even in batches. The new design does address many
of your issues & there is much more RF bypassing around the
oscillator & multiplier.
I expect that the additional ceramic leaded caps may be adding more
bypassing & also some inductance which is fixing the stability
issues. This problem does change with different HY-Q crystals so
it's a real pain. The coil L1 should not be used to move the frequency
more than a couple hundred Hz as the tank circuit needs to resonate
at the crystal's frequency. Using L1 to move more than this will
reduce the stability of the oscillator & increase the phase
noise. Best to try & tune with your trimmer cap in series. I
would also suggest using a 10pF NPO trimmer & use a NPO ceramic
across make up the capacitance & reduce any drift. "
Update
21st Nov 2009
The
transverter is all up and running but this note has been added here
(rather than at the bottom) as this information is specific to the
L.O. PCB.
The LO would still not come up on frequency with it's highest frequency
per the trimmer capacitor adjustment falling about 2KHz short of
the 1151.000 MHz target. If I adjusted L1 to try to move it the
last little bit then the oscillator would drop out. The tuning range
of the trimmer moved the frequency from 1150.976 to 1150.998 but
just didn't quite make it to the 1151.000 mark.
A
few minutes on the web confirmed that the Butler oscillator uses
a series resonant crystal - which is what Hy-Q produces under their
TS-07S code. A few more minutes showed that the EME65 circuit was
essentially the same schematic as created by G4DDK and had no easy
fine-trimming. I then chanced across the Butler
circuit from W6PQL which showed a series trimmer capacitor PLUS
a shunt inductor across the 96MHz crystal.
Extract
of the important segment of the W6PQL schematic :

The
Minikits info suggests using either a series inductance or series
capacitance to trim the crystal to frequency - but it doesn't suggest
both. I didn't have any ~400nH inductors so I tried a 1uH in parallel
with the crystal and it still would not reach the desired frequency.
I then tried 2 in parallel = 0.5uH = 500nH and still no joy. I suspected
that the Q was probably not high enough so then jumped on the web
to find a calculator for a single layer coil. The philips #2 screwdriver
on my bench was about 5mm diameter so I played with some dimensions
for turns and length to aim for 300nH to 400nH of inductance. The
final version was 10 turns of 0.8mm enamelled wire wound on the
5mm screwdriver former and occupying about 10mm length. This coil
was soldered across the crystal pads underneath the PCB.

Underside view showing the air-wound coil across the crystal.
Yes, it got crushed a bit pushing it down to provide good
clearance but still does the job.
Note
that the PCB is now surrounded by a tinplate shield - an
addition since the earlier photos. The PCB is mounted on
10mm tapped standoffs and the 30mm wide tinplate strip was
soldered to the top of the pcb while being pushed down against
the bottom plate. The corners were made by just pushing
it around a piece of 42 x 19 pine so are not really good
squares. Nevertheless, it still functions as desired.
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Top view showing the 2-10pF trimmer soldered to the top
of the PCB pins.
The
last photo above these shows the ceramic one used previously.
The
red wire through the hole will eventually be replaced by
a feed-through ceramic...
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While
I was at it with the soldering iron, I removed the on-board ceramic
frequency adjustment trimmer, placed PCB pins in the holes then
added an 810 series plastic-style 2-10pF trimmer to these on the
top of the PCB. When I powered up the PCB, voila - it was about
1151.003 MHz. A quick adjustment on the 2-10pF trimmer and it was
on frequency. The adjustment of L1 became much broader too - and
the oscillator no longer seemed to drop out.
The
moral is that if you can't get the EME65 to net to frequency, add
the series trimmer and the shunt inductor in one hit. If you have
390nH SMT inductors then they will most likely work. If you don't
have any, wind up an air-wound coil to add.
Frequency
stability comment : The EME65 with the crystal heater moves about
1KHz from cold to hot but in my case the majority of this shift
happens within 2-3 minutes of switch-on. After that the frequency
shift is minimal ( < 100Hz at 1151) so the injection frequency
has been set up at least half an hour after that - and there it
stays. The crystal heater has been on enough over the recent months
for the ageing process to happen almost completely - but remember
that newly built LO's with crystal heaters will drift.......
Just
another comment : with the transverter running towards full power
on SSB, there was an obvious frequency shift due DC power supply
voltage "wobble" even though the actual oscillator is
fed from a 78L08 regulator on board. If you listen to the LO signal
on a receiver set to a SSB mode, you will hear the frequency shift
as you adjust the multiplier stage trimmers - and this is the cause
of the warble. My fix was to include a 7809 positive 9 volt regulator
in power line to the whole L.O. PCB - and the warble disappeared.
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Step
2 : 3rd July 2009 : Build up the
EME72B transverter PCB.
Actually
the construction of this PCB was relatively simple given the way
the surface mount components were supplied - individually separated
and stuck onto a partial- A4 back-page and all clearly identified
as to marking/value. I congratulate Mark on this idea.
The
first step in the instructions was to check for swarf (unwanted
/ leftover PCB material) around the MMIC amplifer holes. On my
PCB, there was a short circuit on 3 of the 4 holes due to a nearly-invisible
track of PCB copper cladding grounding one of the tracks/pads.
A sharp knife readily removed the material and an ohm-meter (DMM)
check then showed open circuit on each one. While talking about
swarf, I found a short circuit due to a fleck of swarf ( /tinning
) on the top of the PCB along the 12V supply rail - identifiable
in the full photo below as the long sideways-T track. It is a
good idea to use the ohm-meter test as each component is soldered
to the PCB remembering that capacitors will read open-circuit
(O/C) so if you have a bypass capacitor reading short-circuit,
then it is either the positioning of the surface mount capacitor
on the mounting point - or you still have a trace of swarf there
somewhere.
Apart
from that the rest was relatively straight-forward.... until I
got to the 78L08 voltage regulator orientation.
Now
the 78L08 mounts on the "top" of the PCB, the same side
as the Toko helical filters but the photo on Minikits transverter
page shows the regulator mounted like this (flat up) :

And
if you look at the photo excerted from my assembled PCB, you will
note that I mounted it the other way around (flat down) :

Before
I soldered it in, I cross-checked the PCB layout supplied in the
instructions, even going so far as to find a data
sheet for the 78L08 to check the lead-out configuration, and
checking the tracks on the PCB to see which was the input voltage
pad etc... I came to the conclusion that the photo on the Minikits
web page was in error (P.S. - which Mark
tells me is not wrong.. ).
The
response email from Mark on 5 July provided an answer :

...
he said that the orientation on the PCB
layout documentation - as supplied with the kit - was in error
!
Why others haven't found this before now is something you need
to wonder about !!!
This image is an partial extract from the complete new layout
document ART72B.PDF with the 78L08 orientation changed over.
Strange
though, I still wonder if Mark is correct on this ?? NO, he wasn't
- see below
The
only construction difficulty I encountered otherwise was that
the holes for the 3 PCB power pins were slightly small - I had
to drill them out before the pins could be pushed in for soldering.
Now
you will note that in my full size photo of the top of the transverter,
only a part of each leg of the SMA PCB mount coax connectors has
been soldered - so far. This is so that I can remove them when
I finally find a local source of tinplate to make up the shields
for all of the 23cm PCBs, then re-solder them on the outside of
the tinplate once the shields are fitted.

Due
to "grandfather's chores" ( due to school holidays etc.),
I wasn't able to get to the point of powering up the transverter
PCB.. but that will be coming shortly (next week ?) when the story
continues.....
P.S.
I went out today (3rd July) to visit Apple Aluminium (here in
Brisbane) and bought some 6mm aluminium rod ( 2 x 4m lengths)
plus some 6m metre lengths of SQUARE boom tube to start on some
yagis - as time permits - or - as required once the transverter
is finished and needs an actual antenna. Thought about making
loop yagis but I consider aluminium rod is easier to work with
and you don't have to worry about de-forming loops in transit
to field day sites...
Continuing
: 7 July 2009 : The LO PCB finally seems to have more-or-less
stabilised at 575.502180 MHz so it is time to move on with the
transverter testing.
Keeping
in mind my contemplations about the correct orientation of the
78L08 regulator - as above - and after re-checking a PDF of the
regulator lead orientation, I left the 78L08 as I had soldered
it onto the PCB and carefully applied voltage though a 390 ohm
resistor to the receive supply pin, measured the voltage on the
regulator output pin - pheww - about +5v out with +6.8v input.
Feeling happy that I expected around that, I dropped the 390 ohm
resistor out of line. The input voltage to the regulator was +12.8V,
the output +7.96V. So I did have the regulator
in the correct way in my photo & Mark's
photo and new layout details were wrong.
After doing that, the test setup was quite simple - a couple of
wires soldered to the +12V Rx and +12V Tx pins and on to opposite
sides of a DPDT mini-toggle switch, common centre going to +12V
as well as to the LO buffer pin on the transverter PCB and the
LO PCB supply as well. Apply the Marconi sig gen at 1296.1 / 3
= 432.0333MHz, 10% AM, at about -50dBm into the 1296 receive input
SMA connector, receive output SMA across to the R7100 receiver
tuned to 145.100. Couldn't be simpler - or so I thought.
Hearing
nothing but white noise at around S8 on the R7100, maybe the LO
is off frequency. No, no sign of the sig gen signal found when
tuning right up and down +/1 MHz. Somehow I hadn't expected that
much noise in the receiver and wondered why. I started tuning
the injection helical filters (1151MHz) and the noise level altered.
Ok, we have LO injection. I thought I had better start checking
some voltages and all started to look more-or-less ok until I
got to the MGF1302 RF preamplifier. It was showing +0.08V on the
base instead of -0.67V. Checking the drain revealed it was +0.8V.
The ICL7660 negative voltage generator was running but the BC857
voltages were weird. The BC857 is used to control the MGF1302
but it certainly wasn't acting correctly. There was about -3.6V
at the bottom of the 47K bias resistor for the MGF1302. I thought
I might have soldered the MGF1302 onto the PCB incorrectly - no,
it is as per the details supplied in the layout and correctly
orientated - probably "stuffed" - but correctly orientated..
No spare available so I just dropped off the hairpins from their
joints and used a ceramic disc capacitor directly onto the drain
PCB track from the input SMA connector, bypassing that stage.
Turned the power back on : still noise - lots of it - too much.
I
went back to the LO helicals and at one point in tuning the second
adjuster, the noise dropped right off and I could hear a little
bit of the sig gen's modulation in the noise of the R7100. I fine-tuned
the R7100 and centred the signal : +5 KHz. It was something to
do with LO - that was for sure. Please note that I hadn't touched
the LO PCB since I did the last adjustments a few days ago - when
it seemed stable. Maybe the ERA3 in the LO was being overdriven
and if I de-tuned the last trimmer on the LO PCB, it should reduce
that somewhat. The difference it made was radical. The white noise
in the R7100 dropped right down, the signal to noise jumped up.
Guess what ?? The LO PCB is the major part of that problem. I
detuned the first trimmer (BFR92A collector, tuned to about 192
MHz), and was greeted with burps, whistles and white noise. Not
happy Jan !
I
was going to set the sig gen to put about -20dBm at 145.1 into
the transmit port but it's not worth even trying it until the
LO instability story is resolved.
Thoroughly
discouraged by my findings, I will have to order more MGF1302
devices and at least one BC857 transistor. Turn off the power
and walk away in disgust about sums up today's transverter testing
activities.
On
the basis that I would eventually get it all functioning, I started
the construction of a 26 element 1296
MHz yagi so that I wasn't at least completely stagnant on
the project.
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Continuing :
8 July 2009 : Ordered more parts from Minikits, should arrive within
a couple of days. Includes a couple of MGF1302's, ERA3 and MAV11 MMICS
plus some SMD NPO capacitors for general use/experimentation.
Following
the saga yesterday, I decided that I would re-check the LO PCB for
stability. Terminated in 50 ohms and visible on the spec analyser
and monitoring frequency on the counter, it powered up ok. I re-peaked
the 4 trimmers (TC1 to TC4) for max output on the analyser on 575.500
MHz and it all seems stable. Following up a comment by Kevin ZL1UJG
on VKLogger, I powered it off, soldered the sides of the L1 coil
shielding can to the PCB - no obvious change. My consideration was
that for the thing to be unstable, the first thing to evaluate was
the bypassing on the supply points since the majority of the rest
of the design has its earthing/shielding taken care of by the double
sided PCB.
I didn't
like the track lengths from the supply feed to the top of L1 or
to the top of L2. Similarly the track to base of the first BFR92A
from the 1nF disc capacitor seemed a trifle long to be super-effective
so I soldered in 5 x 1nF SMD caps on the top of the PCB as per the
photo. The ceramic discs added to the underneath of the PCB earlier
were left in place - if for no other reason, the extra bypassing
wouldn't hurt.
The positions
are : 1 & 2 : each end of the 560 ohm, 3 : 'hot' (trimmer) end
of the 18 ohm, 4 : 'top' end of the 820 ohm (towards the crystal),
5 : across the 1nF ceramic disc pigtail ('cold' end of L2).
Everything
was more stable - even putting my hand near the PCB was causing
less frequency shift than before. By no means is this an exhaustive
test but I tuned all of the trimmers in turn and none caused anything
other than a shift off the peak output point except for TC1 and
TC2 which also caused a minor frequency change. TC3 & TC4 -
no frequency change, just a peak in output. Maybe it is now stable
( ???? ).
.
The 5 x 1nF SMD capacitors soldered to the top layer of the PCB
and to the pigtails of the relevant components, angled slightly
upward to prevent short-circuiting to the PCB.
(Note : check each position with a ohm-meter that there is no S/C
before continuing)
Click for a larger image.

Closer
view of 3 of the SMD 1nF cap positions - showing part of how it
was done.
Sorry but the camera doesn't focus really well on close-ups.
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Continuing
: 8 July 2009 -
8PM - receive & transmit side tests.
Seeing as
how the LO seems to be stable now, it was worthwhile to try and
re-test the (pre-amp-less) receive side.
Test configuration
: EME72B LO input from LO PCB, sig gen at -50dBm at 432.0333 into
the 1296 RX input port, RX IF output to the R7100.
Procedure
: Powered on the LO and the Tvtr PCBs with +12V power supply in
the receive mode. Could hear the sig gen but displayed R7100 signal
level poor - made sure that the receiver was on-frequency - yes.
Adjusted
the 1151 MHz LO helical filter - noise, burps, whistles yet again.
Finger near the input of the ERA3 LO amplifier - goes crazy. Finger
near the output - stable. Obviously with the high gain of the ERA3,
the LO chain is unstable yet with a 50 ohm load on the LO PCB all
is ok. The ERA3 must not be providing close enough to a 50 ohm load
to the LO so it was time to get vicious about this instability.
I soldered a conventional 47 ohm 1/4w resistor directly across the
LO input socket (at 575MHz, this type of resistor is ok with ultra-short
leads) and before the 10pf coupling capacitor to the ERA3, knowing
that it was going to reduce the LO input to the mixer by around
6dB. Powered the assembly back up and it was stable regardless of
where I tuned the 1151 MHz helical filter adjusters - so tried the
output trimmer on the LO PCB - still stable. Well worth the drop
in LO injection if you have complete stability ! When I get a bit
further along, I will increase the resistor value to reduce the
LO injection level drop - but not at the price of any sign of instability.....

The 1151
MHz LO helical filter was peaked by using a diode probe directly
at the ADE11X mixer pin, tuned normally. The 1296 helical filter
between the mixer and the 1296 T/R switch diodes was peaked using
the reduced signal level from the sig gen and then the 1296 helical
filter between the ERA receive amp and the (if it was connected)
MGF1302 stage was peaked. The sig gen level was about -70dBm at
432 MHz so the 3rd harmonic would have been somewhat lower level
(sorry haven't measured its level WRT 432). Just remember, this
is without the RF preamp in circuit.
Given all,
it looked like it was going to work once the preamp was functioning.
It was time
to set up the transmit side of the EME72B transverter.
Test configuration
: EME72B LO input from LO PCB, 0dBm at 145.100 into the TX IF input,
RF load / power meter etc on the 1296 TX output port. Spec analyser
still on 575.5 & R7100 on 1296.1 MHz.
Procedure
: power on the LO & Tvtr PCBs, +12V power in the transmit mode.
Diode probe on the 1296 output SMA connector centre pin.
RF output
Reading : bugger all ! Multimeter time again. Measure the voltage
on the ERA3 transmit amplifier output pin - about 3.5V - ok. Measure
the voltage on the MAV11 output pin - 0V - wrong. The 220 / 270
ohm parallel SMD resistors were hot enough to burn the end of my
finger. DMM : zero ohms on the MAV11 output pin to ground. Unsoldered
the 68nH supply RFC. Still zero ohms on the MAV11 output pin. Unsoldered
the MAV11 - now open circuit. Measured the MAV11 output to common
pins as > 200 ohms so not short circuit. Checked the PCB for
swarf around the output pin and there was a ultra-fine hair-like
strand of swarf poking up in the air near the output pin. OBVIOUSLY
I HAD DISLODGED IT - BUT NOT REMOVED IT ENTIRELY when I de-swarfed
the PCB at the beginning of the construction. With the MAV11 soldered
to the PCB, it must have been contacting the output pin hence the
short circuit and zero volts. Resoldered the MAV11 back to the PCB
- still measured O/C on the output track. Resoldered the 68nH RFC,
still no short circuits evident. Bravely re-applied the +12V power
- yes, positive volts on the output pin, RF power meter just reading
above zero on a 1 watt scale and diode probe about 0.17V. Repeaked
the transmit side helical - RF power meter now reading higher (around
25mW / +14dBm ) and diode probe about 0.34V.
Varied the
input level from the sig gen at 145.1 in 1dB steps down to about
-20dBm and the RF output at 1296 varied in sympathy. Listened to
the receiver with its internal 20db attenuator on and 0dBm I.F.
drive, initially at 1296 - S8, for the 1151 MHz LO - < S1, for
the mixer image at 1005.9 - not detectable. More conclusive tests
and actual level measurements to be carried out later.
Hot damn
- this thing is going to work !!!!
Time to give it up for the night & with the positive outcomes,
I will probably sleep better !
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Continuing
: 8 July 2009 - checking the sig gen - a Marconi 2019 - Freq range
- 80KHz to 1040MHz, RF level from +13dBm to -127dBm, AM & FM.
Time to see
what the 3rd harmonic of the sig gen measures with respect to on-frequency.
Note - top freq of the generator is 1040 MHz so can't do it at 1296....
Marconi generator
in to R7100 tuned to 990.000 MHz, internal attenuator on - S5 =
-64dBm
Marconi re-tuned
to 330.000 - to achieve S5 again, the generator output had to be
raised to -20dBm
Therefore 3rd harmonic attenuation is 44dB.
So if the
sig gen is set to -70dBm and tuned to 432.0333, the actual 1296.1
level is -114dBm.
Just to confirm
the 44dB, I retuned the receiver to 1020.000 MHz, again -64dBm to
give S5, sig gen to 340.000 MHz, attenuator changed up to give -20dB
before S5 was again displayed. Consistent....
As such,
the receive side of the EME72B is hearing -114 dBm with the MGF1302
preamp bypassed. This low noise GaAsfet device has a gain rating
of 11dB at 4GHz so should provide a similar value at 1.3GHz, maybe
a little more. Just from that, the finished device should hear in
the order of -127dB - the lower extremity of the Marconi sig gen
!
Now if only
I could find the place I "safely" stored the RF power
block after I bought it a few months ago. After looking through
multiple boxes in the workshop over about 3 hours, it just doesn't
want to be found.
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Continuing
: 12 July 2009 - Replaced MGF1302 rf preamp FET
The bits
arrived on Friday but have been busy trying to get a Trimble
Thunderbolt GPSDO running so the transverter was put aside for
a couple of days.
Duly unsoldered
the old MGF1302 and the temporary BC557 and cleaned up the PCB pads
today. Installed these new parts - and yes - the original MGF1302
was oriented exactly the same way. Powered up the PCB and about
+2.7V on the drain (in lieu of +0.8) and the gate now had a small
negative voltage.
Set the sig
gen to 432.0333 MHz again, output level to -70dBm and connected
the transverter IF out to the R7100. The signal was quite strong
in the receiver so the sig gen output was reduced to around -85dBm
and the signal was still quite audible. { -85 + -44 (3rd harm attenuation)
= -139 dBm (less generator leakage). }
I subsequently
did a few tests comparing the basic R7100 and the transverter receive
performance :
Basic R7100
@ 1296.1 requires -64dBm for S1 (USB mode, 1KHz tone) { -64 + -44
= -108dBm }
Transverter
+ R7100 @ 145.1 requires -74dBm @ 1296.1 for S1 (USB mode, 1KHz
tone) { -74 + -44 = -118dBm }
Side note : Basic R7100 requires -103dBm for S1 @ 145.1 (USB mode,
1KHz tone)
The R7100
starts to hear the rising sig gen signal at about -85dBm ( ie -85+-44
= -129 dBm)
The transverter/R7100 starts to hear the rising sig gen signal at
about -94dBm (ie -94+-44 = -138dBm)
This test was based on when the received signal was actually starting
to rise in the background noise level as the generator level was
increased and while I don't necessarily believe that the transverter/R7100
combination is going to hear signals at -138dBm, it is just another
comparison point. At some stage, I should do an actual Signal/Noise
measurement (SINAD).
Noted that
without a coax connected to the RX input (1296), the MGF1302 was
somewhat unstable (unterminated input).
From
VKLogger dated 18/7/09 - http://www.vklogger.com/forum/viewtopic.php?f=40&t=8472&start=0
:
Doug
- Incredible detail and a very good read upon visiting your site.
I will retrieve my project from the corner where I threw it in disgust
many months ago and check the regulator orientation, and solder
dags etc.
Many thanks,
Dan VK2GG
It
seems that I am not the only one who has had "issues".....
Continuing
: 19 July 2009 - Finally located the MHW1815
RF power block tonight whilst looking for circuit/paperwork
for the shack 1GHz frequency counter - so this week will see the
mod's from http://www.geocities.com/vk3rtv/ampmod.html
applied to the module - then hopefully powering it up on 1296
!
{ Note : when I tried to save & print their page it was not
entirely successful. I have extracted the page details and placed
a local copy - without their weird formatting
- on the VK4ADC web site, with some extra notes added about the
extra SMD caps found on the MHW1815.
In
essence, the values of various capacitors within the power amplifier
block have to be increased to lower the operating frequency from
1800/1900 MHz down to 1300 MHz....
"Use
a 13.8V supply initially for testing. Use an input signal of approximately
10dbm ( 10mW ) and a maximum of 17dbm ( 50mW ) at 1240MHz. The output
should be 5W - 7W if all is well. A supply of up to 24V can be used
with an increase in output power to approximately 15W - 20W."
I will be running it on 13.8V so hope to see about 5W+ out of it.
20
July 2009 : Did the initial mods within the module, mounted it on
a heatsink with the 5V regulator, bypasses and coax in/out, got
about 300mW out of it - instead of 5 watts - before I killed it
with a slip of the tweezers... Now waiting on getting another one
before I can continue with the project...
Visit
the MHW1815 page to see my final comments
regarding these conversions at the bottom.
Update
21st Nov 2009
The
transverter is all up and running and there are notes further up
this web page regarding extra mods I made to the EME65 L.O. PCB.
There
have been a few changes in direction along the track as available
time became less and success with the MHW1815 mods seemed to evade
me.
In
the end, I took the easy way out and bought an EME162
1 watt 1296 driver PCB kit and the 1296 PA PCB kit from Minikits
so that I could make the 2009 VK Spring Field Day deadline I
had set for myself. My greatest issue was locating a Mitsubishi
RA18H1213G power amp module in time - Minikits had none, nor did
any other suppliers around the world....
I
created a PICAXE-base sequencer with some simple delayed pin activations
for inclusion in the box - details
here.
The
photos of the completed transverter will be added shortly, probably
after the field day. As they say, a picture is worth a thousand
words.....
Update
11 Dec 2009
The field
day has come and gone and the 23cm transverter worked well.
I did have an issue with the RF gain control on the old Kenwood
TR751A but given that it has had virtually no use for well over
5 years, that is not really surprising to me. One thing I did note
was that when using what was supposedly our "field day calling
frequency " of 1296.150MHz, stations who were supposedly on
1296.150 just simply "weren't". I noted frequency variations
of up to around 2 KHz...... I did have a minor "FM-ing"
of the frequency reported whilst transmitting and have yet to investigate
that properly and maybe insert a low dropout voltage regulator into
the supply line to the LO PCB. Alternatively, it could actually
be within the TR751A !! The top heatsink became warm - but not overly
hot - during the field day but given that it was a hot day in the
first place, the actual temperature rise might only have been around
10 degrees centigrade. During the set-up of the transmit side in
the shack, using FM as a carrier source to do adjustments &
measurements, the heatsink became warm - but then again, it WAS
key-down for quite a few minutes at a time !
UPDATE
2010 : See the new page about the PLL synthesiser project to fix
the crystal frequency drift issues..
The transverter
was built into a 220 x 145 x 55mm diecast box and utilises a heatsink
225mm long (the extra 5mm was NOT trimmed off, it resides at the
front to provide a level of physical protection for the LED indicators),
105mm wide and with a rated thermal resistance of 0.9° C/Watt,
This has been affixed to the "top" of the diecast box
using thermal transfer compound as well as screws. The only connections
into the box are 12V DC power in (hard-wired), a BNC socket for
the I.F. connection to the transceiver, an N female for connection
to the 23cm antenna and a 3.5mm socket/jack which supplies the PTT
and ALC plus ground connections, again back to the transceiver's
remote control port. To set up for operation on 1296 SSB, simply
add 12Volts and the 23cm antenna !!
At this stage,
the box has not been painted but should receive a coat of paint
after I create the new "companion" 70cm/432MHz transverter
using the same size diecast box & heatsink (hopefully) early
in 2010. That way both will actually be the same colour, probably
matt black or hammertone grey.
The photos
below illustrate how it all went together.. { click on each photo
to view larger scale in a separate window }

This
is the overall inside view of the completed transverter
. Sequencer at top LHS, ant c/o relay at top RHS, LO at
centre left, main transverter PCB at centre, 1 watt tx driver
at lower RHS, PA PCB at RHS.
No
real apologies for the lack of nylon ties to neaten it up
as it was finished only a week before the field day and
working on other equipment had priorities too !
|

The
PA PCB is actually mounted on the back flange of the box
with the RA18H1213G mounted through a rectangular slot cut
in the diecast box directly onto the heatsink extrusion.
|

The
antenna changeover relay assembly has SMA connections and
uses RG316 minature coax to the PA & RX inputs and a
Cellfoil 9006 lead back to the bulkhead N antenna connector.
|

This
view shows the 1 watt TX driver PCB mounted on the side
flange of the diecast box (again using thermal compound)
and also provides another view of the slot in the diecast
for the PA RF power block.
|

The
sequencer is at RHS, LO surrounded by tinplate shield and
the upper edge of the transverter PCB. The quick mid-air
20dB 3-resistor-attenuator was included at the TX IF port
feed at the last minute to further reduce the drive from
the TR751 IF source with it set for about 100mW output.
|

The
"far end" view from a different angle.
|

Upside-down
with the "lid" on.
The
adhesive rubber feet act as spacers off the top of the TR751A.
|

Top
view of the transverter shows the heatsink structure a little
better. All screws used in the assembly were countersunk
into the diecast material.
|

External
rear panel view.
3.5mm plug/socket to RHS for PTT and ALC,
centre N connector to antenna,
12V power in at top LHS and BNC below it for connection
of the IF at 145 MHz.
|

Front
view of the transverter mounted atop the TR751A.
Red LED at top LHS is TX, green below it is just power on,
red to their right flashes if the 3.5mm plug is not inserted
into the rear panel socket. In other words, there is no
RF power reduction through ALC in place - DON'T TRANSMIT
!!!!
|

RHS
side view showing the 2 mounting flanges that hold the transverter
onto the TR751A. In practice the transverter is a snug fit
into the flanges so only one screw on each side is required,
one front & one back.
Note
- the flanges are just 90 degree angle pieces of aluminium
stock and are screwed to the top of the TR751A via the original
4 top cover screws. No extra holes were drilled...
|

LHS
side view showing the flanges and, again, a single retaining
screw in the front flange.
|

Angled
view of the rear shows the connections a little clearer.
The transverter is fused separately to the TR751A before
the power leads are joined to become a single overall lead
to the power plug
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That concludes
this web page about the development of a working 23cm / 1296 MHz
transverter. I hope my trials and tribulations have helped you work
out your own methodology towards getting equipment built and working
on this band. I also have to mention that being able to use equipment
that you have built, even from a kit of parts, gives you some level
of extra satisfaction and sense of achievement. It certainly has
for me.
THE
END
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Any
feedback would be appreciated :
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Last
edit
:
23-Feb-2010
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