Thursday, December 29, 2022

Flying PigRig (7). Transmitter working

 I was very careful to install the finals correctly,  I read the instructions,  then checked the pinout of the BD139s on the data sheet, then....  then I managed to install them backwards anyway...

The board layout for this PCB is not the best in my opinion.  The holes are too small and the blank area between the pads and the ground plane is to narrow too.   With the small holes, it is impossible to use solder wick to desolder the holes.  The surface tension of the liquid solder holds the solder tightly in the hole and it's a real fight to desolder a part and get it out.  I managed to tear up a land going to one of the finals and had to solder a wire in to replace it. 

At power supply of 13.6 volts, the output to the 50 ohm dummy load is 12.2 volts RMS.  The waveform is shown below.   Power into the load is 3 W. 

After this I'll work on the cabinet.  Gonna make a simple 3D printed cabinet



Flying PigRig (6). Receiver checks

 Yesterday, I finished adding the last parts to the PigRig:  the lowpass filter inductors and a couple of more inductors.  I tested the receiver.  The AGC circuit was killing the mixer so I just disconnected it.  I kluged in the volume control and connected some headphones and a random wire antenna.   The receiver is fixed tuned at 7.030.7 kHz, but I heard some background noise and some faint CW signals. 

As it stands now,  I've wired around the keyer, which wasn't working right, and I've also disabled the AGC circuit. 

Next up is installing and checking the finals.  Then putting it into a cabinet.




Tuesday, December 27, 2022

Flying PigRig (5) -- Oscillator ok, keyer problems

 Link to PigRig schematic

Link to PigRig assembly instructions

At this point I am at Step 12 in the assembly instruction.  This step covers the winding and installation of remaining toroids.  The remaining steps involve installing the antenna lowpass filter toroids and L2, the inductance in the 12V power feeding the centertap of the finals. 

Before proceeding, I decided that this would be a good time to stop and test the low power circuits before proceeding to mess with the transmitter finals. 

Oscillator check

The oscillator works well, and voltages are in line with the table of oscillator voltages given in the instructions.  The trimmer capacitor C26 was bad, it jammed and wouldn't turn.  I replaced it with a capacitor from a trimmer assortment I bought a few months ago. 


The trace above is at the base of oscillator transistor Q4.  7.4 volt peak to peak. 

Keyer Ckt:

The keyer circuit consists of  a small ATtiny13A microcontroller programmed as a simple keyer chip. On powerup it defaults to a 15 wpm iambic keyer.   The circuit appears to be working except that the keying is modulated by pulses with 760 us period and about 10% duty cycle as shown below.   This is the "KEY" output of the keyer. 
I was thinking this is some kind of PWM signal but there's no integrator circuit that would convert the signal to an analog voltage.  I've put an inquiry on the 4 State mailing list about whether this pulsing is normal or not.  If I can find the source code to the keyer, I can check it to see if the pulsing is programmed in.  For now,  I guess I'll work around the problem

Checking U4 (keyer) pin 2, for the sidetone,  I get a square wave that's 641 Hz, which is within 3% of the nominal 625 Hz given in the instructions. 

The dot and dash intervals on the keyer KEY output are shown below, left and right respectively.  Notice the pulse modulation:



The dit interval is 74 ms, dah is 232 ms.  Using Farnsworth: 
$WPM = \frac{60}{50\cdot\tau_{dit}}=16.2 WPM$
which is close to the nominal 15 WPM in the instructions.  

For now I'm going to remove the keyer chip and wire a straight key from the drain of Q10 to ground.   I won't have a sidetone signal, but that's not a big deal.  

I'll test transmit stage 1 amp at it's input to T1, then move on to test the receiver.

Monday, December 26, 2022

Flying PigRig (4) -- Schematic transcribed.

 I am planning to start testing the 40 meter PigRig that I have. The schematic provided with the assembly instructions is very crowded, making it difficult to understand the functions of the circuits.  As an exercise, I transcribed the schematic to KiCad and redrew the the circuits to show the unit's functional blocks.    The resulting PigRig schematic is in two pages, shown below.

Click each image to enlarge.  PDF copy of the schematic is located here. 







Thursday, December 22, 2022

20-Meter High Performance Direct Conversion Receiver (6) with update

I did some troubleshooting of a motorboating problem with the 20m direct conversion RX we've been working on.  We moved the RX and TX circuit boards to separate cabinets in get more room around the boards and to cut possible interference between the RX and TX wiring, especially for the antenna tuner and oscillator variable capacitor wiring.  We also install and modification from the TX QST article (Dec 1978). The mod, shown in the diagram below, cuts the connection that supplies power to  the RX preamp Q3. The supply lead is routed to the transmitter "RX MUTE" switch, which supplies 12V to the preamp when the RX operates and disconnects the supply when the RX MUTE is active.

The circuit had severe motorboating, which went away when I removed the RX MUTE mod.  I think we can run without the RX MUTE mod,  so I'm going to leave it without the mod for now.  Later we can add an RF choke and bypass capacitance to the RX MUTE line that would probably fix the motoboating. 

The RX has a lot of hum and noise, but I suspect that's due to my setup:  I don't have a real antenna or even a decent ground in for my workbench.  

A bigger problem is that the VFO drifts too much to follow CW signals.  There are two capacitors in the oscillator tank that I will replace with NPO caps, to see if that cures the problem. 

Dec. 23: diagnose oscillator drift.  Replace C19 and C20 with NPO caps.  
  • Drift is less severe
  • Lowest frequency is about 14.2 MHz, need to fix
Dec. 23: noticed that oscillator produces about 500 mV RMS, but according to LTSPICE model and QST schematic, amplitude should be 2 V RMS.  Changed out the oscillator transistor Q4 for another MPF102
  • Amplitude increased slightly to 600 mV RMS.  
  • Disconnected oscillator from mixer by removing C22.  Oscillator amplitude increased to 800 mV RMS.
  • Check 1N914 diode D1 forward voltage.  

QRP LABS 10W PA (1) MOSFET bias circuit

 I first mentioned the QRP LABS 10W power amplifier that we're working on in blog entry Loose Ends (1).   This QRP Labs power amplifier (PA) seems to be popular and there are several YouTube videos about the amp.  I watched a series of videos about this amp by NA5Y. Link here.  He goes into a detailed discussion of the amplifier's circuit which I found very interesting. 

The PA has an interesting bias compensation circuit for the first push-pull amplifier stage.  This PA 1st stage is shown in the bottom of the circuit below.  It consists of a pair of BS170 MOSFETs in a push-pull configuration. The bias for the FETs is supplied via the centertap on the secondary of T201. 

The bias circuit feeding the gates of Q203 and Q204 is temperature compensated, and, to me, the circuit seems both simple and elegant. It consists of Q202 and Q201 and associated resistors and diode, shown in the upper left of the diagram below. 

When power MOSFETs are operated as linear amplifiers, they are notoriously unstable with temperature. The FETs have a negative temperature coefficient for the threshold voltage. Being square-law devices the drain current is given as: 

$I_{DS} = K(V_{GS}-V_T)^2$  

Extracting some data from the Fairchild BS170 datasheet, $K = 78 mA/V^2$ and $V_T = 2.0 V$.

The threshold voltage temperature coefficient, extracted from the graph above, is 
$TC =-016$% per degC.  The circuit is designed for an idle current of 20 mA in each transistor. With a 12 volt power supply and 20 mA current, then each device dissipates about 240 mW.  The design temperature is 25C (77F).  Through a combination of elevated ambient temperature and operating inefficiency, let's say the junction  temperature is raised to 60C (140F).  In that case the threshold voltage will decrease from 2.0 volts to:

$V_T(60C) = 2.0V\cdot\left[1-(60C-25C)\cdot-0.0016\right] =1.89 V$

This increases the power dissipation in each transistor to 353 mW,  nominally exceeding the 350 mW datasheet rating of the BS170 transistor.   In practice, what happens is that power dissipated by the transistor raises the junction temperature of the transistor which lowers the threshold voltage which causes the dissipated power to increase, which raises the junction temperature....  This positive feedback loop is called "thermal runaway" and the cycle ends when the transistor is destroyed.

The bias supply circuit, taken from the schematic is shown below. 

VDD1 is the input voltage, assumed to be 12V, while VBIAS1 is the output of the circuit that sets the quiescent gate to source voltage of the amplifier transistors.   Let's redraw the circuit in a classis "foldback circuit"  configuration: 


Now we see that the circuit operates MOSFET Q202 as a DC current source, with negative feedback supplied by the Q201 NPN  transistor. We know that the silicon 2N3904 transistor, operating as a linear amplifier, will have a base emitter voltage of about  $V_{BE} = 0.65V$.   Given this the current in Q202 can be calculated: 

$I_{DS}=\frac{V_{BE}}{33\Omega}$

which works out to about 20 mA.   Now add the voltages from ground through R206 through the source to gate of Q202 and through diode D201 to VBIAS1 we get:

$VBIAS1 = V_{BE} + V_{GS}-V_D$

D201 and Q201 are both silicon devices so we know that 

$V_{BE} = V_D$     combining the two equations gives: 

$VBIAS1 = V_{GS}$

Now if Q202 is thermally connected to the two amplifier transistors, and the characteristics of all transistors match, then VBIAS1, supplied to the the amplifier transistors' gates, will produce the same quiescent current in those transistors as Q202.  So each amplifier transistor should have 20 mA quiescent current. 

If the temperature of the transistors goes up, the threshold voltage will decrease but Q201 will reduce VGS of Q202 to maintain Q202 drain current to 20 mA.  This reduced VGS will be reflected in VBIAS1, which will reduce the gate to source voltage of the amplifier transistors to maintain their quiescent current at 20 mA. 

As can be seen,  the bias circuit compensates for changes in transistor temperature and also makes the quiescent bias currents independent of the VDD1, the circuit supply voltage.   

For this circuit to function well however, the three MOSFETs have to have well-matched characteristics, and furthermore  their junction temperatures must track as well.  In practice, if the transistors all come out of the same bag from the manufacturer, then the characteristics usually match fairly well.  Using a curve tracer or some jig, the transistors can be selected manually to match. 

Temperature tracking is more problematic, since the TO-92 transistor package of the BS170 is not designed to transfer heat efficiently to a heatsink, but is designed to operate free standing in air.  This amplifier has a scheme to tie the three transistors to a common heatsink to match temperatures.  It will be interesting to investigate how well that scheme works. 

 






Wednesday, December 21, 2022

Tuna Tin S (9) Installing screw inserts in cabinet

 Still learning Fusion 360, a rocky experience, I designed a simple test block to practice putting M3 inserts in 3D printed cabinets for the Tuna Tin S. 

The inserts were ordered off Amazon  Here's a link. 

The test block is PLA material and consists of an array of 4 mm diameter holes in a 10 mm thick block. The infill is set to 20%, and the wall thickness set to 0.8 mm. 

I used a 10 Watt Ungar Princess model soldering iron.  According to Ungar's 1967 catalog it was newly introduced for microelectronic soldering at the time.  The heating element has, according to the catalog, has a tip temperature from 550F to 650F.  The soldering iron belonged to our grandmother, Ruth Chandler, who was an assembly worker at Dorsett Electronics in Tulsa in the 1970s.  So the iron is around 50 years old  ;-)  . 


I placed the insert tapered end outward on the tip of the soldering iron. 


I let the insert heat up for awhile, then inserted it into the hole of the test piece.  It sinks into the test piece gradually,  and I stopped when the top of the insert was even with the surface of the test piece.  Alignment doesn't seem to be much of a problem.  A recommendation from a YouTube video, linked here, is to stop inserting the insert when the top is just above the surface of the plastic, and then do final placement pushing the insert flush with a flat tool like a hammer's striking surface.   I tried that way and it worked well.  I also tried just doing the whole thing freehand and didn't see much difference in alignment.  The screws I used were 8 mm long M3 screws. 

The screw is driven by an Allen wrench.   I can exert quite a bit of torque, as shown in the photo below, and the insert holds without breaking the plastic.

I'm planning to use these M3 inserts, along with M2 inserts to design all 3D printed cabinets for projects going forward.