Difference between revisions of "SSB6 Design"

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[[FILE:SSB6_P1916-720px.jpg]]
 +
 +
== Design ==
 +
 +
* 6 element filter
 +
* [http://w7zoi.net/filters/9megxfils.pdf W7ZOI Crystal Filter paper] has several crystal filter designs
 +
** Narrow bandwidth bandpass filters for CW/SSB
 +
** This is the 6 crystal SSB6
 +
* Used for transmit/receive
 +
* 9 MHz nominal frequency
 +
* 50 Ohms in/out impedance
 +
* Bin crystals using [[Colpitts Crystal Oscillator]]
 +
** Hand select close values from a pile of crystals
 +
** Can get much closer than 10% of bandwidth with 50 crystals
 +
* [[W7ZOI Filters on Kits and Parts Boards]]
 +
** Other filter builds
 +
** 5 or less crystals
 +
 +
== W7ZOI SSB6 Schematic ==
  
 
[[file:XTAL-SSB-6Crystals.PNG]]
 
[[file:XTAL-SSB-6Crystals.PNG]]
 +
 +
* Response curve
 +
 +
[[file:W7ZOI_SSB6_Curve.PNG]]
 +
 +
== Build ==
 +
 +
* SSB6 filter is too big for [[W7ZOI_Filters_on_Kits_and_Parts_Boards|Kits and Parts board]] (5 crystals limit)
 +
* 2500 Hz bandwidth
 +
 +
[[file:FT37-43_10_turns_9MHz.PNG]]
 +
 +
=== Schematic ===
 +
 +
[[file:SSB6_SCHEMATIC.PNG]]
 +
 +
==== Dishal Values ====
 +
 +
* Impedance = 195.9
 +
<pre>
 +
RefDes Dishal  RefDes W7ZOI
 +
Ck12  87.3    C3/C9  82
 +
Ck23  110.9  C4/C8  100
 +
Ck34  114.4  C6    100
 +
Cs1    110    C2/C10 120
 +
Cs3    369.5  C5/C7  470
 +
</pre>
 +
 +
[[file:Dishal-sim-01.PNG]]
 +
 +
=== Measured Crystal Values ===
 +
 +
* 6 crystals within 7 Hz of each other
 +
** Selected from 50 purchased
 +
 +
<pre>
 +
Number Freq        Delta from average
 +
09    8.997791    -7.7
 +
12    8.997791    -7.7
 +
41    8.997793    -5.7
 +
06    8.997794    -4.7
 +
21    8.997798    -0.7
 +
38    8.997798    -0.7
 +
</pre>
 +
 +
=== Enclosure 80x50x20 ===
 +
 +
* Fits in 80x50 extruded enclosure
 +
* Material: Aluminum
 +
* Color: black
 +
* Size: approx.80*50*20mm
 +
* Thickness: approx.1mm
 +
 +
[[file:Enclosure-80x50x20.jpg]]
 +
 +
== Performance Measurements ==
 +
 +
=== Overall ===
 +
 +
* NanoVNA
 +
* 2.5 KHz / div
 +
* Initial measurement shows issues (solved later on this page)
 +
 +
[[file:SSB6_NanoVNA_9MHz_2.5KHzPerDiv.png]]
 +
 +
=== Detailed ===
 +
 +
* 1 KHz/div
 +
* Bandpass looks about 2500 KHz = good
 +
** Left freq = 8.99762 MHz
 +
** Right freq = 9.00005 MHz
 +
** Delta = 2.43 KHz
 +
** Center frequency = 8.99885 MHz
 +
*** Implies crystals are properly matched?
 +
* Insertion loss at "best" point (red marker) -5.14 dB = OK
 +
* Deep skirts = good
 +
* Ripple looks bad
 +
* Right side low
 +
 +
[[file:SSB6_NanoVNA_9MHz_1KHzPerDiv.png]]
 +
 +
=== Compared to SSB4 ===
 +
 +
* Fcenter = 8.998MHz
 +
* Span = 10KHz
 +
* 1 KHz/div
 +
* Skirts much deeper on SSB6 than SSB4
 +
** -90 dB on SSB6 at window edges
 +
** -60 dB on SSB4 at window edges
 +
* Passband much flatter on SSB4
 +
* Insertion loss lower on SSB4
 +
* SSB4
 +
 +
[[file:SSB4_vsS_SB6_NanoVNA_9MHz_1KHzPerDiv.png]]
 +
 +
=== Improvements ===
 +
 +
* Investigate changes to remove ripple and clean up right side of passband
 +
 +
==== Clean Board ====
 +
 +
* Cleaned board
 +
* Removed wires on transformer that were not clipped flush-ish
 +
** No effect - same ripple, same drop at the right side, same insertion loss
 +
* No change
 +
 +
[[file:SB6_NanoVNA_9MHz_1KHzPerDiv_Added_Grounds.png]]
 +
 +
==== Add grounds to cases of crystals ====
 +
 +
* Had to scrape away solder mask to solder
 +
** Through hole vias were plated through
 +
** Would be better with ground pads with cleared solder mask and thermal relief (Version 2)
 +
* No change
 +
 +
[[file:SSB6_P1889_Soldered-Grounded_Cases_720PX.jpg]]
 +
 +
==== Incremental Build and Test ====
 +
 +
* Start with unpopulated board
 +
* Add SMA connectors
 +
 +
[[file:SSB6_P1887_Test_01_SMAs-Installed_720PX.jpg]]
 +
 +
* Added transformers
 +
* Installed 200 ohm resistors at input caps to ground
 +
** At C1, C11
 +
 +
[[file:SSB6_P1891_tEST_02_TRANSFORMER_TEST.JPG]]
 +
 +
* Measure transformer impedances from NanoVNA
 +
** Input
 +
*** 48.9-j0.900 Ohms
 +
*** VSWR 1:1.031
 +
** Output
 +
*** 48.7-j0.714 Ohms
 +
*** VSWR 1:1.031
 +
* Impedance is flat over passband
 +
* Transformer working as expected
 +
 +
[[file:SSB6_NanoVNA_9MHz_Transformer_Input_Impedance.png]]
 +
 +
* 1-30 MHz scan
 +
* Toroid flat to board or tilted up = same performance
 +
* Not flat over band, but OK at 9 MHz
 +
 +
[[file:SSB6_NanoVNA_1-30MHz_Transformer_Input_Impedancee.png]]
 +
 +
* Add machine socket pins to install parts
 +
 +
[[FILE:SSB6_P1892-720px.jpg]]
 +
 +
* Install caps in socket pins
 +
 +
<pre>
 +
08 8.997809 10.3 10.3
 +
30 8.997810 11.3 11.3
 +
48 8.997812 13.3 13.3
 +
50 8.997814 15.3 15.3
 +
31 8.997818 19.3 19.3
 +
46 8.997822 23.3 23.3
 +
</pre>
 +
 +
* Parts installed on pinned card
 +
 +
[[file:PinJig-01.png]]
 +
 +
==== Fixed First Card ====
 +
 +
* Compared pinned board to first board
 +
* Noted C5 and C6 were swapped
 +
* Repaired
 +
* Sweep
 +
 +
[[file:PinJig-02.png]]
 +
 +
* Excellent results
 +
* 2.625KHz bandwidth - close to 2.5KHz design goal
 +
* 2.5 dB insertion loss
 +
* Low ripple.
 +
* Fcenter = 8.998892 MHz
 +
 +
[[file:PinJig-03.png]]
 +
 +
==== SSB4 vs SSB6 ====
 +
 +
[[file:SSB4_vsS_SB6_NanoVNA_9MHz_1KHzPerDiv-fixed.png]]
 +
 +
* Input complex impedance across passband
 +
 +
[[ile:SSB6_Input Impedance_InPassband.png]]
 +
 +
== References ==
 +
 +
* [https://sq2gxo.wordpress.com/2010/04/05/crystal-ladder-filters-i-software/ Crystal ladder filters – Software]
 +
* [https://www.arrl.org/files/file/QEX_Next_Issue/Nov-Dec_2009/QEX_Nov-Dec_09_Feature.pdf Crystal Ladder Filters for All] - ARRL QEX
 +
* [http://fa-nwt.akadns.de/blogs/media/blogs/dj6ev/quarzfilter/deDishal2026.zip DISHAL software by DJ6EV]
 +
* [http://jvgavila.com/other/Crystal_Test_Set.pdf A Practical Test Set for Comprehensive Crystal Testing]
 +
* [http://pages.suddenlink.net/wa5bdu/crystal_slide_show.pdf Crystal characterization and crystal filter design]
 +
* [http://www.hanssummers.com/xtalchar.html Crystal parameters Written by Hans Summers (QRP Labs)]
 +
 +
== Sorted crystals table ==
 +
 +
* [[W7ZOI_Filters_on_Kits_and_Parts_Boards#Sorted_9_MHz_Crystals|Sorted crystals table]]
 +
 +
== Assembly Sheet ==
 +
 +
* [[SSB6 Assembly Sheet]]

Latest revision as of 10:59, 30 October 2021

SSB6 P1916-720px.jpg

Design

  • 6 element filter
  • W7ZOI Crystal Filter paper has several crystal filter designs
    • Narrow bandwidth bandpass filters for CW/SSB
    • This is the 6 crystal SSB6
  • Used for transmit/receive
  • 9 MHz nominal frequency
  • 50 Ohms in/out impedance
  • Bin crystals using Colpitts Crystal Oscillator
    • Hand select close values from a pile of crystals
    • Can get much closer than 10% of bandwidth with 50 crystals
  • W7ZOI Filters on Kits and Parts Boards
    • Other filter builds
    • 5 or less crystals

W7ZOI SSB6 Schematic

XTAL-SSB-6Crystals.PNG

  • Response curve

W7ZOI SSB6 Curve.PNG

Build

FT37-43 10 turns 9MHz.PNG

Schematic

SSB6 SCHEMATIC.PNG

Dishal Values

  • Impedance = 195.9
RefDes Dishal  RefDes W7ZOI
Ck12   87.3    C3/C9  82
Ck23   110.9   C4/C8  100
Ck34   114.4   C6     100
Cs1    110     C2/C10 120
Cs3    369.5   C5/C7  470

Dishal-sim-01.PNG

Measured Crystal Values

  • 6 crystals within 7 Hz of each other
    • Selected from 50 purchased
Number Freq        Delta from average
09     8.997791    -7.7
12     8.997791    -7.7
41     8.997793    -5.7
06     8.997794    -4.7
21     8.997798    -0.7
38     8.997798    -0.7

Enclosure 80x50x20

  • Fits in 80x50 extruded enclosure
  • Material: Aluminum
  • Color: black
  • Size: approx.80*50*20mm
  • Thickness: approx.1mm

Enclosure-80x50x20.jpg

Performance Measurements

Overall

  • NanoVNA
  • 2.5 KHz / div
  • Initial measurement shows issues (solved later on this page)

SSB6 NanoVNA 9MHz 2.5KHzPerDiv.png

Detailed

  • 1 KHz/div
  • Bandpass looks about 2500 KHz = good
    • Left freq = 8.99762 MHz
    • Right freq = 9.00005 MHz
    • Delta = 2.43 KHz
    • Center frequency = 8.99885 MHz
      • Implies crystals are properly matched?
  • Insertion loss at "best" point (red marker) -5.14 dB = OK
  • Deep skirts = good
  • Ripple looks bad
  • Right side low

SSB6 NanoVNA 9MHz 1KHzPerDiv.png

Compared to SSB4

  • Fcenter = 8.998MHz
  • Span = 10KHz
  • 1 KHz/div
  • Skirts much deeper on SSB6 than SSB4
    • -90 dB on SSB6 at window edges
    • -60 dB on SSB4 at window edges
  • Passband much flatter on SSB4
  • Insertion loss lower on SSB4
  • SSB4

SSB4 vsS SB6 NanoVNA 9MHz 1KHzPerDiv.png

Improvements

  • Investigate changes to remove ripple and clean up right side of passband

Clean Board

  • Cleaned board
  • Removed wires on transformer that were not clipped flush-ish
    • No effect - same ripple, same drop at the right side, same insertion loss
  • No change

SB6 NanoVNA 9MHz 1KHzPerDiv Added Grounds.png

Add grounds to cases of crystals

  • Had to scrape away solder mask to solder
    • Through hole vias were plated through
    • Would be better with ground pads with cleared solder mask and thermal relief (Version 2)
  • No change

SSB6 P1889 Soldered-Grounded Cases 720PX.jpg

Incremental Build and Test

  • Start with unpopulated board
  • Add SMA connectors

SSB6 P1887 Test 01 SMAs-Installed 720PX.jpg

  • Added transformers
  • Installed 200 ohm resistors at input caps to ground
    • At C1, C11

SSB6 P1891 tEST 02 TRANSFORMER TEST.JPG

  • Measure transformer impedances from NanoVNA
    • Input
      • 48.9-j0.900 Ohms
      • VSWR 1:1.031
    • Output
      • 48.7-j0.714 Ohms
      • VSWR 1:1.031
  • Impedance is flat over passband
  • Transformer working as expected

SSB6 NanoVNA 9MHz Transformer Input Impedance.png

  • 1-30 MHz scan
  • Toroid flat to board or tilted up = same performance
  • Not flat over band, but OK at 9 MHz

SSB6 NanoVNA 1-30MHz Transformer Input Impedancee.png

  • Add machine socket pins to install parts

SSB6 P1892-720px.jpg

  • Install caps in socket pins
08	8.997809	10.3	10.3	
30	8.997810	11.3	11.3	
48	8.997812	13.3	13.3	
50	8.997814	15.3	15.3	
31	8.997818	19.3	19.3	
46	8.997822	23.3	23.3
  • Parts installed on pinned card

PinJig-01.png

Fixed First Card

  • Compared pinned board to first board
  • Noted C5 and C6 were swapped
  • Repaired
  • Sweep

PinJig-02.png

  • Excellent results
  • 2.625KHz bandwidth - close to 2.5KHz design goal
  • 2.5 dB insertion loss
  • Low ripple.
  • Fcenter = 8.998892 MHz

PinJig-03.png

SSB4 vs SSB6

SSB4 vsS SB6 NanoVNA 9MHz 1KHzPerDiv-fixed.png

  • Input complex impedance across passband

ile:SSB6_Input Impedance_InPassband.png

References

Sorted crystals table

Assembly Sheet

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