More Evaluating the SoftRock Lite on 630-Meters

Last night I decided to run a few tests. I don’t have an elaborate lab, but I do have two calibrated signal generators and some other test equipment.

What I had read about the SoftRock not responding to signals on even harmonics of the LO frequency is not true according to my tests. First I looked at MDS (minimum discernible signal) at 474 kHz (LO frequency + 10 kHz) with a signal generator connected to the receiver. I could still clearly see the signal in HDSDR at -135 dBm. Next I measured at 938 kHz (2 x LO frequency + 10 kHz) and got -57 dBm. At 1402 kHz (3 x LO + 10 kHz) I found it to be -53 dBm. There are some things I don’t understand about this result. Theoretically at 1402 kHz it should be down no more than the SoftRock front end filter attenuation at that frequency plus a few dB because the LO third harmonic is 10 dB down from the fundamental. According to my modeling of the filter and spectrum analyzer sweep of the same filter outside the receiver, it attenuates 41 dB at this frequency. 41 plus 10 is only 51 dB down according to theory. Yet I was seeing 82 dB difference in MDS. That doesn’t make sense to me. What is clear both from this test and from those broadcast stations I was able to identify while listening on the SoftRock is that both the second and third harmonic response is considerable.

I spent several hours carefully examining the strength and number of broadcast signals making it through the front end selectivity. My external bandpass filter removed all traces of broadcast stations being heard with the receiver. Its calculated and measured response is -60 dB at 900 kHz, -84 dB at 1400 kHz. The filter I plan to build for the SoftRock should be -66 and -88 dB respectively.

I attempted to run a close spaced IMD test on the receiver. With signals on 473 and 474 kHz, I detected no IMD products when both of these signals were 90 dB above the noise floor. This is probably sound card dependent but it indicates to me that the SoftRock hardware has good strong signal performance. I reduced one signal to barely audible and left the other at 90 dB above noise floor. Switching the strong signal on and off did not noticeably affect my ability to hear the weak signal. I need a different test setup to go beyond 90 dB in these tests, though I am satisfied it is as good as it needs to be.

This continues to look like it should be a relatively low cost, high performance 630 meter receiver once the added front end filtering is in place.

 

 

More on SoftRock Lite II 630-Meter Performance

Last night I performed additonal tests on the Softrock to determine the impact of third LO harmonic response in the medium wave broadcast band. Broadcast signals were stronger than the previous night and the situation got ugly in a hurry after sunset. This receiver will need external filtering to be useful on 630 meters.

Here is a recording of the 630 meter WSPR segment, first without and then with an external bandpass filter.

 

That just about says it all, but here are some images that tell the story. I will be trying a prototype for a filter designed specifically for this application and will post about that when finished.

Here we see the entire available band when using a sound card sampling at 192 kHz. This is with no external filtering. Note the many spikes in the center pane. Many of these are broacast stations that are not really in this band.

Full band view with external band pass filter. Note how many of the signals disappear.

Zoomed in view of 630 meter band without external filtering. Note the broadcast signal right in the middle of it.

This shows the 630 meter band with an external bandpass filter. The unwanted signal is gone.

This is the WSJT-X waterfall. I had the external filter in for most of this. I switched it out breifly at around 2335z. Notice all the junk that shows up, wiping out the WSPR signal.

Evaluating the SoftRock Lite II on 630-Meters

This is not intended as a review per se of the SoftRock Lite II with 455 kHz IF option. This is a summary of my experience with the receiver during initial evaluation. My test methods are certainly not standardized and results may be unique to my environment.

The build notes for the kit were often confusing but there were plenty of warnings that one should not expect this to be like assembling a Heathkit with detailed step by step instructions. They sometimes tell you to do something, then in the next paragraph tell you to be sure to do something else before the step they just talked about. I suggest reading ahead before doing anything. There are some typos and inconsistencies. The part about the toroidal transformer I found particularly confusing. They use the terms primary and secondary interchangeably. I found it necessary to read the various links for more information and weigh various statements against others to understand what I was actually supposed to do. I do not feel this is a project for a first time builder.

The oscillator did not work properly without changing one of the bias resistors on Q2. R16 had to be changed from 22.1k to 10k in my case. Reading through the archives of the softrock40 Yahoo group this seems to be a very common issue, yet it is not mentioned in the build notes. I would have preferred to know going in so that I could perhaps decide to mount R16 differently in case it had to be removed later.

Customer service was absolutely outstanding. There was a kit packaging error with the unit we received. When I contacted Tony about it, he was very friendly and immediately mailed the correct packet of parts (the extras needed for the 455 IF option) to me even though I was not the purchaser of the kit, merely the builder.

I suggest heeding the advice about trying the receiver on battery power first. I stupidly connected the test sample to my station’s main 12 volt bus and then spent the better part of two days trying to troubleshoot a receiver that, as it turned out, didn’t have a problem! My 12 volt bus runs many things including some network devices. I discovered during this process that it has about 400 millivolts peak to peak of noise. This manifested as a rather complex AC waveform riding on top of the DC. I don’t know if that was the problem or the fact that connecting to this bus grounds the SoftRock PCB to the station ground, which they warn you not to do. I am not certain exactly how this messed up the SoftRock but the receiver was completely deaf. I could see a lot of noise on the RF signal going into the mixers when I probed it with a scope or spectrum analyzer. The level was also jumping around all over the place. I saw similar noise on the mixer output, and all I could hear from the receiver was a low level buzz. The in-circuit waveforms I saw around the mixer bore a striking resemblance to what I  later discovered on the 12 volt bus. The receiver works fine on a 9 volt battery and on an isolated linear wall wart.

What about performance? First of all, this receiver’s sensitivity is excellent, far more than needed for MF operation.

Its local oscillator is more stable than I would have expected. My test setup involves putting a very low level (inaudible) signal into the receiver from my HP 3325B function generator. Drift of the HP is on the order of a couple of milliHertz regardless of environmental changes so it is a reliable standard for this test. I monitored the output of the SoftRock using Argo set to QRSS30, QRSS60, and QRSS 120 in order to get different resolutions. With this setup  I can measure drift to better than +/- .01 Hz. Here are a few more details on this setup. I fed signal from the HP 3325B to an unused input on my receive antenna switch. This allowed me to monitor 630 meter WSPR activity using WSJT-X while simultaneously evaluating drift with Argo. I set the injected frequency to 475,900.000 Hz, which is 100 Hz above the top of the WSPR band. Since I was feeding an unused port on the antenna switch, I had some 80 or 90 dB attenuation; thus the minimum output level of the 3325B (-56 dBm) was not a problem. The I and Q outputs from the SoftRock are fed to an HTOmega Claro sound card which can sample at 192 kHz. I used HDSDR for the receiver, piping its output audio through VB Cable to WSJT-X, Argo, and Spectran. The latter was used only as a convenient means of outputting the audio stream to my speakers.

Before making any measurements, I calibrated the LO frequency and front end in HDSDR. The Claro sound card gives more than 100 dB rejection of the image frequency (test conditions: 474.000 kHz input, image around 454 kHz). My other sound card, which is VIA HD audio on the PC motherboard was not as good, providing only about 75 dB image rejection after careful tweaking. It also overloads at a level much lower than the Claro.

With the SoftRock sitting in a typical spot in my shack, cover removed from the Hammond box to allow free air flow, there is a cyclic drift of less than +/- .06 Hz as my furnace cycles and ambient temperature in the shack varies a few degrees. In another location (affected by heat of my rack mounted PC), cover on, cyclic drift associated with furnace activity was +/- 0.15 Hz. When I wrapped the receiver in a towel and stuffed it into a plastic bag the cyclic drift was less than +/- .01 Hz. Lastly I conducted an open air test (cover off) observing frequency change with a 10ᵒF temperature change in the room. it moved 0.7 Hz. Stability of this unit is more than adequate for CW, WSPR, JT9 and other fast or slow modes. Except when wrapped in a towel and plastic bag, drift becomes an issue for super slow modes such ad QRSS30 and slower or DFCW of similar speeds. I believe this can be compensated by using a proportional heater on the SoftRock LO crystal. This is an experiment I plan to try at some point. My station is not in a particularly temperature stable room. Better results may be obtained in other locations. Bear in mind this was a test sample of one, and there may be variation from unit to unit.

There is one major shortcoming of this unit as a 630 meter receiver, and that is its response to signals around the third harmonic of the LO. Remember that we are feeding the mixers with a square wave. Square waves are rich in odd harmonic content. I measured the LO third harmonic (1392 kHz) at 10 dB down from the fundamental 464 kHz. This is a problem since there are many strong signals around 1392 kHz in the middle of the medium wave broadcast band! The SoftRock input filter is only 40 dB down at this frequency. With the LO harmonic at -10 dB and the filter at -40 dB that puts these signals only 50 dB down from its response at the intended frequency, nowhere near enough. Without external filtering, the unwanted response to broadcast stations is a deal breaker at my station. With my outboard bandpass filter in addition to the SoftRock filter, response at 1392 kHz is 105 dB down, still not really enough as some of the stronger stations near the low end of the range (where filter attenuation is less) can still be heard. Bear in mind this is a known issue with simple SDRs of this type and this kit was never intended to be used as a receiver connected to an antenna. It was intended to connect to the IF in a conventional receiver where it would be afforded a great deal of protection by receiver tuned circuits and filters. The 630 meter band itself is “clean” when using my external bandpass filter in conjunction with the SoftRock’s internal filter, but not with the SoftRock alone. (Note: I measured the second harmonic of the LO at -32 dB. If I understand my theory correctly, and that is questionable, I believe the mixer will not respond to signals on even harmonics, making this a non issue. If I am wrong about that, then the second harmonic is also problematic)

Despite most of my receive antennas being down due to storm damage during last night’s test run, the SoftRock did very well receiving 630 meter WSPR activity and one station that was sending “TEST TEST” on CW.

I find the SoftRock Lite II with 455 IF option to be a very promising receiver for 630 meter work but it will need additional band pass, low pass, or medium wave broadcast reject filtering. Without an outboard filter the test unit does a credible job receiving WSPR activity on 630 meters at times. At other times that segment is wiped out by unwanted response to broadcast stations. I strongly recommend that it be used with external filtering. The filter I am using can be built for about $10 (shipping not included) using all new parts. A well stocked junk box could reduce that. More on this to follow in a subsequent post.

 

The Dreaded SMD & Building a 630-Meter SDR

My new found interested in LF and MF is leading me in directions I didn’t expect. I have never been a fan of software defined radios; not because I have anything against the technology. I am well aware it is the future, if not the present of radio and the many advantages. My problem with SDRs for my own use is that if I have to do everything with a keyboard and mouse it diminishes the fun of operating. I am a knob twiddler. I like the old form of human to radio interface. Some years ago I operated from a multiop VHF contest station using an early SDR. I hated it, and even though I love VHF contesting, to be completely honest it just wasn’t fun with that radio. It wasn’t the performance or lack thereof. It was simply that I didn’t enjoy operating with a keyboard and mouse to control the radio. Of course a few modern SDRs have optional human interfaces using knobs, but they tend to be rather expensive.

On LF and MF, operating is very different. It often involves monitoring (or transmitting on, but without direct human interaction) a frequency for many hours, no settings needing to be changed. Thus, at least in the type of operations that are currently taking place there tends to be minimal interaction with the radio in any case. I also have not liked the fact that my only station transceiver has been tied up with this monitoring activity, keeping me from DX on the 160 through 2 meter bands. The apparent solution seemed to be an inexpensive SDR which could operate stand-alone.

I have had a fear of working with SMD parts since my first and only project involving them: the building of a simple OCXO kit a few years back. The OCXO worked when completed but I found soldering the parts difficult and the work was… shall we say… visually unappealing. I am a few years older now and my eyes are not great! I need prescription glasses to read anything, and a magnifier to read instructions on just about any household product these days. Would I be able to work with SMD? My interest in trying a very inexpensive SDR on LF and MF led me to seriously think about it. I spent many hours watching videos on how it is done, and many more lusting after SMD soldering and rework stations I can’t afford. But something unexpected happened. I began to feel a certain confidence that I could do this, and better than before.

I wanted to try a SoftRock Lite II receiver kit with the 455 kHz IF option – which should make a fine little SDR for 630 meters. If this worked out I had some ideas about modifying one for 2200 meters, following ideas and notes provided by Larry, W7IUV. While I was contemplating when I might afford to buy one (my budget was severely over-extended during recent VHF projects), Bill, KB1WEA decided to buy one for me to assemble on his behalf, evaluate and gain experience with. He must have believed me when I said I could do this! I was only half sure that I believed me!

The first thing I was going to need was a soldering iron with a much finer tip. All I had were some old Radio Shack 30 and 60 watt pencils and a 475 watt beast left over from the days when farmers soldered wash tubs and the like. I took an old, burned up tip for one of the 30 watt pencils and began to slowly reshape it on a stationary belt sander using a 320 grit belt. When I was satisfied with the more or less conical shape I hand sanded with 600 grit and then 1200 grit paper to obtain a smooth surface. It didn’t look too bad, but the proof would be in actually soldering SMD parts. I also purchased some .015″ diameter “Kester 44” solder and paste flux for the project. I would end up not using the paste flux.

It wasn’t long before the kit arrived. Looking at it I had a few pangs of doubt. The whole thing sure was small! Nevertheless, armed with my hand crafted soldering tip, lighted headband magnifier, tweezers and vise I was ready to dive right in. I read through the build notes (which more or less pass for assembly instructions), noting in particular the warning about tiny SMD capacitors flying out of tweezers never to be seen again. I knew this from personal experience with the OCXO kit. The first step of the build said “Install a SMD capacitor at…” Oh, great. Start me off easy, why don’t you? I fearlessly (that’s my story and I’m sticking to it) grabbed a part with the tweezers and almost immediately heard the dreaded “twink!” sound of its escape. My hearing is better than my eyes and I also heard it hit the hard laminate floor. I was going to find that thing if it took all day. With lighted magnifier on my head I proceeded to crawl ever so slowly around on hands and knees, head down to accommodate the six inch focal length, head scanning left to right looking for the part. My cat Boo came along and took quite an interest in this operation. If there was something worth finding on the floor he wanted first dibs on it! It might be a tasty morsel or a new toy. I wish I had a video of this. He commenced doing exactly what I was: slowly inching forward, eyes down, head scanning left to right. Side by side we worked our way along a swath of floor. An hour later I found the escaped capacitor. Eureka! Gotcha, ya little bugger! Boo had become bored or convinced that this theory of there being something on the floor to find was all in my imagination. He was now sound asleep in another room. I did find the part in a spot I had seen him pause to sniff and examine closely twice. Perhaps he had seen it and decided this thing was far too small to be of any use.

Assembly proceeded well after that. I modified my approach to dealing with the SMD parts. Instead of picking them up with tweezers for transport to the board, I placed them on the board with my fingers, used the tweezers to gently nudge them to and fro. Once happy with alignment, I held them down with pressure from the tweezers while tacking one end or one pin. This worked much better for me. I was concerned about ESD on the sensitive chips, but I used my tried and true completely improper methods: boil water to create humidity, wear an anti-static wrist strap grounded to the PCB and to the soldering iron with a clip lead! It looks ridiculous but I have had pretty good luck with this method. I make no claims whatsoever that my SMD soldering is professional quality. It isn’t. But it seems to get the job done and believe me it looks a lot better than my work on that OCXO!

In order to evaluate performance in a typical use scenario and to avoid damaging the tiny receiver, I packaged it in a Hammond diecast box. I used a BNC socket for the antenna and coaxial jack for DC power. I didn’t have any TRS (stereo) audio connectors so I cheated and just drilled a hole in the box to run the audio cable through. It can always be changed later.

All in all, assembling this kit was a pleasure. By the end I was actually finding it more pleasurable to work with SMD parts than all that tedious lead bending and cutting with the through hole parts! The most tedious part of the build was winding and installing the toroidal input transformer.

 

Comments on the Jackson Harbor press LF Converter

After discovering my Yaesu FT-2000 receiver sensitivity is -75 dBm at 137 kHz, I needed something better to receive the 2200 meter band. The Jackson Harbor Press LF Converter was suggested. I was sent a kit by a friend. It is the previous version which uses FT-37-61 cores for the inductors in the low pass filter.

Assembly was quick and easy, taking about an hour. I modified the low pass filter slightly since I wanted to concentrate on 2200 meters and have maximum rejection of the medium wave broadcast band. I mounted mine in a Hammond die cast box with BNC connectors for RF input/output and a coaxial power jack for 13.8VDC.

My signal generator minimum output is -137 dBm. This produced a very clear tone, so I estimate the converter MDS is at least -140 dBm. Next I measure IF leakthrough and found it to be on the order of 50 dB. I could detect a tone at a level of -90 dBm. This isn’t great, but noise on LF would mask another 30 dB or so of signal. In actual operation for about one week monitoring all night (half of this time with a 10 MHz IF, the other half 4 MHz) I have not detected any actual problems with signals on the IF frequency being heard.

That brings me to the subject of LO drift. There is less drift with the 4 MHz LO frequency, so that is the only one I made extensive measurements on. There is enough IF signal present at the converter output to amplify with one of my 2N5109 preamps and feed to my HP 5335A counter. It is winter here so the temperature in my shack varies slightly as the furnace cycles on and off. With the converter sitting on top of my rack mounted computer which gives off some heat I found a cyclic drift of between 0.8 and 1.3 Hertz after looking at several cycles. Each cycle was slightly unique. I lowered the thermostat by 6 degrees F and after allowing a few cycles for things to settle I looked at the drift again. It was about the same as before but everything had shifted up approximately 5 Hertz. After moving the converter to a location not influenced by heat from the computer, similar measurements were obtained. Overall the LO shifted down a couple of Hertz but the 0.8 to 1.2 Hz cyclic variation as the furnace cycled on and off remained mostly unchanged. I replaced the small trimmer capacitor with a fixed 22 pf NP0 ceramic and a 1-10 pf piston trimmer. This did not measurably improve the situation.

I find the converter very adequate for general LF listening and acceptable for casual WSPR monitoring on 137 kHz. The serious WSPR reporter will probably want better frequency accuracy than this converter can provide. For QRSS and DFCW the converter is not acceptable. This amount of drift will cause serious problems for those modes.

It is possible the LO could be stabilized with a crystal heater but since my FT-2000 has too much drift to be useful even if the converter were perfect I am not going to pursue that. Another option would be to use a precision OCXO in place of the onboard LO. Suitable units can be found on eBay for around $50.

Adding 630 and 2200 Meters to the MFJ-259B

As I began to explore the world of MF and LF I realized it wouldn’t be long before the need to assess antenna possibilities arose. Specifically I would be needing to know whether it was going to be possible to construct antennas for these bands with the space and supports I have available, and without killing other bands. I read this article by KB5NJD discussing his 630 meter modification of the MFJ-259B based on earlier work by KL7UW. Although the 259B has some limitations (and even more so when operating on frequencies it was never designed for), this caught my eye because I own one. Even with the limitations it should be plenty good enough to answer my question about antenna potential. I soon learned that John, KB5NJD had also got his working on 2200 meters.

The earlier work was based on experimental use of junk box ferrite cores. I had no ferrite cores in my junk box and no real idea what I needed. I don’t think it is unreasonable to believe others may be in the same situation. I made it my goal to come up with a method which could easily be duplicated with off the shelf parts. In order to accomplish this, I initially purchased several different cores of different material to experiment with. This is exactly the kind of expense I was hoping to spare others by coming up with a standard “recipe” that could be followed for the modification. The resulting modification uses two FT-37-W ferrite cores and one DP3T switch.

The 630 meter inductor consists of 17 turns #24 wire on one FT-37-W core. The tuning range I obtained is 280 to 590 kHz. The 2200 meter coil is 45 turns of #30 wire on one FT-37-W core, which tunes 105 to 220 kHz. These are wired with a DP3T switch so that one throw is normal operation of the MFJ-259B on its original lowest range, 1.7 to 4 MHz. Position two is the 630 meter range, and position three is the 2200 meter range.

Modification is simple. Open up the unit, remove the battery compartment and locate the band switch. With the analyzer upside down and the bottom facing you, it is on the lower left portion of the printed circuit board.

We are going to need to cut one circuit trace connected to the band switch. The detailed photo shows its location. This is the trace that connects the 1.7 to 4 MHz range coil when the band switch is in that position. I used a razor knife to cut the trace. The “common” switch contacts wire to the solder connection at each end of the cut trace. One output of the switch is shorted with a piece of wire so that when the switch is in that position these two points are connected, just as they were with the original circuit trace. Another pair of output contacts has the 630 meter inductor connected across it, and the last has the 2200 meter inductor similarly connected. I drilled a hole in the bottom of the case to mount the switch. Remember the batter compartment! I forgot about the space it takes up and the first hole I drilled didn’t leave room for the switch when the batter compartment is in. I had to drill a second hole, but I managed to hide this fact with labels I made for the inside and outside.

This is the inside after the modification is complete.

 

 

 

The outside after completing the modification.

 

 

 

As mentioned earlier, this has some limits. Don’t expect the R and X values to be exact on the new bands. For that matter, don’t expect them to be exact on any band! This is not a high end instrument. It is likely that the presence of reactance will affect resistance readings and vice versa, but if one first tuned out the reactance, then deals with resistance this should get you close enough for a lot of projects. Below is a table of  measurements I made using resistors with no reactance present.

RESISTOR     160m R   160m X   630m R   630m X   2200m R   2200m X
-------------------------------------------------------------------
0.1 ohm      0        0        0        #        0         #
1 ohm        1        0        1        0        1         0
10 ohm       10       0        10       0        9         0
51 ohm       51       0        51       4        48        13
50 TERM      49       1        49       4        47        12
100 ohm      99       6        100      0        91        28
240 ohm      246      0        251      0        180       110
510 ohm      505      165/0*   529      0        207       270/0*

#   No reading displayed
*   alternating between two readings shown
50 TERM was a precision 50 ohm termination for reference

At a later date I hope to do some testing with known amounts of reactance present and see how this affects things. This isn’t as simple as the resistance tests and will take a considerable amount of time.

 

In Pursuit of 2200 Meters: My Receiver Won’t Do It

Since my participation in Crossband Night several weeks ago I have been getting more and more interested in 630 meters. I have been listening to the WSPR beaconing stations most nights, and have found it is relatively easy to hear Europe and Hawaii when conditions are good. But, as always I am more attracted to the extreme. 2200 meters is the extreme!

I have attempted to hear stations on 2200 several times. It took two weeks to realize any success at all. I was barely able to detect signals from WD2XES and VO1NA on “below the noise” digital modes. It was obvious my system was deaf, but I blamed it on the antennas. After all, what could you expect from a “Beverage” that is less than 0.1 wavelength long? When I finally did hear stations, it was using an 80 meter inverted V. I did realize, however, that there were some issues with the Beverages not related to length. The transformers were not designed for this low frequency and probably had some loss if they worked at all. Later analysis with assistance from WA3TTS showed them to be about -3 dB. That’s not too bad. I also feed 26 volts DC down the coax to each Beverage feed box to power the direction switching relay. I use bidirectional Beverages made from WD-1A field phone wire. The chokes in the bias tees, it turns out, were 140 uH which barely offered 120 ohms of inductive reactance; clearly not enough. The capacitors in the bias tees were 0.1 uF or 12 ohms capacitive reactance; not too bad but it could stand some improvement.

After modifying the bias tees by adding 1 uF capacitors in parallel with the 0.1 uF and swapping out the chokes for some having almost 6 mH of inductance I found the system was still completely deaf. I built a W1VD preamp which measured 22 dB gain. That brought medium wave broadcast signals up to a level my receiver couldn’t handle. I had IMD products and garbage everywhere! Next I built a bandpass filter which rolls off more than 60 dB by the time it reaches 600 kHz and continues to roll of sharply above that. Now the IMD was gone with the preamp in line. For the first time I could hear some NDBs (nondirectional beacons used at airports for navigation) around 200 kHz, but still nothing in the 2200 meter band at 135.7 to 137.8 kHz.

At this point I began to sense my receiver itself (an FT-2000) might not be up to par on sensitivity that low in frequency. I had already discovered the built in 10 and 20 dB preamps acted like attenuators at this frequency! How to measure it? My Agilent E8285A test set is not specified to work below 400 kHz. While its signal generator will go down to 100 kHz I feared the level would be far from calibrated. I had a recently calibrated HP 3325B but its minimum output level is 0.001 volt peak-to-peak or -56 dBm; far too much to be of use in checking receiver sensitivity. Nevertheless I tried it and found the signal much weaker at 2200 meters than it was at 630 meters or 160 meters. At that point I grabbed every type N attenuator I had and started stringing them together. I realized very quickly that the receiver MDS (minimum discernible signal) was no better than about -75 dBm at 136 kHz! Wow, that is bad! Even my W1VD preamp would only bring it to -97 dBm, still deaf as a post!

Then an idea dawned in the dim recesses of my mind. I had a HP 1980B oscilloscope which I trusted to be in calibration at least for voltage measurements. I decided to use the scope to check the output of the Agilent service monitor at 160, 630, and 2200 meters. Lo and behold, I found it holds up pretty well, the output increasing only a couple of dB at 100 kHz. I then proceeded to measure receiver MDS at 1810, 475, and 136 kHz. On 1810 it was quite a bit better than -137 dBm, which is the lower limit for the Agilent. I didn’t bother using attenuators to find out just what it really is. Suffice to say it’s around -140 dBm. At 475 kHz it is -130 dBm or about 10 dB worse but still not too bad. My earlier test at 136 kHz was confirmed: -75 dBm. Wow. Just wow.

At this point I know the FT-2000 is useless for 2200 meter receiving. I will try something else. Stay tuned!

Building a Hipot Tester

I have been building and modifying amplifiers for almost as long as I have been a ham. That’s some three and a half decades. It all started back in the early 1980s, shortly after I became a ham. I knew from the outset that DXing and contesting were in my blood. I had a lust for high power but didn’t think I could afford an amplifier. Then I stumbled across a partially built 80 through 10 meter amplifier carcass at a hamfest. I managed to make a deal and brought it home. It had four 811A tubes and needed some work to be complete. So began a learning experience and the first of many amplifier projects. Since then I have built amplifiers for all bands between 160 meters and 70 centimeters, ranging in power from a few hundred watts to legal limit.

During all this time building and using amplifiers I have had my share of glitches. A good number of those involved high voltage arcs which were both destructive and, in many cases, quite frightening! In the early days I didn’t know hipot (high potential) testers existed. Somewhere around the turn of the century Steve, K0XP, educated me (at least partially) on the subject but I did not pick up the ball and run with it at that time.

Recently the VHF bug I thought I had eradicated from my system came back with a vengeance. I found myself in possession of a 2 meter transverter and decided to convert my 4CX1500B amplifier from 6 meters back to the band I had originally built it for: 2 meters. I didn’t expect any surprises with this one, since it had worked rather well for me on 2 meters a decade earlier. However, upon completion it arced somewhere, destroying the zener diodes in the screen supply. I made some modifications, replaced the diodes and had yet another arc while testing. After the third such incident I began to wonder if maybe – just maybe – it might be time to build a hipot tester.

After a bit of research I decided to build a 0 to 10,000 volt tester. I spent a day on eBay locating parts and when they arrived another day putting the tester together. A hipot tester is really nothing more than a high voltage (usually variable) power supply with current limiting and current metering. The idea is to determine in a relatively non-destructive way whether a part can withstand the voltage it is rated for or at what voltage a part begins to break down. We are looking to measure current of a few microamps. Hipot testers are current limited so that even if the device under test were to suddenly become a short, the amount of current allowed to flow would not result in big bangs, blinding arcs, catastrophic failure of the tester or the like.

I won’t go into full construction details here. There are a number of hipot tester construction articles on the web and elsewhere. My tester uses a 10,000 volt furnace ignition transformer with a small variac to adjust the voltage and a 100 watt light bulb in series with the primary. The light bulb is for primary current limiting should something go horribly wrong. The high voltage is converted to DC with a half wave rectifier and filtered by a .05 microfarad 10kV glassmike capacitor. There is a 100 megohm, 15 kV rated resistor in series with a 100 microamp meter to read tester voltage (100 microamps equals 10,000 volts). There is a current limiting resistor (at the moment 25 megohms) in series with a large 20 microamp meter to measure current through the device under test.

Front panel of hipot tester

Front panel of hipot tester

After building this tester I learned right away that microwave oven diodes which claim to be rated for 12 kV probably aren’t. My diode failed (shorted, naturally) around 6000 volts. I was glad I put that light bulb in the transformer primary! It suddenly went from no visible glow whatsoever to near full brilliance when the diode failed. So much for that. Wanting to get on with testing tubes, I grabbed fifteen 1N4007 didoes and wired them in series. It’s not pretty but it works.

Rear view of hipot tester

Rear view of hipot tester

The next thing I learned is that with a few thousand volts on that output current meter, its plastic case and internal parts take on an electrostatic charge that causes the pointer to swing upscale even when no current is flowing! Not only that, it remained there for more than an hour after turning off the tester! That wasn’t good. I could not find mention of this problem in any of the hipot tester articles. I decided to solve the issue by moving the meter from the positive side to the negative side of the tester. That way there wouldn’t be several thousand volts on that meter unless the device under test failed. I see no problem with this since current is current. I now wonder why people put the meter in the positive lead. For the most part we stopped doing that with plate current meters on amplifiers a long time ago. Why not with hipot testers?

A 4CX1500B tube under test, showling screen grid to plate leakage of about one microamp at 10,000 volts.

A 4CX1500B tube under test, showing screen grid to plate leakage of about one microamp at 10,000 volts.

The tester is working well and will prove very useful around here. I can now test transmitting tubes, capacitors, transformers and many other parts for leakage or voltage breakdown issues. Please note that i purposely did not say I can safely run these tests! There are risks here! For one thing the tester is not enclosed, leaving 120V AC mains and high voltage circuits exposed where one could come into contact with them. The clip leads used to connect the device under test are no doubt a bad idea at these voltages too. I understand and accept the risks, but I do not suggest others build or operate the tester as shown here.

One additional note I would like to add concerning resistors in high voltage circuits. Most of us are accustomed to selecting resistors based on resistance, power rating and perhaps tolerance. We rarely think about voltage ratings, but resistors do have a maximum voltage that they can withstand, and it may be far less than we think. Let’s look at an example to help illustrate this. The 100 megohm resistor used in the voltage meter circuit of this tester will have 100 microamps flowing through it when the meter is full scale. The math tells us this resistor will need to be able to dissipate one watt (I squared times R). But wait! Your average one watt resistor has a voltage rating that is probably somewhere in the 300 to 500 volt range. In this application it will have 10,000 volts across it when the meter is at full scale reading! Even though a high value resistor (in this case 100 million ohms) may claim to be able to dissipate one watt of heat, we cannot actually get anywhere near that dissipation without exceeding its voltage rating and having it go up in smoke and fire. One solution is to put many resistors in series. If we use resistors rated 500 volts we will need 20 of them in series to be safe in this application. That’s a lot of resistors! Naturally the resistance of would need to be 1/20th of our final value, or 5 megohms. I opted to buy resistors designed for high voltage. IRC, Caddock, and others make such parts. The resistor I selected for this application is made by IRC and is rated for 15,000 volts, 3 watts, 100 megohms. The same caveat applies to the current limiting resistor at the output of the tester. Should a device under test short, that resistor will have the full supply voltage across it.

IRC 15,000 volt resistor. Its body is three inches long and it uses a spiral wound resistive element to withstand such high voltage

IRC 15,000 volt resistor. Its body is three inches long and it uses a spiral wound resistive element to withstand such high voltage

630m Crossband Night 2016

I had never thought much about 630 meters or 2200 meters until I was asked at the last club meeting to say something about those bands. My response, slightly paraphrased: “Uh…”. I really didn’t think much about it following that either, until I saw a post by Steve, VE7SL, about 630 Meter Crossband Night which would be November 12 local time. During this event, a number of Canadian amateurs (they already have this band in Canada) would be looking for crossband QSOs, transmitting on 630m and listening on 160, 80, and/or 40 meters. I guess that’s why they call it Crossband Night! Many of the US experimental stations (FCC Part 5 licenses) would be on beaconing and working each other. I decided to give it a shot and see if I could hear anything using my Beverages which range in length from 550 to about 700 feet.

The first station I heard was VO1NA on 477.7 kHz looking for crossband contacts. I gave him a call on his 80m QSX frequency and had a very nice QSO with Joe at 2222 UTC. I have posted a recording of it to AudioBoom: VO1NA. His signal got considerably stronger later in the evening.

Following that QSO I hard WG2XKA in Vermont beaconing on 472.0 kHz with a booming 599+ signal, WH2XHA in Pennsylvania beaconing with a 559 signal.

At 0006 UTC I had another crossband QSO, this time with VE3OT. Mitch had a nice 579 signal on 477.0 kHz. AudioBoom: VE3OT.

Other stations heard during the evening were WD2XSH/46, amazing 599+ signal from Pennsylvania, WD2XSH/31 in Virginia, and my best DX of the night WG2XIQ in Texas, a distance of 1725 miles. AudioBoom: WG2XIQ.

It was a fun evening and something different to do. I wish I had been able to hear or work a more distant station. PE5T, Kees in the Netherlands worked VO1NA and called CW several times but I never was able to copy him. I listened for the several VE7 stations that were active for as long as I could keep my eyes open. From comments I saw posted the following morning, I gather conditions in VE7 improved after I shut down. I hope I didn’t miss an opportunity! Unless I can figure some way to press one of my existing antennas into service for transmitting, I doubt I will be getting on 630 meters when it opens to US hams. I am already having problems trying to fit effective DX antennas for some bands into the space I have available.

Keeping a Dinosaur Alive

The PC I use for ham radio is old. Very old. The CPU is a Pentium 4 running at 3.0 GHz with 2.5 GB of system RAM. The operating system is Windows XP Professional. It has three monitors attached, each running at a resolution of 1920×1080. It runs most of the DX Lab suite 24 hours a day, 7 days a week plus Firefox, Loop Recorder, DX Atlas, and a few other essentials. This is really too much for such an old system, but I need to get at least a few more years out of it. Typically it has been taking four or five minutes to reach a stable desktop after a restart, plus another three or four minutes to load the apps. Logging a contact takes ten to twelve seconds of CPU time, making it rather impractical for use during contests or other “run” times. I use N1MM Logger for that, later exporting the log and importing to DXKeeper. It is very fast even on slow systems. Unfortunately that means running without many of my favorite tools, but one cannot have everything!

This morning, while downloading new SRTM and land cover data for use with Radio Mobile Deluxe, I received a not-too-friendly message from Windows informing me that I was about to run out of hard drive space. This system only has a 40 GB drive. The SRTM data and my collection of DX sound files take up a lot of space. Obviously I was going to have to do something!

I cleaned up the drive, using the Windows utility and manually. I moved some infrequently used files over to the linux box. The advantage of this over archiving them on DVD or similar media is ease of access – the linux box is always on the network. In the end I was able to free 5 GB of space. Whew! After this operation and subsequent defragmenting of the drive, I checked for any performance increase. None. Rats! But at least I wasn’t running out of disk space any more.

Then I decided I might as well go all in and take a risk. Some time ago I had installed Advanced System Care 4 on the system, following the recommendation of a trusted and very knowledgeable software developer. I had tried it back then (two or three years ago) and found no real improvement in system performance. But it had done no harm either. After backing up some critical data and creating a system restore point I nervously started ASC, which immediately told me I had better upgrade to version 6. Immediately following the upgrade to version 6 it informed me version 7 was available. Uh, OK. So I upgraded again. I let it perform a system scan. It said I had several hundred assorted problems. Well, duh! The system runs MS Windows! Naturally it has countless problems. My apologies to those who like MS. I don’t, but until good ham radio software becomes available for linux I allow it to remain under my roof. After a good bit of hesitation and trepidation I committed to making the recommended changes. I noticed it marked a couple of things to be completed on the next system restart: chkdsk to repair a disk data problem, and defragmentation of the Windows registry file.

The predominantly blue screens on reboot (one each for the deferred actions mentioned) were a little scary but everything seemed to go well. Blue screens anywhere near a boot-up make my stomach queasy! I can’t begin to count (nor would I want to count) the blue screens of death I had back in the Windows 95 days! I was quite surprised to see the desktop appear in less than 90 seconds following the final reboot-within-a-reboot. Most interesting. I just about fell off my chair when the DX Lab suite plus extras was up and running within ~80 seconds of starting launcher! Whatever ASC did, it made a big difference. I have spent a few hours testing the system and software for any signs of problems. I have not found any. Everything is significantly faster than before, though still much slower than one would like. Thanks, IObit! Hopefully this will help the system hang on and slow my descent toward insanity during the years before I can ultimately scrap the dinosaur and build a replacement.