The G59D Multiband HF and 4-6m SDR S/H Sample and... Assembling Manual

The G59D Multiband HF and 4-6m SDR S/H Sample and Hold Transceiver
Assembling Manual
Dipl. Ing . Tasić Siniša –Tasa YU1LM/QRP
Copyright note: Unauthorized commercial use, resale, or electronic transmission of this file is strictly prohibited. All rights
reserved under the trade mark www.GenesisRadio.com.au
The Genesis will give any waranty or has no responsibity for sucessfully assemblig G59D KIT and its work with devoted
GSDR software. Full support ahs been given and it is possible obtain from the Genesis and interested Genesis Yahoo group. This is not
plug and play project results are hardly related to sound card quality (better card better results) and work with different OS and PC!
The new G59.. SDR HF and 6m transceiver KIT is successor previously successfully Genesis published monoband and
duoband SDR KIT transceivers G180, G80, G60, G40 and G3020. The new G59 has improved performances over the previously
published with usage some new modern IC components and improved design. The assembling new SDR transceiver has allowance
because it has several SMT components not too small only and all other components are through hole and easy soldering components.
The new one Genesis transceiver G59 is a “black” box type transceiver all comands are coming from PC via USB connection. The G59
has next specification which is hardly related with used sound card, better sound card will give better transceiver performance. This
results are achieved with EMU-0202 USB sound card:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Receiving range is going from 1.5MHz to 75MHz. Receiver is optimized for HAM bands!
Min synthesizer step is 1Hz and it is adjustable. It is possible improve stability with built in quasi oven circuit.
It support demodulation/modulation all type modulation CW/SSB/FM/ DIGITAL and it is software related.
IIP3 32-35dBm and it depends from setting in used GSDR Genesis PowerSDR software [1].
MDS is -116 to -122dBm this result depends from used sound card with RF preamplifier turn on MDS is from 132 to -134dBm.
Image rejection is from 35 -60 dB with hardware realization only, with software is possible achieve result better
than 60dB.
RX Sensitivity is 0.15-0.2uV for 10 dB S/N ratio and max S/N measured ratio is 70dB.
SFDR (Spurious free dynamic range) is 93-100dB (over 100dB with G59C option), this results are with signals
spaced 5 kHz and more. Results are not changing very much if we spaced two test signals to classical 20 kHz or
more
Receiver 1dB compression point is + 10dBm!
Receiver has independent connection for second antenna.
Receiver is supporting transverter work with independent RX input.
Transmitter output power is 10W min with GPA10 KIT and it is adjustable in software to almost 0W.
Transmission is possible only at HAM bands
Carrier suppression is from 45-60dBc with hardware realization
Image rejection is from -35dBc to -50dBc with hardware realization and it is possible adjust to 60dB or more in
GSDR SDR software.
G59D has built in microphone preamplifier with adjustable 2 position gain.
It has built in IAMBIC CW keyer with independent CW monitor
G59 has control circuit for keying RF linear power amplifier
Power supply +12 to +14V/3A minus power supply at ground
Specified operating temperature range is from 0C to +55deg C
Dimensions 240 x 240 x 88mm weight 1.5kg
Predicted time for assembling for average experienced builder 100 hours or 12 days
The G59D KIT assembling is straight forward process if we strictly obey proposed ten phases in assembling. It
is process where is not allowed and permitted to hurry up in assembling and mixed phases only exception is if you
are expert for SDR radios but we are not recommending changing proposed way. The assembling process is not for
real beginners KIT G59 has over 700 electronic and hundred mechanical parts. For the builder it is necessary to have
some elementary knowledge in electronic and soldering skill. It is not necessary to have some special instruments
and tools. Required tools and instruments for assembling are: iron solder (30-60W), wire cutter, tweezers, screw
driver and digital multi meter (DMM). Although not absolutely necessary oscilloscope, SA (spectrum analyzer), NA
(network analyzer) or test receiver are welcome. These additional instruments will simplified and speed up
adjustment process and help in obtaining max specification from G59 SDR transceiver KIT.
G59 KIT is flexible hardware with some option for future system upgrade in many fields for example 2m and 70cm
transverters and ATU tuner. The G59 SDR transceiver has two double side PCB first is G59 PCB or low power
HF+6m 10mW SDR transceiver and second one is GPA10 PCB with linear 10W or more power amplifier, low pass
filters , SWR bridge and high SWR circuit protection circuit. Both PCBs are acting as SDR transceiver but it is
possible to use every PCB independently G59 PCB as SDR transceiver for VHF/UHF and microwave transverters
and GPA10 as linear RF power amplifier for some other transceiver system. At picture 1 is given interconnection
between this two PCB and PC sound card. The G59D has all processes as ordinary G59. There are few changes to
enable work at 4m these changes are listed down:
Phases which are different to elementary G59 KIT!!!!!!!
Phase 3 – G59D Local Oscillator LO Circuit Assembling
Local oscillator LO circuit and their components are marked with letter “G” at PCB G59 visit page devoted to this subject
http://genesisradio.com.au/G59/phase3.html
Picture 15 - Si570 G59 LO frequency generator
The change for G59D is that is necessary change Si570 type instead Si570BBC000141DG (max working frequency around 260
MHz ) with Si570BBB000141DG (max working frequency is 810MHz). New limitation for G59D design is max frequency for divider
FF IC3G 74LVC74 and built in LP filter (75MHz). Except Si570 change there is no need for any other changes!!!
Picture 24 - The G59D local oscillator LO circuit schematic diagram in REV1 added R20G from TP1 to ground
Phase 5 – G59 Input-Output High Pass-Low Pass Filter Circuits Assembling
The G59 receiver input/output high pass and low pass filter circuit and their components are marked with letter “N” at G59D
PCB http://genesisradio.com.au/G59/phase6.html . The receiver is one of the most important subassembly in all transceiver designs
especially in the new SDR technology. The Genesis receiver can work without any input filter for transmitter sections LPs or BPs are
necessary parts. To prevent overload input receiver S/H(sample and hold) mixer with very strong signals MW stations from
neighborhood and static voltage damages at RX input is high pass filter with -3dB at 1,5MHz. Attenuation unwanted bandwidth is in
vicinity 40dB what is more than enough. From the other side the same situation is with strong FM station and their signals are removed
with low-pass filter -3dB corner at 75-78MHz. To test this circuit it is necessary to remove temporary wire connection for initial test
first. Connect processor circuit nylon connector SV3PA with this circuit connector SV3PB with 4 lines flat cable K3 (see section with
wire connection at the article end). Next step is to connect RX input BNC1 to the antenna and start GSDR software. Now you can hear
signals from the band. Pressing ATT and preamplifier button you can notice change in signal strength and noise floor level!
Picture 32- The G59 receiver RX gain distribution
HP/BP/LP
[dB]max
ATT
[dB]
RF
[dB]
-3
-3
-3
-3
-3
-3
-3
-3
-17
-17
-17
-17
0
0
0
0
0
13
13
0
0
0
13
13
PREAMP
AF1 STAGE
[dB]
OVERALL
GAIN [dB]
24
24
44
44
24
44
24
44
4
17
37
24
21
41
37
54
Table 1 – The G59 RX gain distribution possibility
You have to find best position for sensitivity and IMD free range with different combination attenuator, RF preamplifier and
audio gain buttons. Combinations are antenna and radio waves propagation sensitive setup. You can measure control voltage at
connection point R4N, R5N and R6N it has to be around +4,5V.
BOM component list for G59 HP/LP circuit marked at PCB with extension “N”
KP1N
SV1NA
KP2N
KP2NB
KP2NC
C1N
L1N
L2N
L3N
C2N
C3N
C4N
C5N
L4N
RL1N
BNC
3PIN
BNC
2PIN
2PIN
3,9nF
1,2uH
47uH
4,7uH
10nF(USM)
1,5nF
3,9nF
4,7nF
5,6uH
12V/1A RELAY
RL2N
RL3N
RL4N
RL5N
RL6N
RL7N
RL8N
RL9N
RL10N
RL11N
L5N
C6N
L6N
C7N
C8N
L7N
C9N
C9N*
L8N
C10N
C10N*
L9N
C11N
C12N
L10N
C13N
R1N
R2N
R3N
C14N
IC1N
C15N
L11N
R4N
R5N
R6N
C16N
C17N
C18N
R7N
R8N
C19N
C20N
12V/1A RELAY
12V/1A RELAY
12V/1A RELAY
12V/1A RELAY
12V/1A RELAY
12V/1A RELAY
12V/1A RELAY
12V/1A RELAY
12V/1A RELAY
12V/1A RELAY
68nH
56pF
180nH
56pF
18pF
180nH
82PF
180nH
82pF
180nH
56pF
18pF
150nH
33pF
68R
180R
68R
10nF SMT 0805
ERA-4XSM+
100nF
47uH
470R
270R
270R
10nF SMT 0805
100nF
100uF/25V
1R
1R
100nF
100nF
C21N
C22N
C24N*
C23N*
R9N
C25N
100nF
100nF
100nF
100uF/25V
10R-15R G59MK3 PCB
15pF
G59MK3 PCB
C9N and C25N is necessary to add to improve RF preamplifier stability in microwave region.
Picture 35 – The G59 High-pass/Low-pass circuit schematic
The L5N inductor is realized from 6.5cm 0.8mm enameled copper wire close wound at borer diameter 3mm
Molded inductors L6N, L7N, L8N, L9N and L10N have big tolerances because of that the -3dB corner of built in LP is
changeable and it is not flat at the end in the most of cases. For G59D and even generally it is better to build in isolated Cu wire self
supporting inductors realized according to the next table:
mark
L5N
L6N-L9N
L10N
Inductivity[nH] Wind at borer[mm]
68
5
68
5
180
5
180
5
150
5
150
5
Wire diam.[mm] Wire length [cm]
1
6.7
0.8
6.2
1
14
0.8
12.6
1
12
0.8
10.6
Coil length [mm]
4
3
8
6
7
5
Number of turns
4
3
8
7
7
6
With these home-made inductors G59-G59C RX has better IMD specification and it is possible adjust very precise inductance
-3dB corner of LP , LP flatness squeezing and spin carefully inductors!
Picture 36 – The G59 High-pass/Low-pass assembled
Phase 6 – G59 Input-Output Band Pass Filter Circuits Assembling
The G59 Input and output band pass filters circuit and their components are marked with letter “B” at G59 PCB
http://genesisradio.com.au/G59/phase7.html . This circuits is very important and their assembling to obtain maximum from G59
hardware in receiving part and in transmitting part too. All BP filters are realized with standard chokes and it is very important to
minimize filter insertion loss to not solder them close to the PCB ground surface. It is necessary that distance is between 3-4mm at that
way we are obtaining minimum insertion loss and satisfied out of band selection. If you want obtain max there is G59C option with
Amidon ring cores instead chokes. This option will improve sensitivity for 1-2dB typically and offered better IMD free range for 3-4dB!
G59C option is offering also better out of band selectivity very important if we have close transmitters in MULTI-MULTI Contest team.
To simplify situation in realization for keeping distance to the PCB the easiest way is to insert ribbon fat cardboard under every choke
during soldering and removing after choke is soldered. For G59D change is that it is BP for 6m removed and substituted with HP! This
combination HP and LP is filter for 6m and 4m!
31.69 MHz 50.57 MHz
-21.19 dB -0.6693 dB
72.07 MHz 100.6 MHz
-0.5508 dB
-0.2837 dB
trans
141.6 MHz
-0.6009 dB
0
-20
-40
50.8 MHz
-23.19 dB
-60
70.25 MHz
-23.42 dB
DB(|S(1,1)|)
HP GENESIS G59
DB(|S(2,1)|)
HP GENESIS G59
-80
DB(|S(2,2)|)
HP GENESIS G59
-100
1
51
101
Frequency (MHz)
151
200
Amplitude frequency response of new HP filter
G59D HP filter 50MHz schematics
L19B and L21B ARE possible realized according to the given table up as L10N. Take care that is necessary that coils are
perpendicular each to other. See picture for assembling down!
Goran YT7PWR will enable in GSDR permission for operation at 4m and combination HP/LP filters for these 2 bands as soon
as possible! RX will work even without HP 50MHZ but performances can be reduced. RX input can be little overload with strong full
HF bands signals especially when RF preamplifier is ON. Reason for IMD is preamplifier overload..
Picture 38 - G59 Input-output band pass filters at G59 PCB details
The component values for this band pass filter type are given in table below. In table are given values for filters which are not
inside G59 but is possible substitute if you want better performances in some individual band and it is possible also to build in this type
filter as special option for specific band as second RX antenna or transverter individual input from VHF/UHF.
Picture 39 - General schematic diagram of BP band pass filter built in G59
BAND
L[uH]
L2[uH]
1.8MHz
3.5MHz
5-7MHz
5MHz
7MHz
7MHz ver2
10MHz
10-14MHz
14MHz
18-21MHz
24-28MHz
28MHz
50MHz
8,2
3,9
2.2
3.3
1,8
2.2
1.2
1.2
1
1
0,68
0.68
0.33
8,2
3,9
2.2
3.3
1,8
2.2
1.2
1.2
1
1
0,68
0.68
0,33
L3[uH
]
8,2
3,9
2.2
3.3
1,8
2.2
1.2
1.2
1
1
0,68
0.68
0,33
C1[pF]
C2[pF]
C3[pF]
C4[pF]
C5[pF]
C6[pF]
C7[pF]
1000
470
390
330
270
180
220
220
120
82
68
39
33
150
150
56
47
82
100
56
4,7
47
4,7
2700
1800
820
1000
1000
1500
680
330
560
220
150
240
100
2200
820
820
560
470
330
430
680
220
150
150
68
47
2700
1800
820
1000
1000
1500
680
330
560
220
150
240
100
150
120
82
47
82
100
56
4,7
47
4,7
1000
470
390
330
270
180
220
220
120
82
68
39
33
15
4,7
15
4,7
Table 2 - Band pass elements for filters built in G59 (yellow marked) with additional band filter solution
Inductor winding for G59C option including inductors for HP/LP section:
L[uH]
8.2
5,6
4,7
3.9
3.3
2.2
1.8
1.2
1
0.68
0.33
0.18
0.15
Core
T37-2
T37-2
T32-2
T37-2
T37-2
T37-2
T37-2
T37-2
T37-2
T37-6
T37-6
T37-6
T37-6
turns
45
37
34
31
29
23
21
17
16
15
10
8
7
Wire diameter[mm]
0.3
0.3
0.3
0.3
0.3
0.6
0.6
0.6
0.6
0.8
0.8
0.8
0.8
Table 3 - Proposal for inductor realization band pass filters in G59Coption
BOM component list for G59D BP filter circuit marked at PCB with extension “B”
BP 1,8MHz
C1B
100nF
C2B
1nF(USM)
C3B
150pF
R1B
1R
Wire length[mm]
500
420
390
360
340
270
250
210
200
190
130
110
100
L1B
8,2uH
L2B
8,2uH
L3B
8,2uH
C4B
2,7nF(USM)
C4B*
C5B
2,7nF(USM)
C6B
2,2nF
C7B
150pF
C8B
1nF(USM)
BP 3,5MHz
C9B
100nF
C10B
470pF
C11B
150pF
L4B
3,9uH
L5B
3,9uH
L6B
3,9uH
C12B
1,8nF
C12B*
C13B
1,8nF
C14B
820pF
C15B
470pF
C16B
150pF
BP 5-7MHz
C17B
100nF
C18B
100nF
C19B
100nF
C20B
390pF
C21B
56pF
C22B
820pF
C22B*
C23B
820pF
C24B
820PF
C25B
82pF
C26B
390pF
L7B
2,2uH
L8B
2,2uH
L9B
2,2uH
BP 10-14MHz
C27B
220pF
C28B
4,7pF
C29B
330pF
C29B*
C30B
330pF
C31B
680PF
C32B
4,7pF
C33B
220pF
L10B
1,2uH
L11B
1,2uH
L12B
1,2uH
BP 18-21MHz
C34B
82pF
C35B
4,7pF
C36B
220pF
C36B*
C37B
220pF
C38B
150PF
C39B
4,7pF
C40B
82pF
L13B
1uH
L14B
1uH
L15B
1uH
BP 24-30MHz
C41B
68pF
C42B
C43B
150pF
C43B*
C44B
150pF
C45B
150PF
C46B
C47B
68pF
L16B
680nH
L17B
680nH
L18B
680nH
BP 50-74MHz
C48B
47pF
C49B
C50B
C50B*
C51B
C52B
C53B
27pF
C54B
47pF
L19B
150nH
L20B
L21B
150nH
C55B
100nF
R2B
100K
R3B
100K
R4B
100K
IC1B
HC4028N
IC2B
ULN2003AN
C56B
100nF
C57B
100nF
L22B
47uH
G59 band pass filter will consume some time and best way is test with some signal generator but it is possible perform test
without any signal source only with antenna. Connect uC circuits with band pass control logic with 3 wire flat cable K4 take
References:
1. www.genesisradio.com.au
2. http://www.silabs.com/products/clocksoscillators/Pages/default.aspx
3. www.yu1lm.qrpradio.com