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

Dipl. Ing . Tasi Sinisa ­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. 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

9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

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 -3 -3 -3 -3 -3 -3 -3 -3 ATT [dB] -17 -17 -17 -17 0 0 0 0 RF [dB] 0 13 13 0 0 0 13 13 PREAMP AF1 STAGE [dB] 24 24 44 44 24 44 24 44 OVERALL GAIN [dB] 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 -0.2837 dB -0.5508 dB trans

141.6 MHz -0.6009 dB

0

-20

-40

50.8 MHz -23.19 dB 70.25 MHz -23.42 dB

DB(|S(1,1)|) HP GENESIS G59 DB(|S(2,1)|) HP GENESIS G59

-60

-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 1.8MHz 3.5MHz 5-7MHz 5MHz 7MHz 7MHz ver2 10MHz 10-14MHz 14MHz 18-21MHz 24-28MHz 28MHz 50MHz

L[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

L2[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

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] 1000 470 390 330 270 180 220 220 120 82 68 39 33

C2[pF] 150 150 56 47 82 100 56 4,7 47 4,7 15 4,7

C3[pF] 2700 1800 820 1000 1000 1500 680 330 560 220 150 240 100

C4[pF] 2200 820 820 560 470 330 430 680 220 150 150 68 47

C5[pF] 2700 1800 820 1000 1000 1500 680 330 560 220 150 240 100

C6[pF] 150 120 82 47 82 100 56 4,7 47 4,7 15 4,7

C7[pF] 1000 470 390 330 270 180 220 220 120 82 68 39 33

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 Wire length[mm] 500 420 390 360 340 270 250 210 200 190 130 110 100

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 C2B C3B R1B

100nF 1nF(USM) 150pF 1R

L1B L2B L3B C4B C4B* C5B C6B C7B C8B

8,2uH 8,2uH 8,2uH 2,7nF(USM)

2,7nF(USM) 2,2nF 150pF 1nF(USM)

BP 3,5MHz

C9B C10B C11B L4B L5B L6B C12B C12B* C13B C14B C15B C16B

100nF 470pF 150pF 3,9uH 3,9uH 3,9uH 1,8nF

1,8nF 820pF 470pF 150pF

BP 5-7MHz

C17B C18B C19B C20B C21B C22B C22B*

100nF 100nF 100nF 390pF 56pF 820pF

C23B C24B C25B C26B L7B L8B L9B

820pF 820PF 82pF 390pF 2,2uH 2,2uH 2,2uH

BP 10-14MHz

C27B C28B C29B C29B* C30B C31B C32B C33B L10B L11B L12B

220pF 4,7pF 330pF

330pF 680PF 4,7pF 220pF 1,2uH 1,2uH 1,2uH

BP 18-21MHz

C34B C35B C36B C36B* C37B C38B C39B C40B L13B L14B L15B

82pF 4,7pF 220pF

220pF 150PF 4,7pF 82pF 1uH 1uH 1uH

BP 24-30MHz C41B C42B C43B C43B* C44B C45B C46B C47B L16B L17B L18B 68pF 680nH 680nH 680nH 150pF 150PF 150pF 68pF

BP 50-74MHz

C48B C49B C50B C50B* C51B C52B C53B C54B L19B L20B L21B C55B

47pF

27pF 47pF 150nH

150nH 100nF

R2B R3B R4B IC1B IC2B

100K 100K 100K HC4028N ULN2003AN

C56B C57B L22B

100nF 100nF 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

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