Wednesday, February 25, 2026

Impedance matching (auto) transformer and common-mode choke for the JPC-7 dipole and other electrically-short (loaded) dipoles and verticals

Figure 1:
The JPC-7 loaded dipole out in the wild!
Click on the image for a larger version.

Loading coils and "electrically-short" antennas

It is well-known that you can make a "short" wire (e.g. one that is significantly shorter than 1/4 wavelength at the operating frequency) resonant by putting in series with it a coil.  There is no "magic" in this as the inductance of the coil, appropriately chosen, can completely cancel out the capacitance of the electrically-short wire, result being that at "resonance" we are left only with a pure resistance.

In an ideal situation, what we would be left with would be just the radiation resistance of this antenna and for such an antenna, this would mean that the feedpoint resistance would be less than 50 Ohms - probably much less!  In reality, the feedpoint resistance would really a combination of "ground" (counterpoise) losses, conductor losses of the antenna, and losses of the coil itself.

What this means is that if you have an electrically short antenna such as a loaded dipole or vertical with only a series loading coil tuned to resonance at the frequency of interest and no other matching scheme, its feedpoint impedance should be well under 50 Ohms on some bands if it is operating efficiently.

This is often not the case with portable antennas!

Figure 2:
The original stainless steel coil (rear) for the
JPC-7 (and JPC-12) with the coil rewound with
silver-plated "jewelry" wire in the front.
Click on the image for a larger version.

The JPC-7

Some time ago I wrote extensively about the JPC-7 (See the article, "Observations, analysis and field use of the JPC-7 portable "dipole" antenna" - LINK) where I discussed the bits and pieces comprising it:  I have used it in the field a number of times, finding it to work as advertised.

In short, this is a loaded dipole - at least on the lower amateur bands (especially 40 and 30 meters) that is intended for portable use:  On these bands (including 20 and 17 meters) it is physically shorter than 1/2 wavelength and it requires the adjustment of its series inductors to resonate.  On the higher bands (15 and above) its overall length approaches and exceeds a half wavelength meaning that it's a full-sized dipole and is (generally) tuned by adjusting the length of the telescoping sections.

Lossy coils!

There is a down-side:  As sold, it has loading coils that are wound with stainless steel:  As noted in the original article, these coils are very lossy, with MOST of the RF power being dissipated as heat on the lower bands (40 and 30 meters in particular - roughly an "S" unit of signal loss) where a fair bit of inductance is required.

Figure 3:
An example of heating of a stainless steel
loading coil on a short vertical - here, made by
Wolf River.  On 40 meters the temperature of
the coil rose by more than 30F (17C) with
60 watts of RF applied for 60 seconds.
Click on the image for a larger version.

The reason for this is that an electrically-short antenna (one that is physically short compared to the wavelength.)  The total length of the telescoping sections alone put together is about 198" (5 meters) - which is about 12.5% of a wavelength at 40 meters implies that the feedpoint resistance would, were there no loss at all, be around 8-10 Ohms, resulting in a VSWR of more than 4:1.

Calculations and measurements indicate that the approximate Ohmic loss of the original stainless-steel loading coil - if we optimistically presume it to have a Q of 47 - would be about 19 Ohms per coil (remember that there are two coils!) and the sum of the two coils would push feedpoint resistance near-ish 50 Ohms.  The result is that roughly 1 "S-unit" (about 6dB) is lost in the coils alone:  Contacts would still be made, but running a "compromised" antenna (e.g. physically small) that already would be less-efficient than its full-sized counterpart and adding another S-unit of loss doesn't sound like an optimal solution!

Using silver-plated copper "Jewelry Wire" (found on Amazon) to rewind the original loading coils dramatically improved the "Q" (approximately 200) and lowering the Ohmic loss to around 4 Ohms.  The result of this is that rather than something in the 40-50 Ohms for the feedpoint resistance, it dropped to "about 15" Ohms on 40 meters - a VSWR of around 3:1 - and even lower impedance than that (higher VSWR) when I reconfigured the antenna for 60 meters (e.g. added extra screw-together sections, moved the coils next to the feedpoint and added extra "drooping" wires to the ends of the dipole).  At the higher bands (20 meters and up) the feedpoint impedance is close enough to 50 Ohms that one can probably forego the auto transformer at all.

For more information about the "Silver-plated versus Stainless Steel" topic, see the blog entry "Rewinding the Stainless Steel coils with Silver-Plated copper wire on the JPC-7 and JPC-12 antennas" - link.

When a worse VSWR is a good thing!

The first thought when being faced with a higher VSWR on an antenna might be that it was made to be worse - but here is a instance where this is not the case.  As noted earlier, an electrically short antenna like a dipole or vertical can be made to be "longer" (from an RF standpoint) with the addition of a "loading" coil - but the job of the coil is to cancel out the capacitance of the, leaving only the resistive portion of the antenna's feedpoint impedance.

For a full-sized dipole or vertical, this resistance is "close enough" to 50 Ohms (perhaps 35-70 Ohms, depending on the antenna and its environment) to provide a decent load to a modern radio - even one without tuner.  But a very small antenna - where a lot more "coil" is required - will have a lower feedpoint resistance unless your coil is very lossy, as was the case with the stainless steel coils on the JPC-7.  With the lower-loss silver plated coil we (mostly) eliminate it as a lossy component - but end up with a different problem.

With a feedpoint resistance of 13-15 Ohms on 40 meters with the JPC-7 and silver plated coil and its resulting 3-ish:1 VSWR one can "fix" this with an antenna tuner to make the radio happy - and I have done this many times, placing the tuner (an LDG Z-11 Pro) right at the antenna (only a few feet/a meter of coax) but almost all common antenna tuners have quite high losses at these low impedances.

Testing with the cover of the tuner removed, I have noted that one ore more of its toroids in particular will run very warm with just 100 watts of power - Figure 4 shows the inside of this tuner showing one of its toroids discolored because of this.  Fortunately, iron-powder toroids are very forgiving of heating with very high Curie temperatures and other than cosmetic (e.g. discoloring the paint) moderate heating won't have any lasting effects as long as it remains intact (e.g. not cracked) and there aren't problems with (possibly-degraded) insulation between turns of the windings.

The other issue is that the balun originally supplied with the JPC-7 - intended for 50 Ohm operation - also got very warm, and after a bit more than a minute of continuous 100 watts at 40 meters the VSWR would start to rise due to its ferrite reaching the Curie temperature, causing the permeability to drop like a rock:  Essentially, the ferrite would "go away" when it got hot - likely not a problem on SSB or CW, but it might be on "key down" digital modes at full power.  This heating seemed to be more severe at the low impedances (below 20 Ohms) than at 50 Ohms.

Eliminating the tuner

Figure 4:
Inside the LDG Z-11 antenna tuner.  The center
toroid shows evidence of have been heated,
apparently due to matching very low "R".
Click on the image for a larger version.

By definition, we can remove the reactive component of the short antenna with the loading coil:  Its inductance will cancel out the capacitance of the antenna at resonance (which is the very definition of resonance) leaving only a pure resistance.  While an antenna tuner is able to cancel out capacitive and inductive reactance - or just pure resistance - we have a situation where, with a properly-tuned loading coil - we have only resistance and for that we don't need a tuner and we can use just a transformer, to change the impedance from whatever it is to 50 Ohms.

An easy way to do this is with an autotransformer.  This is a device with just one winding and in this case - where we are trying to tune to a feedpoint resistance lower than 50 Ohms - we can feed our power across the ends of the entire coil and tap it at various points along the winding to get our desired (lower) impedance.  For my application, having several taps between about 10 and 40 Ohms (plus the natural 50 Ohm feed impedance) would assure the ability to attain a VSWR of better than 1.5:1 for any purely resistive impedance between 7 and 75 Ohms.

The tyranny of the "electrically small antenna" and efficiency

It's worth noting several things about electrically-small low-band HF antennas - which includes portable antennas like the JPC-7, JPC-12 as well as mobile antennas - and how they interact with common antenna tuners (which an autotransformer is not):

  • Any efficient, electrically-small vertical antenna will have a very low impedance once it is resonated:  For example, a "perfect", loss-less 1.5 meter (4.9 foot) long vertical antenna system on 40 meters would have a radiation resistance of about half an Ohm.
  • Without losses due to the coils and stainless-steel telescoping rods, etc., the feedpoint resistance of the JPC-7 would, at 40 meters, be in the vicinity of 3-5 Ohms, depending on how many screw-together sections are used (e.g. the longer, the higher).
  • Any automatic (or manual) antenna tuner that you are likely to ever use for portable operation will have rather poor efficiency when trying to match at lower than 20 Ohms or so - which translates to heat as demonstrated in Figure 4.

These facts - among others - conspire against having a small, efficient mobile antenna for the lower HF bands (e.g. 80-40 meters).  In the real world, losses (coil, antenna wire, ground) will conspire to make the feedpoint impedance much higher than the "less than an Ohm" that the would theoretically be - and any difference between the feedpoint resistance at resonance and the predicted radiation resistance is where most of the power in such an antenna system is lost:  In a typical antenna of this sort, the vast majority of transmitted power is lost in heat rather than radiated.

With significant efforts, it may be practical to get the losses of such an antenna system (which includes not just the antenna, but the series matching coil and ground losses an other factors) down to about 10 Ohms - still far above the 0.5-5 Ohms of our "perfect" antennas in the examples above - but as we know, physics conspires against us as trying to force-feed such an antenna with a tuner will probably put it into the impedance range where it is very inefficient.

It's worth noting that many simple and inexpensive mobile antennas achieve at least part of their "matching" to 50 Ohms simply by being lossy:  Most of the power is simply burned up in the coil.  This method is convenient in that it simplifies the problem with matching and is often accompanied by much wider tuning bandwidth (reducing the need to frequently re-tune when one changes frequency) than with our hypothetical "high efficiency" antenna, but the trade-off is poor efficiency.

Auto transformer for impedance matching

Another way to handle this is to simply transform (pun intended!) the impedance downwards from 50 Ohms - and one way that this could be done is with a transformer of some type - and the simplest of these is one with a single winding, called an autotransformer:  Such transformers are commonly used to match a random wire (9:1 matching to about 450 Ohms) and for end-fed half-wave antennas (49:1 matching to about 2450 Ohms) - but we can also efficiently transform the impedance downwards.  By designing appropriately, this transformer can be made to be very efficient.

It would seem that the use of an auto transformer for matching a low-impedance antenna - such as a low-band mobile antenna on a vehicle - used to be more common decades ago, but has fallen out of favor, possibly due to the easy and cheap availability of automatic antenna tuners:  Devices that do this function include the Atlas MT-1 (see Figure 5) and the Swan MMBX, both of which have a number of low-impedance taps. 

Figure 5:
The Atlas MT-1 autotransformer,  The variety of
taps available provide the possibility of achieving a 1.5:1
match to any resistive loads between 9 and 75 Ohms.
Click on the image for a larger version.

My initial thought was to use a ferrite toroid as the core for the auto transformer.  As a general rule of thumb, a transformer should ideally have an inductive reactance of about ten times that of the operating impedance at the lowest frequency (e.g. 500 Ohms for a 50 Ohm system) but, in a pinch, just three times the operating impedance (e.g. 150 Ohms for a 50 Ohm system) was "OK".  With this in mind I wound 7 turns on an FT140-43 toroid with multiple taps.  The inductance of this arrangement was about 45uH which correlates with about 1900 Ohms at 7 MHz - well above the target inductive reactance but it would have been difficult to achieve the multiple taps needed to attain the impedance steps with fewer turns.

This transformer - wound on ferrite - did not work well at all!  When testing it on the antenna, I could not achieve a sensible match and I quickly realized that the problem was due to leakage inductance of the transformer itself.  An ideal transformer would simply transform the voltage according to the tap's turns ratio, but any practical transformer will place some amount of inductance in series with the supposedly ideal tap, and it was likely this spurious series inductance (which needed only to be a few uH to make it "un-matchable") was totally messing up the attempt to tune the antenna, departing far from the ideal transformer at RF.

Measuring the self-inductance of the Atlas MT-1 confirmed this:  Its end-to-end inductance was about 2uH and the inductances between the taps and ground - the results of these measurements made using my HP-4275A LCR Meter (at 4 and 10 MHz - interpolated at 7 MHz) are as follows:

Tap marking
(Ohms)
@ 4 MHz
Inductance uH
(XL Ohms)
@ 7 MHz (Interpolated)
Inductance uH
(XL Ohms)
@ 10 MHz
Inductance uH
(XL Ohms)
521.87uH
(46.6)
1.8uH
(79)
1.74uH
(116)
230.95uH
(24.4)
0.95uH
(41.8)
0.95uH
(61)
180.77uH
(18.1)
0.75uH
(33)
0.72uH
(47)
130.61uH
(14.3)
0.57uH
(25)
0.53uH
(35.8)

Figure 6:
The impedances (XL ) of the taps on the Atlas MT-1 auto transformer versus frequency.

While "about 2uH" of inductance at 40 meters (7 MHz) doesn't fit the "3x reactance" rule-of-thumb (e.g. 79 Ohms XL in a 50 Ohm system) it will still work OK, acting as a parallel inductance across the antenna - but the important part is that there will be a fraction of the leakage inductance compared to the version with the ferrite core mentioned above:  A small amount of this inductance would lower the resonance frequency slightly, but not disastrously so.

Figure 7:
The auto-transformer, wound on a T157-2 iron-powder
toroid with taps terminated with 2.5mm banana plugs.
Click on the image for a larger version.
Replicating the auto transformer

Rather than reinventing the wheel, I decided to (more or less) replicate the electrical properties of the MT-1 (and similar devices) and for this I chose a T157-2 Iron-powder toroid.  With a target inductance of "about" 2uH I wound 13 turns of 16AWG silver-plated PTFE (Teflon) insulated wire which should, in theory yield about 2.4uH - but when compressed together on the core it yielded about 3.6uH which correlates with about 158 Ohm at 7 MHz -  almost exactly 3x the 50 Ohm system impedance.

As can be seen in Figure 7, taps were placed at 6, 7, 8, 9 and 11 turns (from ground) by scraping the insulation off the side if the wire and tack-soldering wires to it providing impedance taps of approximately 11, 14, 19, 24, 36 Ohms - plus another wire across the 50 Ohm feed for the higher bands:  These impedances resulted from where the turns landed and it was convenient to attach taps rather than from any attempts to obtain specific or precise impedances:  After construction, I labeled the leads with the approximate impedances - for obvious reasons!

I used five taps to allow a selection of an impedance to be able to obtain about 1.25:1 VSWR or better, but if I were happy with just 1.5:1, I could have chosen fewer taps in the manner of the Atlas MT-1 discussed, above.

As the impedance of a tap is related to square relation of the number of turns (e.g. twice the number of turns results in 4x the impedance) there's a pretty simple formula to follow to calculate the impedance of a tap:

Ztap = (Zsys) / ((Turnstotal/Turnstap)2)

Where:

Ztap = Impedance of the autotransformer tap

Zsys = System impedance (typically 50 Ohms)

Turnstotal = Total number of turns on the autotransformer (13 turns in our example)

Turnstap = Number of turns from the bottom (ground) end of the autotransformer to the tap

In other words:

 Ztap = (50) / ((Turnstotal/Turnstap)2)

Taking our 13 turn autotransformer as an example, we can calculate the impedance at any turn.  Taking the 8th turn as an example:

Ztap = (50) / ((13/8)2therefore,

Ztap = 18.9 Ohms 

Or, if you know the desired target impedance and want to calculate the turn on which to make that tap, here's the above formula rewritten to solve for it:

Turnstap = Turnstotal / √(Zsys /Ztap)

I also included a "50 Ohm" tap (which is connected at the "top" of the transformer, across all of the windings) so that I could still use the common-mode choke (described below) even when operating on the higher bands (20 meters and above) where the natural impedance was close enough to 50 Ohms that I probably wouldn't have needed the autotransformer for impedance transformation, anyway.

At the end of the flying leads are 2.5mm "banana" plugs - which plug in to the feedpoint of the JPC-7.  These allow the selection of taps on the auto transformer which permits the VSWR to be minimized for those bands for which the feedpoint impedance is significantly lower than 50 Ohms:  A bit of care is required to prevent the "floating" banana plugs from touching each other (or anything else metal) but this isn't actually much of a problem.

Initial testing using a kludge of clip leads, I verified with my NanoVNA that the auto transformer worked as it should (e.g. I was able to attain less than 1.5:1 VSWR on 60, 40 and 30 meters) and almost as important, the tuning with the auto transformer was only slightly different from that using the original balun indicating that the leakage inductance of the auto transformer was not much different than that of the originally-supplied balun.

Adding a common-mode choke

Feeding a dipole (which is a balanced antenna) with coaxial cable has the inherent hazard of RF appearing on the coaxial cable feedline due to the symmetry of the antenna.  Excessive RF on the feedline can result in a "hot" rig - that is, RF energy appearing on the chassis of the radio as well which can result in distortion (RF getting into the microphone) and/or malfunction of peripherals (outboard keyer malfunctioning, USB interfaces crashing, interference to the sound card) and out "in the field" where one may not have an elaborate ground system already, this may be more likely than at home.

Figure 8:
The auto transformer (left) plus a common-mode coaxial
choke (right).  The choke is wound on an FT140-43 ferrite
toroid.  Both toroids are in the foreground for comparison.
Click on the image for a larger version.
The "input" to the auto transformer is simply the opposite ends of its 13 turn winding which would normally be soldered to an RF connector.  Rather than doing that, I soldered it to a 36" (91cm) piece of RG-316 PTFE coaxial cable - the shield going to the "bottom" (ground) side of the auto transformer, insulating the connections with adhesive-lined heat-shrink tubing.  The rest of this RG-316 was wound on an FT140-43 toroid yielding 13 turns using the "cross-over" technique where about half of the turns are wound on the opposite side of the toroid:  This method is said to (slightly) increase the series choking impedance at higher frequencies (e.g. 15 meters and up).

Not having a UHF connector designed for RG-316 on hand, I used a crimp-type PL-259 intended for RG-58.  I stripped more than usual of the jacket from the end of the coax, folding the shield over the outer sheath.  Using some PTFE tubing and part of the jacket stripped from the coax itself I was able to increase the effective diameter of the inner dielectric.  Assembling the cable - remembering to include the ferrule and pieces of adhesive-lined heat shrink - I was able to fold the outer shield over the ferrule after a bit of tugging on it to increase its inner diameter.  At that point, I was able to crimp the ferrule into place, securing the coaxial cable firmly.

Figure 9:
The auto transformer with the common
mode choke on the JPC-7's feed.
Click on the image for a larger version.
Since RG-316 is fairly small (it's the same size as RG-174) - and because the weight of the connecting coaxial cable and the common-mode choke itself would be hanging from the cable - I protected the connector with several pieces of adhesive-lined shrink tubing - using a smaller piece just behind the connector to increase its outside diameter and then a larger piece over the ferrule, onto the previous piece of tubing.
 
Not content with this, I wound several turns of "miniature" paracord (1.15mm diameter) onto the ferrule and tied it securely, feeding both free ends underneath yet another piece of heat-shrink tubing that was then installed over where I'd tied the paracord - taking careful care not to damage the cord when applying heat to shrink it.

These two strands of mini-paracord were then counter-wound over the RG-316 as can be seen in Figures 8 and 9 and were tied to the ferrite core of the common-mode choke such that when hanging, the weight of the connector was on the cord and not the coaxial cable:  I did a similar thing between the core of the auto transformer and the balun to prevent the cable itself from being pulled.

Putting it on the antenna

Figures 8 and 9 shows the combination auto transformer and common-mode choke at the feedpoint of the JPC-7 loaded vertical.  As noted earlier, testing showed only a slight difference in tuning between the lowest VSWR achieved with the original 1:1 balun and the transformer-choke combination indicating that its effect was minimal:  As figure 10 shows, transmitting 100 watts on 40 meters also resulted in only very slight heating of the auto transformer - certainly a much lower amount of signal loss than that which resulted in the heating and discoloring of the toroid in the antenna tuner pictured in Figure 4.

Figure 10:
Thermal infrared view of the autotransformer
(top) and common-mode choke (bottom)
after 60 seconds key-down with 100 watts
on 40 meters.  The temperature of the
autotransformer increased only by about 2F
(1C) while the common-mode choke got about
10F (6C) warmer.
Click for a slightly larger version.
Testing the common-mode choke
 
The efficacy of the common-mode coaxial choke was also verified:  Without it, grasping the shield of the coaxial cable with one's hand would result in slight detuning of the antenna, but with it, there was no detectable effect - and there was no detectable amount of "hot rig" due to the presence of common-mode currents flowing beyond the choke and onto the radio's chassis - even without the use of a counterpoise/ground wire.
 
The presence or lack of effect of the change of antenna tuning when body capacitance is introduced is a simple - but effective - means of determining the presence of RF current on the feedline at the point where it is grasped.  Figure 10 shows that this core heated only minimally - also indicative of low loss.

Does it work?

I have put this configuration pictured in Figure 9 on the air several times since assembling it on 60 through 15 meters.  As expected, the best match on 60 meters (<1.5:1) required the 11 Ohm tap while 40 meters seemed fine with either the 11 or 14 Ohm tap.  20 meters, on the other hand, found the best match using the 36 Ohm tap while 15 meters worked well with either this or the 50 Ohm tap.  Again, the heating of the autotransformer at 100 watts was also minimal on any band - even on the 60 and 40 meters where the losses would probably have been the highest.

Conclusion

The use of an autotransformer rather than an L/C antenna tuner is a time-honored means of matching an "electrically-short" antenna, so what has been presented is nothing new - but it may be "new" to some of the readers.  For a portable antenna such as this, its size and relative simplicity can't be beat as it's far smaller than any antenna tuner that could handle 100 watts at the low impedances that may be presented - and it's certainly lower loss as well!

The only "complication" is that which is already intrinsic to this type of antenna:  As this is a dipole, there are two elements - each with its own coil and telescoping rod making it a bit "fiddly" to tune, something best done with a VNA or antenna analyzer.  With this antenna I keep a card that is marked with the physical locations of the tap positions of the two coils for the various bands:  These are held up to the coil and the sliders adjusted, quickly getting "close" to a match with the analyzer used to do any final touch-ups on the tuning.

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Related pages:

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This page stolen from ka7oei.com

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Friday, January 23, 2026

How I prevented QRM to HF reception from my solar and AC inverter at Quartzfest

Figure 1:
White board from Quartzfest!
Click on the image for a larger version
As it happens, I found myself at QuartzFest in Arizona in the latter half of January, 2026 where we set up some banners proclaiming the existence of the Northern Utah WebSDR (link) - but I also scribbled on a small white board the words "QRM-Free Solar is possible - Ask How!".

Between the SDR, this message and the diverse portable HF antennas erected, I have had a lot of conversations over the past several days about these and many other topics, meeting new people and re-acquainting myself with others that I've seen on and off over the past several years of my attending QuartzFest (this is year #4 for me.)

RFI-less solar IS possible 

During the "Solar Walkabout" - an on-foot tour to look at how others camping have deployed their solar panels - I volunteered to have folks look at what I'd set up:  It's nothing obviously special - a glass-panel 200 watt Renogy folding array and another Renogy "flexible" solar array - but there is one major difference:  It does NOT produce HF QRM, meaning that I can plant my portable antennas near my panels and not get any interference on HF.

As I've done some previous articles on this, what I'll present here is mostly a set of links to those articles with a quick overview, but this effectively puts that information in one, handy place.

Let's start with quieting the Renogy solar charge controllers:

Reducing QRM (interference) from a Renogy 200 watt (or any other!) portable solar panel system- Link

Figure 2:
My humble, RF-quiet solar array at 2026 Quartzfest
Click on the image for a larger version.
The main issue with Solar charge controllers is that you have a "dipole + transmitter" situation:  The panels themselves do NOT cause RFI, but the charge controller is effectively a transmitter - especially if it's a PWM and/or MPPT-type - and the legs of the "dipole" are the solar panels (possibly long wires connected to large, rectangular pieces of metal) and another set of wires going to the battery - which also find their way around your RV/campsite via the inverters, DC wires, etc.:  It is no surprise at all that RF finds its way out of these things!  By adding filtering, we are effectively "shorting out" the the RF at the feedpoint of this hypothetical dipole and preventing it from radiating.

To quiet these panels, I added bifilar-wound ferrite toroids - but also bypass capacitors:  The toroids (ferrite) alone will probably knock down the QRM by 2-3 "S" Units, but if you are getting S-9+ interference from your solar, simply knocking it down to S-6 or S-7 when you are in the boondocks - where the natural noise floor is closer to S-1 or S-1 - is still pretty bad!

The key here is adding capacitors in addition to the ferrites and this method is perfectly capable of quieting even the noisiest of solar chargers.  It is also vitally important to put this filtering physically close to the noisy device and use good-quality bypass capacitors. 

Figure 3:
Filtering on the bottom of the Renogy controller
making it RF-quiet.
Click on the image for a larger version.

While the above blog entry showed a modest (200 watt) system, the above can be scaled up for higher-power systems:  Larger wire will handle more current and larger toroids will accommodate it!

RF Quieting a Samlex 150 watt Sine Wave inverter - Link 

Another component of RV/camping with power is the inverter to run mains-voltage devices, and these can be terrible noise sources.  The article above shows how it's possible to make one of these devices completely quiet.  For the older Samlex inverter - which was terribly noisy out-of-the-box, it is now quiet enough that I can power LED Christmas lights from it that are strong from the same mast as the antenna and I get NO RFI (the LED Christmas themselves don't produce QRM).

I was fortunate that there was enough room in the Samlex's case to be able to add this filtering, but it may be added externally as well, provided that the leads are kept short.

What follows below are some methods for quieting UPSs (Uninterruptable Power Supplies).  These are very much like the inverters in an RV in that they produce mains voltage from battery power - and the same problems with RFI occur:

A high-current DC (and AC) noise filter for UPS or RV use - Link

This shows a rather extreme example (an 8kVA UPS) where high currents are involved:  Such would be the case with a kilowatt-class DC-AC inverter or even a large PV system.

Containing RF noise from a sine wave UPS - Link

This article shows the techniques involved in quieting a lower-power UPS, but it also introduces some other components:  Rather than winding your own filter using toroids and wire, you can get "Line Filter" modules from electronic parts supplies (e.g. Digi-Key, Mouser) with brand names like "Corcom" or "Delta" (among many others.)  These are self-contained modules with the components built-in - available in a wide variety of voltage and current ratings - that can do an excellent job of filtering.

 

Completely containing switching power supply RFI - Link

This is an extreme example, but it shows how one might be able to make even the noisiest switching power supply quiet - and this might be important to someone who is trying to get every device in their ham shack - whether it be at home or on the road - quiet.  This method is foolproof in its effectiveness, but it is also likely overkill for many applications, but it discusses the "how and why" these techniques can work.

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I hope that this helps those who venture out in the wild with their RVs, solar power and battery system and still be able to operate HF.

This page stolen from ka7oei.blogspot.com

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Thursday, December 25, 2025

Neon bar-graph VSWR/Power meter using the ИН-13 (a.k.a "IN-13") "Nixie" - Part 3 (of 3)

Figure 1:
Power/VSWR meter using ИН-13 neon bar-graph indicators.
This was taken prior to installing the dark plastic to
improve contrast
Click on the image for a larger version
In Part 1 (link)  I talked a bit about the origination of the design - and how the high voltage for the Neon tubes were generated and how the tubes would be driven along with the "Tandem" power detector using the AD8307 logarithmic amplifiers. In part 2 (link) I showed how the tubes were connected and mounted, the laser-cut acrylic backplane and the associated LED-based edge lighting.

In this - the final installment - we'll see how it all goes together.

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As I'm wont to do, I used a PIC microcontroller for this - chosen because I'm more familiar with it than something like an Arduino - and something more "powerful" (an ESP or similar) would be overkill and arguably more difficult to implement as we'll see.

In the PIC environment I have used - for decades - the PICC compiler by CCS (Custom Computer Services) having started out with a very early compiler of theirs.  Programming in K&R C allows me to get pretty close to the "Bare Metal" of the microcontroller where I tend to write in low-level code and extensively use the interrupts and state machines to get things done.

Before delving right into details about the code, let's first look at the remainder of the schematic - and rather than make you, the reader, go back and look at previous installments, I'll include them all below in their entirety, starting with the controller and power supply.

Figure 2: 
Schematic of the controller and LV and HV power supplies.
Click on the image for a larger version.

The controller that I chose for this is the PIC18F1330 - an device in an 18 pin package that sports a built-in clock to permit operation at 32 MHz with no external crystal, PWM generators and a multiplexed 10 bit A/D converter.

High voltage control

As can be seen, "PWM1" is connected directly to our high voltage transistor, Q301 which is used to do a voltage boost, with R301 - a pull-down resistor - used to turn it off when the processor is in an indeterminate state.  As mentioned before, I tend to use state machines and interrupts heavily in my microcontroller code and with a PWM frequency of 31.25 kHz to generate the high voltage, I also have the interrupts occurring at that same rate, driven by the same clock source as the PWM.

Within the ISR (Interrupt Service Routine) there is a state machine that reads the A/D inputs - namely the high voltage, the forward power and the reverse power - but there's a catch here:  There is only ONE actual A/D converter - and this poses a problem.  Generating a stable high voltage requires a closed loop feedback - and with a processor there's always going to be a bit of delay, but what's worse is that since we have only a single A/D converter we must constantly switch it between the three voltage sources that we must measure - but this has several steps:

  • Set the A/D channel.  After doing this we must wait for a time for the A/D MUX switch to settle - but we can't afford to sit and "spin our wheels" in the ISR as we don't have the time:  While we are in our the ISR we really can't do much else.
  • Start the conversion.  Once our MUX has settled we can safely start our conversion.  This takes much longer than setting the A/D channel - but much shorter than our ISR period.
  • Get the result.  On the next ISR cycle the A/D converter will have finished and we can put the result in memory and set flags to indicate to the rest of our code that it's ready to be processed.
    • Note:  At this point we can conserve time a bit and upon getting our result, we can set the A/D channel for the next conversion:  This means that we get a new A/D reading every other ISR cycle.

 To minimize "lag" in our closed loop voltage control, I do the following "gets" of analog data:

  • Get the HV reading
  • Get the Forward power reading
  • Get the HV reading
  • Get the Reverse power reading

By alternatively grabbing the high voltage reading every fourth ISR cycle we can use this information to "tweak" the PWM duty cycle:  If the voltage is too high, we reduce the duty cycle slightly and if too low, we increase it - and this adjustment, within the ISR, is triggered by a flag that is set every time we get an update of its voltage.

Before we leave the discussion of the high voltage generator I'll note that it's triggered by the detection of RF:

  • Immediately on the detection of RF from the transmitter, the high voltage generator is activated.
  • About 3 seconds after the last detection of RF from the transmitter, the high voltage generator is turned off. 

According to the specifications, these neon tubes have only a limited lifetime - as is the case with any gas discharge tube that is glowing - so it makes no sense to "wear them out" unless there's information (e.g. a reading of RF power) to be displayed.  Additionally, the high voltage generator in my unit produces a just audible bit of RF interference in the form of weak "birdies" spaced at the 31.25 kHz PWM interval - and shutting off the high voltage generator soon after transmitting has stopped prevents their being heard.

Backlight control

Let's now look at the diagram of the backlight drivers.

Figure 3:
Tube and LED drivers - along with buffering from the power detectors.
Click in the image for a large version.

As can be seen there are three LED backlight drivers:  One for the Forward power using white LEDs, one for the Reverse power power using blue LEDs and another for the VSWR using Green LEDs.  In order to adjust the brightness, these are also driven by a PWM signal that is smoothed and fed to a the same sort of "precision current sink" circuit using an op amp and transistor as the Neon tubes themselves.

While there are other PWM channels on the PIC18F1330, I chose to use a "software" PWM as I already had available a rather fast ISR (31.25 kHz) that would be able to provide a smooth enough control voltage:  As can be seen in Figure 3, a 150k resistor and 0.1uF capacitor (e.g. R501 and C501, respectively for the "FWD" channel) are used to smooth the PWM signal - the two components providing a time constant of about 15 milliseconds (67 Hz).  In the ISR the "software PWM" uses 128 steps and at the 31.25 kHz rate this yields a frequency of about 244 Hz - about 4 times that of the R/C filter making it pretty much flicker-free while allowing a fast response time.

The way the "software PWM" works is that in the ISR there's a counter that goes from 0-127, and the value of this counter is lower than or equal to our desired PWM (brightness) value, the corresponding PWM output is turned ON - otherwise if it OFF.

Dimming LEDs in a "believable" way 

Before moving on from the LED brightness control, it's worth mentioning something about the way the human eye perceives brightness.  While the actual LED brightness varies quite linearly in proportion to the PWM setting of 0-127 (off to fully "on"), if we wanted to slowly dim the LED from full brightness to off - and we simply decremented the value from 127 down to 0, our eyes would perceive it as dimming slowly at first - and then suddenly going out.  Perhaps it's my OCD kicking in, but I prefer a dimming LED to seem to fade out to nothing - and do so gradually without it perceptibly "snapping" off.

My intent is that when RF power is detected, the relevant backlight LEDs (always the "Forward" LED and the "Reverse" or "VSWR" as selected) are immediately turned on - but 30 seconds after RF is detected they are turned off.  As I found a "sudden turn-off" to be visually jarring, I decided to dim the LEDs slowly - but based on past experience with driving LEDs I knew that to make them visually dim "evenly" would require a bit of extra math.

The trick here - to set the dimming so that it seems to gradually fade out to nothing - is to use a fourth root and a bit of multiplication as follows:

  • Start with the brightness value of 0-127
  • "Invert" this value by subtracting it from 127 (now it's 127 to 0)
  • Multiply by 128 (this can be done by shifting the bits left seven times if using an unsigned integer)
  • Take the square root
  • Multiply by 128 again
  • Take the square root again
  • Subtract that value from 127
 The result of the above is a more visually pleasing "dimming" of the LED - one that appears - to the eye - to fade out "evenly" to extinction.

Calculating the RF power and VSWR

One advantage of using the AD8307 logarithmic amplifiers is that it gives us a reading in db per volt to the tune of about 25 millivolts per dB - and we can calculate return loss very easily - simply by subtracting the reverse from the forward readings.

Figure 4:
The ИН-13 neon bar-graph Wattmeter/VSWR bridge showing
the instantaneous forward and reverse powers, with the
neutral-density filter installed.  (Very difficult to photograph!)
Click on the image for a larger version.

Return loss - while representing reflected power - is not how most hams think about reflected power - and VSWR is voltage - not power.  What we need to do is to translate our return loss to VSWR and the easiest way to do this is with a table - rather trivial to do in a microcontroller.  As we don't really need a lot of resolution on our VSWR meter (it's enough to represent "tenths" of a VSWR reading between 1.0 to 3.0 - and subsequently lower resolution than that at higher VSWR) the table need only consists of a couple dozen entries in the form of cascading "if-then" statements that spit out the VSWR directly.

We could do it with logarithms and floating point math, of course, but that's overkill!

As for calculating power in watts, there's no need for this:  If you look closely at the Forward Power scale in Figure 1 you'll note that it is already logarithmic:  The A/D values are simply offset and scaled to the PWM values needed to drive the tubes to the designated markings!

Peak and average values

As the power level of an SSB waveform is very "peaky", most analog meters only provide something roughly resembling an RMS value since they cannot move fast enough to capture the peak.  As we get new forward and reverse values every eight ISR cycles our update rate for the power readings is around 3.9 kHz.

As the bandwidth of a standard SSB signal is on the order of 2.5 kHz, we are sampling our power more frequently than its fastest rate-of-change and this means that not only are we likely to be able to capture a reasonably accurate representation, but also be reasonably assured that our forward and reverse power reading samples - which are about 128 microseconds apart - will also represent the same part of the the waveform:  Were this not true the VSWR readings could be "smeared" with the power changing between the instants that the forward and reverse power samples were taken.

As it happens, we really don't need the ultimate in temporal resolution for VSWR, so the calculation of "return loss" can be averaged a bit with no ill effects - and, in fact, the VSWR reading is quite stable at the widely disparate power levels intrinsic to SSB, anyway.

The code itself does have "peak" and "average" modes and the former uses a "sliding peak" detection - that is, it has a bit of a "hang time" on the output sent to the forward and reverse power displays to better-indicate the peak value and visually hold it.  The "average" power is more of a "sliding average" over the past hundred milliseconds or so and results in a "busier" display, with more movement.

Tube calibration

A quick look at the data sheets for the ИН-13 tubes will reveal that they are not well calibrated in terms of "milliamps-per-millimeter" with a fair bit of variation being allowed.  The ИН-13 tubes have lines painted on them at the factory indicating the "low" end (near the wire pinch) and the "high" end (near the tip) and these represent the useful and linear range over which the current can be represented.

The firmware thus includes - for each tube - a set of calibrations, accessible by the "mode" buttons in Figure 2 - that can be used to set the bottom and top of the scale.  This process will yield the needed PWM values - and thus the current - for the low and high end of the display and in so-doing, our microcontroller will "know" how to scale each tube to indicate with the best-possible accuracy.

Having been using this device for several years, now, I have observed that the tube sensitivity changes more with temperature than aging - but as it's not intended to be a "precision" indicator of power:  I only check the bottom/top scale calibration every year or two and have resisted the temptation of including temperature compensation.

Final comments

The only change that I made to this device after its construction was to add a sheet of 70% (dark) theater gel in front of the display to improve contrast.  While the neon tubes themselves and the laser-etched plastic look cool on their own, the display looks a bit "cluttered" unless a somewhat dark piece of plastic covers everything:  While this does dim the display a bit, the dark plastic - since it affects both the incoming and reflected light - offers the illusion that the display is brighter as the contrast is improved.

If you have any questions about this project (including underlying code and/or hardware) please let me know via a comment, below.

* * * * *

This page stolen from ka7oei.blogspot.com

[END]








Thursday, November 27, 2025

Adding ALC and overdrive protection to the MFJ ALS-500M "500 watt" amplifier

Figure 1:
The ALS-500M front panel.  Because this
this unit is equipped with the 10 meter low-pass
filter, the "AUX" position on the front panel
switch is used to select 10/12 meters.
Click on the image for a larger version.
The MFJ ALS-500M is a (nominally) 500 watt amplifier that was produced by MFJ, capable of covering from 160 meters through 15 meters - and 12/10 meters if so-equipped.

If you own an ALS-500M, you may have realized that it is a bit awkward to use:  If you are using it with a 100 watt radio, driving it with this much power will not only cause it to be badly overdriven - causing terrible on-air distortion on an SSB signal - but it will likely cause damage to the amplifier itself by throwing about twice as much power at it as it needs to work properly.  For this reason one must use a 50 watt radio (does one even exist?), one that puts out much less power (not taking advantage of the full-power output of the amplifier) or, more likely, always remember to turn down the output of a 100 watt radio and hope that it doesn't have a problem with "overshoot" (an issue described later).

To understand the problem, a friend's ALS-500M was powered from a variable-voltage supply with known-accurate wattmeters - one on the input to measure drive power and another to measure the output power, the amplifier itself terminated in a known-good 50 ohm load.  This same test set-up included a known-accurate DC ammeter as it was determined that the ALS-500M's own ammeter wasn't particularly accurate.

With this set-up, the characteristics of a friend's ALS-500M were measured on most amateur bands in terms of input and output power, at both 14.5 and 12.5 volts from the power supply.  (The voltage at the amplifier was lower than this due to resistance of the factory-supplied DC power cable.)

Freq (kHz) PWR In PWR Out DC Voltage DC Current
1825 5 65 14.5 18

8 180 14.5 31

22 300 14.5 43

30 410 14.5 52

45 525 14.5 60

60 600 14.5 63.5

6 82 12.5 21

22 300 12.5 43

30 450 12.5 56

45 480 12.5 59

65 500 12.5 63





1975 6 90 14.5 23

20 350
45

33 480
56

45 560
63

60 600
66.5

33 425 12.5 53





3650 6 80 14.5 23

20 290
47

36 425
60

50 500
66

62 500
70





3850 6 78
22

19 300
45

33 410
57

50 450
61

63 490
67

33 370 12.5 54





5371 6 95 14.5 27

18 340
52

34 480
64

50 525
71

34 380 12.5 60





7050 4 85 14.5 22

18 350
47

30 400
53

52 460
59

33 350 12.5 50





7250 5 87 14.5 23

18 350
46

33 410
53

52 480
58

33 350 12.5 49





14225 4 95 14.5 26

18 310
47

34 380
53

52 400
56

33 290 12.5 47.5





18100 5 75 14.5 22

20 210
37

35 260
41

55 300
44

35 200 12.5 36





21250 6 95 14.5 23

24 210
35

37 275
38

56 280
39

37 200 12.5 33





28345 5 68 14.5 25

22 275
50

34 325
55

52 390
62

34 300 12.5 53

From this data we can determine several things:

  • There are no instances where more than 50 watts drive is useful.  If you were to graph the input versus output power in the above chart you would see that the curve "flattens" by the time you get to about 50 watts drive meaning that further increases of input power do not result in the same proportion of increase in output power.  It is at this point that the amplifier is becoming very non-linear and severe distortion of SSB and AM signals will result if one attempts to drive it to still-higher output power.
  • While described as a "500 watt" amplifier, this is clearly optimistic. While barely capable of about 600 watts at 160 meters, the maximum usable "clean" (non-distorted) output drops to about 400 watts at the highest band, 10 meters.  This effect is due to physics:  The transistors in the amplifier are simply less capable at higher frequencies.
  • The power output is lower with a 12.5 volt supply than a 14.5 volt supply.  This is also due to physics and clearly specified in the manual:  You'll get 25-100 watts less output at the lower voltage, depending on the frequency and drive power.

Too much power is NOT a good thing!

The ALS-500M manual clearly warns against driving with too much power for the reasons mentioned above, but in addition to producing a bad-sounding signal on the air, feeding too much power to the amplifier (more than about 60 watts) is significantly exceeding the specifications of the (expensive!) transistors and it will dramatically increase heating of the components:  On this test amplifier, even briefly driving it at 65 watts caused the input power resistors to overheat slightly, resulting in an obvious smell, not to mention completely "flat-topping" (severely over-driving) it.

Why no ALC?

Since at least the 1960s both amateur transmitters and amplifiers have included an ALC (Automatic Level Control) circuits.  In a typical amateur transmitter, this circuit monitors the transmitter's output power and if it exceeds the pre-set threshold (e.g. 100 watts for a radio rated at 100 watts) it will send a signal back to reduce the output power.  RF amplifiers have a similar circuit:  It detects the amount of RF being output and sends a negative voltage back to the transmitter driving it.  If the output of the amplifier gets too high, this voltage causes the transmitter to reduce its drive power.

In both cases this circuit does two important things:

  1. Prevents excess drive to the amplifier(s), which prevents distortion of the transmitted signal.
  2. Preventing damage.  All amplifiers have electrical and thermal limits above which they may be damaged and/or their operational lifetime may be dramatically shorted. 

Despite most commercially-produced amplifiers made for the past 60 years having a circuit to produce an ALC voltage to feed a radio the ALS-500M does not - which is all the more confusing as this circuit is not complicated at all:  Having this circuit would help in the prevention of grossly overdriving the ALS-500M and having bad signals on-air and it may have saved many ALS-500M's from damage.

Adding an ALC circuit

As it made sense to do so, an ALC circuit was added to my friend's ALS-500M:

Figure 2:
This is the schematic of the ALC circuit.  It develops a negative voltage related to the RF output
power that is fed into the transmitter driving it.  When properly adjusted, this feedback loop will
limit the maximum drive to the amplifier, reducing the probability of distortion and damage.
Click on the image for a larger version.

 The circuit is quite simple - consisting of just TEN components including the output jack.  Here's how it works:

  • J1 is the existing "RF Out" jack on the ALS-500M, an SO-239.
  • Resistor R1, attached to the RF Out connector, samples the transmit power.
  • Resistor R2 - with R1 - form a voltage divider:  At 500 watts into 50 ohms with R1 being 12k, there would be 447 peak-to-peak volts on the RF Output, but it is divided to 34 volts peak-to-peak at the junction.
  • Capacitor C2 couples the RF to diodes D1 and D2, blocking DC.
  • Diode D1 clips the positive-going voltage and together with D2, forms a voltage doubler circuit.
  • Capacitor C3 filters the output of diode D2 - a negative voltage -  removing residual RF.
  • Potentiometer R3 allows adjustment of the produced ALC voltage so that the proper threshold may be set for the transmitter being used to drive it.
  • Capacitor C4 further filters any RF from the ALC line.
  • J2 is a phono ("RCA") jack used to connect the ALC voltage to the driving transmitter.

Here are links to a few of the more difficult-to-get parts:

Frequency compensating capacitor C1

Capacitor C1 requires more explanation.  Real-world components aren't like their "ideal" theoretical counterparts and resistor R1 is no exception:  Even though it is a "resistor", it has some capacitance - albeit small - plus there is some stray capacitive coupling between the center pin of the RF Out connector and the nearby components.  Because of this, at higher frequencies, some RF energy "leaks" around R1, causing more voltage to appear at the junction between it and R2:  This higher voltage would cause more AGC voltage for a given power level and in testing, while 500 watts produced about -37 volts at the top of R3 on 80 meters, it took only about 150 watts to produce that much voltage on 10 meters.

Figure 3:
The as-built ALC circuit built atop the RF OUT connector,
using it for component support.  To the right of the large
resistor is the ALC adjustment potentiomteter and jack below.
Click on the image for a larger version.

We actually want this roll-off at higher frequencies to occur for the simple reason that the ALS-500M cannot output the same "maximum" power on each band - this level decreasing as frequency goes up - but as we can see from the table, whereas we could "safely" output about 400 watts at 80 meters at 12.5 volts, we'd probably want no more than 325 watts or so at 10 meters, so our ALC output voltage should be the same at those two power levels.

Capacitor C1 - placed across R2 - "compensates" for this:  Being a capacitor, it has lower impedance at increasing frequency and we can select its value to give us about the same ALC voltage at 400 watts on 80 meters as 325 watts would on 10 meters.  For the ALS-500M and our circuit, a value of 6.8pF turned out to be about right - but this would vary with components:  A variable capacitor (something adjustable over approximately the 2-15pF range) would allow easy adjustment of this compensation.  A suitable device is this

 Construction of the ALC circuit

Figure 4:
Another view of the ALC circuit.   R1 is the
large resistor, C2 in the foreground, C1 is the
large capacitor in the bacground.
Click on the image for a larger version.

Figures 3 and 4 show how the ALC circuit was laid out atop the "RF Out".  In the top-center of Figure 3 we see the "RF Out" connector and R1, the 12k resistor and clustered around R1 - and using the ground lug (plus an added lug) on the "RF In" connector we see the other components.  Just to the right of center in Figure 3 - between the RF Out connector and the DC connector we see R3, a 10k potentiometer and below it - partly obscured by R3 - is the "ALC Out" jack.

Figure 5 shows the rear panel of the amplifier - the "ALC ADJ" potentiometer (R3) near the top and the Phono (RCA) plug below it - both labeled.  Looking at the label of the ALC ADJ control, you will notice that the label shows that rotating it counter-clockwise will result in "minimum" power - but this corresponds with maximum ALC voltage.  While this may seem counter-intuitive, remember that the the more negative the ALC voltage, the more it will try to reduce the output power of the transmitter - but if the potentiometer were turned fully clockwise (no ALC voltage at all) it would be the same as disabling the ALC altogether.

In testing with an Icom IC-7300, setting the ALC control to "Min" (e.g. maximum ALC voltage causing the greatest amount of power reduction) resulted in no more than about 80 watts out of the amplifier, no matter the "RF Output" setting on the radio and this indicated that the ALC was doing its job.  Setting the ALC control for about 425 watts at 80 meters resulted in about 325 watts on 10 meters, maximum - both within the "linear" and safe range of the amplifier.

Figure 5:
The rear panel of the modified ALS-500M.  The ALC adjust
potentiometer is between the RF OUT and DC IN connectors
with the added "ALC OUT" jack below.
Click on the image for a larger version.

ALC Overshoot and other anomalies

In many radios, ALC isn't perfect:  There will be a slight lag in many radios between the appearance of the ALC voltage and the radio's cutting back in transmit power - some of this being due to the radio itself having "ALC Overshoot" and some being due to the ALC voltage from the amplifier being a bit slow to respond.  What this means is that it is possible for the radio to briefly output WAY more power than expected for a brief instant before throttling back.

On the air, this can cause a burst of amplifier overdrive at the beginning of words/syllables - often showing up as a "popping" (or "clicking" on CW during key-down) and over time, this burst of high power could damage the transistors and other components in the amplifier.  What this means is that you SHOULD NOT rely entirely on the ALC to limit the output power - you should, at the very least, turn down your transmit power to about 50 watts or so even if you have the ALC.

Figure 6:
Rather than remove the Filter board to get access to the
T/R relay, the cable that had connected to the input of the
amplifier deck was soldered to the ground plane to allow
splice a piece of RG-316 to reach the new attenuator on the
back panel.
Click on the image for a larger version.
Some radios have another problem:  They can do ALC overshoot even without an external amplifier - briefly driving their own amplifier  to much higher than expected power.  Some radios - even if you turn the power down - rely on feedback from their built-in wattmeter and will briefly output higher than the desired output power.  Both of these mean that you could still end up with a somewhat "dirty" signal on the air even if you believe you have taken steps to prevent it.

Overdrive protection:  Adding a 3dB pad.

While adding ALC to the ALS-500M is a "no-brainer", it would be easy to forget to connect the ALC - or your radio and amplifier combination could still cause the "popping" or "clicking" from brief overdrive conditions even if you turn down your power and/or connect the ALC.  To prevent this, it would be a very good idea to prevent too much power from ever reaching the amplifier circuitry itself.

Figure 7: 
The 3dB (actually 2.995dB)
"Pi" resistive attenuator.  At 100 watts
input approx. 16.7 watts is dissipated in R1,
around 24.5 watts in R2, and about 8.8 watts
dissipated in R3 - about 50 watts total.
Click on the image for a larger version.
As you can see from the chart above, there is never a frequency or band combination where more than 50 watts drive would yield clean output power.  What this means is that we could lose half of the drive power of a 100 watt radio and still push the amplifier to its useful limit - and protect its expensive transistors and other circuitry against an accidental "oops" should we accidentally overdrive it.

The addition of a 3dB attenuator would accomplish this, soaking up half the transmit power before it gets to the amplifier allowing the user to set their radio to 100 watts output.  The easiest place to install this attenuator would be on the input of the amplifier - but this would also affect the receive signal by about 1/2 "S" Unit:  If your S-meter reads well above S1 on even the quietest band, you won't "miss" any signals by doing so:  A 100 watt 3dB "pad" can be found commercially and on the surplus market if you look carefully.  The other down-side of having a 3dB pad inline would be that if your turn the amplifier off, you are still losing half of the transmit power.

Figure 8:
Holes drilled in the back panel in preparation
for mounting the power resistors used for the
the 3dB attenuator.
Click on the image for a larger version.
A technically "better" solution would be to place the 3dB attenuator right on the input of the RF power amplifier circuit, inside the amplifier.  Doing so avoids placing this loss in the receive path and it will also not affect the transmit signal when the amplifier is turned off.  Figure 7 shows this attenuator schematically.

These resistors must, collectively, be able to dissipate 50 watts of power and rather than trying to assemble a large mass of lower-wattage resistors, we can use thin or thick film power resistors in transistor-like package which may be bolted to a heat sink. For the ALS-500M, there is a flat area on the rear panel that is next to amplifier deck and large enough to accommodate these resistors and dissipate the power dropped.  Examples of suitable resistors include:

  • 18 Ohms, 100 watts:  Bourns (Riedon) PF2472-18RF1  (DigiKey P/N:  696-PF2472-18RF1-ND - link)
  • 300 ohm, 100 watts:  Bourns (Riedon) PF2472-300RF1  (DigiKey P/N:  696-PF2472-300RF1-ND - link)

Figure 9:
The three resistors comprising the attenuator, mounted on
rear panel of the amplifier for heat sinking.  The white
RG-316 coax from the T/R switch comes in from the left
while that going to the amplifier input goes to the right.
Thermal paste is used under the resistors' tables to enhance
thermal conductivity to the case.
Click on the image for a larger version.
These particular resistors are "Thin Film" and their construction is such that while not intended specifically for RF applications, they work perfectly well at HF and into VHF for a non-critical application like this - plus they are relatively cheap!  These resistors have metal heat sinks, but these are isolated from the resistor elements within, having only a few 10s of pF of capacitance coupling between the internals of the resistor and the ground when bolted to the case.

The coaxial cable from the T/R switch to the input of the amplifier will need to be extended (carefully splicing the two together, minimizing the length of the ground/shield connections) to reach the resistors when mounted on the rear panel:  RG-316 PTFE coaxial cable was used for this (but RG-174 would have been fine at this power level) and the short jumper that connected from the output of the attenuator, back to the input of the amplifier.

Figure 9 shows the attenuator, mounted to the back panel of the radio with a small amount of thermal compound:  The RF power from the T/R switch enters from the left and one leg of 300 resistor R1 is connected directly to the shield of that piece of coaxial cable.  The center conductor then connects to the junction of it and R2.  On the other side of R3, the process is repeated, the shield of the coax tied to the shield as well:  This cable then connects to the input of the amplifier module.  Between R1 (on the left) and R3 (on the right) is a piece of 12 AWG (2mm) wire that connects together the shields of the "in" and "out" coaxial cable at opposite ends of the attenuator.

Figure 10:
An internal view of the amplifier, showing all mods.  The
white cables in the foreground are to/from the 3dB rear-
panel attenuator and in the upper-left can be seen the
circuitry that was added for the ALC.
Click on the image for a larger version.

Final results:

While it might seem wasteful to throw away half of the drive power, doing so protects the power amplifier from being damaged by overdriving when one inevitably forgets to reduce the output from the transmitter.  It also protects those that might be listening on the air to a badly distorted signal:  Adding the ALC circuit is, I believe, a necessary addition as this helps prevent even mild overdriving of the amplifier that is still possible under some conditions - even with the added attenuation.

* * * * *

This page stolen from ka7oei.blogspot.com

[END]