Difference between revisions of "800 MHz Exciter"

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=== 800 to 900 MHz ===
 
=== 800 to 900 MHz ===
 
== R1 to R2 ==
 
  
 
The basic premise of converting the 800 to 900 MHz is four major parts:
 
The basic premise of converting the 800 to 900 MHz is four major parts:
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* Change the module ID  
 
* Change the module ID  
 
* Change the module version ID
 
* Change the module version ID
 +
 +
This should cover the entire 902-928 MHz ham band after the conversion, and up to 941 MHz for the commercial band.    This is wide enough to cover the 12 MHz offsets of the older 33cm ham band.  The issue will be the tuning values may not work that far from the alignment points.  If you have the EPIC 3 SCM it will not work outside the frequency limits of 935-941 MHz, and there is no work around for this (even with a real 900 MHz unit).
 +
 +
It's important to ensure commercial band coverage as the unit will align on 935.025 and 940.0975 MHz.  If the VCO can't lock, it cannot align.
  
 
It's important to have a known good working 800 MHz unit before starting work.  If it is not working at it's intended frequency, fix it first.   
 
It's important to have a known good working 800 MHz unit before starting work.  If it is not working at it's intended frequency, fix it first.   
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=== Converting VCO ===
 
=== Converting VCO ===
  
The main interest for us will be in the VCO section of the board.  This VCO is covered by a shield with a tuning capacitor visible through it.
+
The main interest for us will be in the VCO section of the board.  This VCO is covered by a shield with a tuning capacitor visible through it. There is a single VCO which covers the entire band, of 850-870 MHz, and we'll be moving this up to 915-935 MHz.  Note the 900 MHz excirer has less range than the 800 exciter, this is due to the smaller tuning range needed and C3209. 
  
Check out the schematic! The Diagram is wrong when it shows the upper and lower VCO!
 
  
 
[[File:UHF Receiver Models TRE6281-TRE6282-TRE6283-TRE6284 VCO correction schematic.png|thumb|Reversed VCO's]]
 
[[File:UHF Receiver Models TRE6281-TRE6282-TRE6283-TRE6284 VCO correction schematic.png|thumb|Reversed VCO's]]
  
The VCO substrate is ceramic, and sensitive to thermal shock, so be careful about this, as it will crack.  I prefer to leave the VCO in place attached to the pins supporting it on the main PCB while working on itTo do this means the copper case must come off in one piece with out letting the board drop from the pinsObviously the problem with this is to get the VCO hot enough to remove the case will cause the pins to reflow as well.
+
The VCO is covered by a solder on shieldThis shield must be removed before we can retune the VCO.   
 
+
First mask of the area with some kapton tape of other heat shieldThe other compounits will melt if not for thisA board preheater and 610 F at 15 l/m of air flow from a hot air wand will have the shield off in in about 60 seconds.  
Prior to preheating I fashion supports out of aluminum foil or other material and jam them between the PCB and the underside of the VCO. I find one at the bottom middle and two on the top corners is sufficientIt's important there be some slight upward tension on the PCB from these supportsThis will prevent the VCO board from falling off it's pins when removing the shield.
 
 
 
Once this is done, mask off the area using hole cut in some foil. This is a heat shield for the other parts of the board. Some times you need to use kapton tape to secure the foil in place.
 
  
 
[[File:UHF RX prepped for desoldering.jpg|thumb|UHF RX prepped for desoldering]]
 
[[File:UHF RX prepped for desoldering.jpg|thumb|UHF RX prepped for desoldering]]
  
Setup the board with an under board pre-heater set to 460f. This is important as you want the board to warm up to close to the melting point of solderThen the hot air wand will heat it the rest of the way.
+
After about 60-90 seconds the shield should lift right off. Be careful and pull the shield straight up.  The other parts under the shield will have been reflowed, and the slightest nudge will move them off the boardOnce it's flowed, and while keeping the heat moving on the VCO case, pull the case straight up with some needle nose pliers. The case should come clean off, though you may need to rock it back and forth a bit.
 
 
[[File:Board_Preheater.jpg|thumb|Underboard pre-heater]]
 
  
Once you have this preheated for a few minutes, use the hot air wand with no tip  15 L/m and 650f on the shieldMove it in a circular pattern while waiting on it to reflow.  A dental pick is a good test for reflow, be aware the solder will not all flow at the same time.
+
If you do move some of the parts by accident, look at the picture below and try to get them back in the same spotThere really is not much under the VCO that will move.
  
Once it's flowed while keeping the heat moving on the VCO case, pull the case straight up with some needle nose pliersThe case should come clean off, though you may need to rock it back and forth a bit.
+
This shield will make the VCO frequency go up by about 2 MHz when in place as wellKeep this in mind for tuning the VCO; it's best to be 5-6 MHz low with the shield off.
Careful you don't disturb any of the VCO parts, as they will most likely be reflowed. If you do, don't panic, just look at the before picture and put everything back to how it was on the VCO. It's a pretty easy circuit to figure out.  
 
  
 
Now the VCO should be exposed and you can tack on some test wires to it while it cools down.
 
Now the VCO should be exposed and you can tack on some test wires to it while it cools down.
Line 80: Line 75:
 
[[File:UHF_RX_VCO_hooked_up_for_mod.png|center|thumb|widths=300px|heights=300px|UHF RX VCO test points]]
 
[[File:UHF_RX_VCO_hooked_up_for_mod.png|center|thumb|widths=300px|heights=300px|UHF RX VCO test points]]
  
Hook up to the VCO as shown, we'll do the Low VCO first.
+
Hook up to the VCO as shown, and remove the Lxxx for the  
  
* 8.5 V power to high and low VCO (not at the same time).
+
* 8.5 V power to VCO.
* 0-12 V on the steering line.
+
* 0-9.2 V on the steering line.
 
* output loops of wire on the VCO output. These are to be looped around a probe and into a spectrum analyzer to view the output.  
 
* output loops of wire on the VCO output. These are to be looped around a probe and into a spectrum analyzer to view the output.  
  

Revision as of 02:26, 1 September 2016

This page covers the 800 MHz exciter in technical detail. This exciter is similar to the 900 MHz exciter and shares the VCO design. The UHF R0 exciter has this same sort of VCO design as well.

Basics

The 800 MHz exciter is pictured below. It's designed to 850-870 MHz commercial band with 12.5, 20 or 30 KHz channels using FM, VSLEP or P25 modulation formats. Like the other exciters in the Quantar series, it can switch rapidly between digital and analog formats.

pictures!

The 800 exciter are similar to the other exciters with the major exception of they only have one VCO (upper) to cover the 20 MHz tuning range. This tuning range is only 2%, where as the tuning range of a single UHF VCO is closer to 3.2% for 16 MHz of tuning range. As is the VCO is discrete parts we have a schematic of it available which really helps.

The Exciter uses the standard truth table for both the exciter ID (VHF/UHF/800/900/etc.) and the board revision. I have little ideal what the board revision is used for.

The Exciter has a CPU with firmware required to control it and reports to the station controller over a SPI bus. There is 1k of EEPROM used for storing the tuning values for the exciter and power amp in the the CPU. This allows you to tune a PA/Exciter and move it between chassis with out needing to retune. The firmware is stored on a 27C512 EPROM, and as of the current writing (Aug-2016) 020.09.018 is the most recent firmware.

The Exciter controls the PA and will shut down if the PA is not present or detects an error.


The service manual excerpt is in PDF and below.


PDF LINK

In PNG format.


Conversions

800 to 900 MHz

The basic premise of converting the 800 to 900 MHz is four major parts:

  • Convert the VCO for the proper frequency coverage
  • Change the module ID
  • Change the module version ID

This should cover the entire 902-928 MHz ham band after the conversion, and up to 941 MHz for the commercial band. This is wide enough to cover the 12 MHz offsets of the older 33cm ham band. The issue will be the tuning values may not work that far from the alignment points. If you have the EPIC 3 SCM it will not work outside the frequency limits of 935-941 MHz, and there is no work around for this (even with a real 900 MHz unit).

It's important to ensure commercial band coverage as the unit will align on 935.025 and 940.0975 MHz. If the VCO can't lock, it cannot align.

It's important to have a known good working 800 MHz unit before starting work. If it is not working at it's intended frequency, fix it first.

It would be good to become very familiar with the schematic and service manual before attempting this.

Tools and test equipment you should have (not an exhaustive list)

  • Hot air station
  • Under board pre-heater
  • High quality soldering iron (metcal)
  • Dual voltage variable DC supply
  • Spectrum analyzer and probes
  • Service monitor
  • Experience working with SMD and reflow techniques

Converting VCO

The main interest for us will be in the VCO section of the board. This VCO is covered by a shield with a tuning capacitor visible through it. There is a single VCO which covers the entire band, of 850-870 MHz, and we'll be moving this up to 915-935 MHz. Note the 900 MHz excirer has less range than the 800 exciter, this is due to the smaller tuning range needed and C3209.


Reversed VCO's

The VCO is covered by a solder on shield. This shield must be removed before we can retune the VCO. First mask of the area with some kapton tape of other heat shield. The other compounits will melt if not for this. A board preheater and 610 F at 15 l/m of air flow from a hot air wand will have the shield off in in about 60 seconds.

UHF RX prepped for desoldering

After about 60-90 seconds the shield should lift right off. Be careful and pull the shield straight up. The other parts under the shield will have been reflowed, and the slightest nudge will move them off the board. Once it's flowed, and while keeping the heat moving on the VCO case, pull the case straight up with some needle nose pliers. The case should come clean off, though you may need to rock it back and forth a bit.

If you do move some of the parts by accident, look at the picture below and try to get them back in the same spot. There really is not much under the VCO that will move.

This shield will make the VCO frequency go up by about 2 MHz when in place as well. Keep this in mind for tuning the VCO; it's best to be 5-6 MHz low with the shield off.

Now the VCO should be exposed and you can tack on some test wires to it while it cools down.

UHF RX VCO test points

Hook up to the VCO as shown, and remove the Lxxx for the

  • 8.5 V power to VCO.
  • 0-9.2 V on the steering line.
  • output loops of wire on the VCO output. These are to be looped around a probe and into a spectrum analyzer to view the output.

A few points about VCO tuning:

  • The VCO will be 73.35 MHz higher than the intended receiver frequency
  • the sweet spot for the VCO steering voltage is 2.5-7.5 v
  • each VCO is designed to cover half the range of the quantar.
  • The Exciter will change VCO's when it hits the range's center frequency +25khz (UHF R2 is MHz) . You can verify this my looking at the steering voltage in the exciter as you change frequencies. A test config file (Codeplug) makes this easy.
  • with the shield on they move up about 2.5 MHz
  • from hot to cold Fr changes about 1.5 to 2 MHz. Hotter makes Fr go down, cool makes it go up.
  • removing capacitance makes Fr go up.
  • removing inductance makes Fr go up.
  • tune a bit below the frequency (2 MHz) and adjust the tuning caps
  • you may elect to move the center frequency lower on the lower VCO and higher on the high VCO if you desire a greater tuning range. I will not be showing this.
  • Get it close, I'm a perfectionist, but really 1-2 MHz from idea will not matter.
  • at higher steering voltages (>9v) the VCO may get dirty. This is normal.

Put 5.0v on the steering line and note the frequency on the spectrum analyzer. You can sweep it from low to high and check the coverage is correct per the table above (it will be about 2MHz higher with the case off).