All posts by Martin Blustine

I studied physics and went on to work in infrared optics, millimeter wave and microwave engineering until retirement. My interests lie in teaching, music, radio astronomy, infrared systems and microwave and antenna engineering. I enjoy writing technical papers about ham radio topics. When I am not operating CW, I enjoy homebrewing ham gear and restoring vintage HP and Agilent test and measurement equipment.

Control Your Rig Remotely With This USB-Controlled Power Station

Introduction

Remote station operation has become more popular now that several rig manufacturers offer accessories to enable the radio amateur to do so. However, there is usually a large expense associated with acquiring these accessories. For some, it may not be cost-effective to own them for occasional use. In this article, we describe a solution for remote operation from another room of your home, your yard, or while on travel. It is also convenient for controlling on/off functions in the shack with the click of the mouse. The solution revolves around a Velleman relay card that can control a number of relays from a computer desktop.

The Power Station

This article describes a USB-controlled AC power strip, Figure 1, that was built around the Velleman K8090 8-Channel Relay Board in kit-form [1]. Varistors were added to the board as a recommended option [2]. The board can also be purchased fully assembled [3].

Figure 1. USB Controlled Power Strip. Each 15A duplex outlet is under USB control. There are just enough contacts on the barrier strip for 8 relays, neutrals, and grounds.

The PC communicates to the board via USB. A free, desktop, graphical user interface (GUI) is provided by Velleman for use as test software, or you may opt to purchase an application such as N-Button Lite [4].

Some type of rig interface is required to control your rig and audio from a PC. You may use the interface in your rig if it has one, or buy or build one of your own.

In order to log onto your computer, see your desktop remotely and hear rig audio, some kind of conferencing software is required. I use TeamViewer [5] to see my desktop and hear computer audio remotely.

Cautionary Notes

You will be dealing with AC line voltage in this project. Keep the clear polycarbonate cover on the enclosure while AC power is applied. Since the Velleman card operates on 12 VDC and control is over USB, all testing can be completed prior to plugging the AC line cord into the wall socket.

The FCC requires some means to disable the transmitter within 3-minutes if something goes wrong during remote operation. Velleman makes a WMT1206 Universal Timer Module with USB Interface [6] that should prove useful for this application. Its relay can handle 8A of AC. There are also similar USB timer modules available on eBay. It’s also a good idea to have the ability to reboot your computer remotely. The exact details of how to implement this FCC requirement are left to the reader but there are plenty of suggestions to be found online.

Kit Construction

An experienced kit builder can assemble and test the board in an afternoon. The added varistors are specified at 125J, 300VAC, 385VDC, and 4500A clamping peak current [7]. If these are not readily available, there are equivalents. A suggestion was made to thicken the circuit board traces that must handle the 16A relay current with additional solder. I didn’t care for this approach and opted to solder bus wire onto these traces, instead. You might find it ludicrous to solder #14 AWG buss wire onto the board, so your other option is to derate the relay capabilities to what the conductors can safely handle since the PCB traces have not been rated. For example, the ampacity of #20 AWG buss wire is at least 5A (11A at 75°C) [8], and that will be good for 575W. None of the circuits that I run from this PCB require anywhere near 575W.  Take care not to damage the PCB traces while soldering. Excessive heat will lift the PCB traces.

Housing, Connectors, and AC Outlets

There are 8 duplex outlets in this project – each one under separate relay control. Each outlet has been wired with #14 AWG. Each relay is rated at 16A, resistive load (see the previous section for derating). The duplex outlets have been spaced far apart so that a variety of line cords and wall adapters will fit without interference. The control board is housed in a Bud Industries PN-1340-C polycarbonate enclosure [9] with a clear cover (not affixed), Figure 2. The clear cover provides visibility for the status lights on the PCB. Bud Industries also manufactures an internal aluminum panel, PNX-91440 [10], upon which the PCB and barrier strip have been mounted. Take care in locating connectors on the housing or the PCB will not fit. The PCB is fastened to the aluminum panel with 4-40 hex standoffs. The Bud Industries enclosure is fitted with 1/2-inch male terminal adapters [11] at either end. DC power for the relays enters the enclosure at the top left through a 2.1mm panel mount connector [12]. The relay power required is 12VDC at 400mA. A 12 VDC wall adapter with a 2.1mm plug can provide this voltage. AC power enters the housing through a cable gland at the lower left. Switchcraft makes the USB connector at the lower right. It converts USB A inside the enclosure to USB B on the outside. The connector was purchased from Newark [13]. The short USB jumper patch cord was purchased on Amazon [14]. A step drill [15] is the most effective way to bore the large holes in a polycarbonate or ABS case without cracking it.

Remote Control

Figure 2. Interior View of Control Board Enclosure. Eight 16A relays are visible. There’s not much space to spare. Take care in wiring the AC connections and in locating the connectors on the housing or the PCB will not fit.

Software Apps

The test software that is supplied by Velleman for the circuit card is adequate, or N-Button Lite [16] may be purchased Figure 3. A screenshot of the lower right corner of the monitor shows the buttons for N-Button Lite. The green buttons indicate that four of the eight relays are active. If you purchase the Bud enclosure with a clear polycarbonate cover as I did, you will be able to see all eight red indicator lights on the Velleman board, one for each relay. They will light when a relay becomes active.

Remote Control

Figure 3. Screenshot of PC desktop. N-Button Lite controls each of 8 relays.

References

References
[1] https://www.jameco.com/z/K8090-Velleman-8-Channel-USB-Relay-Card-Kit_2123952.html
[2] https://www.velleman.eu/products/spareparts/?code=vdr300
[3] https://www.amazon.com/Velleman-VM8090-8-Channel-Relay-Card/dp/B00CPCQ88Y
[4] https://www.serialporttool.com/GK/n-button-lite/
[5] https://www.teamviewer.com/en-us/?utm_source=google&utm_medium=cpc&utm_campaign=us|b|pr|19|jul|Brand-TeamViewer-Exact|free|t0|0|dl|g&utm_content=TeamViewer_Exact&utm_term=teamviewer&gclid=Cj0KCQjw5ZSWBhCVARIsALERCvzZflNoCfAiFgi9STEIDiJkCtRuazuukru
[6] https://whadda.com/product/universal-timer-module-with-usb-interface-wmt206/
[7] Velleman, op. cit. https://www.velleman.eu/products/spareparts/?code=vdr300
[8] https://en.wikipedia.org/wiki/American_wire_gauge
[9] https://www.budind.com/product/nema-ip-rated-boxes/pn-series-nema-box/ip65-nema-4x-box-with-clear-cover-pn-1340-c/ – group=series-products&external_dimension
[10] https://www.budind.com/accessories/aluminum-internal-panel-pnx-91440/
[11]https://www.homedepot.com/p/1-2-in-Male-Terminal-Adapter-R5140103/202043509
[12] https://www.amazon.com/2-1mm-DC-Power-Jack-Chassis/dp/B073PKZPQ7
[13] https://www.newark.com/switchcraft-conxall/ehusbbabxpkg/usb-adapter-type-b-rcpt-a-rcpt/dp/08N9043?gclid=Cj0KCQjw5ZSWBhCVARIsALERCvycmWj-i38ykHaPrlbG8Eb-uxCyxcpZzdNWmZ0r7Z2iV9zgd7CpVKAaAh5KEALw_wcB&mckv=_dc|pcrid||plid||kword||match||slid||product|
[14] https://www.amazon.com/inch-USB-2-0-Male-Cable/dp/B079ZP65SN?th=1
[15] https://www.homedepot.com/s/step%2520drill?NCNI-5
[16] Relay Pros, op. cit. https://www.serialporttool.com/GK/n-button-lite/

Tilt-Over Bases for Antenna Masts That You Can Build

Introduction

Most of us have installed temporary antenna masts and have looked for a way to raise, lower and guy the masts while working alone. This was the case when I wanted to raise three masts for temporary antenna testing. When I couldn’t find any tilt-over bases that were sturdy, I decided to design and build some of my own from readily available materials.

I wanted mast bases that were rugged and heavy, not thin and flimsy. I discovered that mild steel [1] with its high carbon content is easy to weld, so I settled on that material. I also found a source for mild steel hinges [2]. They were perfect matches for mild steel plate. (In case you prefer aluminum, heliarc welding has become routine. It all depends upon what the welder quotes for a price and how heavy you want the bases to be.)

A sketch of what was built appears in Figure 1. All of the dimensions are based upon available materials. The only cutting required was to fabricate a steel shim [3]. When the tilt-over base is in its upright position, this shim, which is the same thickness as the hinges, maintains the spacing between the steel plates.

tilt-over bases

Figure 1. Design Sketch. The small holes in the left base plate accommodate 3/8” spikes (see text). The steel tube is welded to the rear side of the right top plate (see text).

A local welder assembled three tilt-over base mounts from supplied 8″ x 8″ x 1/4″ mild steel plate, 3″ OD 11 gauge steel tube, 6″ x 6″ steel hinges, and 3/4″ x 3/4″ x 6″ steel bar stock. The steel plate, hinges and bar stock were ordered from Amazon, while the tubing [4] was ordered from Coremark. The ID of the base tube is 2.75″ (70mm), 11ga. This is a loose fit for the cap at the bottom of most fiberglass masts. I used felt blankets [5] as shims for a tighter fit and to protect the masts. The base mounts are anchored to the ground with 3/8″ x 12″ galvanized spikes [6]. Four ½” holes drilled in the bottom plate for this purpose are visible. The spikes prevent the bases from sliding while the masts are being raised and lowered.

Once welded, the welding flux should be removed. Since high carbon steel will rust, the welded assemblies were cleaned and prepped with phosphoric acid [7] and steel wool before priming with spray metal primer [8]. The primed bases were spray-painted [9]. The finished product is shown in Figure 2.

tilt-over bases

Figure 2. Tilt-Over Bases. These tilt-over mast bases are sturdy and stable when anchored to the ground with 3/8″ x 12” galvanized spikes. The tilt-over feature makes it easy to raise and lower portable telescoping and non-telescoping masts while working alone.

A typical installation is shown in Figure 3. The 33’ (10m) masts shown were guyed at two levels with guy rings. Four Dacron paracord guy ropes were used on each guy ring. Fluorescent orange paracords were used for enhanced visibility. Temporary ground anchoring is accomplished with polycarbonate Orange Screws [10] as shown in Figure 4. Taut-line hitches are used to tighten the guying ropes – a useful knot to remember.

The mast is raised with two lower guy ropes in place. The ropes are adjusted to hold the mast a few degrees past vertical until the final two lower guy ropes are placed. Finally, the upper four guy ropes are placed.

Figure 3. Typical Installation. Guying is performed at two levels. The mast is raised while working alone with two lower guy ropes in place. The ropes are adjusted to hold the mast a few degrees past vertical until the final two lower guy ropes are placed. Finally, the upper four guy ropes are set. A post level, visible on the mast, is used to true it up. Photo courtesy of N4UM.

Figure 4. Guy view. The masts are guyed at two levels. Eight Dacron paracord ropes are used. The paracords are fastened to the guy rings with snap hooks. Tensioning is adjusted with taut-line hitches. Photo courtesy of N4UM.

Figure 5. Orange Screw Ground Anchors. The guy ropes are adjusted with taut-line hitches. During antenna range testing, the Orange Screws were set in sandy soil. Three masts remained standing during two weeks of rain and stiff winds.

Figure 6. Antenna Range with 3 Tilt-Over Bases in Use. An antenna range was constructed with three fiberglass masts and tilt-over bases. The dimensions of the range are as pictured. This 140’ range was left unattended during 2 weeks of Florida spring wind and rain. Note that paracord back-guys were employed at the very tops of the north and south masts to relieve the lateral loading due to the weight of the wire. Without back-guying, the top sections of the telescoping masts are apt to snap off.

References*

[1]https://www.amazon.com/s?k=8+x+8+x+1%2F4+steel+plate&crid=188CJTXB7VM3W&sprefix=8+x+8+x+1%2F4+steel+plate%2Caps%2C585&ref=nb_sb_noss_2
[2]https://www.amazon.com/Hinge-Weld-Heavy-Metal-Doors/dp/B0821HQQSJ/ref=sr_1_5?crid=3UEBPDTTXJFF8&keywords=6%22%2Bsteel%2Bhinges&qid=1656544819&sprefix=6%2Bsteel%2Bi%2Caps%2C107&sr=8-5&th=1
[3]https://www.amazon.com/1018-Drawn-Steel-Square-Stock/dp/B09GY7MQ2V/ref=sr_1_3?crid=3DB0BOW75U320&keywords=3%2F4+steel+bar+stock&qid=1656544926&sprefix=3%2F4+steel+bar%2Caps%2C192&sr=8-3
[4]https://www.coremarkmetals.com/electric-welded-erw-round-steel-tube
[5]https://www.homedepot.com/p/Everbilt-2-in-x-4-in-Heavy-Duty-Self-Adhesive-Beige-Felt-Blanket-3-Pack-804614/306229475?
[6]https://www.lowes.com/pd/Grip-Rite-12-in-x-3-8-in-Spike/3610436
[7]https://www.homedepot.com/p/Klean-Strip-1-Gal-Concrete-Etch-Metal-Prep-and-Rust-Inhibitor-GKPA30220/100406369
[8]https://www.homedepot.com/p/Rust-Oleum-Stops-Rust-12-oz-Flat-White-Clean-Metal-Primer-Spray-7780830/100143442
[9]https://www.homedepot.com/p/Rust-Oleum-Stops-Rust-12-oz-Protective-Enamel-Semi-Gloss-White-Spray-Paint-7797830/205585926
[10]https://www.sportsmans.com/camping-gear-supplies/tents-shelters/tent-accessories/orange-screw-small-ground-anchor-4-pack/p/1531885?channel=shopping&gclid=Cj0KCQjw8O-VBhCpARIsACMvVLMO-RmVGrVvtXURmIiQcQRsAo_r91rbskWRWtAzqqAUniop6Wnm5QYaAutREALw_wcB
[11]https://www.amazon.com/Orange-Screw-Ultimate-Ground-Anchor/dp/B01D3UIA5A/ref=asc_df_B01D3UIA5A/?tag=hyprod-20&linkCode=df0&hvadid=167119746601&hvpos=&hvnetw=g&hvrand=17637355299886752168&hvpone=&hvptwo=&hvqmt=&hvdev=c&hvdvcmdl=&hvlocint=&hvlocphy=9002271&hvtargid=pla-307839372670&psc=1

*The references cite readily available sources of supply. You may be able to find lower prices for materials or substitutions elsewhere.

A QRO L-Matching Network for 40 or 80 Meters

Introduction

L-matching networks provide an efficient means of feeding end-fed half-wave antennas. The advantages of being able to feed a half-wave antenna from one end cannot be overstated.  It is very easy to hoist the matching network on a halyard or to mount the network to the side of a building. The matching network will also support the transmission line and one end of the antenna wire. It has been stated in another article [1] that this matching network will provide a match for a single band, and that the efficiency of networks such as these can exceed 95%, typically 98%.

Not long ago, a QRO L-matching network was completed for my friend, N4UM. Until then, L-matching networks were constructed with 100W operation in mind [2]. This time, the objective was to build a matching network that would work with a 600W linear amplifier and that could be converted for operation on either 40 or 80m by changing a capacitor and moving the tap on an inductor. N4UM likes to configure wire antennas in the inverted-L configuration with the matching network close to the ground, so that was a consideration. The resulting L-network is the subject of this article.

Design

Since the load impedance for an end-fed half-wave antenna depends upon antenna height, configuration, conductor dimensions, and ground properties, a value of 3200 ohms was selected as a compromise.

A quick way to arrive at the values for the matching elements is to estimate the impedance transformation ratio required. For example, if we needed to transform from a 50-ohm source to a 3200-ohm load, the impedance transformation ratio would be 1:64. From this, we can calculate the unloaded Q and the reactance values for the inductor and capacitor from

The unloaded Q = 7.94, and the reactance required for the inductor at the design frequency is 397 ohms. The reactance required for the capacitor is 403 ohms. If we were designing for 40m, we would calculate the inductance and capacitance from the reactance formulas at, for example, 7.050 MHz.

The same procedure would be followed to calculate the component values for the 80m band. We leave that computation as an exercise for the reader.

Construction

The 40m matching network was constructed so that it can be converted to 80m by moving the coil tap and changing the capacitor from approximately 50 pf to approximately 100 pf. The network is intended for use with a 600W linear amplifier. The inductor for this network consists of a 3″ long x 2″ DIA air coil, #16 AWG, 9 turns per inch [3]. The doorknob capacitor is an HEC HT50 NPO characteristic 50 pf +/-10% at 7.5 kV [4]. The capacitor in the photo was measured on an HP4262A LCR meter. It measures 53.6 pf. All of the components were found on eBay, but references have been provided for all new materials. The L-Network is in the lowpass configuration: series inductor followed by shunt capacitor, Figure 1. You may recall from matching topology that if the shunt element is close to the load, the match is from low to high impedance – in this case from 50 ohms to 3200 ohms. The turns of the coil were shorted at the cold end of the coil at 16T. The inductance of the remaining portion of the coil is approximately 9.4 μH. The network is housed in a Bud Industries PN-1328-DGMB ABS box [5]. The 1/4″-20 screw terminal on the left end of the enclosure, Figure 2, has been provided for a counterpoise connection. Counterpoises were covered in an earlier post [6]. The screw terminal has been connected internally to the coax shield at the SO-239 connector. The 1/4″-20 antenna terminal is located on the right end of the enclosure as shown in Figure 2.

Figure 1. Convertible L-Matching Network Wiring Diagram. The moveable tap, optional counterpoise connection, and test load connection points are shown.

 

Figure 2. (Top) Convertible L-Matching Network for 40 and 80m. For 40m operation the inductor is tapped at approximately 16 turns from the cold end, and the HEC doorknob capacitor is approximately 50 pf. The inductor tap can be moved and the capacitor may be changed to convert from 40m to 80m operation.  When an antenna analyzer is available, the conversion can be performed in minutes. (Bottom)  L-Network Side View. The tapped inductor and HEC high voltage doorknob capacitor is visible. The UHF connector and counterpoise stud are also visible.

By this time you have probably observed that the component values are not exactly as calculated.  Many times the capacitor value will not be a standard value. This will result in a different load impedance than the design value. Since the high voltage capacitors are somewhat expensive, the objective was to find surplus capacitors on eBay. If more exact values are required, contact HEC, and they will see if they can find something close to what you need.

Test

The network was evaluated with a 3200-ohm non-inductive potentiometer load [7]. The antenna analyzer employed was an MFJ-226 [8]. The 1.2:1 bandwidth of the network under resistive load is 150 kHz, Figure 3. The turn loss at 7.062 MHz exceeds 48 dB, Figure 4. The Smith Chart in Figure 5 displays an excellent match for a 3200-ohm non-reactive load. Figure 6 shows the corresponding reactance of 0.03 ohms at 7.062 MHZ.

Figure 3. VSWR Plot. The 40m L-network is swept across the entire band illustrating better than 2.0:1 performance over the entire band.

Figure 4. Return Loss Plot. The return loss at 7.062 MHz is better than 48 dB.

Figure 5. Smith Chart Plot. The L-network is swept over the entire 40m band exhibiting an excellent match.

Figure 6. Reactance Plot. The reactance zero crossing is at 7.062 MHz.

Operation

If a counterpoise wire is used, a common mode choke should be positioned at the matching network SO-239 connector. If no counterpoise wire is employed, a common mode choke should be positioned in the coax at a distance of 2m (6.56′) from the SO-239 connector for 40m operation. For 80m operation, that number should be doubled. It should be possible to ground the counterpoise terminal to a nearby ground rod if the antenna is configured as an inverted-L, but that configuration has not been evaluated. The voltage gradient on the inductor increases toward the antenna end of the inductor. A ceramic insulator was not required at the antenna terminal because input power is limited to 600W.

References

[1] Blustine, M., Highly Efficient L-Matching Networks for End-Fed Half-Wave Antennas, June 11, 2022.
https://www.n1fd.org/2022/06/11/l-matching-networks/
[2] Ibid.
[3] https://www.bwantennas.com/coilcat.html
[4] http://catalog.highenergycorp.com/category/ceramic-capacitors
[5] https://www.budind.com/product/nema-ip-rated-boxes/pn-series-nema-box/ip65-nema-4x-box-dark-gray-with-mounting-brackets-pn-1328-dgmb/#group=series-products&external_dimensions_group=0&internal_dimensions=0&indoor_outdoor_group=0&nema_rating_group=0&ip_rating_group=0
[6] Blustine, M., op. cit.
[7] https://www.jameco.com/z/3299Y-1-502VP-LF-Bourns-5K-ohm-1-2W-25-Turn-Cermet-Trimmer-Potentiometer_240590.html
[8] https://www.eham.net/reviews/view-product?id=12464

 

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