ASCEL Electronic AE20401 Installation and operating instructions

Æ20401
5.8 GHz Frequency Counter
/ Power Meter
Assembly and
Operation Manual
REV 3.1 EN
© 2015 Ascel Electronic

Table o Contents
Safety Information.....................................................................ii
Handover of a evice Built From a Kit....................................iv
Intended Use.............................................................................iv
ES Warning.............................................................................v
AE20401 5.8 GHz Frequency Counter / Power Meter..............1
Circuit escription.....................................................................2
Soldering....................................................................................4
Component Reference................................................................6
Assembly..................................................................................14
Adjustment of the input amplifier............................................18
Troubleshooting Checklist.......................................................20
Power Supply...........................................................................22
Case Mounting.........................................................................23
Operation..................................................................................25
Circuit iagram.......................................................................44
Bill of Materials.......................................................................46
Component Placement iagram..............................................49
ata Interface...........................................................................50
Specifications...........................................................................53
i

Warning
Please read this manual before you assemble and use this kit.
Keep it accessible for all users at all times.
Sa ety In ormation
Know and follow the applicable regulations for
electric devices in your region. In Germany,
these are especially V E 0100, V E
0550/0551, V E 0700, V E 0711 and V E
0860. Pay attention to the following safety
advices:
• isconnect the power supply before opening the case.
• Work on devices only if you made sure that they are
disconnected from any power supply, and any possible charge
inside is discharged.
• evices must only be used if they are mounted in a case in a
way that prevents the user from touching any live wires or
parts. isconnect the device from its power supply during
assembly.
• Always check the power cords for breaks or damaged
insulation. Replace any defective parts immediately.
• Seek advice from a qualified expert if you are not sure about
any specific value of a part, an installation procedure, or how
to connect accessories.
ii

•Always check if the device is suitable for the intended purpose
before putting the unit in use. Seek assistance from a qualified
professional or the manufacturer if you are not sure.
• The manufacturer assumes no liability for errors made during
assembly or operation.
• evices that need a supply voltage greater that 24V may be
assembled by professionals only, to avoid hazards from
improper assembly.
• In schools, educational institutes or workshops, the use of this
unit must take place under the supervision of qualified staff.
• o not put this unit in use in an environment where the risk of
fire or explosion or explosive gas, vapor or dust is present.
• If the unit must be repaired, use original parts only. The use of
inappropriate parts may lead to a safety risk.
• Avoid working alone.
• Keep electronic parts away from children.
• o not replace parts with such that does not meet the required
parameters. For example: never replace a fuse with another one
with higher nominal current!
• Other regulations may apply. Please check the local safety
regulations for assembling electronic devices.
iii

Handover o a Device Built From a Kit
(in countries where applicable)
If you hand over a device built from a kit, you legally become
the manufacturer. This mean you are responsible for complying
with the appropriate regulations for electronic devices. All
accompanying papers, in particular this manual, must also be
passed over. Where necessary (for example in the European
Union) you must also publish your identity to the consignee.
Intended Use
(in countries where applicable)
The intended use of this device is measuring frequencies and
power within the given limits.
• Other uses are not approved!
iv

ESD Warning
What is ESD?
ES (Electrostatic Dis-
charge) is the sudden flow
of electricity between two
objects caused by contact
or an electrical short. It
can reach very high voltages of many kV. In some cases even
over 100kV!
Causes of ESD
The main cause of ES events is static electricity. Static
electricity is usually generated through tribocharging, like
walking on a rug, ascending from a fabric seat, removing some
types of plastic packaging or using non-ES compliant tools.
Danger of ESD
The high voltage pulse can easily destroy electronic parts. ICs
and FETs are very sensitive to high voltage. Even a short,
single touch may destroy a part!
How do I prevent damage due to ESD?
Always ground yourself while working with electronic parts. A
grounded conducting wrist strap and proper anti-static work
surface mat will help prevent ES damage. Also make sure
that the soldering iron is grounded and ES -safe.
v
Warning symbol for an
electrostatic sensitive device

AE20401 5.8 GHz Frequency Counter /
Power Meter
The AE20401 combines three different functions:
- A frequency counter, that range from mHz resolution with
reciprocal counting algorithms to 5.8 GHz with the optional
Channel B Module
- A pulse counter (Channel C)
- And a power meter (optional Channel PWR Modules) that
can measure from -55 dBm (3 nW) to +30 dBm (1 W) / -5 dBm
in the range from C to 500 MHz / 10 MHz to 8 GHz. The
value of external attenuators can be included in the readings.
It can measure Frequency/Period (Channel A/B) and RPM
(Channel A). The number of pulses per revolution is adjustable.
Offset and Smooth functions and selectable Trigger Edge
extends the possible applications even further.
The USB interface1 allows remote control of the frequency
counter with the included software. The easy, plain text
command protocol allows simple integration with external
tools and systems. Every single function of the device can be
remote controlled.
All SM (Surface Mounted evice) components are already
soldered, so the kit is also suitable for beginners in electronics.
The comprehensive manual should help answer all questions
that may arise during assembly.
Please read the complete manual (especially if you are not yet
experienced in electronic engineering) before building the kit.
1optional
1

Circuit Description
The circuit diagram of the AE20401 can be divided into several
parts, which are described here.
The digital part is based on microcontroller IC1. IC1 controls
all functions, computes the readings, and drives the LC . The
USB port is handled by the FT230X UART-USB Bridge (IC5).
IC8 is the 2.5V reference for the A C (analog to digital
converter) that is used to convert the analog output of the
Power Meter Module to a digital value.
The 5V digital supply comes from the linear regulator IC4. 1
protects IC4 from reverse polarity of the input voltage.
ecoupling capacitors are placed next to all ICs. Each module
has their own power regulation and decoupling capacitors on
their own boards.
Channel A/C input circuitry: the C offset is removed from the
signal first. Then it is impedance matched and fed to the input
amplifier. 2/ 3 limit the signal in case of input overload. P1*
is used to attenuate it. A high-speed comparator (IC6) with
hysteresis is then used to compare the signal against a reference
voltage. (see chapter "Adjustment" for details).
Now a 5Vpp square wave that is the same frequency as the
input signal is available which can be processed by the digital
(logic) ICs. Along with the signal from Channel B, which is
already divided by 500 in the module, it is divided by 2 by a
high speed flip-flop (IC2), then further by 8 by a 4bit counter
(IC3).
2

Now, all these signals are routed to a multiplexer (IC7), where
three signals are available: the comparator output from Channel
A, the divided-by-16 signal, and the divided-by-1000 signal
from Channel B.
The microcontroller selects one of these signals, depending on
active channel and mode, which is processed to create a
reading.
The analog output from the Power Meter (Channel PWR) is
converted to a digital value by the microcontroller's internal
A C. This digital value is then used to calculate the power.
Since the Channel B Module uses 3.3V internally, voltage
dividers on the data lines (R17/R19, R23/R20 and R22/R21)
reduce the amplitude from 5V to 3.3V.
The external input (EXT) is protected against overvoltage by
R15 together with 4/ 5.
The separately drawn CLK footprint can accept either a
standard crystal oscillator or the optional 1ppm TCXO Module.
R2 is a high power resistor capable of withstanding short
overload events on Channel A/C without damage – however, it
is important not to exceed the specified maximum limits, as
higher input voltages may damage the frequency counter!
3

Soldering
Please read the following pages if you are not yet experienced
in soldering. Good soldering is a matter of practice! Practice on
old boards until you feel confident before assembling the kit.
• The parts are mounted on the silkscreen side of the PCB
Except parts whose designators ends with an asterisk (like
S1*) These are mounted on the other side!
• Do not inhale the fumes from the flux! Wash your hands
after soldering! Wear protective glasses!
• If you use additional flux, make sure it is suitable for
electronics use! Non-suitable flux may contain acid which will
damage the traces on the PCB over time.
• Try to solder fast. Heating up for too long may damage the
components and the board.
• Solder wire with a diameter between 0.5-0.75mm (0.02"-
0.03") is most suitable for through-hole components. Lead
solder is easier to use than lead-free solder.
• A clean, non-oxidized tip is essential for good soldering. Use
a wet sponge or a metal wool tip cleaner to regularly clean the
tip. The metal wool cleaners are superior to a wet sponge as
there is no temperature shock.
4

• When soldering active components (ICs, Transistors,
LE s...), it is very important to prevent overheating the
components. They should be soldered in no more than about 5
seconds. In addition, it is important not to confuse the polarity!
See the next chapter on individual component types and their
correct orientation.
• To solder:
1. Use the tip of the soldering iron to simultaneously heat
up the PCB and the component leg.
2. Add solder. It should melt around the component leg.
3. Wait a moment. o not move the part you just soldered
for a few seconds while it is cooling down. Moving it
may cause the solder joint to crack.
4. Then remove the iron. With lead solder, the solder joint
should be glossy.
• After soldering, use side cutters to cut the leads straight above
the solder joint.
• After you are finished, check all components for correct
placement and orientation. Also, check for unintentional shorts
on the board. Small solder leftovers may cause shorts which
can damage the board or the components.
• Use isopropyl alcohol (IPA) or a specific PCB cleaner fluid to
remove flux residues. Flux is corrosive and should not remain
on the board.
5

Component Re erence
1 Resistors
To save PCB space, the resistors are mounted standing. To
install:
1. Bend the leads in form and put the
resistor through the corresponding
mounting holes.
2. Bend the leads aside to prevent the
resistor from falling out.
3. Solder it accurately on the back
side.
4. Cut the remaining leads above the solder joint.
The resistance value is given with colored bands on the
resistor. The code consists of four, five or six bands. With four
bands, the first two are the base value (see table below), the
third is the multiplier to the base value and the fourth is the
tolerance. Five-band code uses the first three bands for base
value. With six bands, the sixth is the temperature coefficient.
The resistor value is:
base value * multiplier [ ± tolerance ]
There are two possible arrangements for the bands order:
6
Type B
Type AType A

Color Codes:
Color Digit Multiplier Tolerance ± in %
None - - 20
Silver - 10-2 10
Gold - 10-1 5
Blac 0 100-
Brown 1 1011
Red 2 1022
Orange 3 103-
Yellow 4 104-
Green 5 1050.5
Blue 6 1060.25
Purple 7 1070.1
Grey 8 1080.05
White 9 109-
2 Capa itors / Ele trolyti Capa itors
Capacitors are soldered the same way as resistors. Electrolytic
capacitors are polar They must be mounted in the correct
orientation! They will be destroyed when installed in
reverse polarity and may even burst!
Please keep in mind that different manufacturers mark the
polarity in different ways. The marking may represent the
positive or the negative terminal! The actual polarity (+ or -) is
printed inside the marker band that points at one of the leads.
7

Capacitance Identification
A three-digit number without letters is the capacitance in pF,
calculated this way:
a∗10b
where
a
are the first two digits
and
b
is the third digit (105 become 10*105 pF = 1µF). One-
or two-digit numbers states the capacitance directly in pF. A
number including the letter "n" is the capacitance in nF, where
3n9 is 3.9nF.
Upper-case characters denote the tolerance according to this
table:
B C D F G H
±0.1pF ±0.25pF ±0.5pF ±1% ±2% ±2.5%
J K M S Z P
±5% ±10 ±20 +50%
-20%
+ 80%
- 20%
0%
-10%
A number following up indicates the electric strength.
Sometimes you may encounter a number like 0.5, this is the
capacitance in µF.
Electrolytic capacitors are usually labeled with the capacitance
in µF straight. µ is where the decimal point is: µ33 is 0.33 µF,
3µ3 is 3.3µF and 33µ is 33µF.
8

3 Diodes
The circular band on diodes identifies the cathode (negative
terminal). The bar depicts the cathode in the symbol. The
positive terminal is called the anode.
iodes are mounted horizontal. Try not to heat up the body of
the diode while soldering.
4 LEDs
LE s (light-emitting diodes) must be soldered with respect to
the correct polarity as well. The cathode is identified by the
short lead and the larger electrode inside.
9

5 IC-So kets / ICs
With ICs (integrated circuits), it is essential to observe correct
polarity. Most ICs will be damaged or destroyed when mounted
incorrectly. The mark on the silkscreen must match the notch
on top of the IC.
Pin numbers are counted counter-clockwise, starting from the
notch.
Note: Please also pay attention to the E D warnings at the
beginning of this manual. ICs are very E D sensitive, they can
be destroyed even by a minor electrostatic discharge event!
10

6 Transistors
Transistors must be mounted in the correct orientation. The flat
side of the transistor must match the correspondent side in the
silkscreen drawing. The leads may not cross.
Note: field-effect transistors (FETs) are extremely
sensitive to E D.
7 Crystal
The polarity of the crystal is not relevant, but the bottom side
of the package is conductive. To prevent shorts, the crystal
should be mounted with a little distance to the board (see
the image on the next page)
11

8 Indu tors
Inductors are soldered just like resistors. They also use similar
color-coding, usually with four bands. The first two are the
base value (see table below), the third is the multiplier to the
base value and the fourth is the tolerance. The inductor value
is:
base value * multiplier [ ± tolerance ]
Color Codes:
Color Digit Multiplier Tolerance ± in %
None - - 20
Silver - 10-2 10
Gold - 10-1 5
Blac 0 100-
Brown 1 1011
Red 2 1022
Orange 3 103-
Yellow 4 104-
Green 5 1050.5
Blue 6 106-
Purple 7 107-
Grey 8 108-
White 9 109-
12

9 Module Pin Headers
The orientation of the pin headers is as follows:
10 Crystal os illator / TCXO Module
Unlike crystals, oscillators are polar. Pin 1 is identified by the
pointy edge, the other edges are rounded.
The TCXO Oscillator Module has the same size and pinout as a
standard oscillator, with Pin 1 as the pointy edge.
If the oscillator is mounted incorrectly, it will cause a
short that may damage the device permanently!
Please double-check the correct orientation This also
applies to the TCXO Oscillator Module It will be
destroyed if mounted with the wrong orientation!
13

Assembly
General note
It is essential to work precisely and systematically to minimize
the possibility of faults. Check every step, each component
placement and orientation, and any solder joint. Follow the
assembly order given in the manual.
Take your time - it takes longer to troubleshoot than to prevent
faults by working accurately.
The most common reason for a malfunctioning device is wrong
component placement: either the component being placed in
the wrong place or back to front. Check resistors with a
multimeter if you have difficulties reading the color bands.
A common mistake is regarding capacitor labeling, such as
n10 = 0.10 nF = 100 pF as opposed to 10 nF. Also, check if all
leads of an IC are correctly inserted into the socket. They tend
to bend during insertion.
After soldering, inspect the board for what are called cold and
dry solder joints. Cold joints occur if the soldering temperature
did not exceed the solder's liquidus temperature, or if the flux
evaporated before it was applied on the surfaces being
soldered. This is usually the result of the soldering iron being
used to heat the solder directly, rather than the parts
themselves. ry joints occur when the cooling solder is moved.
They often occur because the joint moves when the soldering
iron is removed from the joint. When using lead solder, the
joint should be smooth, bright and shiny. The joint should be
reworked if it is not.
14