Clifton LAboratories z10040b Installation and operating instructions

Z10040B
BroadbandNortonAmplifier
AssemblyandOperationManual
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V
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ersion1.3August2009
CliftonLaboratories
7236CliftonRoad
Clifton,VA20124
(703)8300368
www.cliftonlaboratories.com
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Z10040BConstructionandOperationsManualPage1
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TableofContents
ModelZ10040BBroadbandNortonAmplifier............................................................................................................3
TrademarksandCopyright........................................................................................................................................3
Warranty...........................................................................................................................................................................3
SafetyInformation..............................................................................................................................................................4
GeneralInformationandSpecifications....................................................................................................................5
Description.......................................................................................................................................................................5
Specifications...................................................................................................................................................................6
Assembly................................................................................................................................................................................7
PartsProvided.................................................................................................................................................................7
Errata:...............................................................................................................................................................................13
ComponentLayout......................................................................................................................................................14
AssemblyOrder............................................................................................................................................................16
PostConstructionAdjustmentandCheckout..................................................................................................26
InputandOutputConnections...............................................................................................................................29
SchematicandTheoryofOperation..............................................................................................................................32
TheoryofOperation....................................................................................................................................................32
Schematic........................................................................................................................................................................35
TroubleshootingGuide..............................................................................................................................................36
VoltageData...................................................................................................................................................................36
ResistanceData.............................................................................................................................................................37
AppendixATypicalPerformanceData.........................................................................................................................38
Bandwidth...........................................................................................................................................................................38
ThirdOrderIntermodulation......................................................................................................................................39
SecondHarmonic..............................................................................................................................................................40
1dBGainCompression..................................................................................................................................................41
InputVSWR.........................................................................................................................................................................41
CommonModeRejection...............................................................................................................................................42
NoiseFigure........................................................................................................................................................................43
AppendixB–PCBMountingHoleDimensions.........................................................................................................44
AppendixC–NortonAmplifierPatent,USPatentNo.3,891,934.....................................................................45
AppendixDIP3,NoiseFigureandGainPerformanceversusOperatingVoltage.......................................51
AppendixEManualBackdating.......................................................................................................................................54

Z10040BConstructionandOperationsManualPage2
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Z10040BConstructionandOperationsManualPage3
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ModelZ10040BBroadbandNortonAmplifier
Version1.22009
(c)2009JackR.Smithd/b/a/CliftonLaboratories.
LastRevised29August2009
TrademarksandCopyright
Materialinthisdocumentcopyrighted©2009CliftonLaboratories.Allrightsreserved.Itis
providedtoallowtheZ10040Bpurchaserstomaintaintheirequipmentandsuchotherpurposesas
maynotbeprohibitedbylaw.
Warranty
Thiswarrantyiseffectiveasofthedateoffirstconsumerpurchase.
Whatiscovered:Duringtheninety(90)daysafterdateofpurchase,CliftonLaboratorieswill
correctanydefectsintheZ10040Bduetodefectivepartsorworkmanship(ifpurchasedasan
assembledunit)freeofcharge(post‐paid).YoumustsendtheunitatyourexpensetoClifton
Laboratories,butwewillpayreturnshipping.CliftonLaboratories’warrantydoesnotextendto
defectscausedbyyourincorrectassemblyoruseofunauthorizedpartsormaterialsor
constructionpractices.
Whatisnotcovered:IftheZ10040Bispurchasedasakit,thiswarrantydoesnotcovercorrection
ofassemblyerrorsormisalignment;repairofdamagecausedbymisuse,negligence,orbuilder
modifications;oranyperformancemalfunctionsinvolvingnon‐CliftonLaboratoriesaccessory
equipment.Theuseofacidcoresolder,watersolublefluxsolder,oranycorrosiveorconductiveflux
orsolventwillvoidthiswarrantyinitsentirety.DamagetotheZ10040Borequipmentconnectedto
itcausedbylightningstrikesisnotcoveredunderthewarranty.Whetherpurchasedasan
assembledunitorasakit,alsonotcoveredisreimbursementforlossofuse,inconvenience,
customerassemblyoralignmenttime,orcostofunauthorizedservice.
Limitationofincidentalorconsequentialdamages:Thiswarrantydoesnotextendtonon‐
CliftonLaboratoriesequipmentorcomponentsusedinconjunctionwithourproducts.Anysuch
repairorreplacementistheresponsibilityofthecustomer.CliftonLaboratorieswillnotbeliablefor
anyspecial,indirect,incidentalorconsequentialdamages,includingbutnotlimitedtoanylossof
businessorprofits.
UndernocircumstancesisCliftonLaboratoriesliablefordamagetoyourequipment
connectedtotheZ10040BresultingfromuseoftheZ10040B,whetherinaccordancewith
theinstructionsinthisManualorotherwise.

Z10040BConstructionandOperationsManualPage4
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SafetyInformation
TheZ10040Boperateswithauser‐suppliedDCpowersupplyof13to15Voltsat100to120mA.
TheZ10040B,althoughdesignedasalowsignallevelpreamplifier,iscapableofRFoutputpower
approachingthe1wattlevel.Thisoutputpoweriscapableofdamagingreceiversorthereceiver
sectionofatransceiverortestequipment.Itistheuser’sresponsibilitytoensurethattheZ10040B
isproperlyconnectedtowhateverdevicesitwillbeusedwith.
TheZ10040Bhasnoreplaceablefuses;ratheraself‐resettingpolyfuselimitsshortcircuitcurrent
toapproximately200mA.
TheZ10040Bisdesignedtobeusedonlywithreceive‐typepowerlevels.Itshouldnotbeusedwith
transmittingequipment.TheZ10040B’smaximumpermittedinputRFpoweris100mW(+20
dBm).PowerinexcessofthislevelmaydamagetheZ10040Borequipmentconnectedtoit,orboth.In
addition,sincetheZ10040Bhasappreciablegain,outputpowerlevelssufficienttodamageconnected
equipmentmayoccurwithinputsignallevelswellbelow+20dBm.
AlthoughtheZ10040Bcontainsprotectivemeasures,alloftheseprotectionmeasuresassumethat
theZ10040Bisproperlygroundedandthatgoodengineeringpracticeshavebeenusedinits
installationandconstructionofthegroundsystem.TheZ10040Bisnotintendedtosurviveadirect
lightningstriketoanantennaconnectedtoitsinput,whetherpoweredupornot.However,the
protectivemeasuresincorporatedintotheZ10040B’sdesignshouldaidinreducingdamage.
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Z10040BConstructionandOperationsManualPage5
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GeneralInformationandSpecifications
Description
Theterm“NortonAmplifiers”referstoaclassoftransformerfeedbackamplifiersdevelopedbyDr.
DavidNortonanddescribedinhisUSPatentNo.3,891,934,grantedJune24,1975andnowinthe
publicdomain.(AcopyofDr.Norton’spatentisAppendixCtothisManual.)ANortonamplifier
permitsthedistortionreducingbenefitsofnegativefeedbacktobeappliedwithoutimpairingthe
fiers.amplifier’snoisefigure.Hence,Nortonamplifiersarealsoknownas“noiselessfeedback”ampli
TheZ10040Bisabroadband(75KHzto30MHz)Norton‐styleamplifierproviding11dBgain
(othergainvaluesarepossible)withveryhigh3rdorderand2ndorderintermodulationintercepts,
IP3andIP2,respectively,withanoisefigurebelow3.5dBovertherange10‐30MHz.TheZ10040B
isdesignedforeitherindoororoutdooruse,withDCpowersuppliedthrougheitherseparate
connectionsorduplexedovertheoutputcoaxialcable.Optionalindoorandoutdoordiecast
enclosuresareavailablefortheZ10040B.
TheZ10040BisderivedfromtheNortonAmplifierdevelopedbyDr.DallasLankfordanddescribed
inhispublicationCommonBaseTransformerFeedbackNortonAmplifiers,dated8June1994,
revised21May2007,availableat
http://www.kongsfjord.no/dl/Amplifiers/Common%20Base%20Transformer%20Feedback%20N
orton%20Amplifiers.pdf.
TheZ10040BmodifiesDr.Lankford’sdesigninseveralrespects:
•erremovalalongwithover‐voltagegastrapAutomaticinputdisconnectuponDCpow
•protection
•ntheDCPower.
Improvedperformancebelow500KHz.
Overvoltageandreversevoltageprotectiono
•wer.DCpowereitherseparatelyorduplexpo
•Optionalbalancedorunbalancedinput.
CliftonLaboratoriesalsoofferstheZ1202ADCpowerinjectorusablewiththeZ10040Btoprovide
DCpoweroverthecoaxialcable.
TheZ10040Bisavailableasakit,includingadoublesided,silkscreenedsoldermaskedprinted
circuitboardsandallelectronicpartsorasanassembledandtestedprintedcircuitboard.Options
includeanindoordiecastenclosureoranoutdoorweatherproofdiecastenclosurewithBNC,UHF
orTypeNconnectors.
Typicalkitconstructiontimeisthreetofivehoursdependingonyourworkpractices.Thekitis
suitableforrelativelyinexperiencedbuilders,althoughCliftonLaboratoriesdoesnotrecommendit
topurchaserswhohaveneverbuiltanelectronickitbefore.Also,ifyouhaveneverwoundatoroid
inductorortransformer,youmightwishtoaskanexperiencedbuildertoshowyouhowit’sdone.
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Z10040BConstructionandOperationsManualPage6
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Specifications
ParameterValue
PCBDimensions3.00”x3.50”x0.75”verticalclearancerequired.(76.2mmx88.9mmx19mm).
Fourmountingholesfor4‐40screwsprovided,templateinAppendixB.
DCPowerRequired
Maximum:15V
Minimum:13.8V[maynotmeetspecificationsbelowthisvoltage.SeeAppendix
Dforperformanceversussupplyvoltageconsiderations.]
Negativetoground,typicalDCcurrent80‐100mAdependingonbias
adjustment.
MaximumRFPower
Input
Donotexceed100milliwatts(+20dBm).IP3performancespecificationsare
basedupon‐10dBmsignalinput;performancenotwarrantedatgreaterinput
levels.
TestConditions
Performancedataisfora1:11:4turnsratiodesign,13.8VDCafteradjusting
balancetrimpotsforminimum2ndharmonicdistortion.Unlessotherwise
indicated,performancemeasurementsaremadewithdirectDCpower,not
duplexed.Figuresstatedas“typical”arenotwarranted.
3dBBandwidth100KHz–30MHz.Typicalbandwidth75KHz‐45MHz
3rdOrder
Intermodulation
Intercept
+50dBm.Measuredat12MHz,inputsignallevel‐10dBm.Protocolasdiscussed
laterinthismanual.
2ndHarmonic
intercept
+90dBm.Measuredat5.35MHz,inputsignallevel‐3dBm.Protocolasdiscussed
laterinthismanual.
Gain11dBnominalat1MHz.
1dBGain
Compression+19dBminput.
NoiseFigure3.5dBmaximum10‐30MHz.Typicallylessthan3dB10‐30MHz.
InputVSWRWhenterminatedwith50ohmload,inputVSWRislessthan2:1overtherange
300KHz–30MHz,andistypicallybelow1.5:1overthisrange.
CommonMode
Rejectionin
alancedInput
ode
B
M
Typically50dBat1MHz,decreaseswithincreasingfrequency.
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Z10040BConstructionandOperationsManualPage7
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Assembly
PartsProvided
Beforestartingyourbuild,pleasetakeamomentandinventorythepartsprovidedagainstthelist
below.Therulerismarkedininchesandand1/16thfractions(somephotosusearulermarkedin
inchesandtenths,identifiedat10THS.).
Anoteonhowcomponentvaluesareidentifiedinthismanual
Thisdocumentfollowstheinternationalpracticeofusingthevaluemultipliertoindicatethe
decimalpoint.Thus,a1.0µFcapacitorisidentifiedas1µ0anda10,000ohmresistorisidentifiedas
10K0.
PhotographQtyIDDescriptionandComments
Component
Marking


4
C1,C5,C8,
C9

1000pFleadedceramic
capacitor.Leadspacing0.1
inches.Partsmaybeloose
ortapedasshown.

102

14
C10,C11,
C12,C13,
C14,C15,
C16,C17,
C18,C2,
C3,C4,C6,
C7

1u0leadedceramic
capacitor.Leadspacing0.2
inches.Partsmaybeloose
ortapedasshownandmay
ormaynothavea
“crimped”lead.

105


1C19
33u63Velectrolytic
capacitor.Thiscomponent
ispolarized.Polarityis
identifiedbytwomethods.
Thenegativeleadisthe
shorteroneandthe
negativeleadismarked
withanegativesymbolon
thecapacitorcase.The
longerleadisthepositive
lead.
33uF63V

Z10040BConstructionandOperationsManualPage8

PhotographQtyIDDescriptionandComments
Component
Marking


2C20,C21
1000pF,1206surface
mountceramiccapacitor.
(Photoshowscapacitorsstill
insidethepapertape.)
none

1D1
Silicondiode,1Aorgreater,
100Vorgreater.Typicallya
1N4007part
1N400x
whereXmay
beany
number
from0to7

1F1
200mARaychem“polyfuse”
PTCvaristor.Thesupplied
partmayormaynothavea
“crimped”lead.
XF020

1FB2Ferritebead[FB1designator
isnotused]Nomarking


2[3‐place]
1[4‐place]J1,J2,J3
J1:4‐place
J2&J3:3place
0.1inchheadersockets
None


1J4
2place0.1inchheaderpin
Maybesuppliedasa
multiplepinstriptobe
brokenasneededbybuilder
None

Z10040BConstructionandOperationsManualPage9

PhotographQtyIDDescriptionandComments
Component
Marking


1NoneShortingjumperfor2place
0.1inchheaderpinsNone

1K1
G6H‐2F‐DC12doublepole,
doublethrow12Vsurface
mountrelay
G6H‐2F‐
12VDC


4
L1,L2,L3,
L4

1m0RFchoke(shielded)
highcurrentNone


1L51m0RFchoke,highcurrent
unshielded5800‐102

2Q1,Q2NPNtransistors,VHF,type
2N51092N5109

Z10040BConstructionandOperationsManualPage10

PhotographQtyIDDescriptionandComments
Component
Marking

2NoneHeatsinksforQ1andQ2None


2None
Nyloninsulatingspacerfor
Q1andQ2.

Notethisspacerhasfour
serrationsintheinner
opening
None

¼watt,1%metalfilmresistors
Thesepartshavefivecolorbands:
1. 1stsignificantfigure
2. 2ndsignificantfigure
3. 3rdsignificantfigure
4. Multiplier(numberofzerosorNin10Nnotation)
5. Tolerance(1%=brown)
Example:brown‐green‐black‐brown‐brown=15011:
150x101,1%tolerance=1500ohms,±1%

2


R1,R6

560R
Green‐blue‐
black‐black‐
brown
2R4,R12
49R9
*firstbandisyellow,but
looksmorelikegreenwith
somelightingsources
Yellow*‐
white‐white‐
gold‐brown
2R10,R51K50
Brown‐
green‐black‐
brown‐
brown

4R2,R7,
R9,R1110R0
Brown‐
black‐black‐
silver‐brown

Z10040BConstructionandOperationsManualPage11

PhotographQtyIDDescriptionandComments
Component
Marking


2R3,R8100RTrim‐pot101


1RV114mmdia.18Vover‐voltage
MOV180M

2SA1,SA2
Sparkgap
Eitherofthefollowingmay
beprovided:
90V

75V

90V(and
datecode)

EC75(and
datecode)

SameasJ4.2TP1,TP2
Testpoints.Useheaderpin.
Maybesuppliedasa
multiplepinstriptobe
brokenasneededby
builder
None
SameasJ43None
3placeheaderpins.Maybe
suppliedasamultiplepin
striptobebrokenas
neededbybuilder
None


4T1,T2,T3,
T4
0.5inchdiameterferrite
cores;buildertowindNone

Z10040BConstructionandOperationsManualPage12

PhotographQtyIDDescriptionandComments
Component
Marking


1PCBPrintedcircuitboard.
IdentifiedasZ10040B
Z10040B
andrevision
number
None1length#24
wireNoneNo.24AWGmagnetwire, useforT2andT4None
None
2lengths#26
wireNone
No.26AWGmagnetwire,
useforT1andT3.One
lengthred,onelength
green.
None

4None
WashersforL1‐L4.Note
thesewashersdonothave
serrationsintheinner
openingandarelarger
diameterthanthetwo
insulatorsforQ1andQ2.

Thesuppliedpartsmaybe
nylonasillustratedinthe
upperphotographorhard
fiberasinthelower
photograph.
None

 
 
 
 


Z10040BConstructionandOperationsManualPage13

Errata:
NoneknownforRev02PCB.


Z10040BConstructionandOperationsManualPage14

ComponentLayout
Topview
C20andC21installonthePCB
bottom.Thereisnosilkscreeningidentifyingthelocationfortheseparts.

Z10040BConstructionandOperationsManualPage15

ComponentOrientation
Asamatterofgoodconstructionpractice,mostbuildersorientnon‐polarizedcomponentsinthe
followingfashion:
•Ifthecomponentiscolorcoded,suchasmost
resistors,orientsothatthecolorcodereadsinthe
samedirectionasthesilkscreeningdesignator.R1,
forexample,isa560ohm1%resistor;colorcoded
greenblueblackblackbrown.Notethatthecolorcode
isorientedsoitreadsleft‐to‐right,justasthe
componentsilkscreenedR1designation.
•Partswithaprintedvaluecodeareorientedsothatthe
partvaluemaybeeasilyread.Forexample,C11isa1u0
capacitor,marked105.Thepartisinstalledwiththe
printed“105”identificationfacingawayfromT1sothatthe
markingismoreeasilyread.
Ofcourse,ifthecomponentispolarized,itmustbeinstalledwith
theproperpolarity.Eventhere,itmaybepossibletorotatethe
part(suchasthe1N4007diode)sothatthepartidentifierisnotobscured.


Z10040BConstructionandOperationsManualPage16

AssemblyOrder
TheZ10040Bisarelativelysimplekit.Themostcomplexpartiswindingthetransformers,and
eventhisisnotdifficult.
Theassemblyordergenerallyfollowscomponentheight—thesmallestcomponentsareinstalled
firs ,and difference,thephotosareoftherev02PCB.)t

thetransformerslast.(Wherethereisno
Ins
t
allthe¼watt1%metalfilmresistors
R1560Rgreen‐blue‐blac
k
‐brown‐brown

R6560Rgreen‐blue‐blac
k
‐brown‐brown
R449R9yellow‐white‐white‐gold‐brown(yellowmaylookgreenishunderfluorescent


lighting)
R1249R9yellow‐white‐white‐gold‐brown(yellowmaylookgreenishunderfluorescent


lighting)

R51K50brown‐green‐blac
k
‐brown‐brown

R101K50brown‐green‐blac
k
‐brown‐brow
n
R1110R0brown‐blac
k
‐blac
k
‐silver‐brow
n
R910R0brown‐blac
k
‐blac
k
‐silver‐brown

R210R0brown‐blac
k
‐blac
k
‐silver‐brown

R710R0brown‐blac
k
‐blac
k
‐silver‐brown
InstallD1,thereversepolarityprotectiondiode.Thiswillbea1N400xseriesdevice,
marked1N400xwherexmaybyanydigitfrom0to7.Observepolaritywheninstallingthe
diode;thediodebodywillbemarkedwithabarorringaroundoneend.Theleadfromthe

markedendgoesintothepadmarkedwithabarandthe+sign.
nstallFB2,theferritebead.(FB1isnotused.)Theferritebeadisnotmarkedandisnot
I
polaritysensitive.
ThephotobelowshowsthePCBatthisstageofassembly.


Z10040BConstructionandOperationsManualPage17

tall1u0capacitors(marked105)at:Ins



C3



C11



C10



C2



C4



C14



C18



C17



C16



C15



C6
C13


Z10040BConstructionandOperationsManualPage18



C12
C7
tall1000pFcapacitors(marked102or)at:
Ins



C1



C9



C8
C5
hephotobelowshowsthePCBatthisstageofassembly.
T






InstallL5,1m0RFchoke,marked5800‐102.
nstallF1(RXE020200mApolyfuse,markedXF020).Dependingontheavailableproduct,I
thiscomponentmayhaveparallel,crimpedleadsorangledleads.
Toinstallthecrimpedleadversion,sliponeleadintothemountingholesothatthekinkor
crimpsnapsacrossthePCB.Putthesecondleadintotheothermountingholeandgently
pull(withlongnosepliers)thesecondleadfromtheundersideoftheboarduntilit


Z10040BConstructionandOperationsManualPage19

l
F1withthecrimpedleadsabovethePCBsurface.Solder.
ftheangledleadeddeviceisprovided,installuntilthebendintheleadcontactsthetopof
ikewisesnapsintothemountinghole.Ifthisprocessistoodifficult,youmaysimplyinstall
I
theprintedcircuitboardpad.Solder.
InstallRV1,theMOVover‐voltageprotector,marked180M.RV1isnotpolarizedandmay


beinstalledineitherorientation.



InstallR3,a100Rtrimpot,marked101.
InstallR8,a100Rtrimpot,marked101.
Installthefour1m0shieldedRFchokes.Thesechokesare
constructedwithaferritecylinderforshieldingandpottedwith
epoxy.Itiscommonfortheepoxytoslightlyextendbeyondthe
shieldbottom.Toprovidebettermechanicalsupport,installa
nylonorfiberwasherbetweenthechokeandthePCBas
illustratedtotheright.TrialfitthechokeandwasherinthePCB.
Insomecases,theepoxywillstillpreventagoodmechanicalfit.
Inthiscase,trimorslottheinsideofthenylonwasherwitha
hobbyknife,beingcarefulnottocutyourselfduringtheprocess.
lternatively,youmayusethewasherwithouttrimming,acceptingasmallgapbetween
hechoke/washer/PCBassemb
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A
t ly.
Recommendedassemblyprocess:FitallfouroftheRFchokeandwasherassembliestothe
PCBbutdonotsolder.Putasmallpieceofflatmaterial,suchasapieceofmetalorthin
woodorplasticontopofallfourchokes,creatinga“sandwich”withthechokesasthefiller
andthePCBandmetalthebread.Holdthesandwichtogetherandfliptheassemblyupside
downsothatthechokeleadsarestickingupandplacethe“sandwich”ontheworkbench.
HoldthePCBdowntoapplypressuretoseatthechoke/washerassemblyagainstthePCB.
Solderoneleadofeachchoke.Aftersolderingoneleadofallfourchokes,pickupthePCB
andverifyeachchokeisseatedaswellaspossibleagainstthewasherandthePCB.Ifany
chokeisnotfullyseated,pressitagainstthePCBwhileheatingthesolderjoint.Afterall
kesarefullyseated,soldertheremainingleads.cho
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

L1
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
L2
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
L3
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
L4
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
Installthethree‐pinheadersocket(female)atJ2.
InstallC19(33µF,63Velectrolyticcapacitor).Thisisapolarizedpart.Polaritymaybe
indicatedbyeither(orboth)ofthefollowing:(a)Thecapacitorhasanegativeside
marking;(b)thepositiveleadisthelongest.InstallC1ensuringthepositiveleadisinserted
intothepadmarkedwiththe+sign.Solder.