MARCH 2007 ily Wa PROVED 5008/0127 $B50* Nzsge0 rammeabie aEt) ectronic. Ignition syste sienna ecres Earn, Historical : Radio Society ¢ of Australia : _. 25 years restoring our / radio historySILICON (Fontents__ Veo OSU Wie Prue CE 10 Taking Glass Beyond The Window Pane Glass is much more than something you look through or drink from. Thanks to computer technology, architects are now using it to make a real statement = by Kevin Poulter 58 The Spark That Changed The World (ld radios are worth restoring but there can be dangers for the unwary. The Historical Radio Society OF Australia (HRSA) has now been operating for 25 ‘years — by Kevin Poulter ts U Dpaiec Swale Projee Build 46 Programmable Ignition System For Cars; Pt.1 Want to program your enn gnitontning maps fran older ca ror the racetrack? Now you can wth cutest programmable carlton sytem Sy Join Cake 34 Remote Volume Control & Preamplifier Module; Pt.2 ‘Second article completes the construction, describes the set-up procedure and shows how the unit is used ~ by Peter Smith 64 GPS-Based Frequency Reference; Pt.1 Its based on a Garmin GPS receiver module and uses the GPS satolites to derive very accurate 1MHz & 10MHz reference frequencies for calibrating frequency meters, signal generators & radio receivers — by Jim Fowe 74 Simple Ammeter & Voltmeter Want to make simultaneous voltage and current measurements, up to 20V and 204? You can with this easy-to-build unit ~ by Ross Tester al Columns 40 Circuit Notebook (1) 12/24V Auxiliary Power System; (2) Portable Headphone Ampitir: (3) Preamplifier For Moving Coll Magnetic Cartridges: (4) Oda/even Day Watering ‘Solution; (5) Fun With Flashing LEDs; (6) LCD Clock Battery Upgrade 82 Serviceman’s Log Variations ofthe original mousetrap by the TV Serviceman 88 Vintage Radio The EILCO 6104 lunch-box FDS radio ~ by Rodney Champness 2 Publisher's Letter 96 Ask Silicon Chip 4 Mailbag 99 Notes & Errata 47 Product Showcase 102 Market Centre a= *% 57 Order Form ‘Simple Amster 8 Dual Mea: ints — Page 74, MARCH 20074 siliconchip.com.auCHIP nen Publisher & Editor-in-Chief Leo Simpson, B.Bus., FAICD Production Manager Greg Swain, B.Sc.(Hons.) Technical Editor Peter Smith ‘Technical Staff ‘John Clarke, BE (Elec.) ose Tester sim owe, B.A., 6.80, VK2ZLO Reader Services ‘Ann Jenkinson Advertising Enquiries Glyn Smith Phone (02) 9939 9295, Mobile 0431 792 293, lyn @ siiconchip.com au Regular Contributors Brendan Aknurst Rodney Champness, VK3UG. Kevin Poulter ‘Mike Sheri, B.Sc, VK2YFK ‘Stan Swan SILICON CHIP is published 12 times ‘year by Slicon Chip Publications Py Lid, ACN 003 205 490. ABN 49 (003 205 490 All material copyright © No part of this publication may be reproduced without the writen consent ofthe publisher, Printing: Hannanprint, Noble Park, Victoria, Distribution: Network Distribution Company, ‘Subscription rates: $89.50 per year in Australia, For overseas rates, see the subscription page in this issue. Editorial office: Unit 1,234 Harbord a, Brookvale, NSW 2100. Postal address: PO Box 139, Colleroy Beach, NSW 2097. Phone (02) 9939 3295, Fax (02) 9939 2648. E-mail: [email protected] ]__19s1 10202082 “Reames ‘od eo 2 Swicon CHIP Publisher's Letter Earth Hour ~ a flawed concept On the ovening of March 31st 2007, Sydneysiders have been invited to tur off their lights for one hour, to domonstrate the deleterious effects of outdoor lighting on the night sky and to draw attention to onorgy consorvation and reduction of greenhouse gases, Tho idea was put forward by the World Wildlife Fund. Oa the face oft, this isa gre ‘As with just about every major city in the world, Sydney unnecessarily radiates vast amounts of heat and light up into the stratosphere every night. Outdoor lighting is just the visible component of that waste and if we can do it on one night, even if only briefly, itmight seta precedent which could be groatly extended. 1'building owners, hisinessos and ordinary residences can be persuaded to cut unnect outdoor lighting, we will cut energy wastage and also allow people to become 4 little more familiar with Sydney's spectacular bight skies. Afterall, the vast majority of the population would not be able to identify the Southern Cross or any of the far more prominent constellations Howover, while the idea of Barth Hour is good, the timing of i is just silly Barth Hour is supposed to run from 7.30-8.30pm. But 7.30pm is not long ater sunset on that evening soit will not be totally dark at that time. Worse still, the Moon rises at 5.41pm that evening and at that stage of the month, itis only two days away from full moon, So any effect of sky darkening by turning lights off thal evening will be langely negated by a big bright moon. Perhaps the WWE and the other promoters of Earth Hour should have consulted with Sydney Observa- tory bofore putting the idea forward! The ideal time to have Earth Hour would hhave been to run from say 8,00-10.00pm (if indeed, it has to be confined to one hou) and to have it about time of New Moon. That way we could have a much botier appreciation of the effect of cutting outdoor lighting, In the meantime, if you want to get the effect yourself, just lake a tip some 100km away from major cities and {owns anywhere in Australia and then you can soe areal dark sky, with all the beauty of the firmament fully revealed, Longwall mining: an environmental disaster Inwiting last month's editorial commenting on iggy Switkows'sroporton nuclear powor I wes conscious that thro wa very Hien the environmental hazards of coal mining inthe report {thought tha hase should have bon om phasisod if Switkowsll was really trying to promote nuclear power. In fact trent looking for oports on the environmental impact of openccteoal mining It could ft ile tet wos relly controversial Howover, just fee wrote that eri a referred othe release ofa new repotton iongwll bal miningin NSW, commtasionedby the Toul Environment Gane Ente, “Impactsofongwall Goel Mningon the Environment im NSW", Itsets out the appalling damage to iors, crooke a ho water abe in general Which occurs when longwall ining is performed, Furermors, it duals tho dumage o Sydney's wate ealcmontta mowhen theNSW government should have Deon doing everything past to ensure Sydney's watr supply. Su! ihe blame cant be all shested home tothe mining compos. Toit Iected hundreds of millions of dollars in ining royalties. Frankly, makes al the NSW governments announcoments and polite relating tthe Stes water resources seom uitery hypocritical. You can dowload the complet report from wwvetec orga For those opposed to the burning of fossil fuels in power stations, to co mining end the export of oa, ts dazning ovidence and another factor which is favourable to th future gonoration of nucluar powor in Australia Leo Simpson siliconchip.com.auPowerful enough to detect interest. Wade Barker suaton $25,400, $55,800" - - Sadie fy I SBE >= = ea free ea APPRENTICESHIP Ny S SPECIFICATIONS Call 13 19 O1 or visit www.defencejobs.gov.auA simple approach to radiator fan switching Tread with interest your article on the automotive temperature switch in the January 2007 edition, Trecently upgraded a 2986 car to electric radiator fans to improve fuel economy and make the engine quieter. ‘The way Igol the fans to turn on and off was simple. | attached acircuit breaker (Altronies $-5595) to the radiator and uused that to toggle a standard 12V automotive relay (Altronics $-4339) ‘The circuit breakers come in different temperature sot points and have built- in hystorosis Rob Clark, Comments on the Intelligent Car Air-Conditioner Controller liked the Intelligent Car Air-Condi- tioner Controller project in the January 2007 issue. My suggestion is to add aan extra function that switches on the air-conditioner every now and again uring the winter months when the air-conditioner is not being used Thave been told that the aircondi- tioner should be switched on for short periods during winter to ensure that the rubber seals don't dry out and thon leak. This extra feature may then save you the cost of replacing the seals and recharging the rofrigerant gas. Not all battery-less torches are fakes ‘Your correspondent Roger Forsey (SticoN Gin, January 2007) must have been unlucky with his battery- less torches. I have bought three of them in various sizes but from auto parts shops. They have all worked ‘well, with the larger ono holding its charge and being able to shine its light at the push of the switch and with no further shaking, In all of them, the “magnet worked remarkably well, tothe point where it would hold a teaspoon in mid-air despite the thicknoss of the torch caso through which the magnetism had to work. Indeed, 1 cautioned my grandsons to keep the MAILBAG Other than having to change the software toadd this feature, the circuit ‘would also need to be changed so that +12V power would be connected to the NO contacts of both Relay1 and Relay2. The NO contacts would need to be connected to the connection be- twoon the air-conditioner Fuse and the air-conditioner relay (or sw Roderick Wall, via email. Source for cartridge styli Tnoted that Rodney Champness was, having difficulty sourcing styli for the Philips RF5 Stereogram (Vintage Radio, January 2007 issue). He could try www.garage-a-records.com. Thoy have just about every component for any turntable, I use them for the oc- casional turntable repair. Pudney & Lee in Wellington, NZ, may also be able to help. Tan McPherson, via email. Partner wanted for electronics development Tam @ Mechanical Design Engineer and my business/hobby is the devel opment of new ideas. [currently have one about to be commercialised and several on-going. One idea under development in- volves programming a chip and dis- ‘magnet away from credit cards! ‘A Google search under “battery= less torchos” will reveal soveral battery torches, all modestly priced. The best that I have found, and a friend brought me four back from Hong Kong, is tho compact, hold-in- tho palm-of your-hand model which is operated by just squeezing the pistol grip on tho underside. ‘This model holds its charge well and is much easier to operate than those wind-the-handle things. gave up on the solar panel jobs: you can’t recharge them if they are in the glove box or in the bedside table drawer. John Richardson, West Pymble, NSW. playing information on a screen for an exercise device. The concept has a novel twist and can be used on most exercise machines and Ihave been lent one by a local manufacturer/importer, who is interested in incorporating the idea into their machines. ‘My knowledge on this subject is limited, so 'm looking for @ partner to dovelop the electronics, so that we can produceiit. A brief search suggests the idea is novel (ie, patentable) and development would be on the basis of their part ownership and income from sales at a later stage. Ifyou live around the Tea Tree Gully area in South Australia, have the skills, and this project interests you, please email me [email protected] and Iwill outline the idea to you per- sonally, under a confidentially agree- ‘ment, so that you can decide. Tony Rossiter, via email Holden airship is actually a balloon The article on the Holden/display airship in the December 2006 issue was very interesting. Ihave beena keen follower of lighter-than-air ships ever since Twas a kid back during WW ‘There are three basic kinds. First, there are dirigibles, which have a complete frame with the gas bags inside and an outer skin over the frame, Zeppelins and the US Navy's Shenandoah-Class airships were of this kind. Then there are the blimps, which have a half-frame in the lower portion of the torpedo-shaped body. ‘The most famous of these are the throe Goodyear blimps. ‘Then there are balloons which have no frame at ll. Examples are the Mont- goliier Brothers” pioneering balloon, tne of the very first to fly, then the hot airballoons of today and of course, the 4 Swicon Cour siliconchip.com.auAdjustable hysteresis for Battery Controlle Tread the article in the December 2006 issue on the 12/24V Battery Isolator with onthusiasm, Over the years | have made up many of the original EA 1992 Low Voltage Cut-Out kits for myself and fellow campors. That kit is reliable and solves the problem of over-discharg- ing the battery. However, | have always boen troubled by the fact that it draws a constant 70mA or so for as long as tho relay is energised. With devices liko refrigerators becoming more ef- ficient both in terms of the current drawn and how much of each hour is taken up with the “on” duty cycl that current drawn by the cut-out is becoming more significant, even if only psychologically so. As you correctly observe, overy microamp is indeed precious. This new controller could be just the bee's knees as a superior replacement, not only because of its nogligible current drain but also its robust current capacity. However, it appears that, in the low-voltage protection mode, it has almost no hysteresis. If set to drop out at say, 10.5V, it would cut back in agai at 11.1. Even with a modest load of 24 or 3A, the device would cut out at 10.5V and the battery voltage would almost immediately drift up to con- siderably more than the 11.1V cut-i voltage. It would cycle thus, with possible bad effects on the fridge etc, ‘until the battory was finally drained enough to not drift up much. This isa problem we experience with the standard cutouts found on some 12V refrigerators over the years, ‘The EA kit has an adjustable hys- teresis, so you can have the control- lercutting out at 10.5V to 11.5V and the cut-in happening at say 12.8V. famous barrage balloons which flew over cities in wartime. Those barrage balloons were large and tethered by strong cables and were there to inter fere with low flying aireraft Contrary to the statement in the article indicating it was either a dit siliconchip.com.au This is an offective solution. Can ‘we add this capability to the new controller? John Keitley, via email. Comment: we referred this question to the designer, Branko Justic, at Oatley Bloctronics. His reply is as follows. The hysteresis ofthe voltage sens- ing comparator of tho 14949 IC is around 8%, which corresponds to 0.8V at a battery voltage of 10.5V. AAs pointed out, this may not be suf- ficient in practice. ‘A simple way to increase the hysteresis would be to add a series resistor and diode combination between the input pin of the com- parator (2) and the open collector output pin (7). With this in place, when the bat- tory voltage is high the open-colle tor transistor is off and the voltage is pulled high (+5V). The additional diode is reverse-biased so this net- work would not have any effect on the voltage at the voltage-sensing comparator. However, when the battery voltage falls bolow the lower set limit, the open-collector transistor is turned on and the series resistor/diode combination would add extra load- ing between the comparator input pin and ground, This means that the battery voltage would have to rise to a higher figure before cut-in, ‘amounting to increased hysteresis. With a series 1N4148 diode and 43kQ. resistor combination con- nected between pins 2 & 7 of the 14949 IG and with the cut-out volt- ago get to 10.5Y, the cut-in voltage was 12,9V, Wo will modify our PC boards to make provision for these componentsand includea note with our kits. Branko Justic, Oatley Electronics Pty Ltd gible ora blimp, the Holden airship is actually a balloon. It has no internal structure or frame and the gondola is attached in the standard balloon ‘manner, suspended by a set of cables from the gas bag, The main difference between a barrage balloon and this air Atmel’s AVR, from JED in Australia JED has designed a range of single board computers and modules as a way of using the AVR without SMT board design Tne AVAS7O module (above) ‘s 2 way of using an ATmegaT28 CPU on a user base board without having olay out the intricate, surface-mounted surrounds ofthe CPU, and then having to manutacture your Board on ‘an SMT robot ine. Instead you simply layout ‘2 square for four 0.1" spaced socket skips and plug in our pre-tested module. The module has the crystal, resetter, AVA-ISP programming haader (and an optional STAG ICE pad), as well as programming signal swtchng.Foraliteexta, we load a DS 1305, FTO, crystal and Li battery underneath, which uses SPI and port G See JED's www site for a datasheet. |AVR573 Single Board Computer| ‘Ths board uses the AVAS70 module and ‘add 20 Ain Dg inputs, 12 FET outputs, LCOY Ke, 2xR292, 1X85, 1-Wire, power reg, ‘ic. See www jedmiero.com.au/aventm $330 PC-PROM Programmer ‘This programmer plugs into a PC pxnter port and reads, writes and edits any 28 oF 2:pin PROM. Comes with plug-pack, cable and software. rmult-PROM UV eraser Alsoavailabe ‘with timer, and a 32/32 PLCC converter. JED Microprocessors Pty Ltd 4173 Boronia Ré, Boronia, Victoria, 3185 Ph 02 8762 3588, Fax 03 97625488 www.jedmicro.com.au MancH 2007 83-phase motors have excellent torque T've worked extensively with the application of 3-phase induction motors in industry and I don't agree with the comments of correspondent Jeff Jones (Decomber 2006 Mail- bag) who says they have poor start torques. Induction motors started direct on line (DOL) have excollent start torque characteristics ~ typi- cally locked rotor start torques are ‘more than twice the motor fall load torque. This start torque remains reasonably constant until the motor approaches its running speed, where the torque delivered by the motor reduces to match the load, agree that reduced voltage start methods decimate the starting tor que (start torque varies as the square of the voltage). Even with DOL starting, high- inertia start loads can trip you up. A classic example for us was the eppli- cation of centrifugal blowers. They often havea small aerodynamic load due to low air volumes but a high mechanical inertial load due to a large diameter but narrow rotor. Motor size is traditionally ostab- lished from the aerodynamic load and this means the run up period to full speed can be long—and with a typical start curront draw of 5-7 times tho full load current, they had a tendency to trip their thermal overloads. This was usually solved by using electronic ovorloads with an adjustable run up time. like your editorials which take an honest and straightforward look at the state of things. There isan eye on waste and sustainability which is good. So why tho extensive feature on the airship in the December i sue? It may be technically interest- ing but is an unnecessary and an exponsive waste of resources for no ship is the rigid tail fins with control surfaces, I was quite surprised at the state- ‘ment that the gondola was built on a steel framo, as this would be nearly 6 SmicoN Carp Mailbag: continued real purpose other than to serve as a floating billboard, If you believe we need more invasive exposure to advertisers then I've misjudged you. I frankly don't seo any point in its existenca. You lead the way in asking why car manufacturers now add frills and not enhanced performance and economy to their cars and yet in the same breeth laud this thing. Tread yourarticle on cheap battery drills and like a man onlightened 1 rushod out to purchase now batteries for my favourite (and ailing) drill. Now repacked, I look to the smart charger and well... phew! It's pretty clever but isn't it really applying a hammer to crack a nut? ‘Why not just charge the drilt the trickle current and leave it at that? OK, it takes 20-30 hours to fully charge but if you can leave it on all the time then itis likely to be Fully charged and ready when you need it. So it goes flat part-way through that job? If you are like me, I wouldn't ‘wait even three hours for a drill to recharge, I'd curse, go to the garage and drag out a lead and power drill and finish the job. OK, that wouldn’t suit a trades- man but they wouldn't use these cheap drills anyway. I'm talking of the home handyman, The extensive kit dovelopment ‘you do for cars is fascinating but the thought of dissecting my car's dash facia to fit any of them is scary. Andrew Buchanan, Comment: we agree that we don’t need any more advertising but we thought the technical story of the airship was of interest. We realise many people would be reluctant to break into their car's wiring but we believe that we should show what is possible twice as hoavy, for the same strength, as aluminium/magnesium alloy fram” ing. I don’t know of any other lighter- than-air vessel with steal in the struc- ture except whera its use is unavoid- able; og, as support for the engines ‘And in many designs this too is made from forged aluminium alloy. The Montgolticr balloon was lifted by methane, which is only one third as dense as air (but easily available in those days). Helium is 1/10th and hydrogen 1/20th as dense as air. The only suitable lifting gas for dirigible airships is hydrogen. ‘The US Navy's attempts to use helium in their dirigibles saw all five quickly lost in storms at sea all of them came down with the loss of all life, Helium is simply too dense to lift that kind of weight. Blimps have a limited weight-car- rying capacity, even with only half the frame of a dirigible, due to the limitation of using the higher density gas, helium, Puro hydrogen is perfectly safe; it cannot explode unless contaminated with oxygen (as will all flammable gases) and will just bum if there is a fire. No Zoppolin other than the famous Hindenberg ever crashed or was lost. The Zeppelins were truly huge. ‘Thoir scale was unimaginable ~ they carried many fully furnished cabins, a ballroom, dining room, galleys and nearly everything an ocean-going luxury cruise ship would have. It was —even built ofaluminium—amassive amount of weight but was lifted with lots of capacity remaining by hydro- gon-filled gas bags which at cruising altitude occupied less than helf the interior of the ship. Too bad that since the Hindenberg's destruction, hydrogen is not preferred for lifting airships, even though it is not really a serious danger or problem = in fact itis easier to contain than he- Iium, the “escape artist” of the gases. Bear Stanley, Atherton, Qld. Audio tones can cause clocks to gain time With respect to the letter in “Ask Silicon Chip” in the December 2008 issue, the writer is quite correct in that AFIC (Audio Frequency Injection Control) tones which are used for off- peak, street light and tariff switching can affect digital clocks. This usually happens when the tones exceed 20V and the clocks race siliconchip.com.audue to multiple zero crossings during the tone burst This can be from minutes to hours, depending on the level. The injected level is usually set to between 3V and 10V superimposed on 240VAG. The signel rises, usually due to the area in question being supplied by a feeder that consists of a long length of overhead cable with an underground subdivision at the end. This can create a resonant circuit at the control frequency which then acts ‘as a voltage doubler. John O'Brien, via email. Remote Telltale for Garage Doors Thave a comment regarding the microswitch arrange- ‘mont for the top &bottom limits on the door track shown on the inset photo on page 59 of the Remote Telltale for Garage Doors in the January 2007 issue, The arrangement shown assumes that the door is going to stop in tho same position each time it reaches its upper and lower limits, Which is not always the caso, particularly if the door is manually raised and lowered. ‘Abettor arrangement would be to orientate each switch at 90° to the insot shown whereby the switch activator points towards the door and a sprung follower is attached to the door to activate the microswitch. An oven better arrangement would be to install a magnet and reed switch which requires no mechanical contact. If your house has a security system that protects the garage doors, the door magnet could activate the addi- tional reed switches when the door reaches its upper or lower position. Mal Land, via email. Comment: we did not envisage that this project would be built fora doorthat was manually operated. However, your ‘comments on manually-operated doors are quite valid. RME equipment search T would like to hear from anyone who used to work GO TO www.rsaustralia.com Professional AM-FM Monitor Receivers Complete Broadcast Studio Off-Air RMR-01 fichier Receiver yom sath Composite Output, Audio Distribution and Alarms RRR-01 __,, versatile Alen Receiver 240 V AC and 12V DC Operation Composite Output - Re-Broadcast - MATV Systems ‘Tunnel Repeaters - Radio News Rooms - Pre Select Up to 32 Mixed AM - FM Stations via RS-485 Control ‘Optional Mode! PSS-01 Wired Controller Available deal AM Receiver for use in Remote Locations SMR-01 ‘Scanning Monitor Receiver Monitoring of up to 8 Mixed Remote AM - FM Services - Failure Report by FAX For Deals and Price, please contact us at ELAN Phone 08 9277 3500 ‘AuDIO Fax 08 9478 2268 2 Steel Court. South Guildford email [email protected] ‘Western Australia 6055 worw.elan.com.au for a company called RME that used to be in Sydney and made broadcast equipment for radio stations. Specifically, 1 am looking for the plans/PC board lay- outs, or even original boards, for the 451M1 LED Level Monitor they used to make. Ultimately, if someone has a complete unit, I would be most interested in buying it but siliconchip.com.au Mance 20077LOCTITE. since 1939 Multicore has been the world leader for soldering materials Prime Electronics, thelr sole distributor in Australia, carries extensive stock of most Multicore products in both Tin/Lead and Lead-Free. This includes Solder Wire, Solder Paste and Gel & Liquid Flux. Prime Electronics is also the sole Australian distributor for Loctite® electronics products Contact Prime - Sydney (02) 9704 9000 Prime - Brisbane (07) 3252 7466 or email us: [email protected] é Mailbag: continued Electrical licensing is still a bureaucratic mess. T'm writing in regard to the electri- cal wiring license debate which will very soon raise its head once again. Asa frequent magazine buyer, Tread many of the responses a few years ago from SILICON CxiP readers and can only agree with the roadors and look in disbelief at the unreasonable electrical licensing rules, especially those in Queensland. ‘As you may be aware, 2007 could be scheduled for a review of the Electrical Safety Act in Queensland ‘which was last written in 2002, since ‘thas been five years since the last publication. 'm writing to give an indication to you and the other readers as to the difficulty in becoming a licensed electrical worker in Queensland from my own experience. Throughout my university stud- ins, completinga Bachelor of Electri- cal & Computer Engineering, I was ‘working part-time at a small TV radio ropair shop as an electronics tochnician repairing TVs, consumer electronics and audio-visual equip- ment for around 20 hours per week. This work was supervised by an experienced and restricted licensed technician and has continued on a part-time basis despite having a full-time engineering position since completion of my studies. board layouts would be the next best Please contact me at happydayradio@ hotmail.com. S. Williamson, via email. Safer method for discharging microwave oven capacitors Tread with some awe the descrip- tion of how to discharge a high-volt- age capacitor in the December 2006 {ssue, on page 94. A doad short on a fully charged capacitors foolish, very frightening and almost as dangerous as leaving il fully charged. Tho cor rect way to deal with it is much less spectacular: a resistor of about 10, ‘When [first bogan my engineering position { was required to confirm my ability to porform some wiring. My position does require me to construct prototypesand teste cal components for use in designs which involves a disconnect/recon- nect licence. Prior to approaching the ESO in Queensland about a licence, I had read the current Safety Act and noticed a clause which is still cur rent, stating thet a person does not require an electrical license for the performance and supervision of electrical work as part of practising the person's profession asan electri- cal engineer. I contacted the ESO to confirm my understanding of the clause. I obtained many varying responses which did not give me any confi- dence in my understanding of the clause before I eventually spoke to the head of licensing at the time who T explained my position and work to and was informed that the work Iwas doing is covered by the clause although the clause would not cover iy second job as a technician. ‘This led me to apply to obtain a restricted electrical license in order to continue the technician work. Applying for a license requires completion of forms which require details, evidence of a trade or call- ing requiring an electrical license, well insulated (eg, contained within a plastic box), connect one side solidly to ground (as one side of the capaci- tor is usually grounded, through the transformer secondary winding and often a high-voltage fuse), and con: nect the other side to each side of the capacitor in turn, Use something like a high voltage screwdriver as pictured in the article, and tape a good quality multimeter probe to il, There should be a small arc if there is any charge in the ca: pacitor, Boawarothat ifthe high voltage fuse has blown, you will need to connect directly across the capacitor but try Smico Gir siliconchip.com.auJP-signed evidence of CPR qualifica- tions and paying the prescribed foe for processing. Several weeks passed without response before eventually getting a Teter stating that an electrical engi- ner is not a trade or calling that re- quires an electrical license and that my application was rejected. I then obtained a number of letters from my employer as evidence of my require- ment to perform electrical work and resubmitted my application. Many weeks passed before gettirig, another lot of paperwork from the ESO containing a training permit stating that I would have o complete atarelevant TAFE college a number of courses and sign-off from an elec- trical worker of my competence to perform the required electrical work. My electrical engineering dogree, according to the ESO, means noth- ing for the purpose of obtaining a license, Tovontually founda TAPE college that permitted metosit fortherelevant xams and practical competency tosts, saving me around $1600 norm- ally required in fees to enrol in the appropriate courses. After eventu- ally having completed all examina- tions for the license, a completion statement of my competence in electrical wiring was sent to the ESO for moto obtain the license. The ESO ‘managed to loso the relovant docu- ‘mentation soveral times, dolaying the process by a further two months the ground method first. This is MUCH safer and then you can go directly ‘across the capacitor. Refer to the WES components Microwave Oven Servic- ing Manual for further information. ‘There are 24% pages of safety notes, quite a fow of which are applicable to those recycling the bits T service electric fence energis- ers and need to discharge the dump capacitors, typically 30,F to 120uF charged up to 900V through a mains doubler or riplercircuit. use asimple pair of multimeter probes with eight 56022 0.5W resistors in sories within the probe bodies (four in each). The probe tips are long enough that I can before I finally obtained a licence. As you may appreciate, the pro- cess for obtaining a licence is ox- tromely difficult and frustrating. 1 believe that electronics technicians should be issued with the license as part of their trade and that electri- cal engineers should have a com- plete unrestricted electrical work Ticonce. Don't get me wrong, I do not believe some electrical engineers after completion of their studies are competent at performing wiring but... they should be. Punishment should be on unsafe wiring rather than based on relovant licensing, ‘The ESO appear to have the rules in place for ensuring business and economic growth for olectricians and have no regard for electrical engineers, electronic diploma gradu- ates, technicians and DIY hobbyists that simply want to construct elec- tronic circuits for their own use. ‘The unrealistic stand the ESO has taken on licensing end the unbeliev- able difficulty in obtaininga license is unaccoptablo. I very much hope that some serious changes are made tothe Electrical Safety Act before the next amendment is published Name and address supplied but withheld at the writer's request. Comment: the Queensland bureauc- racy continues to amaze with their ongoing stupidity with regard to electrical licensing and safety. The other states are not much better. short thom togethor after about five sec- onds, just to make sure the capacitor is discharged, here is enough energy in these capacitors to destroy the tip ofa screwdriver. With regard to microwave trans- formers, its easy to cut off the exist- ing secondary (with a hacksaw and cold chisel combination) and wind a new low voltage secondary on it. OK, maybe it will not be pretty or 99% efficient but the primary winding is generally well protected and it isa big impressive-looking heap of iron. David Walters, Dubbo, NSW. it’s ne fluke that Agilent’s new fandheld DMM... is designed especially for electronics professionals. Inrocing the new UI252A Dl rom Agent ‘Tecinaoges, the werd ease in Test enrement The UI252 comes wth = 45 digtrecutin on both ap, ~ est enc DV accra, Tre RISAC ~ Dnltarperatire Capactance Oto oom ~ nae Frequnny Cote; Nats Functions — Proganmaiecure-nae gentoo ~ Recharges bat, ack LCD day Free P caecty stare fr dat aes (cponat cate require) Bue aad rte = 3 year Autatan vanity and ata very affordable price! Model Ui2514 $586 + 6ST Model UI2528 S641 + GST Dowrlaad produc brochures, vew ering ‘demos, and prchse ote ot ‘eameasurement neta, lense andere dotbuted strat vie by Neasirenent novation. Tel: 1300 726 550 bet nine memati siliconchip.com.au Marcu 2007 9Silicon. One of the Earth’s most prolific substances, yet so important in our 21st century lives - from computers to disc technology - and glass. jar from simply being a soo Frit iris dp glass is often shaped and ‘value- added’ to suit many applications. ‘You would know glass can be pro- duced to block or reduce heat, glare or noise (or a combination of all three) It can be tinted, it can be one-way, it can be patterned. But these days, thanks to the humble PC, glass can be so much more Much of the glass enhancement would be infinitely more labor-inten- sive, expensive and complex —in fact, may not even be possible to produce = without computers Here we look at a major glass sup- plier's use of computers to help manu- facture some unique products. DMS Glass in Melbourne is one of the largest glass enhancement manufacturers, producing products that we often soe but usually don’t appreciate the technology employed to make il. Like not being able to see the ‘wood forthe trees, glass is traditionally something you look through, not at DMS Glass's vast plant has made ass for sites like the Olympic Games facilities at Homebush, Hong Kong Airport, Crown Casino, Rialto tower, Melbourne Entertainment Centre, Melbourne Museum and Flemington Racecourse, to name a fow. Just some of the products they make include laminated (toughened) glass, ballistic (bullet-resistant) glass and Digiglass, a laminated, printed glass invented in Australia, nd ‘The convention Centre at Darling Harbour, Sydney has DMS Enviroshield laminated glass = This product was chosen for properties and the large pete windows. excelent heat control ight transmis.Each manufacturing step (and in- deed the whole plant) is controlled by 'mid-weight’ PCs or higher-power specialty computors, This rosults in some huge machinery controlled by modest size computers ‘Toughened glass Toughenod glass is manufactured by exposing ordinary annealed glass to oxtromely high temperatures. in an oven prior to entering a chilling chamber. This process induces stresses with- in tho glass that enhance the panel's strength by approximately five times. A PC controls the speed, time and temperature of the glass when itis in the various phases of the toughening plant. Laminated glass Laminated glass is manufactured by inserting a Poly Vinyl Butyral (PVB) interlayer betwoon two sheets of glass, with the clean-room environment ensuring blemish-froe glass The assomblod glass is transferred to an oven and roller press (to force out any trapped air) via an automated roller systorn. Computersensors detect siliconchip.com.au Veto un theglass movement, with aPCcontrol- ling the production-line flow. The laminated glass is exposed to tomporature and pressure in an autoclave to finalise the bond. When laminated glass has more than two glass panes, a PVB interlayer is placed between each glass layer. Stopping a bullet Ballistic glass is @ laminatod glass with multiple layers of glass and in- terlayors, designed to remain intact after attack by bullet, hammer, axe or similar weapon. This glass isalso used for prison windows Some ballistic glass is designed to maintain intogrity against blast. It is manufactured in accordance with Australian/New Zealand Standards ASINZS 2943. The thickness and quantity varies depending on the ballistic throat level No one ballistic glass is suitable to moot all levels of ballistic threat and therefore a ballistic glass designed to protect ageinst a 9mm pistol threat is considerably thinner than glass de- signod to withstand a 357 Magnum. Partofthe AS/NZS 2343 compliance requirements are that the sample glass This is the result igh-powered weapon shot. The glass is marked, but still intact, Ballistic glass is laminated glass or multiple layers of glass and interlayers that vary in thickness and quantity depending on the ballistic threat level. By Kevin Poulter panols are shot throe times within a set spacing with no ‘spall’ fragments penetrating a paper backing, attended a number ofballisticglass teats, in adiscrete undonground firing range in Molbourne’s suburbs. Few neighbours would know that below 1 small factory, firearms are used for tests or training most of the time. The glass resistod the best offorts with all kinds of firearms, with bullets and axes not managing to open ahole. There was plenty of cracking but there was no way that anyone could enter a building protected by this glass—even when the number of shots exceeded test paramotors Blast-rosistant glass is far moro challenging to develop, due to the uncertainty of the size and position of the bomb, plus the associated forces. Extensive, detailed tests are carried out to design a glass capable of with- standing the worst case example. Digiglass DMS's own printed and laminated Digiglass is an amazing product. The industry historically has never been vory inventive at decorating with glass but this medium has cortainly opened Man 2007 41Very little glass is either cut or processed by hand these days. The human operator has been replaced by PC consoles in nearly all aspects Jags cutting, edge- laminating, CNC precision notching, toughening and thing. I's staggering to see npact of computers within the DMS 60,000 square metre factory and the glass industry in general, in the glass panels, encapsulating the the life of the panel. up whole new areas ~ memorials, mausoleums, decorating skylights, features in walls or entire cladding of buildings. DMS glass international Market ing Manager, Gerard McCluskey and inventor of Digiglass, said “We are continually taking the product into ‘Toughened glass is manufactured by exposing ordinary annealed glass to extremely high t speraturs in an aven prior to ent This process induces stresses within the glass that enh a chilling chamber. ice the panel's strength by approximately five times, compared to annealed glass. The PC controls the speed, time and temperature of the glass when w {CON CHP the toughening plant. ‘The internationally patented Digiglass process digitally p onto a specially formulated PVB interlayer wi resilient to UV fading The digitally printed age between 3 ting images directly ss which are inated between image for ‘compatible i is then la new areas, where glass has novor been Door ““Qurrole is creating an understand: ing of what its capabilitis aro. Histor cally glass has always been perceived as a product that keeps out the wind and rain, Now with tho latest tech: niques and manufacturing processes, it can achieve a lot more.” Five years ago, screen-printing or adhesive films wore used to place imageson glass. The adhesive mothod was high maintenance and detorio rated quickly ‘The solution was simple in concept, if not in the development. For years, DMS has added a film lemination to tho contre of glass, for strength or UV control. Thon in a stroke of inspira tion, Gerard McCluskey experimented with adding ink-jet print onto the interlayer McCluskey continued: “We ran some experimental prints and got a fantastic result, so thought ‘what are wwe onto hore!" There were problems with adhesion, bocause the inks con- taminated the surface of the interlayer, so another uncontaminated interlayer was placed on top. Now with two uncontaminated interlayer surfaces against the glass, we achioved very good adhesion. Tho rest, as they say, is history The internationally-patonted Di- siliconchip.com.auGlass orders from perhaps many Toaded on a PC for for the lowest-waste layouts. This is a vital step in effic- iency and economy. The computed data is fed to the cutting table at giglass process consists of digitally printing images directly onto a spe- cially formulated PVB interlayer with compatible inks, resistant to UV fading when glazod externally. The printed interlayer, in high-resolution full colour, is then laminated between Grade-A safety glass panels, encapsu- lating the image and protecting it for the life of the panel. This technology is now sold around the world, luskey is excited with the Di giglass versatility. “The beauty of our product is we can produce a panel today and replicate it in 10 years time for whatever reason. If it needs to be replaced we can make a copy, or even change the colours or tonings tomatch it to the latest surroundings. DMS established worldwide patents but not possessing the international clout to rebuff copycat interlopors, engaged DuPont to market the product outside Australia and New Zealand Now buildings and features such as the Memorial to the Canberra Bush Fires and many in USA feature Digiglass. How it’s done A graphic artist makes the image graphic file on a PC, then the file is loaded into a DMS PG for formatting. Graphic file sizes can be as large as 1GB. Once formatted for production siliconchip.com.au A diamond-tipped wh shapes. A sheet of pattern of holes, round t e glass at great speed, cutting the ‘moved on the table, as air is ng the glass ‘float’ easily on command, When in the through a correct position, the airflow is reversed, with the suction holding the glass ready for shipment. the data is forwarded by cable to a very large ink-jet printer deep in the fac tory. Even the inkwells make a home printer seom tiny! The image or pattern is printed onto the interlayer film, in a dust-free environment. Specially developed propriotary inks and interlayers ara jome glass is cut by a hi ely new inno. 1s or complex shapes. Ag prescure jet of water, Water jet cut on and is extremely effi firmly in place. Some tables rise to vertical, vertical storage of the glass until usod in combination to offer the ideal adhesion, resolution, and dimensional properties needed The printed film is then taken to the Jaminating-room, @ clean room ‘with a multi-million-dollar computer controlled laminator. Boing PG generated, last-minute ng of glass is at when cutting multi-ply ihe process is controlled by a PC. Manet 2007 43changes and previews, such as four different color versions of the samo image for comparison, are no problem. Applications are as varied as the imagination ~ even, bus shelters, where Digiglass creates a feeling of openness and cleanliness, while still offering people a good view of, approaching buses or people. Even vandalism soems to have been reduced ~ as soon as Digiglass started putting images within glass, less panels needed replacement, Perhaps it was because the glass was now telling story, it had a theme or had a pictorial image and was no longer something simple to be destroyed. Beauty and brains. Digiglass is visually dramatic and beautiful, plus just as strong and practical as any glass. The product meots AS/NZ, 2208 Grade A Safety Class standards. ‘A vory successful but initially unanticipated application is Digiglass images in laminated glass momorial products ‘The product has beon recognised by DuPont in the Austral- ian and New Zealand Innovation Awards, as a finalist in the Construction and Architecture calogory. Tho walls in the lift at the new Mercedes Benz Mol- boume showroom are Digiglass, displaying their notable sports cars. Located in South Melbourne, the showroom is predominately a steol and glass structure, designed to convey the sanse of quality associated with the automo- biles on display. The outside of the building is DMS Enviroshield Sun- ergy Glear Hoat Strengthened Laminate. The 12.76 mm laminated glass, which incorporates XIR 72-74 film by 44 Silicon CP The fully automatic glass lamin: finish, glass is asseittbled then transferred to an aven and press via an automated roller system, controlled by comput Southwall Tochnologies, created a neutral colour, energy- efficient product with exceptional solarand thermal control properties, The glass has an exceptionally high light-transmission of 72% to maximise daylight, while offering increased comfort and superior reduction in solar heat gain (0.47 solar heat gain coefficient) and minimising outside noise. Glass is a very unforgiving product. It is unlike any other building product. It’s brittle but it’s probably the most hard-working and long-term building product; one that needs very little maintenance. When processed for strength, it's suitable for stairs and walkways, or even for armored vehicles. Computing power Until the 1980s all glass processing, including cutting and edging, was done by hand. The skills ofthe tradesmen had to be at « very high level but now, with advances in computers end electronics, hi-tech methods of cutting and edging glass are employed Gna area where PCs now save time and money is op- timisation. For best efficiency and economy, the ‘jigsaw’ shapes of a number of orders are placed inio a computer program and the best use of the available shoot-glass arca is plotted. This enables the biggest shoots of glass to be cut into shapes for two, five oF even ten different customers. ‘The computer optimising application can reduce the off-cut factor down to a minimum, with @ waste factor of 5% regularly achioved. n process. In the white room e8s and a blemish-free glass i the PVB interlayer. ‘his which ensures clea: ther sid Sensors detecting the glass movement.Most often the lange shoets of glass arecatintocustomerordered oblongs but any conceivable irregular shape can also be cut. To order irregular Shapes (for example a peantt-shape tabletop) designers supply a precise template in wood, ‘The template 1 photographed, then goes into a CAD syst If out of square or irregular, shapes and dimen slons can'tbe taken, a probe is used to touch multiple points, automatically sending data back to'tho computer and rapidly creating the overall pancl “The optimised and shaps dataisfed into the cutting and/or hote-cutting machines’ computers. Cutting and holedrillingis achieved elther ona rapid diamond-cuter, the lneaaeupaly pow ert] water cult sion drilling of glass is vital for accurate installation of itings such as orhole dill With the latter, holes © andles, hinges et. All processing of glass must be completed prior tothe drilled from both sides at'the sarne toughening process as once toughened its considered a finished product. These time, to avoid burs and chipping computersiriven drilling notching and routing machines offer pinpoint accuracy. (known as ‘shelling’) With the table-type glasscutter, a single operator can glide a huge sheet of glass into position with aso, thanks to a cushion of air. ‘A multitude of holes all about the size of drinking- straws, are fed air under the glass. This onablos the operator to ‘glide’ the heavy glass into position. Then the air is evacuated, holding the glass firmly and precisely in place. While their hole-cutting CNG machines make a complete cut, the shape ‘cutting’ tables only score the outline, so most glass-cutting tables now have automatic breakout capabilities. An airdriven foot pump activates bars that rise up underneath the scored glass, to push the cuts apart, Some tables rise to vertical, allowing glass tobe stored vertically, until ready for shipment. ‘Tracking the glass Large manufacturing plants need to track orders to ensure timely completion, schedule production, optimising and capacity planning. DMS glass has introduced a barcode system, s0 each step is ‘read’ on completion and automatically recorded into the sorver's files. Hoat treatment will dislodge the barcode, so at a number of ‘stages, the stickers are removed and subsequently replaced with new stickers after treat ment. The advantages of barcoding are many, such as quick reordering a part if it does not pass inspec tion and maximis-ing the output and officioncy of production machinery. Computers are integral right through the manufac- turing process and even include DMS glass delivery. As the trucks make their way to the clients, the ¢ monitored on screen by a Global Positioning ished Mercedes Melbourne Car Showroom chose Digiglass to depict vehicles of various eras in the showroom lift. ‘The Digiglass mural only requires routine cleaning, as the image is protected within the laminated glass. System! sc siliconchip.com.au Manic 2007 15By JOHN CLARKE Prog | system) For Cai Want to program the ignition timing on your car? Now you can, with this completely new design. It can be used in older cars which presently do not have electronic ignition or used as an “interceptor” for cars with engine management systems. UR PREVIOUS Programmable nition was originally published in March 1996 a tobe popular project with readers. This w: subsoquently updated as tho Program: mable Ignition Timing (PIT) Module in the June and July 1999 issues of Sisco Cut. The updated PIT module included 16 Siicon CHP a basic 2-step advance curve and a 1-step vacuum advance that changed the timing according to engine load jon, itwas used to control the from the Ignition ‘oN Cutis far more advancod tures and its ability to produce an accurate advance curve. Its also a complete stand-alone ignition system id by an engine position ives the ignition coil. It can be tr many sensors trigger and the BV signal cm cars Engine Control Unit (ECU Th ordor to measure engine load, the Programmable Ignition can uso a Sensym absolute pressure sensor. In fact, provision has been mado to mount this sensor directly on the PC board the sensor then being connected to the ongine manifold via plastic tubing Altematively, you can connect the ignition circuit toan existing manifold pressure sensor if present. This is ‘commonly called a Manifold Absolute siliconchip.com.auPressure (or MAP) sensor and is found ‘on many cars these days. You could also uso a secondhand MAP sensor from an auto wrecker, Changing the timing A fully effective ignition system needs to increase the timing advance with increasing RPM and to alter the timing according to engine load all with a fair dogrea of precision. Addi- tionally, some means to detect deto- nation (knock) and retard the timing would bean advantage. In this way, the {ignition can be advanced further than ‘would otherwise be possible without knock sensing This latest SILICON CHIP Program- mable Ignition incorporates all these features, What's more, there is an op- siligonchip.com.au tion to select between two separate ignition-timing curves usinga switch. This option is ideal if you are running, both petrol and gas, where a different timing curve is required for each type of fuel. Fig.1 shows the complete system. It comes in four modules: an LCD Hand Controller, a Programmable Ignition Timing (PIT) module, an Ignition Coil Driver module and a Knock Sen- sor module. The first three modules are mandatory, while the fourth, the Knock Sensor module, is optional. ‘The heart of the system is the Pro- grammable Ignition Timing module, based on a PICI6F88-E/P micro. Itis programmed by the LCD Hand Con- troller and it delivers a signal to the Ignition Coil Driver. The latter, as its name suggests, thon drives the igni- tion coil. LCD Hand Controller ‘The LGD Hand Controller is simi- lar to the one featared im our book “Performance Electronics for Cars”. It was originally designed for setting up the Digital Pulse Adjuster, Digital Fuel Adjuster and Independent Boost Controller projects featured in that book. ‘Tho Hand Controller is used dur- ing tho initial sotting-up procedure. It plugs into the main unit and can be used while the engine is either run- ning or stopped. It is then normally disconnected from the main unit after all adjustments have been made. Using the Hand Controller, you can set all the initial parameters and also ig: this diagram shows the idules used in the Programmable Ignition System. ‘The LCD Hand Controller is used only during the initial set-up. program the ignition advance/retard curve, Several pushbutton switches on tho Hand Controller enable these changes to be made. Knock sensor ‘The optional Knock Sensor mod ule enables “pinging” to be sensed and the ignition timing retarded for a briof period. In brief, engine pinging is monitored by the Knock Sensor and ‘the Programmable Ignition Timing (PIT) module for the first 6ms after each spark. However, at high RPM, there is less than 6ms between each firing and so knock signal monitoring is done between each spark and the start of the next coil dwell period. When engine knock is detected, the timing is retarded for the next 10 sparks, The amount of retardation varies according to the severity of the knock signal. More dotails on this are given in the specifications, rent uses ‘The Programmable Ignition can be used either as an interceptor or for fully mapped ignition timing. In the intorcoptor role, it can vary the existing ignition timing by advancing or retarding it from its current value — ie, it can be used to alter the timing signals feom the car's ECU. ‘Alternatively, when used to com- pletely replace the existing ignition liming, you will need to obtain the advance/retard curve for your vehicle so that the entire timing curve can be produced by the Programmable Ignition. For some vehicles, you may ‘Maron 200717‘Advance and retard adjustment over a wide range Plug-in LCD Hand Controller for adjustments Hand Controller LCD shows values and settings for adjustment Suitable for single-coll ignition systems with a distributor Can be used as a timing interceptor or as a replacement ignition Ignition timing mapped against RPM and engine load Interpolated values used for RPM and load values between sites Optional single map or dual timing maps Single map has 15 RPM sites x 15 engine load sites Dual maps each have 11 RPM sites x 11 engine load sites 1° oF 0.5° adjustments Dwell adjustment Knock sensing indication with optional ignition retard Suits 1 to 12-cylinder engines (4-stroke) and 1 to 6-cylinder 2-stroke engines ‘Two debounce settings High-level or low-lovel triggering Points, reluctor, Hall effect, digital signal or optical triggering ‘Works with many pressure sensors (MAP sensors) Minimum and maximum RPM adjustments Minimum and maximum engine load adjustments Diagnostic RPM and load readings ‘Add-on knock sensing unit (optional) Requires evenly spaced firing between cylinders. For V-twins, you will ‘need two ignition systems and a separate trigger for each cylinder. be able to obtain the curves from the manufacturer, For other cars, you will neod to plot out the existing curve and transfer the resulting timing map to the Programmable Ignition. Plotting out this timing curve is not hard to do and can, in fact, be done us- ing the Programmable Ignition system itself and a timing light. In practice, the ignition timing is mapped out in an array of either two 18 Sticow Cap 11-RPMby 11-ongine load site maps or asa single 15-RPM by 15-engino load site map. ‘Timing arrays (or ignition maps) are the most common method that car manufacturers use to set the ignition advance curve for both RPM and engine load Mapping isa way of plotting the ad- vance curve as a sorias of steps rather than setting an ignition advance or relard value at every possible engine RPM and load value. Thus mapping sets the ignition advance or retard values at specified preset points for both RPM and engine load. For example, we can specify the tim= ing advance to be 25° at 3000 RPM and 26° at 3400 RPM, However, we do not specify individual values at 3100,3200 or 3300 RPM. Instead, the advance values at these RPMs are interpolated Ge,calculated), based on the values set for 3000 and 3400 RPM. At 3200 RPM, the amount of ad- vance is easily calculated because it is exactly in the middle between the 3000 RPM and 3400 RPM sites. Tho advance change between 3000 RPM and 3400 RPM is 3° (io, from 25° to 28°) and half of this is 1.5°. So the advance required at 3200 RPM is simply 25° + 1.5° = 26.5". Another calculation is required for engine load values that are in-between tho specified load sites. our Programmable Ignition, if you require two separate engine ad- vance curves then you need to solect the 14x11 arrays. If only one advance curve is required, you then have the option of using a 15x15 array for preater accuracy. By the way, don’t confuse the igni- tion timing map with the MAP (mani- ssute) sonsor, They are two ly different things. Plotting the timing values ‘Wo used the Programmable Ignition, the LCD Hand Controller and a timing light to plot out the ignition timing values for a 1988 2-itre Ford ‘Telstar. We'll describe exactly how this is done in some detail in a later article ‘The resulting timing vs RPM values ‘were tabled (Table 1) and then plotted using Microsoft Excol. These files will be available on our website so that you can use the tables and edit the values (ust by wiping over the values and rewriting them) to suit your car's engine. It is nat really nocossary to use Excel though and you can just as easily use a pencil and piece of paper to draw out the map instead. Fig.2 shows the ignition timing vorsus RPM and engine load from 1000-5000 RPM. Since we have 11 RPM sites, each RPM site covers a span of 400 RPM RPMO is an extra site and is shown covering the range from 0-1000 RPM. The RPMo wording is shown on a dif forent line because it is not an actual siliconchip.com.auRPM site and cannot be adjusted. It has the same values as RPM1 RPM0 is shown because it explains what the advance curvo is below the minimum RPM1 site while the en gine is being started ne thing happens for RPM above RPM11. In this case, the advance romains at the RPM11 values, ingine load is shown with LOAD1 as the minimum engine load while LOAD11 is the maximum engine load. LOAD is usually accessed when the engino is on overrun while LOADI1 is usually accessed under acceleration or when the ear is climbing hill. The load values were measured using a second hand pressure sensor from an automotive wrecker, These were then converted to load valuos ranging from 1-11 ‘The curve can be plotted in three dimensions showing RPM, load and ignition advance. Ifyou use our Excel filo, then the curve will be eutomati- cally replotted when ever a value is altered Using the Hand Controller ‘As mentioned above, the Hand Controller is used to enter the settings and to enter the ignition map. The values are displayed on the 2-line 16 character LCD screen. There are eight direction pushbuttons, a Run/View pushbutton and a Rosot. The Reset switch is recessed to pro- vent accidental activation. Itis used to return all mapped advance or retard values to 0°. The eight direction push- buttons alter the values and can. con- figure the display to show the different settings or a different load site. Finally, the Run/View pushbutton only works in the Timing mode. This ‘mode is selected using a jumper link on the Programmable Ignition Timing Module. RUN modes ‘The Timing mode has four possible display modes, solocted by prossing the Run/View pushbutton. It solects one of four modes called SITE, FULL, DIAG and VIEW ~ in cyclic fashion. Each display mode showsaslightly difforont aspect of the mapping sites. One feature in common is that they all display the MAP and the current advance or retard value on the top lin although there is a difference in the displayed value as we When tho 11x11 maps are selected siliconchip.com.au 1x 11 Ignition Timing Map i Engine Load COVEN Peery ae ‘Advance , (Degrees) asso een ier 15 x 15 Ignition Timing Map LIAL | PP A alls ezteal Engine Loa Fig.3: this 3-dimensional graph i (from the sottings mode}, the display will show either MAPo. or MAPS, depending on which map is selected. Ifthe 15x15 map is selected, then the display will only show MAP, without Wipes Des o eee Peet ea eae nee ce Sena Advance (Degrees) Pn Cen the alpha or beta symbo Following the MAP legend, the display shows the advance or retard value. The display format depends ‘on whether the setting is for 0.5° or Mane 20‘The LCD Hand Controller connects to eeu nr Len program in the various settings and 1 ‘mapls) and can display all pro 16-character LCD module, Pg ane 4° resolution. In all cases, a “=” sign indicates a retard value, while a “+” sign indicates an advance value. When thoro isno change in advance orretard, tho value simply shows 0.0 for the 0.5° resolution sotting or 0 for the 1° resolution setting, The advance or retard value is changed using the Up (4), Down (v), Step Up (4) and Step Down (¥) push- buttons. The « and ¥ pushbuttons increase or decrease the setting by the resolution value; ie, by either 0.5° or ¥° for each switch press. By contrast, the & and ¥ push- butions change the advance/retard value by 2° on 0.6° resolution and by 4° on 1° resolution. The resulting values aro stored in memory and remain there evon if poworis turned off, unless they are changed by the pushbuttons or by the Reset switch Attheend of thetop line, thedisplay shows either SITE, FULL, DIAG or VIEW, to indicate the selected mode, Note that the SITE, FULL and DIAG ‘modos aro called the “Run” modes because they show what sites are ac cessed while the engine is running, ‘Site mode The SITE mode is displayed each time the Programmable Ignition is powered up when the Run/View mode fs selected with the jumper link. In this mode, the second line shows 20 SuCON Cu rea} eon) the ignition timir PreK) the current RPM site and the current LOAD sito. These aro from sites 1-11 when the 11x11 mapping is selected or from 1-15 when the 15x15 mapping is selected. The advance or rotard value is shown as the value entered at that load site. In practice, the LOAD and RPM sites only change with changes in ongine RPM and engino load. In othor words, this isa real time display that shows the current load and RPM sites and the curront advance or retard value setting. Full mode Prossing the Run/View pushbutton brings up the FULL mode. In this case, the second line shows the RPM site as before (eg, RPM1) but italso shows the actual position between this site and the next. For example, with the 11x11 ignition timing map (Fig.2), each site is 400 RPM away from the next. In practice, however, the RPM is measured in'100 RPM steps. As a result, the display shows the RPM 1 position as RPM 1:0, RPM 1:1, RPM 4:2 or RPM 1;3. These values corr spond to 1000, 1100, 1200 and 1300 RPM respectively. There is no RPM 41:4 position as this becomes the RPM 230 site for 1400 RPM. Ifyou don't understand this, it will become clearer when we describe how the Programmable Ignition isset up in the forthcoming articles. Similarly for the LOAD sites, the position within the site is shown after the semicolon (:). Note that the word LOAD is abbroviated to just LD, so that the values fit within the display line. In the FULL display mode, the advance or rotard value is the inter- polated value that is calculated for the positions between each load site. Let's go back to our earlier example and consider the RPM 6 (3000 RPM) and RPM 7 (3400 RPM) sites. At these sites, the advance is 25° and 28° re spectively. This means that at RPM 6:0 the advance value will be displayed as +25.07, while at RPM 7,0 the value will be shown as + 28.0". ‘The interpolated value will be shown for RPM values between these two sites. For exemple, at 3200 RPM (RPM 62), the advance value will be 426.5, Consequently, this the value that will be shown at site RPM6;2, Note that this is a simplistic exam- ple bocause we are ignoring the fact that the LOAD value could also in-between LOAD sites. In that c both the RPM and LOAD values are interpolated to give the advance or retard value Note also that if the advance or re- tard values increased or decreased in this mode, it will be the interpolated value that is displayed rather that the site value, The site that will be siligonchip.com.auchanged is the next lowest RPM and LOAD site, Having said all that, interpolation can be switchod off within the settings if required. Knock sensing When knock sensing is set, the dis- play shows the modified timing value after knock retard is taken into ac- count. This means that ifthe display is showing +26.0" and the knock sensing subsequently introduces a 6° timing rotard, the display will then immedi- ately show +20.0°. This is the actual advance value used for ignition. Noto that engine knock detection is indicated by an exclamation mark (!) that is positioned between the RPM site value and the LOAD on the second line of the display. The () is shown when knock is detected, regardless as to whether the knock retard feature is on or off. Tho knock symbol is shown in the SITE, FULL and DIAG display modes. Diagnostic mode Pressing the Run/View switch again switches to the DIAG mode. This is the diagnostic mode and is very useful when it comes to dotermining your engine's RPM range, as woll as moasuring the output range from tho MAP sensor. In this mode, the second line shows the actual RPM with 100 RPM resolu- tion and the actual LOAD value from 0-285. The advance/retard value on the top line normally shows the in- jolated value in the same way as the FULL mode. ‘As mentioned above, interpolation can be switched off and this is useful when measuring the manufacturer’s advance curve (more on this in a later article), Pressing the Run/Viow pushbut- ton yot again switches to the VIEW mode. This is not a real-time display because the RPM and LOAD sites do not change with the engine RPM or load, Instead, you can step through ‘ach site manually using the Right (>), Stop Right ()»), Loft (4) and Step Left (09) pushbuttons, The b and 4 pushbuttons increase ordecrease the LOAD site value. When increasing the LOAD site value and it reaches its maximum value (either 11 715), prossing the switch again causes the RPM sito to increase by 1 and the LOAD site to return to 1. In this way, siliconchip.com.au ‘Timing adjustment resolution: 0.5° resolution advance and retard or 1° resolution advance and retard. ‘Timing adjustment range: 60° for 12-cylinder engines, +90" for 8- cylinder engines, +120° for 6-cylinder engines, +127” for less than 6 cylinders. Using less than 75% ofthe limit is recommended to prevent timing “drop-out with sudden RPM changes. Timing adjustment accuracy (above Low RPM setting): 0.2% for a 2-cylinder 4-stroke, 0.9% for a 6-oylinder 4-stroke, 0.4% for an B-cylinder 4-stroke (note: 0.3% is equivalent to 0.12° at 40" advance or retard for a 6-cylinder engine). ‘Timing update: the update period is the Timing calculation period: 700s maximum. Timing jitter: =5,s at 333Hz (Sus is equivalent to 0.3" for a 6-cylinder, engine at 10,000 RPM). Minimum input frequency: 0.6Hz (corresponds to 36 RPM for a 2- cylinder 4-stroke engine, 18 RPM for a 4-cylinder 4-stroke engine, etc). Maximum input frequency: 700Hz (corresponds to 14,000 APM for a 6-cylinder 4-stroke, 7000 RPM for a 12-oylinder 4-stroke. Cylinder settings: 1-12 cylinders for a 4-stroke engine and 1-6 eylinders for a 2-stroke engine, between successive firings. Minimum RPM setting: 0-25,500 RPM in 100 RPM steps ‘Maximum RPM setting: indirectly set by RPM/SITE ~ 0-25,500 RPM in 100 RPM steps. Minimum load setting: 0-255 in steps of 1 (corresponds to 0-5V). Maximum load setting: indirectly adjusted by changing loads per site (0-255 in steps of 1). Debounce adjustment: 0.4ms or 2ms. Dwell adjustment: 0-25.3ms in 0.2048ms steps (multiplied with voltage below 12V). Dwell variation with supply: x1 for >12V, x2 for 9-12V, x3 for 7.2-9V, x 4 for 72, Firing edge selection: low or high. ‘Spark duration: 1ms. Map settings: two 11x11 maps (MAPa and MAPB) o single 15x15 map. Knock input range: 0-5V (0-1.25V = no retard; 1.25-5V = progressive retard in 16 steps). 9° at 3.75V, 12° at 5V for 1° resolution; 4.5° and 6° respectively for 0.5° resolution, Knock monitoring (requires an additional knock circuit): monitored for the first ms after firing, This period is reduced at higher RPM with the start of dwell. Optional 4000 RPM or 6000 RPM sensing limit. Ignition retard activation (when enabled) is set for a minimum of 10 sparks with the onset of knocking. Internal test oscillator: 4.88Hz. Response to low RPM setting: 0-25,500 RPM in 100 RPM steps. ‘Typically set at around 1000 to 2000 RPM, Marci 2007 24sitallaldy ‘When we presented our last very popular High Energy Electronic Ignition ‘System, in the December 2005 & January 2006 issues of SILICON CHIP, We stated that “in a future issue we would present a development of the Elec- tronic Ignition to allow ignition timing to be altered. That project will allow the existing timing to be fully mapped on the basis of engine RPM and inlet ‘manifold pressure”. In fact, provision was made on the PC board for the extra parts that would bbe required to make the system fully programmable. A new program for the m= ‘crocontroller would complete the system .. oat least, that was the plan. It didnt work out. Instead, we have had to effectively spit the original PC board into two parts and add a few more components into the bargain. Now what was that about mice and men? It goes like this: The best-laid plans o' mice an’ men Gang aft a-gley, ‘An''lea’e us nought but grief an’ pain For promised joy. ["To a Mouse” by Scottish post Robert Burns (1759-1796)]. you can step through the entire igni- tion-timing map. ‘The same thing happens when de- creasing the LOAD site value. After roaching 1, the RPM site value is de- creased by'1 on the next switch press ‘and the LOAD site goes to either 11 or 15 (depending on the MAP setting). The and 4 switches just alter the RPM sites up or down without altering the LOAD site, In this way you can check the ignition advance or retard settings for each RPM site at a particular LOAD site, ‘Note that the b, , € and « push- buttons do not operate in the SITE, FULL and DIAG modes. In these modes, the sites are only changed in response to engine RPM and load inputs. Settings The Settings display is invoked whon jumper LK1 in the Programma- ble Ignition Timing Module is moved to the settings position. This display is used to sot up the programmable ignition to suit your engine. The display will initially show . The < and > brackets indicate that each setting can be se- lected with either the left (4) or right (©) pushbutton switch. Tho values within the sottings are thon changed using the * and ¥ pushbuttons. ‘These values (except for the oscillator selting) are stored in memory and do not change unless altered using the Up and Down pushbuttons. 22 SicoN Cae Note that the oscillator setting is, always off when power is re-applied to the Programmable Ignition. Pressing the > pushbutton brings up the Cylinder setting, You can then select cylinder values from 1-12 for fa 4-stroke engine and from 1-6 for a 2-stroke engine. During this timo, the top line of the display will show STROKE and then two numbers ~ ie, 4 and [2] for 4-stroke 2-stroke engines respectively, Directly below those on the second lines the word CYLINDER and the selected cylinder numbers (the bracketed numberis the cylinder value for a 2-stroke ongine) Thecylinder value is changed using the * and ¥ pushbuttons. Note that fa dash is shown in tho two 2-stroke column when odd 4-stroke cylinder numbers are selected, as this is not a valid setting for a 2-stroke engine. The next foursottings are for adjust- ing the range of the RPM sites and the LOAD sites, These aro orucial in insuring you get the full use of the available sites. In other words, there is not much point in having the RPM sites covera renge from 0-25,000 RPM whon, for example, the engine does not run above 5000 RPM. In this cas you would only bo using 20% of the available RPM sites (ic, RPM 1, RPM 2 and part of RPMS only) for mapping the advance curve. The first of thoso settings is the Minimum RPM. This sets the RPM for the RPM 1 LOAD site, The display shows SET MIN RPM X00 RPM, where the X represents a number from 0-255. ‘Typically, this is sot at the idle speed for the car but it may be set differently depending on how you want tho igni tion curve to operate (more on this in a later article). The settings can be changed from 0RPM through to 25,500 RPM in 100 RPM steps. In practice, you would use the DIAG (diagnostic) setting mentioned above to determine the minimum and maxi- mumengine RPM range. Alternatively, you can use the idle and red-line specifications for your engine. ‘The second setting is for the Maxi- mum RPM, This valuo of RPM is in- directly set by the value of the RPM. per site (RPM/SITE) adjustment, as shown on the top line of the display. Itcan be set from 0-25,500 RPM in 100 RPM steps. ‘Tho second line shows the maxi- mum RPM. This is calculated based on the minimum RPM setting and the RPM/site value. tis shown in the sec- ond line of the display as MAX RPM X00 RPM, where X is a number from 0-255. An ERROR indication is shown instead of the maximum RPM if the setting would be over 25,500 RPM. ‘Tho reason why we adjust the RPM/ SITE value rathor than the Maximum RPM directly is because the Program- mable Ignition requires a discrete number of 100 RPM steps between each RPM site In practice, the RPM/SITE value is altered so that the maximum RPM is et orjustover the value required. You can also adjust the minimum RPM setting toachieve the best compromise forthe, adjustment. ‘An example may help here using the 11 x 11 map. If, say, the minimum RPMis setat 1000 RPM, tho RPM/SITE value can be set to say 400 RPM for a 5000 RPM maximum or to 500 RPM fora 6000 RPM maximum. Thus, ifyou had a red line of say 5500 RPM, you could set the RPM/site valuo to 500 for the 6000 RPM maximum. Alterna- tively, you could lower the minimum RPM value to say 800 RPM, with the RPMisite set to 500 for a 5800 RPM ‘maximum. ‘The third and fourth sottings are for the LOAD sites. Again, in_pract you would use the DIAG (diagnostic) mode to determine the minimum and maximum values from the MAP sonsor. The maximum load values oc- cur when the car is accelerating up a hill, while minimum load values are siliconchip.com.aupresont under very light throttle con- ditions and when the engine is being overrun in low gear downhill ‘The Minimum Load adjustment can be set from 0-255 in steps of 1. These (0-255 values correspond to the 0-5V output from the MAP sensor. ‘This value is set to the reading obtained in the DIAG (diagnostic) modo when the engine is being overrun, By contrast, the Maximum Load is adjusted indirectly by changing the loads per site (LOADS/SITE) setting This can be changed in steps of 1 from 0-255. The socond display line shows the calculated maximum load (MAX LOAD) value based on the minimum load and the LOADSYSITE setting ‘An ERROR indication shows if the calculated maximum LOAD value is over 256. In practice, the Minimum Load and the LOADS/SITE settings are adjusted so that they cover the range of the MAP sensor output, although they may slightly overlap the required minimum and maximum values. Other settings that follow these map- ping values are: (1). MAPS: here you can select either the two 11x11 maps {mapo.and map) or the single 15x15 map. Note that any ignition values mapped into an 11x11 map will no longer be correct if the map is subsequently changed to 15x15 array and vice vorsa. Instead, ‘you havo to ro-onter the values. {@). Resolution: this sets the resolution ofthe advance/retard adjustments and can be either 1° or 0.5°. Once ignition values have been entered into the map on one resolution setting, thoy will be incorrect if the resolution is changed to the alternative setting. (9). Response To Low RPM setting: at low RPM, the engine speed can change quite quickly. Because the calculation for RPM can only occur between each detected firing pulse, the response to RPM changes can be too slow and can lag behind thi engine. ‘This can noticeably retard tho ignition with increasing RPM. ‘The Response To Low RPM setting is included to improve low RPM re- sponse, particularly at starting. The downside of this setting is that there is some slight ignition retardation but thisis loss than 1° for typical low RPM settings The RPM value can be set from 0- 25,500 RPM in 100 RPM steps. The Low RPM Response operates for RPM siliconchip.com.au igmitig ‘Atypical internal combustion engine has one or more pistons that travel up and down inside cylinders to turn a crankshatt. As a piston rises inside its cylinder during the compression stroke, a mixture of fuel and air is com- pressed. In petrol and gas engines, this fuel-alr mixture is then ignited using a spark to drive the piston as it starts its downward stroke. ‘This ignition must be timed accurately to ensure maximum power and ef- ficiency. I the mixture is fired too late in the cycle, power willbe lost because the piston will have travelled too far down in the cylinder for the burning fuel to have maximum effect. Conversely, i the mixture is ignited too early, it will “push” against the piston in the wrong direction as it rises towards top dead centre (TDC). Ideally, each spark plug is fired so that there is just enough time for the ignited fuel to apply maximum force to the piston as it starts its downward ower stroke. In practice, the fuel takes a certain amount of time to burn and so the spark pug needs to be fied before the piston reaches the top ofits stroke or top dead centre. At low engine RPM, the spark only needs to occur a few degrees before top dead centre. However, as engine RPM rises, the ignition must be fired progressively earlier in order to give the fuel the same time to fully ignite —ie, the spark timing must be progressively advanced as engine RPM rises. This timing requirement is called the “RPM ignition advance curve” and is, often around 6” betore TDC atid, sing to about 40” at the engine's recom- mended maximum RPM (the redline). As stated if the sparkignites the uel fer to early, then the piston may be pushed downwards before it reaches top dead centre. However, ifthe igni- tion is only early by a small amount, then the engine will exhibit a knocking soundas the piston rattles within he cylinder. Ths effectis called “detonation” (also called “pinging” or *knocking”) and can cause serious engine damage in severe cases, Engine load is also an important factor when it comes to ignition timing. Under light loads, the advance timing can usually be atthe maximum. However, ‘when the engine Is heavily loaded, such as when accelerating or powering Uphil, the fuel takes less time to ignite because of higher fuel pressures and ‘temperature (and because the mixtures richer). Asa consequence, as engine load increases, the ignition timing must be retarded to prevent detonation. Nati MORN AN ‘Typically, you can use the O.4ms de- below the set value (typically just bounce setting but the alternative 2ms below idle speed). Above this setting, the standard response to RPM occurs, By contrast, the response at higher RPM is satisfactory because there is only a short period between plug fir ing and the engine spoed will not vary much during this timo. Usually, the setting isadjusted so that it operates at engine cranking speed but stops when the engine reachos idle speed. In other cases, it may be necessary to raise this RPM limit so that the engine can rev correctly from idle. (4). Debounce: the debounce setting affects the trigger input and its resil- ence to anoisy signal, as can typically occur with points bounce in older car ignition systems. Unless corrected, points bounce can upset the detection of engine RPM and affect the timing debounce setting can be selected ifthe ignition appears to be erratic due toa noisy input sensor signal. (6). Dwell; dwell is the period during which the ignition coil “changes” be- fore each phig firing. Itisalterable from between 0-25.3ms in 0.2048ms steps, We have provided an oscillator feature (cee below) that allows the ignition coil to be driven by the Programma- ble Ignition and the spark produced by the coil monitored. The dwell is then progressively adjusted upwards from Oms until the spark reaches its maximtim voltage. The dwell is then increased slightly above the set value to ensure there is more than sufficient spark when the engine runs, In addition, the dwell is automati- Mancu 2007 23lasiw SaNSOF athe Sf PROGRAMMABLE IGNITION TIMING MODULE Fig.4: the Ignition Timing Module is based on a PIC16F88-E/P microcontroller. This processes the input trigger, MAP sensor and optional knack sensor signals and provides outputs to drive the Ignition Coil Driver circuit (Fig.5) and a tachometer. It also monitors the Hand Controller's switches and drives the LCD. 1 iNdooe Riven cally increased when the battery volt age is low —io, tox2 for battery voltages between 9V and 12V; 1ox3 for voltages between 7.2V and 9V; and to x4 for voltages below 7.2V. (6). Edge: this sets the ignition to trigger from either a low-going input signal edge or a high-going signal. In most cases, a high-going signal edge must be selected but some optical, Hall-Effect and reluctor outputs will require the low-going edge selection. (7). Knock: this sets the KNOCK re- tard feature either ON or OFF and sols the LIMIT at either 4000 or 6000 RPM (these settings are all shown on the LCD). Pressing the 24 SILICON CHE © and ¥ pushbuttons cycle the selections between these options ‘The LIMIT setting sets the RPM value at which knock sensing ceases. This is usually sotto 4000-6000 RPM because at higher revs, the engine noise drowns out any knocking and so would either be undetectable or would cause false reaclings. Note that knocking will only be detected if the soparate knock sens- ing circuit (to bo described) is added and a knock sensor is installed on the vehicle. (8). Diagnostic: this sots the intorpola- tion cither ON or OFF. It is normally set to ON and should only be set to OFF when making ignition curve measurements using the Programma- ble Ignition and a timing light. (9). Oscillator: this sets the internal os- cillator ON or OFF. I's normally OFF ‘ut can be sot to ON to test the ignition coil spark with varying dwell settings. The oscillation rate is about five times a second (SHz). Circuit details OK, so much for all the fancy fea tures built (or more accurately, pro- grammed) into the unit, Let’s now take a look at the circuit details. ‘The circuit for the Programmable Ignition can be split into three sec- siliconchip.com.autions. Fist, there is the Programmable Ignition Timing circuit, as shown in Fig.4. To this is added an input trigger circuit, depending on the ignition trig- ‘ger used —see Fig,6. This can be either points, optical, Hall effect or reluctor, or can be taken from the engine man- agement unit (EMU). Finally, a separate circuit, control- led by the Programmable Ignition ‘Timing circuit, drives the ignition coil ~ see Fig. The LCD Hand Controller, to be described in Pt.2, is a completely separate unit which connects to the Programmable Ignition Timing module via a DB25 cable. As stated, its used only during the setting-up procedure, after which it isno longer required un- less you wish to reprogram the system (eg, to alter the timing map). ‘The main circuit (Fig.4) is based on IC1 which isa PIC16F88-E/P high-tom- perature microcontroller. This micro processes the input trigger and MAP sensor signals and provides an output todrivethe Ignition Coil Driver circuit, It also drives the LCD module in the Hand Controller and monitors the Hand Controller's switches. ‘Timing signals for IC1 aro provided by crystal X1. This sets the internal oscillator to run at 20MHz, which enables the software programmed into IC1 to run as fast as possible. In operation, IC1 accepts the igni- tion trigger signal at its RBO input (pin 6) and drives its RB3 output to switch the ignition coil (via the drivercircuit) accordingly. As shown, the RBO input cled from excess voltoges by a 2k@ resistor, which prevents ve current flow in IC1's internal clamping diodes. Clamping occurs when the voltage goes below OV or if it goes above the +5V supply (ie, the input is clamped to -0.6V or +5.6V). ‘Tho 1nF capacitor at the RBO input shunts transient voltages and high- frequency signals, to filter false timing signals, Transistor Qé isalso driven from the trigger input. The transistor is used to provides tachometer output at its col- lector. In operation, Q4's collector is normally held high via 2.29 pull-up resistor but switches low each time the transistor tums on (ie, when the trigger input is high). Q4’s collector output can be used to drive most modem tachometors. However, an impulse tachometer (now vory rare) requires a different con- siliconchip.com.au 91 susate or hoor? é SE IGNITION COIL DRIVER roczawaasieicninony Fig.5: the Ignition Coil Driver is based on transistors Q1-Q3. Darlington transistor Qi switches the ignition coil, while the four series zener diodes across Qi prot nection and this type should operate when connected to the ignition coil’ negative terminal. MAP sensor ‘The MAP sensor signal is.applied to the analog AN2 input of ICI via a 1,8kQ resistor. A 10nF capacitor filters out unwanted high-frequency signals to prevent false readings. In operation, the AN2 input meas- ures an input voltage ranging from 0- Vand converts this toa digital value ranging from 0-255. This is the value that’s read from the DIAG (diagnostic) display, Note that +5V supply and ground rails are provided for the sonsor. When the Sensym sensor is used, it can be directly mounted on the PC board used for the Programmable Ignition ‘Timing Module, The optional knock sensor signal is applied to IC1’s analog AN1 input (pin 18). As bofore, this input accepts signal voltages from 0-5V and converts them to digital values. Conversely, ifthe knock sensing cir- cuitis not used, this input must be tied t voltage spikes when the transistor turns off. to ground using jumper link LK2 to disable the knock sensing function. ‘The third analog input at AN3 (pin 2)isused to monitorthe +12V ignition supply. As shown in Fig.4, his supply voltage is divided down using 100k istors and filtered using acitor before being applied to the AN3 input. This divider eff tively converts the supply voltage to 4 0-5V signal which is then used to determine if the dwell period should be increased to compensate for a tow supply voltage. Note that the voltage across D1 is accounted for in this measurement. Link LK1 selects either the timing map display or the settings display. In the settings position, the RAS input is tied to ground via a 10kQ resistor. Convorsoly, when LK1 is in the tim: ing position, RAS is tied to SV via the 10KQ resistor. Note that the RAS input differs from the other inputs in that it cannot be Giroctly tiod to one of the supply rails otherwise the micro could latch up. ‘The 10kQ input resistor eliminates this problem. Mane 2007 25RELUCTOR PCKLP Figo: the seven input ‘triggering; (d) triggering Piranha optical pickup. (CRANE OPTICAL HOKU? PRANHA OPTICAL ICKUP ‘circuits: (a) points triggering; (b) ignition module (see text); (c) Hall effect & Lumenition ym an engine management module; (e) reluctor pickup; () Crane optical pickup; and (g) Switch S1 is used to select between the two 11x11 timing maps. When Sis open, RAd is pulled low via the 10KQ rosistors and mapat is selected. Conversely, when $2 is closed, RA4 is pulled to +5V and mapf is selected. Note that this switch operates only when the 13x11 maps are selected us ing the LGD Hand Controller. Ithas no cffect ifa 15x15 map is selected, Driving the LCD Pins 7, 8 & 10-18 of the microcon- troller are used to drive the LCD mod- ule in the Hand Contzoller (viaa DB25 connector). The 10 resistors in series with these outputs act as stoppers to oop RF signals out of 1C1 In addition, the RAO input at pin 17 monitors the switches from the Hand Controller. Tho associated 1k resistor pulls the input voltago to OV unless a switch is closed, at which point the line is pulled high to +5V. ‘The 10nF and 1n¥ capacitors filter out RP signals. Power supply Power for the circuit is derived via the ignition switch. This supply is then filtered using inductor Lt and tho 100nP capacitor. Diode Di pro- 26 SicoN Cir vidos reverse polarity protection, after which the supply is decoupled using a 1000uF capacitor. Asa further precantion, the circuit is protected from voltage spikes using transient voltage suppressor TVS1 This clamps any high voltages that may otherwise damage following components, Following TVS1, the supply is reg. ulated to +5V using regulator REG1 This is a low-dropout device and is usod here to ensure that a rogulated +8V supply is maintained during statt- ing when the battery voltage can drop well below 12V. A 100,F capacitor decouples the regulator's output, while @ 100nF ca- pacitor (located close to pin 14 of IG1) shunts high frequencios to ground. Ignition coil driver Fig.5 shows the Ignition Coil Driver circuit It’s fairly straightforward and is based on transistors Q1-Q3. Qi is a Darlington transistor spe- cifically made for ignition systems. Ws capable of handling currents in excess of 10A and voltages excoed- ing 400V. As shown, four 75V zonor diodes (2D1-ZD4) are connected in series betwoen its collector and emitter torminals. These protect the transistor from excess voltages by clamping its collectorat 300V, which is well within its rating The circuit works like this: when the input signal is low (or there is no signal), transistor Q3 is off, Q2 is on (due tobase current through the 1.2k82 resistor) and Ql is off, Conversely, when the input subsequently switches high, Q3 turns on and switches Q2 off by pulling its base to ground. Asa result, Qi turns on and current flows through the primary winding of tho ignition coil Tho ignition input signal now subse- quently switches low again and so Q3 immediately turns off due to the 4708 resistor betwoon its base terminal ‘and ground. And when that happens, Q2 switches on and Qt switchos off, interrupting the current through the ignition coil ‘Asa result, the coil’s magnetic flux rapidly collapses and this generates a high voltage in the secondary to fire one of the spark plugs. The inF capaci- tor on Q3's base is there to suppress any RF signals that may otherwise be injected when the current through the ignition coil is interrupted (ie, when Qi switches off sliconchip.com.auResistor Rt is included to make the module more versatile, In our application, Ri is not used and is replaced with a wire link. For other applications, where a soparate igni- tion coil driver is required, Ri will be required. Typically, a 47022resistor would be used for a 5V drive signal while a 1.2k0 resistor would be used for a 12V drive signal Finally, the module can also be configured to drive transistor Q1 when the input signal switches low. In this case, Q3 is left out of circuit and a link installed between the pads on the PC board for its base and collector leads, The 1.2kQ resistor pull-up is also re- moved from circuit Trigger inputs ‘The Programmable Electronic Igni- tion is configured for the appropriate trigger input during construction. ‘The seven possible input circuits are shown in Fig. The points -trigger is shown in Fig.6(a) and includes a 1000. 5W wire- wound resistor connected to the 12V supply. This resistor provides a “wet- ting” current for the points to ensure thereisagood contact between the two mating faces whon they aroclosed, The wotting current is sufficient to keop the contacts clean but not so high as to damage them. ‘The ignition module version is shown in Fig.6(b). This is essentially the same as the points input except that a transistor inside the ignition module switches the input to ground instoad This typo ofinput has boon included because some electronic ignition systems do not provide access to tha actual trigger (usually a reluctor) and the only output is the ignition coil driver transistor. In this caso the coil is roplaced with the 1002 resistor to provide the necessary pull-up to +12V when the transistor is off Fig.6(c) shows the Hall Effect trigger. Iuusos a 1000 curtent-limiting resistor to feed the Hall sensor, while the 1k resistor pulls the output voltage to 45V when tho internal open-colloctor transistor is off. Conversely, the output signal is pulled to OV when the internal transistor is on. Note thatthe same circuitis used for the Lumenition optical module. ‘The engine management input eir- cuit is shown in Fig.6(d) and is quite simplo, Its 0-5V output signal connocts siliconchip.com.au nt Rca M emery Toner ance Rear an ssombly details will be in Pt2 next month, tothe triggor section of the main circuit in Fig. Reluctor sensors are catered for using the circuit in Fig.6le). These produce an AC signal and so require a more complex input circuit In this case, transistor QS switches on or off, depending on whether the reluctor voliage is positive or negative. It works as follows. Initially, with no reluctor voltage, QS is switched on via current through VR1 and a 47kQ resistor. The voltage applied to Q5's base depends on the 10k® resistor across the reluctorcoil and the internal resistance of the reluctor. ‘Trimpot VR1 is included to provide for a wide range of reluctor types. In practice, VR1 is adjusted so that Q5 is just switched on when there is no signal from the relucior. The 10k resistor provides a load for the reluc- tor, while the 470pF capacitor filters any RF signals that may have been ced. 10 2.2nF capacitorensures that quickly switches off when thereluctor signal goes negative. Finally, Fig.6(f) & Fig.6(g) show two different optical pickup circuits. Fig.6(0) is for a module that has acom- ‘mon 0V supply connection (eg, Crane), while Fig.6(g) is foramodule that has common positive supply (eg, Piranha). Im each case, current for the LED is supplied via @ 1200 resistor, while the photodiode currant is supplied via a 22k9 resistor. Software The software for the Programmable Ignition is the largest and most com- plexwe have developed to date, Inall, the final assembler code totals some 6020 lines to perform all the necessary functions, including monitoring the ignition trigger and pressure sensor signals and providing an output based on tho ignition timing map. Basically, tho software includes several multiply and divide routines (some 24-bit) to calculate the timing, based onthe RPM and load site. These routines are also used to calculate engine RPM and the interpolated advance/retard values and must be performed constantly to maintain the correct timing as engine RPM and load vary. ‘We managed to perform all the re- quired calculations in under tms ~fast enough for high revving engines. ‘A significant part of the software has also been devoted to the many fun tions accessible via the Hand Control- Jorand to allow the Hand Gontrollerto be used while the engine is running. In the end, we used all the data ‘memory space ofthe PICTBF88 to store the ignition timing maps and the ad~ justable parameters, along with some 97% ofthe program memory. SC ‘MancH 2007 27BENCHMAR 41 Watt HiPower RED LED Emitter High fox bethane light ont type logue fu of 30, up to 100,00 Is of battery if, requtes nl low DC voltage to operate (19 to 31V © 350A), ool and safe fo touch, eludes data, 24251 sqs9 GND 9 =88 CATHODE (Ve) 2.3x2 8.0 ae mci aed) Z4251 to Z 4253 41 Watt Hi-Power BLUE LED Emitter High fxn ght oust pia lamipous fh of 10, eter fe up to 100,000 hows, {equre cl lon OC vltags to operate (299V 390V.6 SSA) cool and ste {te touch superior ESD protection (4,000 wot) nudes data Zan58 sqss SAVE $4*° Medium Duty Figure 8 Speaker Cable 34c/m March 2007 (72 =88 CATHODE (-Ve) S19 3x2 a ANODE (+Ve) [slo Z4251 to Z4253 4 Watt Hi-Power WHITE LED Emitter sgh rift Fgh eu pica anineus flo 29, battery He pt 100 000 Pe reas oi low DC vatage to operate (2990-39 8 350mA, cool we {otouc, superior ESD provecton (6000 vo) ncades dat 2252 sqss SAVE °4°° erage this month only Perse Oxygen Free Co yer Speaker Cable High conductvty, low oe Fig 8 Oxygen Fee Copper (OFC) cable wih ulvalexwansucert PVE inlaton, and tinned copper conductors fn oe side ofthe Fig fx o idm party identiieaton!matching. Conductors: 30x 0.12ren ‘OFC, roeesariandl wes O Sen W 2008 39c¢/m Electronic Digital Calipers These sales ste! daa eaipars leate a Aig CD scran intemal an estrml meas jo, depth mening Blade, mm & Inch massurement 'Supped In farina cary s2g°° DICK='SMITH Products also fable through www.dse.com.au know-how to make it easyLook what’s HOT! fall F AE SA A | ose \i\\4 A 30-Piece Mini Bit Set with Handle High qulty dim mints made fom superhacd S2 grade see! oy Sippind compat wih a Vmm extorsion shaft nda quay rele $4999 sigh mata these tightening machanem ‘that securely holds the shafts The bas re adi labled stoves and thon athe ‘components ao stored ins pose cary eas. 187 Deis a Lead-Free Silver Solder Hobby Tube 1 grams of slder na handy sperser tube, commended forse ony with ron-dad or ose ricaledwclderng Wen Leach ree Solder sgee ps, 10090 Promotion from 28/02/07 to ) s) ‘Aedes aly sown eto ete ders 5798 re tun Ts eldar 999 tn SuperHard Bit Set hed hex bits re oa tio king and haley and al the port are stored handy panic ery eae 1 45 538° 3-48V Regulated 25 Amp Heavy Duty DC Powor Supply Hea iy 35 peer spy nt 2A fron aby ode sie toner out stage Caton OSE ‘ersen etres een neon poten Tage! a vedere iodine aerate eee ie ether tr proteceon ce ‘ee ma ie ney 894910) innate ote Ss. atic Wet Wipes ‘Neomentt pack, Contain 106 aistatic Tnetoo wet wipe tonelates, ea for eeaning computor ereone (RT, LCD, apps plasma ana Ucb TW Serer CD and DVD ces, photocopiers and fated sg9s ANTI STAT ver Wie MITH know-how to make it easy DICGreat savings © Swann Car RESIS Vie sa eyo ese csi your moble phonel Features ive cote ta you PC with e357 Dlyback elds Mawar Sreeam to share viseo & ti Tages works with ead phone brande an provider equnsntaret rece a cs wth ‘ending conten eareended Heavy Dut Solder Sucker esl fr beter $@Qs9 MITH know-how to make it easy DIC ©@Swann I Video Recorder (Guck and ay to ntl, & channel Sait ideo recorder wih audi (Capable of pisure inte nd fetue onpicure function aed up Slowing conection to yout existing Fetwork or montoring va the tteb fom eromate PC Gohware Ineudec). L590 DI nH 300W Power Inverter Frosdes man power for uipmert retebook, Flores ped carers hi From your venice, m0 Hluminated Pocket Magnifier Grest for emeeing components, PCBS, and other Gora yrs a rmeaniaed i 2érn coated eas es, 40% magneton, cary auch Shas ute LED to prove Fghing af te we Stadium 240V Easy Etch Engraver s9gs3 propery by marking your Sletrants and vluabies Incdos AC adaptor and tong cord, TH 70) Products also Svailable through www.dse.com.auKit clearance time 30% ‘ OFF CIQMES a = and tif ect selected . Eee kits. IN-STORE NOW! SEE Silicon Chip IN-STORE Magazine con Radio Control Sunset Cruiser re FOR MORE a SUAlLs MASSIVE Bo archer ane KIT . SAVINGS S350 DICK='SM TH know-how to make it easy Promation from 28/02/07 to 283/07DICKS'SMITH @ Products also available through www.dse.com.au Know-how to make it easyideas for all! DIC H Lab Power Supply 3-30V DC 20 Amp “Ths igh efioney ste mode power sel) provides selectable cutout voltages from 3¥t0 Soy ith masimur contnuouscurent of 208, 2d low ple and nose ouput ail in a compact fe with an ntegtal viable speed cooling on Formas Mex 3 output “niteh ean be selected to overrise the front ponel vorobe voltage selection, elloming the omer supply tobe safely used wih high power sr audio and vaio traremvttg equipment Feutores large LED fron panel Metring and heavy-duty banona sockets. 0 1755 Fe weTRODUCTO ba Ey) Se 50 A.V Rechargeable Professional Modular Cordless Screwdriver Crimping Too! Durable metal gearbox with Tis profesional grade raping tools femve-avong moulded boy, ‘orwordreverseconrl, hr mains charge accosory bts Ind wsvuctons, ree Spring loaded overmouded handles provide greater comfort ding multe 249° sB9” Available in-store or through our { ve Reavy catton bese for Fax: (02) 9642 9155 5 aligator clips. T5715, Direct Sales Division teot Mail: DICK SMITH ELECTRONICS s@ss Direct Sales Reply Paid 500, PO Box 500, Regents Park DC NSW 2143 / with Magnifier Phone: 1300 366 644 (Local call charge) 3nd adjustable positon (No stamp required) be DICKG*SMITH Promotion from 28/02/07 to 27/03/07 know-how to make it easyE'VE PRESENTED the Remote Control & Prea plifier project asa stand-alone module because wo believo that many cot structors will want to build it into an existing case. Itis designed to fit ush behind a front panel, hence the LEDs and the rotary encoder are located along the front edge of the board Howover, all of these devices can be mounted independently on a panel and wired back to the PC board via short flying leads if desired, Note that if the infrared receiver includes an external metel shield (600 photo), then stops must be taken to ensure that it is insulated from tho chussis, We suggest a short strip of in sulation tape on the inside ofthe front panel, with a hole cut out to match the hole in the panel. Do not rely on the paintwork to provide insulation! ‘The display board should be mount- ed to the right side or above the main 34 SILICON Cx Second)articlecommletes thejconstruction:a: (gives|thelset-unjnrocedure) board (ie, away from the audio section) on standoffs behind an appropriate cutout. Additional header sockets (or cut-down 40-pin IC sockets) can be stacked vertically to inorease the display hoight for a flush fit. Both the red and blue displays look great with tinted filters! ‘Asmentioned earlier, threo different power supply configurations are pos- sible. You could also power the unit from an existing regulated DC source if available. The minimum require- rmonts aro: #15V @ 20mA and +5V @ 120mA. Note that the two (analog & digital) supplies must share a con mon ground. This means that ifthey're located on physically separate PC boards, their grounds must be cabled separately to tho single “GND” at CON1 Mains wiring ‘As usual, all 240VAC wiring must be carried out in a safe and profossional manner, meaning that we're assuming, that you already have the relevant ex- pertise or can obtain assistance from someone who has. Most importantly, the assembly must be housed in an earthed metal enclosure, The mains earth must be properly connect this chassis and this can be achieved via a double-ended 6.3mm spade lug fastened securely to the base with an Max 10mmscrew,shakeproof washer and two nuts ~ soe Fig,16, ‘A basic wiring layout is shown in Fig.14. Themains section ofthe wiring will obviously need to be amended if the module is to coexist with a power amplifier, which will at least share the mains input socket and power switch. Note that if using a separate, chas sis-mounted transformer, alternative arrangements must be made for mains fusing. This is best achieved by using an IEG sockot with an intogral fuse. Once the mains wiring has boon completed, go back and check that each connection is secure and well insulated. Ifnecassary, use heatshrink siliconchip.com.autubing to completely cover any ex: posed terminations. That done, use your multimeter to check continuity betweon the earth pin of the mains plug and any convenient point on the chassis that is devoid of paint. This check must be repeated later whon the case is assembled. At that time, use your meter to chock that all panels of the case are earthed —without exception! Low-voltage wiring Asa first step, disconect the mains cord to prevent mishaps while work: ing under the hood. You can then complete the assembly by running all the low-voltage wiring, Ifa separate transformer has been usod, its two secondary (15VAC) windings must be terminated at the transformer input (CON1) ofthe power supply board, Twist the wires together and keep them as short as possible to reduce radiated noise. Next, connect the +15V, -15V & GND outputs at CON2 and +5V at CONS cn the power supply to the matching inputs at CON1 & CON2 of the Remote Volume Control & Preamp module. Note that the GND output at CON3 on the power supply is not used! Uso only heavy-duty hook-up wire for the job. Take great care to ensure that you have all of the connections correct ~ a mistake here may damage the control module. We suggest four different cable colours to reduce the chances of a mistakol Ifyou wish todo able to control left/ right balance from the front panel, then you'll also need to install a pushbutton switch. This will enable you to use the rotary encoder for both volume and balancoadjustmonts, The terminals of the switch are simply wired between the BALANCE and GND inputs at CONS. Having said that, balance ed- justment is @ raro requirement after initial setup (which would bedone via remote control), so most constructors will not need this switch. The module also provides a second. switch input at CONS labelled CHAN: NEL. This is intended for a possible future multi-channel upgrade and should not be connected, as it cur- rently has no function. Use good quality shielded audio cable for all the audio connections Terminate one end of the cables in RCA plugs for connection to the control module's inputs and outputs. Depend: siliconchip.com.au 240NAC NT Fig.14: follow this basic diagram when hooking up your module. Use heavy- duty hook-up wire for all of the low-voltage power supply connections. For the mains side, use only mains-rated cable and be sure to keep if well away from the low-voltage side. A few strategically placed cable ties will keep everything in position, even if a wire should happen to come adrift ing on your requirements, you may ‘wish to it chassis-mount RCA sockets at the other end and mount these on the rear of your case. Finally, you'll need to make up the cable for the main board to display board connection, This is simply a length of 20-way IDC ribbon cable terminated with 20-way plugs at either end (see photos). Wo used a 12cm length forthe prototype but we expect that if could be at least twice as long without causing any problems. Avoid routing the cable close to the analog section of the control module. Earthing So far, you should have just two wires connected to the chassis earth point - the mains earth wire from th IECsocket and a second wire to the “E input (at CONS) of the power supply. Now run en additional mains-rated .greon/yellow earth wire from the pad just to the left of the rotary encoder to the chassis earth point. This solidly earths the body of the encoder to pro- tect the microcontroller from static discharge. ‘To earth the audio ground, run an- other wire from the chassis earth point I your infrared ree iver module has a ‘metal shield like this one, then be sure to insulate it from the front panel as doscribed in the text Mant 2007 35Fig.15: the 2-digit readout displ Pe erie cen to the free pad situated between CONS: & CONG on the control module, again using mains-rated green/yollow wire Both earth wires should fit intoasingle spade crimp terminal to mate with the free end of the chassis-mounted lug, This earthing method will reduce the chances of creating an audible “earth loop” in your system but suc- cess is not guaranteed! For example, if your power amplifier also earths the audio signal, an earth loop will exist once the two are hooked together. This may or may not be a problem. If you notice more hum in your audio system after connecting the preamp, then try disconnecting the arth wire to the control module. Never, ever, disconnect the mains earth from the chassis! Testing Before applying power for the first time, bear in mind that the mains input end of the power supply circuit board is live! Accidentally placing a finger under the board or contact- ing the mains input terminal block (CONA) screws might well prove fatal! Therefore, it is important that the power supply board is socurely rs flashes an indicator when muted. Note that the channel select Se comune sect le & ode is for mounted in a chassis ~ not floating around on your bench! ‘Assuming the board is correctly installed, apply power and use your multimeter to measure the three rails, at the supply outputs (CON2 & CONS). Ifall is well, the +15V, -15V and +5V rails should all bo within +5% of the rated values. Now measure between pins 10 & 12 and then pins 10 & 13 of IG1’s socket on the control module. You should get readings just below the #15V levels, measured earlier. Finally, check be- tween pins 5 & 4; again, the reading should be just below the earlier +5V measurement. Now switch off and allow about 30, seconds forthe 1000p filter capacitors to discharge. You can then insert IC1 & IC2 in their sockets, making sure that the notched (pin 1) ends line up with notches in the sockets! Before moving on, you must now program the microcontroller (IC2) if it’s blank ~ see the "Microcontroller Programming” panel Initial setup Once construction and testing are complete, a simple sotup procedure ‘Table 1: jumpers must be installed on both JP1 & JP2 during the initial setup. 36 SILICON CrP oP om ([arORTONTNTERACEON CON, L_ [SET NOB 12 [is OA) Wass SeRS | 8S (23 | Sel ruTURE MIE CHANNEL UPGRADE, ‘Table 2: jumper JP3 should be installed in the 1-2 position. must be followed to prepare the mod- ule for use, Before beginning, make sure that you've set up your remote control as per the information pre- sented last month in the “Universal Infrared Remote Controls” panel. First, check that the power is switched off, then install jumper shunts on JP1 & JP2 (see Table 1) and JP3 pins 1-2 (Table 2}. A jumper must also be installed on CONS pins 1-3 (see Fig.7 and photos) at all times except when the microcontroller is being programmed. Note that if this jumper ismissingat power up, the display will flash an error code of "90". Now apply powor while observing the “Ack” LED. It should flash five times to indicate that the unit is in set-up mode. The 7-segment display should be blank, except for the the “mute” indicator continuously flash- ing. Next, point your remote at the on- board infrared recoiver(IC3) and press the numbers “1” or “2” twice. Its significant which of these numbers is chosen. A “1” enables display blank- ing, meaning that the display will go blank oight seconds after each volume or balance adjustment. Conversely, 2" disables this feature, causing the display to be always on. On the second press, the “Ack” LED should flash five times again, indicat- {ng that the code was received and the chosen equipment address (TV, SAT, AUX, etc) successfully saved. You should now power down tho unit and remove the setup jumper P1) only. ‘This procedure can be repeated in the future should you wish to change the equipment address or display blank- ing option. In use ‘As mentioned elsewhere in this arti- cle, volume span is effectively 127dB (-95.5dB to +31.5dB). As the PGAZ310 supports 0.5¢B gain steps, there are 256 steps from minimum to maximum volume. To fit this on a2-digit readout and make it more intelligible, the level isscaled down to 200-85 range by divid: ing it by three. The result is accurate to 1.54B, so you'll need to adjust the volume/balance by three points before you see a change in the readout. Note that “64” corresponds to OdB (unity) gain — values bolow this attenuate the input signal, whereas those above it amplify. ‘fo increase or decrease the volume, siliconchip.com.auhit the “Vol Up" or “Vol Down” but- tons on your remote, or turn the rotary encoder. With jumper JP2 installed, each press (or click of the encoder) moves the volume by just 0.54B. If the remote’s button is held down so that it automatically repeats, the adjustment steps jump to 1.5dB after fone second, ‘Some audio systems may not requ the fine 0.5dB adjustment steps, ‘To increase the steps to 1.5dB for every button press or click, remove jumper JP2. In this case, holding down the remote’s buttons makes no difference to the step size, which always remain at 1.5dB, To adjust the balance between the left and right channels, use the “Ch Up” and “Ch Down” buttons on your remote instead. Alternatively, press the optional front-panel. “Balance” ‘button and use the rotary encoder Bach press or click adjusts the level by 0.5dB, regardless ofthe state of JP2. However, holding down the remote's button for more than one second will case a temporary shift to 1.54B adjust- ment steps, When in balance adjustment mode, the left inverted decimal point flashes. (see Fig.15). Two dashes on the LED displays indicate that the balance is contred, Hitting the “Ch Down” button moves Rissounlaiit on the first two s, a single dash is shown in the Tottdigit position indicating the diree- tion of “movement”. Likewise, one or two presses ofthe “Ch Up” button from the contred position results in a single dash in the right digit position, Subsequent prosses display a num: ber indicating the relative attenue- tion level of the opposing channel For example, if the current volume level is set to 50 and the balance is favouring the left side and reads 5, the actual levels are: left = 60, right = 45, After four seconds of inactivity, the unit automatically reverts to vol- ume adjustment mode. To bypass the four-second delay and immediately exit balance mode, use the volume up/down buttons on your remote or press the “Balance” button egain. Both channels are simultaneously adjusted when the volume is increased or decreased, maintaining the balance separation. Note that when either channel reaches the maximum volume sotting (ie, 85), further commands to It's a pleasure to measure eee) aD Power Supplies Oscilloscopes RF Generators Frequency Counters ne Soe, SoS Fig.16: the mains earth lead ‘must be securely attached to the base of the metal chassis. Here's how to assemble a suitable earthing point for attaching two spade lugs. The two nuts lock the assembly in place. ‘increase the volume are ignored. When one channel reaches the ‘minimum volume position (0), further commands will continue to decrease the volume in the other channel until both aro at minimum, if they are not idntical. Increasing the volume from this minimum position restores the original balance separation. Muting Muting is achieved by hitting the ‘Spectrum Analysers HAMEG Instruments have always been recognised for the consistent quality and no- compromise value of German engineering. And now the news is even better! With more new products, an attractive educational discount scheme and lower prices for 2007 you owe it to yourself to find out more. Call us please on 1-300-853-407 HAME> Instruments oe eee siliconchip.com.au ed a Smartcal, Cnc ‘Mancn 2007 37Fig.17: here's how to set the fuse AVR Prog, as used with the AVR ISP Serial Programmer. Once you've set all of the options exactly shown, click on the “Write” button. F YOU'RE BUILDING this project, {rom a kt, then the microcontroller (C1) wit have been programmed and you can ignore the following informa- tion. Alternatively, if you've sourced all the components separately, then you'll need to program the micro- controller yourself. A 10-way header (CON8) has been included on the PC board for connection to an “in-sys- tom" type programmer. Temporarily remove the jumper between pins 1 & 8 of CONB to allow connection of the programming cable. Also, make ‘sure that there's a jumper between pins 1 & 2 of JPS. We described a suitable low-cost programmer in the October 2001 Configuration and Security bits (gametes elo’) Sooo BeaLsckot 7 Loskz. Leck S851 F WOTON TF stich) F CROPI F EesAve T eoorSz1T~ aooTszn/” a0gTRST pobLevel BODEN SUTI T Suro T exseLa F exseL2 F CrSeLT T exsELO Fig.i6s the parallel port programmer uses PonyProg, which has an entirely fuse configuration menu. Again, copy this example and hit the “Write” button. dition of SiLicON CHIP, Kits for the programmer are cutrently available from Aitronics (Cat. K-2885), on the ‘web at www.altronics.com.au.Note that if you are using this particular programmer, the “Atmel AVA. ISP” software described in the instruc- tions is no longer available. A suit- able alternative, named *PonyProg’, is available free from www.lancos. ‘com. Set up PonyProg for the “AVR ISP (STK200/300)” parallel port in- terface as described in the included documentation for compatibility with the programmer. ‘Some readers may also be famil with the more recent "AVR ISP Se: rial Programmer’, described in the ‘October 2002 edition. This newer programmer will do the same job bbut connects to your PC via a serial (rather than parallel) port. Kits for this programmer are available from Jaycar Electronics (Cat. KC-5340) ~ see www jaycar.com.au. Note that as published, the AVR ISP Serial Programmer cannot pro- gram the ATMega8515 ~ the code in the programmer's on-board micro must first be updated. An update is available from the Siicon CHIP website. If you've purchased your programmer as a kit, this update will already have been periormed, (Once you have a suitable program- mer, together with the necessary cables and Windows software to drive it, all you need to complete the job is, ‘copy of the microcontroller program. for the Remote Volume Control & Preamplifier module. This can be downloaded from our website in a file named*DAVOL ZIP". This archive contains the file "DAVOL. HEX’, which needs to be programmed into the rmicro’s program (FLASH) memory. Just follow the instructions provided with the programmer and software to complete the task. Finally, the various fuse bits in the ‘ATmega8515 must be correctly pro- grammed, as depicted in Figs.17 & 48. lf you miss this step, your module may behave erratically! “Mute” or'12" buttons, depending on yourmodel ofremote. Hitting the mute iton a second time immediately stores the original volume level, while pressing the “Vol Up" bution restores the volume level and simuliancously increases it by one step. Note that pressing “Vol Down” while muted does decrease the vol- ume level shown on the display but it doesn’t turn the muting off. This, allows you to wind down the volume 38 Silicon Cir to a respoctable level first — perhaps when you've been caught out with the wick wound up far too high! Mut- ing is indicated by the flashing of the second inverted decimal point (Fig.15, top left), which will continue to flash even during display blanking (wh enabled) Multi-channel upgrade Finally, we've reserved buttons 1-6 and the optional “Channel” front panol switch for @ possible future multi-channel upgrade. This would allow up to five simplerslave modules to be daisy-chained off CONS, all un- der your command via remote control! Pressing any of these buttons causes * (meaning “Channel 1") to appear on the display ~but has no other fun- tion at present (Fig.15, top right) That's it— your new Remote Volume Conirol is ready for use. Sit back and enjoy the music st siliconchip.com.auFor all those innovative, unique, interesting, hard to find products comer om VicroGra es Jac omer eT OCS Tis unt lows the user erase isn i ran ce gta pat ee ae Sqr: [email protected] — Sessa ee cae $88 WWW.Mgram.cOM.aU fie? sion Wireless VGA Gateway x raat A fret oer a > standard 3021p ato be > ‘Wels VO Gta, = et t0sz587” $540 USB VGA Adapter aoe sos sro Keyed PCle to ExpressCard Rockby Electronics Pty Ltd Device: PNA Deseo: 14 Way 0 . Spacina Festi payag, ~~ P.0 Box 1189 Huntingdale Victoria 3166 (03) 9562 872 3 Pair Jumper Lead set Calor omer eas ‘8mm Red 7-Segment CA Display | Device 180236520 Type Cum owe Or Si tam SucOIWD aw: 19575265 mivorvie ‘SMC PCB 50-Ohm Devise SMC502.7135 Impsah cia a mings Hall Effect Micro Switch 20mA Sink) Deve: XLI03 Des: Hal ie Miro Switch Verlavbc love Le 20m Sink Manu: HONEYWELL ody Sie: 24318 [Ome 1 Dat Shot Ave” #32025 ‘30V 4A 20W P-CH SMD FET Pony: -CH aa ie: suvgres 7.3728MHz Crystal Oscillator ain 7.372800Ke Load Copp Pachage 14-DIL ao a ae ("FKC2 WIMA Polycarbonate Cap. | Jo < se en — Senet ay #24799 ‘Multiturn Trimpe sivervie 1kQ. 24-Turn Natu 1K Type Tip Ad Power Rating. SW Mano Spec 6eY #33756 ‘3-28pF Film Trimmer Capacitor ei ae nce EO So nics < re SRS <—S Type: Rail Supped Taped Reet gaqgq2” = NNOTY Web Address: wnw.rockby.com.au Email: salesdeptrockby.com.au + Stocks subjctto pir aOdd/even day watering solution Recent changes to garden water- ing laws have caused problems for some sprinkler controllers. The author's old controller could water on set days of the week or could be programmed to water every 2, 3 or 4 days, for example. However, to suit Victoria's odd/ ‘even day watering cycle, it would need to be programmed for every 2nd, 4th or 6th day and then reset at the end of every month with an ‘odd number of days. ‘New controllers that can handle this scenario without a reset at the ond of the month are expensive (upwards of $250). The author set- tled on the reasonably priced Orbit 94946 (around $50), which can handle odd/even days and accounts for calendar months. Its only weak point is that it cannot water every odd 4th day, for example. To get around this problem for ‘minimum cost, the pump output from the Orbit controller can be con- nected to the 24VAC input of some older controllers ~ in this case, a Pope (see Fig.1). The non-switched 24VAC lead must be common to both units, as shown on the dia ‘gram. The sprinklers simply remain Fun with flashing LEDs Flashing LEDs can be used in a variety of ways, some of which may not be immediately obvious. This collection of circuits (Figs.1-11 on the facing page) should provide some ideas. The basic flashing LED circuit is shown in Fig.1. Adding an ordi- ary LED in series (Fig.2) results two flashing devices, while two parallel (Fig.3) gives an “astable multivibrator” effect. Want to flash more than one ordinary LED? Easy, just add any general-purpose, small-signal NPN transistor (Fig.4) to flash several at SILICON CrP Fig.1: this diagram shows how the pump output from an Orbit sprinkler controller can be connected to the 24VAC input of a Pope controller to give ‘greater programming versatility, wired to the Pope controller. In the author's setup, the Orbit controller is programmed to water every odd day and the Pope con- troller to water every Wednesday, Thursday, Saturday and Sunday. The end result soos the garden watered four times a fortnight, on odd days, ‘once. Replacing the resistor in the basic circuit with a piozo buzzer (Fig.5) provides “beep-beep-beep” alarm is addition to the flashing LED = very attention getting! ‘The basic circuit can alsobe used to drive one or more digital ICs, as shown in Fig.6. In this example, the 4017 decade counter’s outputs can each drive a LED (or up to throo in series) for an eye-catching display. One possible use mightbe to arrange the LEDs in an electronic die to achieve an ever-rolling die effect. Schmit trigger type CMOS gates can also be used with success. In Fig.7, four gatos drive four ordinary LEDs. This is altered slightly in Fig8, where the gates are paired to Many other watering combina- tions are possible using this basic scheme. For example, setting one controller to water on Monday, Thursday and Sunday will result in watering three odd days a fort- night. Ralph Smith, Melbourne, Vic. ($35) gonerate two multivibratorflashers. Up to six LEDs can be driven from a single 4584 or 4106 hox inverter package (Fig.9). Again, this can bbe rearranged as desired to drive alternate pairs (Fig. 10) If all you need is lots of LEDs flashing together, then replace the rosistor in the basic circuit with a 5002 reod rolay (Jaycar SY-4030) = see Fig.11. This simple circuit will drive as many LEDS as the re- lay contacts can handle, and could work well as a bicycle tail-lamp, The flashing LED used in alt of these circuits came from Jaycer Electronics, Cat. ZD-0240. A.J. Lowe, Bardon, Qld. ($100) siliconchip.com.ausiliconchip.com.au ‘Mancu 2007 4go Siligon Clilp Binders. These binders will protect your copies of SILICON CHIP. They feature heavy-board covers & are made from a distinctive 2-tone green vi They hold i2iesues® | | LCD clock Ree en eee will ok great on your bookshelt mounting a “super” capacitor across pee meeae battery upgrade the cell holder. A 0.047F value was The button cells used in LCD used inthe prototype, but youcould % SILICON CHIP logo printed in clocks are expensive to replace, also use a larger 1F unit (available gold-coloured lettering on spine & often have auseful lifeoflessthana from Altronics and Jaycar). With ihe Sover eect ea tear eee eke ce a bottom drawer when needed! One _ the prototype runs for more than 3 Buy Te and get tnem postage ee ont lemons when the aa cal Setar ae rear removed Price: $413.95 plus $A7 p&p per All that’s needed to modify a ‘Take particular care with the ‘order. Available only in Aust. typical LCD clock for operation polarity of the capacitor and bat- Geil Nale wih the larger call isan AA call tory holdet, as aocidental reversal Silicon Chip Publications holdor(availablo from all the usual of either {tem may result in clock PO Box 139 outlets) and some double-sided tape and/or capacitor damage. Unfortu- Collaroy Beach 2097 | to altach the holder to the rear of nately, a diode cannot be used as a Nae eee polarity protector dusto its forward Fax (02) 9999 2648 or phone (02) povtseienen eresketen eet $999 6295 & quote your creat | | battery rmsiat isthe noed torosot Michael Ong, card number. thedateandtimeafteritisreplaced. City Beach, W.A. (S25) ete © Learn how engine management systems work © Build project to control nitrous, fue injection and turbo boost systems of signal frequency, temperature and votage test instruments to check fuel injector duty cycle, fuel mixture and brake and coolant temperatures Mal order prices: Aust. $A22.50 (incl. GST & PAP); Oversea $426.00 via airmail. Order by phoning (02) 9839 3295 & quoting your credit card number; or fax the details to (02) 9839 2648; or mall your order with cheque or credit card details to Silicon Chip Publications, PO Box 139, Collaroy, NSW 2097. 46 Swico Gear siliconchip.Three specialised high per- formance AM-FM radio broad: cast receivers, designed and manufactured in Australia by Elan Audio, offer protessional users significant advantages ‘over traditional receivers Normal communication re- celvers.are designed to receive speech only and nave high ain, narrow bandwidth and a restricted audio-frequency response in order to pick up low-level radio signals with ‘minimum interference and ‘maximum ineligibility They usually suffer from high detector distortion and sideband clipping and generally donot sound particularly pleasant on speech, and quite bad on music. ‘The new Elan radio receivers are designed specifically to receive broadcast programs and have wide bandwidth input and IF ci- cultry with low-distotion detectors. llthree receivers use the same “front end” receiver ‘module developed by Elan Audio, which is based on a hgh performance car radio IC developed by Philips in Europe. ‘The RMR-01 Monitor Receiver System is designed for use by radio broadcasters 2s ‘the primary high-quality studio off-air moni- tor receiver or as a general monitor receiver, attransmitte sites. Italows a broadcaster to accurately judge transmission quality and to Order Form/Tax Invoice Silicon Chip Publications Pty 1s ABN 49 003 205 490 PRICE GUIDE: SUBSCRIPTIONS | YOUR DETAILS a Pease ote mont ote, Asal: yr ‘08980 2s sare tyre tnder 4105 2yte «Binders $8209 Nea $095 29S enn SAID Overeas (yh nn SATIS 2 ‘$0 PRICE GUIDE: OTHER PRODUCTS (all prices include GST on Aust. orders) Postcode Daytime Phone No.( “SILICON CHIPBACKISSUESin stock: 10% iscountfor 10 or moreissues or photocopies, Ausra SA 50 acu Ing pp). Overseas: $A13 each (eluding p&p by a) “ELECTRONICS AUSTRALIA: projec photocopies. Austla 'A.50 each fncking pp), Overseas: 6819 each (ncudng Email address (it applicable) Method of Payment: p&p by a. “BINDERS: BUY 5 or more and got thom postage feo. ‘A Cheque/Money Order Visa Card Master Card (Avalable in Aust, ony): $413.9 each plus $7 pp per oder Card No, “ELECTRONICS PROJECTS FOR CARS, VOL.2: Aust SAt4.85; Overseas $410.00. (Pics induce pap & GST shor apa) Card expiry date: py “PERFORMANCE ELECTRONICS FOR CARS: Aust. $h2250, ess $900. Pos howe pap 8 SST Signature wees), Subscribe to SILICON CHIP on-line at: www.siliconchip.com.au Both printed and on-line versions available TO PLACE Phone (02)9939 3295 qj Faxthisformto guyz Mail this form, with your gar Mon-Fri (02) 9939 2648 cheque/money order, to: YOUR —Piesschiave yourcredt ——wihyourredteard tals Son ip ublestons Py ORDER ‘card details ready 24 hours 7 days a week PO Box 198, Collaroy, N ‘Australia 2097 &The Spark That Ghar While its origins were in the 19" century, it is widely recognized that radio - and in particular broadcast radio — was one of the most significant developments of the 20" century. by Kevin Poulter fier the turn of the contury wore capable of bridging continents but wore limited to telegraphy only ~ Morse code. They spawned a lot of interest amongst experimenters and wireless enthusiasts but asa consumer item, they werea lame duck. Ittook a lot more devel- ‘opment to boable to trans mit (and receive) voice and music. But over the next two decades such development did occur and radio broadcasting, as we know it today, became a reality The equipment to receive those broad- casts naturally followed Thanks to some inspired and creative inventors and producers from the early 1920s onwards, we can nov Took back and se radios that are absolute works of att, The wiring is superb and the casos lovingly constructed to showcase the finest possossion in the home. T: spark-gap transmitters which came into vogue Many of these treasures should be in museums but due to a luck of space and resources, plus the overwhelming demand for diversity in their collections, few radios are restored and displayed in public Fortunately, 25 years ago a group of radio enthusiasts cre- ated an organisation dedicated to saving and restoring many of theso iconic contrepiaces of the 20th contury way of life, Now many collectors’ homes display jaw-dropping. collections of radio equipment and ephemera (posters, plans, circuits, advertisements and photographs). The HRSA (or Historical Radio Society of Aus- In the 1920s, ‘coffin’ radios were connected to mnal horn speakers like this Amplion. The first car audio systems even had horn speakers. 58 SiicoN Gs iP tralia), was established by a small group of radio enthusiasts, motivated by Ray Kelly, in April 1982. Today, the HRSA has about 1000 members throughout Australia, with a number in overseas countries as well, Not just domestic radios... Australian mantel radios are the common interest, how: ever the HRSA includes collectors of al types of receivers and oven military radio equipment, television receiv- ors, radiograms and more recently transistor radios. The most advanced mombers hava 400 to 1,000 radios in their collections, sormuch of Australia's radio heritage is proserved. ‘What inspires people to share their love of radio and related J, information? It is the history, electronics innovation, devel- opment and amazing quality of workmanship in older ra- dios. One of the groatest moti- vations is the thrill of finding and restoring a docropit radio, or even rescuing ono from tho all too common imminent final journey tothe tip and bringing it tos new condition Stories that chill the blood of col- loctors abound, like a huge collection of 78 RPM records in fine condition, offered to potontial collectors but as the owner was too far away, there was no ro- sponse. So the whole lot wore burnt in a bonfire, Another company, not so long ago, hhad too many valves, so a skip was hired, filled with these hard-io-get parts and sont to the tp. Most collactors especially like to have at least ono nostalgic example of the radio make and model that bought the world to their kitch- ‘ns or lounge-rooms through- ‘out their childhood. The development, enjoy- ment and subsequent collect- siliconchip.com.auing of radios, had its origins with the music-box the first mochanical device that reproduced tunes at will. We are familiar with the ‘barrel’ cylinder music-box, however there were also disc versions. Some had different dises or eylin- ders with a choice of tunes, either fixed in the music-box, or removable, like CD players. With this conceptual background, Bdison made a monu mental leap forward. He recorded sound onto materials such as wax, then reversed the process to replay it. From this earliest reproduction of sound via a noodle there is @ direct evolution to the sound, vision and computer discs we enjoy loday. Edison made two more vital discoveries in radio's early history: the carbon microphone and the diode valve. The difficulty with the diode was thet he couldn't think of an immediate application, so it was left to others to develop many years later, The first radio “broadcasts” Once the first sparks were sent through the air as Morse Code (which, incidentally, occurred in Italy in 1895), radio, had bogun. A host of inventors including Marconi made valuablo contributions, until the public broadcasting of voice and music around 1920. Most radio broadcasts of the day were ad-hoc affairs by amateur operators using their own “home brew” gear. There were no such things as schedules or programming! Part of the reason was that there was virtually no receiving equipment, at least not in the hands of the general public: ‘The first public radio broadcasting station is usually credited to Dutch ‘mateurHanzo Idzarda, who commenced transm sions from his station PCGG in this AWA C siliconchip.com.au ‘The first bakelite radio, the AWA Radiola C37, ie of the AWA, feet, is one of the most sought-after radios damaged, though most not iy as this. HRSA jer Ray Hosking restored 7 to like new. The Hague on 6 November, 1919, ‘The BBC start ed rogular broad- casts on station 2MT from London on 14 November, 1922 (even though it had been Vv transmitting for some months before) and Australia joined the radio revolution when radio station 2SB began public broadcasting on 23 November 1923. 2SB, owned by Broadcasters (Sydney) Ltd, had been in a race with rivals Farmer and Company, who promised in ‘August 1923 to start broadcasting from theirstation, 2FC, on November 15. 2FC didn't make their deadline and startod on December 5", (288 later became 2BL and both 2FC and 2BL were later absorbed into the Australian Broadcasting Commission, or ABC) ‘Some suggest 2SB wasn't the fist station to “broadcast” in Australia, It was the first to “officially” broadcast rogular programming but the honour of frst in Australia belongs to ronowned radio pioneer, Charles Dansie Maclurcan, whose station 2CM in Agnes St, Strathfiold started in 1921 with a 90-minute concert every Sunday night. Maclurcan in fact had the firs licence to broadcast in Australia And if you're looking for a question to stump even the most ardent trivia bulls, the first piace of music “officially” broadcast in Australia (on 2SB) was “The Swan” (Lo Cygne), from Saint Saens’ "Carnival of the Animals” (Camaval dos ‘Animaux). Do it yourself! Soon private and ‘commercial con- structors were ‘making sw perb valve radio 18- Manct 2007-59and crystal sets, aided by a host of magazines on the subject. Reception was regenerative or superheterodyne (superhet). True crystal sets, now highly sought after by collectors, were built into wooden basos or omate boxes. My grandfather built a crystal set with twin headphones, so heand his wife could both listen to radio in bed at night The valve receivers in the 1920s wore in ‘bread-box’ shape, with a lid for access to the electronics and valve replacement, Collectors irreverently nickname radios of this era ‘coffin radios’, due to their outline. Wood was the most common cabinet material, though a few were in metal, with the brand embossed on the case or added as an embossed metal plaque, 930, two new styles appeared, ‘Cathedral’ and ‘Con- ‘The Cathedral mantel and table radios had a curved ppoak, reminiscent of Gothic-stylo archways and windows, finished in wood or B akelite while the Console was a big, sound, floor-standing, waisi-height radio. ‘The Console benefited from its spaciousness, with room for a large speaker and the huge case acting as a superior bafile. The Console's sound wes big, with rich tones. Both types became immensely popularas manufacturors competed for the finest decorative furniture appoaranco, at ‘THE CRAZE THAT'S SWEEPING THE WORLD PRESENTED TO AUSTRALIA, Sor the first time “aac, BRISBANE Se Sto) “ ee See © SMALLER THAN A MANTEL CLOCK (¢ WEIGHS SAME AS AJUNIOR MOVIE ‘CAMERA © GUARANTEED SAME POWER AS FULL-Size SET © GUARANTEED SAME RANGE AS FULL-SIZE SET ure dn MICKEY MOUSE £1 2x 2 ASTO 5 VALVE SUPERHETERODYNE 60 SILICON GHP Siueeee Sa nas | 1) ‘c infringement battle with Disney, the next model was licenced and had a Mickey on the dial a colour transfer on the reat (Below let): once Astor could legally use the name and image of Mickey Mouse, the character featured prominently on thei radio and advertising, such as in this advertisement from the December 1933 edition of Wireless Weekly. an affordable price. Householders took great pride in displaying them as the feature of their homes. Inthe early 30s, a plastic-like material called Bakelite revolutionised the mass-production of radios (and indeed many other products, diverse as wall power/light switches, pens and n women’s jewellery such as bangles). Pro- duced under immense pressure, Bakelite could be manufactured into cases with thousands of identical shapes, with many different colours. It was very durable and simply wiped clean, Australia’s first Bakelite set, the CB7 made by Amalgamated Wireless of Australia (AWA), was made in 1932. Soon manufacturers found they could add flecks or veins of colour, re- sombling marble, making radios that are now highly sought-after, And radio electronics progressed beyond regoneralive receivers to lop-performing superhet designs Mains power was not supplied in many towns and farms, so battery sets were very common, People in the bush demanded high performance so they could hear distant stations Clearly, so Australian radios compared well with the best in the world During the Cathedral era in the 1930s, As- tor radio introduced the Mickey Mouse radio a small mantel with big radio performanc ey objected to the use of his character's name and Astor chairman Sir Arthur Warner fought his request for a small royalty through the courts, until Disney won. ‘Once Astor was obliged to pay royalties, they took full advantage of the rights and produced arevised Mickey Mouse radio, with a cartoon Mickey on the front and the rear and in adver tising, This radio had a very long product life, with a version still being sold in 1943. siliconchip.com.auWhen Astor decided ta drop the Mickey Mouse drawings and not pay royalties, a new plastic-cased radio was still, checkily called ‘Astor Mickey’. Both Astor Mickey radio series had longevity, selling for about a decade, Imagine the tooling and production savings. Today an electronic product's sales life can be less than a year. Certainly this is true of car audio manufacturers who produce ono or two model range updates every 12 to 18 months. AWA, led by Sir Emost Fisk, designed technologically advanced radios. The AWA C87 bakelite sot, previously mentioned, is now one of the most sought-after and valu: able radios in collections today. By the mid-thirties, AWA designed a large mantel radio said by some to be modelled after the AWA building head: quarters in Sydney. Due to the skyscraper like appearance, the radio has the moniker ‘Empire State’, after the famous classic American skyscraper. The style remained in a umber of diffeent variations for many years The small Bakelite mantel radio became the most afford- able and purchased radio in the 1940s, with most moving from the big radio in the lounge room to a more compact, unit in tho kitchen, After all, the kitchen is where most people had the time to listen, Danger, Will Robinson, Danger! While some early battery-operated radios are still oc casionally discovered, nearly all collectable radios theso days are mains-operated. And they aro obviously old, 60 tho HRSA promotes safety as paramount. For example, in some models of the Empire State ra dio, heat-insulating material was placed betwoen a valve and IF (intermediate frequency) transformer, to avotd the transformer drifting off tuning as the radio heats up. The {insulating material? Asbostos! Don’t blame the manufacturer — in its day, asbestos was considered a wonder insulator and nobody knew of any harmful effects. Today we know that you should not break up or even touch this material without protection. Some. authorities even maintain the slightest inhalation is highly dangerous. Despite this, left alono, asbestos poses little health risk, so most states still allow sales of collectable appliances with this material Incidentally, wo have also seen asbestos in radiograms sillconchip.com.au (| under the chassis or in the mains cord. Unfortunate) Older radios should not be turned on, ‘to see if they work’, as capacitors and other components short or open circuit with age. These capacitors have obvious leakage. Restorers replace capacitors with modern types. To show future generations how the original radio looked, the chassis is photographed befure repairs. The replaced capacitors are then stored in a plastic bag near the radio. ‘The ultimate restoration involves cleaning out the inside of the original capacitor, leaving a hollow exterior shell. ‘A.21% century capacitor is placed inside and when re- installed in the radio, it’s impossible to tell from the original, from much later times ~ in the 1950s — 80 take care. Other hazards include old rabber-covered wiring, either the rubber perishes over the years, often leaving bare cop- per wire exposed. As a matter of course, old mains cords should be replaced. Ifyou want to maintain at least a look of authenticity, woven-cloth-covered mains cable (as used for oloctric irons) isa reasonable substitute. HRSA members use an authentic-looking brown cotton-covered cablo. "There are other electrical safety considerations too, per- haps not directly associated with the radio but with the home it lives in! ‘Some pre-50s homes, for example, have power points with Active/Neutral transposition, as they were wired before modern electrical rules. This means you can turn the mains switch off at the wall and the radio will go off. But live (Active) wires still go to the radio. Touching this exposed Active and the chassis or other earth, will be a shocking experience! Using a cheap neon screwdriver, the author found two out of four power points in one 1950s schoolroom danger ously reverse-polarity! So it’s vital to check your power points. In addition, the uso of an carth leakage lead or socket (RCD) is highly advised. Regardless, the plug should be removed from the wall before attempting repairs, justin case. ‘Another killer ~ literally ~ can be those old-style “mir- HRSA meml 42V vibrator in his radio shed at Ci Adelaide hills, Near the shed is a 82V wind-powered generator restored with parts scoured from the Nullabor Plain and other remote parts of South Australia. It supplies a large bank of ex-telephone exchange batteries with two 1930 Ruston-Hornsby diesels for backup. Mauct 2007 61ola Transistor wembers, ror image” double adaptors. These were outlawed at least 20 years ago but its amazing how many still turn up. They seemed like a good idea at the time but by design, one ofthe two outlets has Active and Neutral transposed. OF course, live-chassis radios are one of the biggest angers to the inexperienced. The AC/DC radios that oper ated directly from a DG supply in some towns should be approached with caution. They don't have a power trans- former, so depending on the polarity of the mains power point, the chassis can be live. Even with a fully closed sot, a knob can still fall off, exposing metal. Or even moro unexpected, the grub-scrow holding the knob may be long enough to touch. Ifthe mains cord is frayed, don't shorten it, as it may be ‘resistance wire, to reduce the input voltage. An isolating transformer is recommended but even this does not result in a 100% safe radio, n of this white ‘marbleised’ AWA. case passes the closest inspection. The severity of the damage — even greater Most FIRSA collectors are from an electronics background, or receive assistance from members with the necessary ex- pertise. At the Society's regular auctions the HRSA complies with electrical safety regulatory requirements, including all equipment for sale displaying a safety notice (further dotails in the web references). ‘eBay has changed the buying and selling of radios. Some collectors find greater access to interesting items, Ifyou are tomptod to give it a go, ask friends about safety and security issues. Bo awaro of statements like ‘not working ~ nocds a valve ~ should be easy to fix’. Translation ~ I switched it on and smoke came out, so I'll got rid of it. Or ‘Valve, New in Box’. This is sometimes described as, “NOS” (New Old Stock). While there are amazing numbers of never-used old valves still in existence, it’s quite com- ‘mon to find a faulty valve in a nice box. ‘The reason? ‘Valve jockeying’, or trying new valves first before proper circuit analysis. This often achieved results, albeit temporary. Without proper circuit repairs, to repair the real fault, many new valves degenerated to the state of the replaced one, Due to the cost and inconvenience of socuring a wide range of valves — and the chance valve replacement was not the solution ~ technicians and hobbyists changed each valve, placing the old one in the box. Unless the valve was in a very poor state, most were kept for valve-jockeying tests. If there was some improvement, then a new valve was purchased. Don’t plug it in and turn it on... final safety tip: never turn on an old radio ‘to see if it works". This is not only dangerous for the operator but can destroy a classic radio in an instant, roducing its value and restorability to near zero in one unwise move. ld parts such as capacitors (they were originally called condensors), transformers and resistors may heve a short, so the radio ‘fries’. Instead of just tuming on an old radio and standing back, check it over first, physically and elec trically. Power transformers and the like are much harder to source than now, reliable, capacitors. Many advocate replacement of all the electrolytic and other suspect (especially paper) capacitors, as if they are nol faulty now, they soon will be. Test tho chassis for shorts and if possible, do a “Megger” test. For the inexperienced, ask someone who knows old radios to do this for you. For more information on restoring early sets, SLIGON than the progress photograph on the left ~ would normally mean it would be thrown out, but sets like this are quite rare, 62 SiicoN Crp siliconchip.com.auAA beautifully restored “Peter Pan” radio, model BKJ (1946- 7), manufactured by Eclipse Radio, Melbourne. Cu? has a “Vintage Radio” column in every issue, written by HRSA member Rodney Champness. 50s optimism After tho war, the world surged with now optimism producing inventive, productive and colourful products. A major development was plastic, with al its coloursand ease, of production. Two radios came to the forefront ~ plastic mantels and radiograms (record players with radios in a Ddeautiful wood console). Colour was everywhere in the kitchen and radios followed suit, with hardly a brown radio in sight ~ the only brown, ‘or other warm tones remaining wore in the timber finishes of radiograms and TV sets, relegated to the loungeroom, Radiograms often have high-performance multi-band re- coivers but fow are collected, due to their size. TVs often end up at the tip too or sadly are stripped and made into fish tanks. That was all the rage a decade or so By the early 60s, transistor radios surged in popularity. Today, their prices are generally lower than the older valve models and the designs appeal to younger members, so there are collectors addicted to these battery portables. Many members of the HRSA mostly specialise in a genre or era—for example, military radios. Many have extraordi- nary knowledge and information on their speciality. This is shared and tracled between members, one of the great advantages of the HRSA. There are also members that offer speciality services, such as repairs to components like speakers, wood or bakelite, Ray Hosking is the master of bakelite repairs and his work is shown here, On completion, his repairs are completely invisible (he can make a silk purso from a sow's ear!) Bakelite is a strong material but eventually becomes ‘more fragile. So the common practice of picking up sets by holding their bakelite top is not advisable ~ always carry radios held from the base SILICON CrP is a keen supporter of the HRSA’s goals and this is highly appreciated by all members, especially as many read SILICON CHIP. In fact one of the winners of the. {inaugural SiticoN Cui? Excellence in Education Technology. award, Lauren Capel, restored a radio and built a power supply, plus MPS playerand mini AM transmitter, drawing on information and advice from HRSA members. siliconchip.com.au The Society's activities include auctions, @ quarterly magazine with information, circuits and. trading pages, meetings around Australia, technical and historic talks, restoration workshops, construction projects, technical library, circuit service, participation in shows and events and a valve/component bank, all for just $27 a year HRSA's big show! ‘To mack the 25th anniversary of the HRSA, the organi- sation is staging a huge national event in Melbourne next ‘month (April). Located in the vast Holmesglen Conference Contre, cnr Batesford & Warrigal Rds, Chadstone, there will be displays and activities for members and the public Highlights will include a radio display, stunning in quality and quantity, an old radio store, a battery store, continuous radio shows from a large room full of con- soles, working portables on parade, posters, images of Australian radios and production, giant auction, swap- ‘moet, guest speakers, radio films, valuations and much Some activities are limited to members only, Members have free entry both days, so membership is encouraged. ‘The members only day is Saturday April 14, from 9 am and Sunday April 15th from 9 am. On the Sunday, public admission commences at 1 pm, Details can seen at the special event web site, www.ozradios.com ‘The event will appeal to any people interested in elec: tronics or vintage radio, Hope to meet you there - you'll certainly find many people, past and present, from the Australian electronics industry to chat to. sc e Radio Waves, is published quarterly, ude storations, auctions, sale of new or used parts and historic radio stories. Marc# 2007 63‘OT TOO MANY decacles ago, the only way most people could gen: was by using a quartz crys Following this it became oscillat possi By about 1980, even higher accu- racy could be oblained by locking a local quartz crystal oscillator with the horizontal sync signals from one of the national TV networks. That's because the networks used @ master timing clock that was locked to an “atomic 64 SILICON CHP clock” based on eithera caesium boam, or rubidium vapour oscillator, ‘The GPS system e. By using this s' ence, it's possible to frequencies with extremely high accuracy — than using the previously listed methods e are necessary to generate yy accurate frequency and time signals needled for accurate position ( ing. And since there least four GPS satellites “in vis any time from as @ frequency .ce— provided you have therright receiving equipment, ‘The only problem was that until a couple of years ago, GPS receivers pensive, However, costs mn quite dramatically’ since then - so much so that hand! fo mobile GPS navigators are now every-with good-quality signals, though ‘The unit is housed in a plastic case and provides accurate 10MMzand MHz This means mounting a smal! active reference aquencis via ront-pandl BNC socket. range of data can also GPS antenna in a clear area outside be displayed on the LCD, including UTC time and date and the recel s high as possible so that it can get antenna’s latitude, longitude and height above mean sea level (see eee teecatal “alee af theta in order to receive th The antenna is conz antenna input of the rer 2 suitable leng good quality 500 coaxial cable. This delivers the amplified 1.575GHz GPS signals to \ the receiver and also feeds the active antenna with DG power (provided by the receiver) ¥ In our case, we chose a Garmin \ GA 29F flush-mount active antenna, which costs about $90. This was fitted tothe top ofthe authors TV a enna mus (e0 photo), Wealso tested €2D-3886 antenna made by Australian WF fim RF industries, which also worked wwoll This unit is available from Dick Smith Blectronies and Tandy outlts for just $69, Maken together, the GPS receiver sel youbackabout $200, The rest of the parts will probably be around WEPEBINE GPS BASED FREQUENCY REFERENCE ib te bald the hole shaban i for about $830. This is usta frac tion of the price you'll pay for 2. @. R commorcially available GPS: based frequency reference, era net aereec tl gre = Clea How it works ‘get a handle on how it al works, refer now to the blo fa-gram of Fig.1. Basically, the frequency of the 10MHz.crystal oscil lator (top, right of Fig.1) is controlled using a phase-locked loop (PLL). This PLL, in turn, uses the very accurate 1Hz pulses from the GPS receiver As you might expect, inside each you because there’sa lot packed into it, module as its reference. However, the of these navigators is a complete GPS Inside, there's e complete 12-channel PLL, configuration is a bit more com ivor module, However you don't GPS receiver which can track and use plicated than normal, so Ie’s look at have to buy a navigator to get the re- up to 12 GPS satellites at once. And this in greater detail ceiver module, because they are also it can provide a swag of GPS-derived Basically, the reason for the added available separately for use in other time, date, position and satllitestatus complexity is that it isn’t easy to con oguipment. And that'sjust what we've information in serial RS-292C text _trola 10MHlzcrystal oscillator using done hero ~ use one of these “bare form — updated each second, no loss. _roference frequency as low as 1Hz—at bones” receiver modules as the heart _Italso provides aone-pulse-per-sec- _loast not using a standard PLL. That's of this proj ond (1PPS) output, where the leacling because with a standard PLL configu. gos ofthe oscillator frequency must accurately ration, the armin GPS 15L, jacked to t id GPS tim- be divided by 10,000,000 (to get Hz}, he GPS module we chose to use is ing system. I's these pulses that we to be compared with the reference 4 Garmin GPS 15L, which is available mainly use in thereference, tocontrol__ frequency in the phase comparator, from local distributors for about $130. _ the frequency of local 10MHz-crystal_ However, such a high division factor Iv’squitea tiny device, measuring just oscillator involves a relatively long time delay 46 X 36 x 8.5mm and weighing in at For best porformance, you do need and this adversely affects the error only 14.1g, But don't let the size fool to feed the Garmin GPS 15L receiver correction feedback, making it very siliconchip.com.au MancH 2007 65ary to receive the GPS signals, ‘The author used a Garmin GA 29F antenna. This was mounted on a plastic junction box and fited to the top of an existing TV antenna mast. difficult to stabilise the PLL. ‘To got around this problem, we di- vide the 10MHz oscillator output by a much smaller factor ~ only 200 times in fact. Thisis done in soparate divide- by-10 and divide-by-20 stages using synchronous divider ICs, so that we end up with 50kHz pulses which have the timing of thoir leading edges (L-H transitions) very closely synchronised with the leading edges of every 200th pulse from the 10MHz oscillator, This means wo have effectively transferred the phaso of the 10MHz oscillator signal (averaged over 20s) to the SOkHz signal at the output of the divido-by-20 dividor. And it's the phase ofthis signal which we feed into the second input of the phase compa- rator, where it’s compared with the leading edges of the 1Hz pulses from the GPS receiver module. ‘The phase comparator docs exactly what its name implies ~ it compares the leading edge of oach 1FzGPS pulse with the 50kHz pulse nearest to itand 66 Siicon Crip generates a “phase error” pulse, the width of which is directly equivalent to the timing differenco. One of these phaso orror pulses is produced at the start of each 1Hz GPS pulse and they can vary in width from zero (when the ‘two signals are exactly in step) up to a theorotical maximum of 20s {when thetwo signals are one period of 50kHz out of step). In practice, we use the PLL’ feed- back loop to maintain a fixed phase error of about 10s (ie, halfway in the range). This gives tho PLL the wid- est possible control range, to ensure reliable locking of the 10MHz crystal oscillator. Deriving the feedback voltage OK, so how do we use the varying phase error pulses from the compa~ rator to produce an error correction feedback voltage for the 10MHz oscillator? Well, what we do is use the error pulses to control an AND gate which then passes pulses from a second crystal oscillator (running at about 10MHz) to an 8-bit binary ‘counter, So as the error pulse width varies, it allows a varying number of thoso “about-10MEH1z” pulses to reach. the counter. For example, if the phase error pulses are 8.018 wide, 80 pulses will be gated through to the counter. And ‘the pulsos are 11s wide, 110 pulses willbe fed through, and soon. Soat the start of each 1Hz GPS pulse, a burst of “about-10MHz” pulses will be fed to the counter, the number of pulses in the burst being directly proportional to the phase error. ‘The counter is actually reset at the end of each 1fz.GPS pulse, soit counts up from zero each time. At the output of the counter we also have an 8-bit latch and a simple digital-to-analog converter (DAC) using a resistor ladder network, After the end of each phase ‘error pulse, the latest error-proportion- al pulse count is transferred into the latch, replecing the previous count. Asaresult, the output of the DACis, ‘aDCvoltage which varies in level each second, according to the phase error. So the phase error has been converted into a varying DC error voltage. Got the idoa? When there's a fixed phase error of say 104s, the counter will have @ count of 100 each time and the DAG will have an output voltage of almost oxactly 1.953V. ‘This voltage will vary up or down in stops of 19.53mV, as the phase error pulses vary in width and the number of “about-10MH2” pulses fed to the counter varies up or down. Each of the “about-10MHz” pulses fed to the ‘counter corresponds to a phase error step of close to 100ns, so our phase error-to-DC error voltage conver- sion circuit has a conversion gain of 19.53mV/100ns or just under 2mV for every 10ns change in phase error. Why two 10MHz oscillators? By now, you are probably wonder ing why we go to the trouble of using a second 10MHz. crystal oscillator to provide the 100ns pulses for the phase error counter. Why not just use the output of the main temperature controlled 10MHz oscillator, at upper right? ‘We use a second 10MHz oscillator because this inevitably drifts in phase compared with tho main oscillator and this introduces a small amount of “dither” into the phase error counting operation. The random noise intro- duced into the DAC's output voltage as a result of this dither allows the PL’s error correction to have a sig- nificantly higher resolution than if ‘we used pulses from the main 10MHz oscillator. ‘The reason for this is quite straight- forward. If we had used the pulses from the main oscillator, the fact that they would be locked to the 50kHz pulses (and hence the phase error pulsesas well) would mean that the DC error voltage could only ever change in 19.53mV increments. This corro- sponds to 100ns changes in phase er- ror. However, the dither introduced by using the second oscillator means that the average error voltage will change in somewhat smaller increments. ‘And that means that we can maintain the main oscillator’s phase locking to much closer than 100ns. As shown in Fig.1, the DG phase er- rorvoltage from the DACiis fed through abuffer toa low-pass ilterstage based on capacitor G1 and resistors R1 & R2- ‘The filtered error correction voltage is then used to control the capacitance of a varicap diode, to fine-control the frequency and phase of the main 0MHz oscillator. This unusual type of PLL system is very effective when it comes to phase-locking a 10MHz oscillator to the GPS 1H pulses but it doos have a limitation, Because it divides down siliconchip.com.au1622 LCD DRRLAY MODUIE ‘Suse PUSES WIT TRADING EDGES) SyNCHRONS#D TO TE LEADING EDGE OF even 200TH Ps OF THe Towle OSC CuTPUT Fig: the GPS-Based Frequency Reference uses a phase-locked loop (PLL) to control the frequency of a 10MHz, rishi ‘ cerystal oscillator (top, righ ). This PLL in turn is referenced to the very accurate 1t1z pulses 1m the GPS receiver module. A PIC microcontroller decodes the GPS data, intorprets the switches and drives the display module. the oscillator frequency by only 200 times instead of 10,000,000, it's just as effective at phase-locking an oscil lator at a froquency of 9.999800MHz 0 9.999600MHz, or 10.000200MHz or 110.000400MEz. In other words, it’s capable at phase-locking at frequencies that are separated from 10,000000MHz by exactly 200Hz or multiples of that frequency difference. This means that when youare setting up the frequency reference, i's very important to adjust the freo-running frequency ofthe main crystal oscillator to within 100Hz of 10,000000MHz. If you don’t, the PLL may lock it to 9.999800MHz or 10.000200MHiz instead of the correct frequency! ‘Making use of the data OK, that’s how the main part of the GPS Frequency Reference works. The only parl we haven't discussed yet is the section down in the lower ieft of the block diagram. This section is functionally quite separate from the ain section. Its purpose is to make use of the stream of useful data that -ges from the GPS receiver module sificonchip.com.au each second, along with (but separate from) those accurate 1Hz pulses. ‘This data is delivered as ASCII text and appears at the module’s RS-23: serial output port, It’s in the form of coded data “sentences”, sent at a rate of 4800bps (bits per second) using a sentence format known as NMEA 1083, This format was first standardised by the US National Marine Electronics Association (NMEA) for information exchange between marine navigation equipment. ‘As shown in Fig.1, we use a pro- grammed PICIF628A microcontrol- Ter to “catch” and analyse this serial data. The decoded data is then feed it to an LCD module. Pushbutton switches $1-S3 are included to allow ‘you to display some of the more eso- eric information for a short timo, as required. Normally, the display simply shows the current UTC time and date (updated each second), plus the GPS fix and PLL locking status. ‘The fourth switch (S4) forces the PIG micro to send an initialisation code command to the GPS receiver module, to initialise it correctly if it ever becomes “confused” (the GPS receiveralso contains a microcontrol- ler, of course). In fact, the receiver ‘module has an RS-232C serial input as well ag the output, provided for this very purpose. However, because this initialisation is rarely required, $4 is not readily accessible like $1.83. Instead, it must be accessed through ‘a small hole in the front panel of the project, using a small screwdriver or probe tip. Circuit details Now that you have a basic under standing of the way the GPS-Base quency Reference works, we should be able to work quickly through the main circuit, to clarify the fine details. Fig.2 shows the main circuit while Fig3 shows the associated display circuit with its LCD module. The two connect via a 16-way header cable. In operation, the Garmin GPS 151 receiver module (lower left of Fig.2) is fed via an external active antenna. The resulting GPS-locked 1Hz pulses are on the grey wire of its 8-way output cable and this goes to pin 5 of a 10. way IDG line sooket that mates with COND, The 1H pulses are then fed Mane 2007 67ms 25v TO DSRAY BOARD. TERNAL ANTENNA The i insane [D5 b6 7 ocouF ks 3 « NAGA —/ B oeator oo | ‘puse 1’ nla os OX _1000 rein: 7ancra| ‘i a ‘nb 82 GPS-BASED FREQUENCY REFERENCE san soar through Schmitt inverters IG11a and IC11b which act as buffer stages. The resulting 5V p-p pulses from IC11b are then fod directly to pin 14 of IC7, which is the phase comparator. ‘The 10MHz crystal oscillator that's 68 Swicow Crp phaso locked to the GPS pulses is based on inverter ICSF and crystal X1, plus varicap diode VC1 and sov- eral low-value capacitors. Its 10MHz output is fed via inverting buffer stage IC3b to CONI and also via IC3e to di vidor stage ICA. This stage divides the signal by 10 and provides two 1MHz outputs, at pins 12 & 15. The pin 12 output is then fed via inverter IC3d to CON2, to provide the 1MHz output signal at BNC connector CON2. siliconchip.com.aueo1ss usasz oy aD CCAPACTTOR VAUE MA NEED 0 Be CHANGED SUIT CRYSTAL ~ SET veo B hizee sort THe hse bole, 'ae r Ie froowte By contrast, the pulse output from pin 15 is fed via IC3e to a second divide-by-10 stage based on ICS. IC3e is necessary to invert the signal at the input of 1C5, because the 74HC160 triggers on the resulting rising signal siliconchip.com.au edges and it's those edges that are synchronised with the 10MHz oscil- lator signal ‘The resulting 100KHs. pulse output from pin 15 of ICS is fod to the clock inputs of JK flipflops 1Cba and IC6b. +5 ie A err ul nea (OFS 1H Puss G buen fal 1 ruse use ‘cOMPAHATOR ent CONE tape Toone tox > = - ruse ow | Fig.2 (above): the complete cirouit for the GPS-Based Froquency Reference minus the display circuitry (LCD & LED indicators). The PLI-controlled 10MIz oscillator is built into a small temperature-controlled oven to ensure stability, with power transistor Qt acting as the oven heater. Mancn 2007 69Fig. pushbutton switches (S1-S4), ‘These are both aro wired for toggle (divido-by-2) operation. The S0kHz pulsos from the Q output (pin 12) of ICéa are then fed to the second input (pin 3) of phase comparator IC7, for comparison with the 1Fz GPS pulses, Note that these 50kHz pulses have their rising edges closoly aligned with the rising edge of every 200th pulse from tho 10MHz oscillator. The phase error pulses emerge from pin 15 of IC7 and are fed directly to the clock gating inputs of 4-bit synchro- nous counters IC8 and IC9 (74HCi62), 70 SILICON CHIP cow 5 i 3300 3300, 3300 2 com a he os we dA ck Ke B® Bq R KE Noo tro | She i * a Aen aio ‘ie ue B oe a NICO! , 2 AL f 7 I i Lhd Stoonmst 2X 16 LCD MODULE 2 PO |e ap ar ee TE ul ler T t val | ws osle |us vel le vev | vew| Ain] St] Be ap osg af ste ‘ : low ES : $¢ GPS-BASED FREQUENCY REFERENCE ose s0s00 display circuit interfaces to the PIC microcontroller (1C1) in the main circuit via IDC connector CONG, It includes the LCD module, three LED indicators (LED1-LED3), switching transistors Q2-04 and four which together form the 8-bit phaso error pulse width counter. This is done bbocause the AND gate shown in Fig.1 is, actually inside the two counter chips, rather than being a separate device. The “about-10MH2” clock oscillator usod by the error counter is based on crystal X2.and inverter stage IC14c Its output is buffered by IC14a & IC14f and fed to the clock inputs (pin 2) of the two counters. The eight output bits from the two counters are then fod to the data inputs of C12, the octal latch, Its outputs are used to drive the rosistive-ladderDAC (digital-to-analog converter). In practice, this counter-latch-DAC sub-circuit is arranged so that it per- forms a new count of the phase error pulse width at the start of every 1Hz pulse from the GPS receiver module. ‘The sequonce is as follows: on the falling edge of each 1Hz pulse (100ms after the start), the counters are reset by a very short pulse on their MR-bar pins (pin 1). These short reset pulses are derived from the 1Hz pulses atthe output of ICi1a. The 1Hz. pulses are differentiated usinga 100pF capacitor and 1kQresistor and fed to the MR-bar pins of IG8 and IC9 via IGt1c. The two counters begin counting when the phase error pulse from IC7 arrives at their CEP pins (7). This al- ows them to count the “sbout-10MHz: pulses which are fed to their CP (pin 2) inputs via buffer stages IC14a and IC14f, Counting continues until the end of the phase orror pulse and then stops. Another very short pulse, this, time derived from the falling edge of the phase error pulse signal and ap- plied via IC11e to pin 11 of IC12, then transfers the count into IC12's latches, replacing the previous count. As a result, the DG output voltage from tho DAC changes in response to the new count. The counters are then reset again at the end of the 1Hz GPS. pulse, ready for the next sequence. ‘The varying DC orror voltage from the DAG is fed first through buffer stage IGi3a and then to a low-pass loop filter which is formed using a 1k resistor (R1 in Fig.t), a 10uF capaci tor (Ci) and three 1MQ resistors (R2). From there, the filtered error voltage is then fed through IC13b to become the automatic phaso correction (APC) voltage. This APC voltage is applied to varicap diode VC1 which varies its capacitance accordingly. Asproviously statod, VC forms part ofthe 10MHz crystal oscillator circuit and its capacitance variations bring the oscillator into phase lock. Trimmer capacitor VC2 and its parallel 4.7pF capacitor are used to initially adjust the oscillator so that its froe-running frequency is within 100HHz of 10MHz = ensuring that the PLL locks correctly to this frequency. ‘Temperature stabilisation OK, so that’s the basic PLL section ofthe GPS-Based Frequency Reference circuit. By now, though, you're prob- siliconchip.com.auGPS 151. receiver module, The upper trace (yellow) shows one of the extremely accurate 1Hz pulses, while the lower (purple) trace shows the start of the RS-232C data stream giving UTC time and date, latitude and longitude, etc, Note that the frequency reading on the reading shows the scope's measurement error ably wondering about the function of bottom line should read exactly 1,000000Fz; the actual slightly above 3.15V and switches Fig.5: shown here are the leading edge of the GPS 1H pulses from the receiver module (upper yellow trace), and the inverted error pulse from the Frequency Reference’s phase detector (lower purple trace), when. the PLL is locked with a fixed phase orror of 11.54us. ‘The jitter visible on the trailing edge of the exror pulse is normal and is caused by noise, GPS propagation variations and s0 on (see tex!) a | heater. This transistor is attached tothe comparator IC2, transistor Qt and the M3952, temperature sensor (1C10). What are they for? These parts are used to achieve tomperatize stabilisation of the main 10MHiz oscillator crystal (X1), varicap diodo VG and its series 15pF capact- tor. In practico, these components are housed in a “mini oven” to koop the tompersture constant. This ove includes a small 70-220 hoatsink (0 which is attached the crystal, the [M3352 temperature sensor and a powor transistor (Qi). It's basically §n insulated enclosure made from a Gut-dowrn 33mm film canistor which is lined inside using expanded poly styrene Tho construction of this mini oven will be described next month. All you need to know for now is that Ic10 (M9352) is mounted inside the enclosure to sense the internal temperature Basically, the voltage across 1G10 is ditvctly proportional to its tem- poraturo (in Kolvins) and this voltage {s applied to the non-inverting input of comparator 1C2. 1C2's inverting input is fed with a reference voltage of close to 3.15V, derived from a volt- ‘ago divider (2k0 & 3.90) across the roguloted SV supply rail. As a result, 1C2's pin 7 output switches high when the temperature sonsor's voltage rises siliconchip.com.au low when the sensor's voltage falls somewhat bolow this level (depend: ing on the hystorosis applied to the comparator). finned heatsink which forms the frame ofthe mini oven, so when it conducts it generates heat to incroase the t perature, As a result of the feedback IC2 is used to control power trans- {stor Qt, which isused here purelyasa provided by IC10, the temperature ingide the mini oven is maintained (1) This unit is a low-cost frequency and time reference based on a Garmin GPS 15L recelver module. It is able to contro! the frequency of a local 10MHz crystal oscillator by reference to the very accurate pps (1Hz) pulses broadcast by GPS satellites (referenced back to UTC as maintained by the USNO). This allows the frequency of the local 10MHz oscillator to be controlled to within about 0.2Hz averaged over a 30-second period and even more tightly when averaged over a longer period such as 30 minutes, (2) The built-in 10MHz reference crystal is housed in a small temperature stabilised enclosure or "mini oven’. Buffered 10MHz and 1MHz outputs are provided for external use. Buffered outputs are also provided for the 1Hz GPS pulses and the phase error signals from the internal phase-locked loop (PLL) used to control the 10MHz oscillator. The error signals allow the user to log instantaneous phase error in the PLL, if this is desired for traceability. (8) The unit provides a continuously updated display on an LCD module, showing UTC time and date, GPS fix and PLL lock status information. It also allows optional short-term display of receiving antenna latitude, longitude and height above mean sea lovel, plus the number of satellites in current view and thelr reception quality. 5) The complete reference operates from 12V DC, which can be from a battery or a mains power supply. Average current drain is approximately 340mA, while peak current drain is about 420mA, Mancn 200771‘The GPS satelite network is controlled and operated by the US Department of Defense (US DOD). Currently there are between 22 and 24 GPS satellites orbiting the Earth, at a height of 20,200km, in six fixed planes angled at 55° to the equator. Each satelite orbits the Earth in 11 hours 58 minutes — je, about twice each day. This means that at least four satellites are within "view" of a given GPS receiver at almost any time, wherever itis located (providing it has a clear sky view), The GPS satelites broadcast pseudo-random spread spectrum AVRew/FactsyAbout{GRs) digital code signals on two-UHF frequencies: 1575.42MHz (known as “L1") and 1227.6MHz ("L2" ‘There are two different code sig- nals broadcast: the "coarse acquis tion® or C/A code, broadcast on Lt only, and the “precision” or P code broadcast on both L1 and L2, Most ‘commercial GPS navigation receiv- ers process only the L1 signal. Each GPS satellite carries elther caesium-beam or rubidium vapour ‘atomic clock’ oscillators, or a ‘combination of both. These are “steered” trom US DOD ground stations and are referenced back to How Accurate Is It? What kind of frequency accuracy Ce uk airs Coa CLR et a See Ue rte] eae me) Drie Meccan erga eee et or an hour. Pei a ney FRRaE aS cue en fea) ¢ Pee one voltage. It also p 72 Siuc for ries BNC sockets f and phase error pulse outputs, plus an RCA Srp ep eens Is the same in relative terms, since eo une ahs by frequency division. So it's quite eee ren) eno eet Ry oes eg ates eld Due mee Ty Coon tet the antenna and for the Gi socket for the phi Coordinated Universal Time (UTC), as maintained by the US Naval Observatory (USNO) ~ itself kept within 100ns of UTC as maintained by the US NIST. This ensures they provide an accurate reference for both the carrier frequencies and the code signals from each satelite. ‘Although the GPS network was designed mainly for accurate terrestrial navigation, the high frequency and time accuracy of the signals from the satellites has made them very useful as a refor- fence source for frequency and time calibration. at very close to 42°C (315K) - within about #1°, in fact. The exact tompora- ture can be adjusted overa small range using trimpot VR RS-232C data The RS-232C data from the GPS receiver module emerges on the yel low lead and is connected (via the IDC line socket) to pin 2 of GON7. From there, it’s fed through inverting buffer ICide to the RB1 input (pin 7) of PIG microcontroller IC1, which is used to process the sorial data Similarly, the RS-232C serial input forthe GPS receiver module is ts blue lead and this goes to pin 1 of CON?. As result, initialisation commands from the micro’s serial output (RB2, pin 8) are fed to the module via inverting buffer Ic14d The phase error pulse from IG7 is also fed to the RB3 input (pin 9) of C1, so that the micro is able to monitor whether or not the PLL is maintain- ing lock, Display circuit The display circuit (Fig.3) interfaces tothe main circuit via connector CON9 and includes the 2-line x 16-character LCD module—which is directly driven by microcontroller IC1 ~ plus its con- trast control VR2 In addition, there are the four con- trol switches (S1-S4) plus three status indicator LEDs (LED1-LED3), in tum driven by transistor switches Q2-Q4. Note that Q2 & Q3 (and thus LED & LED2) are controlled by the micro itself (via RA1 & RA2), whereas Q4 (LEDS) is siliconchip.com.au1 ABS instrument case, 158 x 155 x 65mm 1 Garmin GPS 15L GPS receiver module 1 external active GPS antenna to suit ~ see text 1 PC board, code 04103071, 142 x123mm 1 PC board, code 04103072, 144 x 58mm 1 16x2 LOD display module, Jaycar QP-8516 or OP-5515 270-220 heatsink, PC-mount (Jaycar HH-8516) 3 SPST PC-mount snap-action pushbutton switches (black) 4 SPST PC-mount mini pushbutton switch 2 10MHz quartz crystals, HC-49U package 4 PC-mount BNC sockets (CONT- CON4) 1 PC-mount 2.5mm concentric DC socket (CONS) 2 16-pin IDC line sockets 2 PC-mount 16-pin IDC header plugs (CON6, CONS) 4110-pin IDG line socket 1/PC-mount 10-pin IDC header plug (CON?) 1 PC-mount RCA socket (CON8) 1 Panel-mount BNC-BNC male- male adapter 2.8>pin IC sockets, machined clip type 4.14-pin IC sockets, machined clip type 5 16-pin IC sockets, machined clip, type 1 18-pin IC socket, machined clip, type driven by the 1Hz pulses from the GPS module via IC1 1b, The microcontroller also scans tho switches. As stated, S1- ‘89 are pressed to display specialised data on the LCD, whilo $4 initialises the GPS receiver module. Power supply Power for the circuit is derived from an external 12V DC supply (eg, a plugpack rated at 500mA or more). ‘This is applied via power connector CONS and diode D1 which provides roverse polarity protection Diodes D5-D7 provideasupplemen- siliconchip.com.au 1 20-pin IC socket, machined clip ‘ype 3.MS x 15mm tapped spacers 2M x 6mm machine screws, round head 7 M3 machine nuts 3.M2 x 25mm machine screws, round head 4.M2 x 12mm machine sorews, round head 7 M2 machine nuts 7 M2 flat washers and star lockwashers: 1 7x2 length of DIL pin header strip 7 4mm PC board terminal pins 435mm fim canister, 34mm dia. x 34mm tong 2 cable ties 4 5kS2 horizontal mini trimpot (RI) 1 10k®2 horizontal mini trimpot (vA2) Semiconductors 1 PIC16F628A microcontroller programmed with GPSFigRFhex (IC1) 1 LM311 comparator (IC2) 2 T4HCO4 hex inverters (1C3,IC14) 2 74HC160 synchronous decade ‘counters (IC4,IC5) 1 74HC73 dual fiptiop (iC6) 1 74HC4046 phase comparator (ic7) 2.74HC161 synchronous 4-bit counters (|C8,IC9) 1 LM335z temperature sensor (C19) 1 T4HO14 hex Schmitt trigger wen) tary voltage drop to reduce the power dissipation in 3-terminal regulator REG1, which delivers a regulated +5V rail to power most of the circuitry. The only sections driven directly from the unregulated +11.4V input are compa: rator IC2 and heater transistor QU in. the mini oven, Other signals That's about it for the eireuit de- scription, excopt to note that various useful signals (in addition to the main 1OMHiz and IM[4zoutputs) are brought out ofthe frequency reference to allow 1 74110374 octal D-type fiptiop (ict) 1 L358 dual op amp (1013) 4 7805 +5V regulator (REG?) + 8D196 PNP power transistor (a1) 3 PN100 NPN transistors (Q2-Q4) 415mm green LED (LED1) 4 5mm red LED (LED2) 1 5mm orange/yeliow LED (LEDS) 4-1N4OO4 diodes (01,05-07) 3 1N6448 signal diodes (D2-D4) 4 B81 19 varicap diode (VC1) Capacitors 1 1000 16V RB electrolytic 4 10F 16V RB electrolytic 1 1Oj.F 25V tantalum 4.4,7uF 28V tantalum 11 100nF multilayer monolithic ceramic 1 2.2nF MKT metallised polyester 1 1nF MKT metallised polyester 2 100pF NPO ceramic 2.33pF NPO ceramic 1 22pF NPO ceramic 1 15pF NPO ceramic 14.7pF NPO ceramic 1. S-10pF N470 trimeap (white) Resistors (0.25W, 1%) 5 1MQ 12.2kQ 168K 12k 147K 1k 2.33kQ, 16802 122k = - 33300 920kQ 2 1800 40 10k2 = 4 1000 168kQ = 1 680. 14.7kQ 1330. 23.30, _ its operation to be monitored, First, the very accurate 1Hz GPS pulses are brought out via IC11d and CONS. Second, an inverted version of the phase error pulse from IC7 ig brought out via IC1if and CONS, And finally, the unfiltered DC error voltage from IC1a is brought out via CONS. Either of the last two signals can be used for logging the reference's operation. ‘That's all we have space for this month. Next month, we'll show you how to build itand describe the setting up and adjustment procedures. SC Mancw 2007 73Here’s one of those really handy little projects that will cost very little but make life a whole lot easier when you want to measure voltage and current at the same time. transistor and diode checking, induct ance, battery checking and 30 on. ‘And when we say cheap, we mean it, You regularly see DMMs for less than ten dollars; indeed one retailer Altronies (who happen to havo a catalog in this issue) has oven given DMMs away to cus- tomers when open- ing a now store! ‘So why would anyone want to build a project such as this jveryone would have a digital Fetes ene quite cheap ones have a huge range of moasurements. Ali do the usual vollage, current and resistance but many throw in continuity {often witha buzzer) capacitance, uss 74 Siicon Cr which simply measures one range of voltage and one range of current? ‘And just as importantly, probably costs as much (if not more than) one of those many-function multi meters? The idea for this project arose when we were “playing around” with bat- teries and chargers (Stuicon GHP. December 2006 and January 2007) Two of the things you must know, and know instantly, when designing chargers and charging batteries are, of uurse, current and voltage. Even with several multimoters available (and used) I was always swapping leads around, trying to work out which leads belonged to which moter (Murphy's law variation 1.3.3: ‘multiple test leads, especially of the same colour, will automatically tangle and lead to errors) Tt occurred to me that what was pally roquived was a simple meter capable of reading volts and amps at the same time Ofcourse, those two are mutually exclusive. Voltage is measured in Ap pric! with a circuit, current is Ly measured in seris (see the panel Meter Shun! ors” ‘and Multipli= jut what if we had one de. J vice capable of doing both? This is it: SILICON CHIP’s simple answer to an oft-ocou ing problem. And when we say siliconchip.com.ausimple, we mean it: two digital pa moters in one small case, one set up to measure 20V DG and the other set up to read 20 DC. And if thoso ranges don’t suit your application, they can be easily changed. However it seemed to us that charg- ing a variety of batteries up to 12V, a 20V maximum was about right. 208. might soom abit excessive but if you're charging car balteries, you could need hat sort of reading, Again, ifyou want to change it, you can! The digital panel meters autometi- ally scale down to show milliamps anyway, if that’s what you need. Which way to go? ‘As [just mentioned, it's based on a couple of panel moters. I toyod with the idoa of using analog meters for a millisecond or two but digital meters are much better for reading relatively constant voltages and currents lance and you've got it. Analog mo- ters come into their own when looking for changes in values ~ you can got a pretty good idea of the way a circuit is behaving by looking at the speed of change. Of course, a ‘scope is usually even better for that purpose, so if { wanted tol could hook up old trusty and look at pretty pictures. But that’s further complicating the issue. OK, so we were going to go with panel meters. As luck would have it, just at that time [was looking at an Oat ley Ele out popped some quite cheap digital panel meters (Cat DPM1) ~ at just $9.00, And even botter, out of tho box, they are wired for 20V DC full sca. ‘$0 I picked up two of them along swith a Jaycar sloping handheld enclo- ‘sure (Cat HB6090) which looked just about the right size. ronicsadvert a siliconchip.com.au About this time that my attention was drawn fo another Oatley E tronics project designed to work with those specific digital panel moters. I's ‘an add-on isolation board with either shunt or divider for different voltages and current, It also has a built-in DG. DCisolated power supply to power the digital panel meter ata very economi cal $-5mA. voce Naasteenent (om ‘necurewent by ROSS TESTER Like most digital panel motors and digital multimotors, these meters do not have a common ground between the input and the battery, Asa result they cannot even me ure the voltage of the battery that is powering them. If it is dosirable to have a common ground between the input and the battery it is necessary to derivea “floating” power supply to $0 SIMPLE AMMETER & VOLTMETER |: Fig.t: It could have been as simple as two di power supply and shunt board only adds a few 9V battery but the is oma 7] wranstomee Tease un) al panel meters (DPMs) and a dollars to the price. It consists mainly of the oscillator based on Q1 and IF transformer IFT1, which is coupled to IFT2 and the voltage oubler rectifier which follows. The 13V zener diode protects against over-voltage Manet! 2007 75Here's the panel meter we used, with the rear view at right sho ing the chip which does all the work (the black blob in the middle). This one is from Oatley Electronics but is similar to many on the market, Note the labels on the side near the input (eft) and power (right) pins ~ you can just see these a powor tho panel meter. The lone transistor and its associ ated components form an oscillator with a frequoncy determined by the 455kHiz IF transiormer IFT1. The nF capacitor applies a feedback voltage from the transformer’s secondary to the base of the transistor to maintain oscillation, The output from IFT1 is, applied to the input of transformer IFT2, [FT2's output is applied toavolt- ‘age doubler mado up of two capacitors and two diodos. The panel meter supply can be any. where from 7 to 11V DC. The output of this simple supply is nominally 9V butitis possible that it could go higher, especially if a higher input voltage ;pplied to the oscillator. Tho 13V zonor diode protects tho panel moter in this case. The shunt Of course, it would be possible to simply add a shunt resistor across the panel meter terminals so that it meas- ures current. However, this would Fig.2: assembly of the Oatley K212 Shunt Board is pretty simple - only the tho two IF transformers have any polarity issues. This board sits on top of the header pins on the de. This samo PC board can also be used as a with 20V FSD. ‘Ammeter DPM wi DPM multipl 76 Siucow Cp the pins soldered to its unde (hence vacant holes) but we used the voltmeter DPM “as it came the bottom e require trial and ereor in cutting the shunt length to get the meter reading the exact current To make lifpa lot easier, the shunt is {instead wired to the add-on PC board which has provision to adjust the cur rent reading via a voltage divider and preset pot The board is the same size us the panel moter and is designed to solder to and stack on the back. Like the panel meters, it’s priced at $9.00 (Cat No K212) One of these was added to the order (I figured that only one would be needed, that to set up the current- measuring meter. The voltage-measur- ing meter could be used “as is”). ‘The only other things that wore required were four heavy-duty ter minals, a 9V battery holder and an on-off switch There's not much to this project ~ either in terms of complexity or cost! In fact, becauso ofits low cost it would make a great project for a school elec: tronics class; something they would jodes, transistor and eof the right-hand photo, find really useful once completed (especially as school electronics, by and large, is limited to battery-pow- cred projects). The voltmeter ‘As we mentioned before, the volt- neteris already configured to measure OVDC. The only things we need to is provide connections between the case terminals and the appropriate pads on the PC board and supply power. We'll look at power shortly. ‘Asa voltmeter is connected in par- allel with the circuit under test, very little current flows, And because we are measuring only low voltage, heavy insulation isn’t required ‘Therefore the connecting wires can be as thin as you like — we used two strands from a ribbon cable but just about any insulated hookup wire is fine, Just make sure it is routed out of the way of the battery case and power switch (especially when the caso is assembled!) Power could be supplied direct from the 9V battery, via the on/off switch to appropriate pins on the PC board. But part of the ammoter (following next) is DC-to-DC isolated power supply wich can power the digital panel meter at a very economical 3-5mA. We checked: this can just as easily supply both DPMs, So to keep every: thing simple we will siliconchip.com.au