A complete HPSDR transceiver

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An example of a complete HPSDR transceiver using the Mercury, Penelope, and Ozy boards and other available hardware and software. It concludes with test measurements that compare the finished transceiver to other commercially available high end transceivers.

By Ron Cox, W9KFB (with help from the HPSDR group who made all this possible)

Specifications

The goal is to build and operate the Highest Performance Amateur Radio Transceiver that can be assembled using components documented on this wiki. Specifically in one case/enclosure, the following is expected:

A totally integrated transceiver with an integrated computer, audio amplifier, speaker, HPSDR components, and 10 to 50 watts of power output. Not included would be the keyboard, mouse, flat panel screen, and antenna tuner. You could compare the proposed rig to commercial rigs such as the Flex 3000, TS-B2000, FT-2000, FT-950, or Ten Tec Pegasus. The transceiver must be mechanically and electrically secure so that one would not hesitate to take one to a field day exercise or a DXpedition as a primary rig.

Enclosure

Rear view of case prepared for installation of HPSDR components

It may be possible to build the rig in the HPSDR's Pandora's box. It is very possible to do so if you are using a laptop computer and can keep the RF powerout requirements to that needed for narrow band modes such as PSK31 and CW. That rig is being built, but two other rigs that were built came closer to meeting the specifications above. Using this experience, the specification goals will be met.

The following information on the Antec New Solutions Case was taken from their web site at [1]. In looking for a good case to build a transceiver that meets the specifications above and that allows you to access and modify the circuitry without getting in the way, we found that this case meets most of the requirements and delivers many unexpected bonus features. The specific Antec case is a model NSK2480 in the "New Solutions Series". Here are the main selling points about this case and power supply that sells for under $100 USD at most internet suppliers that carry Antec cases:

Power Supply

  • The power supply is acoustically quiet and highly efficient.
    The 80 PLUS® Certified EarthWatts 380W power supply
  • The 80 PLUS® Certified EarthWatts 380W power supply is also very quiet electrically and has no detectable switching power supply signals. If any spurious signals are detected in testing, we will eliminate them using clamp-on ferrites.
  • Universal input (100 - 240 volts at 6 Amps with 50 or 60Hz). This power supply must power all the HPSDR components that we put in this case.

Case Structure

View of case after installation of Intel D945GCLF2D board
  • 0.8 mm cold-rolled steel construction
  • Triple-chamber structure to isolate power supply and amplifier heat for cooler & quieter operation
  • 4 Drive Bays are used for HPSDR components, no optical or hard drives will be mounted here

The internal HDD trays are removed to allow room for HPSDR components (see photo).

  • 4 Expansion Slots - Only one will be usable as an expansion slot because we will use a Mini-ITX motherboard
  • Front-mounted ports for easy mike and earphone connections: 2 x USB 2.0 (example: Griffin Knob and/or USB DSP headset); Audio in and out (analog mike and headset)
  • Unit Dimensions: 5.5" (H) x 17.5" (W) x 16.3" (D); 13.97cm (H) x 44.5cm (W) x 41.4cm (D)

The height of the enclosure makes it possible to mount the HPSDR Atlas, Mercury, Ozy and Penelope boards.

Cooling Design

  • Advanced cooling system: 2 side mounted 120 mm TriCool™ 3-speed fans

The fans really only cool one of the three chambers, the one with the computer mounted in it, but they are very low noise when set at low or medium speeds.

Motherboard and CPU

Sony DRX840U 20x External Dual-Layer DVD Burner

From experience building several HPSDR transceivers in this case, we have found that all is needed is a small footprint Mini IPX motherboard. No extra I/O cards are required if one uses virtual software ports. By using SATA drive ports exclusively we can use such a small motherboard. A intel DQ45EK Desktop Board was ordered for this project, but a better lower cost solution is to use the new Intel D945GCLF2D board with a Dual-Core Intel Atom Processor and Integrated Graphics. A test of running PowerSDR on this processor resulted a CPU usage of less than 30%!

Memory Module

The Intel D945GCLF2D Motherboard will only work with up to 2 GB of 667MHz single module speed memory. The cost was $28.99 USD with a $10 USD mail-in rebate.

Disk Drive(s)

The motherboard will service two serial SATA ports (3.0 GB/s) and one parallel ATA IDE interface with UDMA 33, ATA-66/100 support. The most cost effective drive available should used. Currently the Hitachi Deskstar P7K500 500GB Hard Drive - 7200, 16MB, SATA-300, OEM for $54.97USD looks to be a good deal for low cost hard drives.

(Optional) External Optical Drive

Rear view of case after installation of iCube speaker
Inside view of case after installation of iCube speaker
Inside view of case after installation of iCube speaker


This facility is used to load programs but there is not enough room in the case for the drive. It is seldom used and a thumb drive is a good substitute for just copying and transferring programs from one computer to another. Sony makes a nice matching portable drive that several hams are using with this HPSDR transceiver as needed via a USB2 cable. The Sony model number is DRX-840U (see photo). Cost is $99.99.

OEM Operating System

The only way to buy an operating system for a new system like this is to purchase the OEM version. Most internet stores should carry it. To be compatible with most of the popular HPSDR software, Windows XP home edition works. Amazon.com lists " Microsoft Windows XP Home Edition SP2B for System Builders [OLD VERSION] by Microsoft Software (CD-ROM) (Windows XP) Buy new: $86.91 2 Used & new from $86.91"

HPSDR Components

Part Name Price ($US)
Atlas Kit- TAPR 35.00
Mercury RX - TAPR 329.00
Penelope TX - NT-Electronics 357.54
Ozymandias- TBD TBD
Alexiares - TAPR TBD
PennyWhistle - TAPR TBD
100 Watt 160 M to 6 M Amplifier - TBD TBD

Audio Amplifier & Speaker

The issue of how to best add an audio amplifier & speaker to a computer/HPSDR rig has been unresolved for some time. We now have a good solution. Normally the Mercury board's line out will be connected directly to the computer's line input. If one wanted amplification, for example in a noisy environment, then an audio power amplifier with appropriate power level would be used. Per the specifications the HPSDR transceiver we are designing and building must have an internal speaker component. A good small speaker with a battery powered amplifier was purchased at Fry's Electronics. It is called the iCube distributed by I_Concepts, and it cost $3.90 USD. The iCube was modified to run on 5 Volt computer power by putting a 5 volt computer style connector on it and using a 10 uf and .01 uf cap in parallel across the power input to the iCube to reduce the low level noise. The ICube was mounted to the cold rolled steel cabinet back with 4 sheet metal screws (see photo).

LayOut of Components

It is not a complex project to layout the components for this transceiver. The motherboard and all her attachments are all located per the the instructions for the motherboard. The best place for the Atlas board is in the Optical Drives Bay. The Alex board set will attach on the wall where the USB2 cord is running to the rear. The decision on witch way to face the connectors is still being considered. If they face the rear, the mike and key jacks will be located on the end plate with the holes for the Alex BNCs. If the Alex boards BNCs face the front on the inside, most of the BNC wiring will be shorter and more direct and not be visible on the back any more.

Power usage model

Here we will track power usage by each Component for wire and connector sizes and power supply loads.

Install Components

Key Jack and Key Wiring

Microphone Jack and Wiring

Wiring

BNC Cables

In thinking ahead of what we are going to need for wiring this HPSDR transceiver, one set of items stand out as essential, BNC cables. First lets count the number of BNC connections in this rig:

1. Mercury 1

2. Penelope 1

3. Alex 9

4. PennyWhistle 2

5. 100 Watt Amplifier 2

Total = 15

For this many BNC connections, it is essential to have reliable 50 Ohm connections that will stand up to harsh physical use. The best results will be to use professionally made instrumentation grade BNC cables rather than buy the tools and learn to make the cables yourself. At Fry's, these quality cables are in the instrumentation section and are branded as "Pomona". From the Pomona data sheet that can be found here: Pomona Model 2249 Cable Assembly with BNC Male on Each End. The advantage over hand built cables are as follows:

  • The molded strain relief is directly bonded to the cable jacket for superior strength and durability.
  • Teflon insulation and nickel tarnish resistant outer shells used in the BNC connector provide long life and

reliability.

  • Gold plated center contacts assure the most noise free connection possible.
  • The connectors and cable are impedance matched.

The length of the Pomona cables are the length in the model number plus 3.37 in or 85.60 mm on each end for the strain relief and connector. The finished 3-D layout will determine number of each length needed.

Testing

Software Installation

All software listed here excluding Fldigi is for Windows systems only. Other software is under development for other operating systems see: HPSDR related software

PowerSDR

For installation instructions go to the Quick Startup Guide and scroll down to "PowerSDR Software Installation", then follow the directions given there.

KISS Konsole

You must try this program as it was written to be a simple interface to the Mercury and Penelope boards. You can find information on downloading and operation at KISS Konsole.

com0com

This program is required to allow programs to communicate frequency , mode, CW and PTT data. It is required software that must be installed to operate the digital modes using Fldgi. Go to [2]to learn about and install com0com.

Virtual Audio Cable

Other than the operating system, this is the only program that is listed on the BOM that must be purchased. The trial version might be used to get familiar with the program, but it is not usable on the air. With out this program you would have to use your built in sound card and external cables which can pick up RF signals. It is a much cleaner installation to use this program. Cost $39.99 USD. Go to this website to purchase and download [3].

Fldigi

This program is required to get operating on digital modes. Follow the recommended settings given below and you should not have any problems. First install the program per the instructions on this web site [4].

Optional Software

CW Skimmer

Complete Bill of Material (BOM)

Part Name Price ($US)
Antec NSK2480 Case and power supply 100.00
Intel D945GCLF2D Motherboard & CPU 80.61
Corsair DDR2 2GB PC3500 memory module 19.99
Hitachi Deskstar P7K500 500GB Hard Drive 54.97
External Optical Drive Sony DVD/CD Rewritable Drive Model DRX-840U 99.99
Microsoft Windows XP Home Edition SP2B for System Builders 86.91
Virtual Audio Cable 39.99
iCube Portable Speaker 3.90
Pomona BNC 2249-C-6 cables (5 at 14.98 each) 74.90
HPSDR Components 721.54+TBD

Performance Testing