Noise @#$&#%#Y&^&$#$!!!@#%@
November 2002

This page constantly is being buggered with, as I am always trying something new, and therefore vacillate between a chronological presentation and a topical one...today the topical approach wins out :-)

Because I drive a 1999 Ford F-150, this page will focus on my own experiences and others' Ford-related experiences that I have found useful.  However, these ideas are likely generally applicable, in varying degrees, to any make/model vehicle.



 Fuel Pumps (particularly that FoMoCo piece of crap)
 Ignition Noise and Grounding Your Vehicle (or at least parts of it)
 Grounding your Equipment
 Isolating your Accessory Runs  New Nov 2002!
 Your Mobile Grounding Toolkit
 Measuring Your Problem



Fuel Pumps--Particularly those on Ford Motor Vehicles

FORD VEHICLES HAVE A PROBLEM WITH THEIR FUEL PUMPS!

ALL Ford fuel-injected motors (which I believe is all motors since 1991) have an in-tank fuel pump that is a disaster on HF.  Guaranteed to radiate S5 on 10m to S9+who cares anymore on 40m and down.  Fortunately Ford recognizes this and makes an electrical filter that seems to work 90% of the time (I don't know why 10% don't, but some Usenet searching shows some failures-to-fix).  The Technical Service Bulletin (TSB) is 98-7-3.  The link is a scanned copy of the 1998 version of the TSB, which actually covers some 1999 vehicles.  Ford updates this TSB annually to account for the continuing carnage into the next model year (sigh...why not solve the problem?)   The filter install requires dropping the fuel tank, so unless you're a gearhead too take it to the dealer to have it done.  In-warranty vehicles should get the service, parts and labor, gratis.

The test for fuel pump noise:  turn on the ignition to the Accessory position BUT don't start the engine.  Listen to your radio.  If you hear noise when you turn the key to "ON" that lasts for a second or two, then quits, it's the fuel pump.  If not, LUCKY YOU!!

If you're out of warranty, or don't want to deal with the dealer (and I wouldn't blame you one bit), there are (at least) two alternatives available.  I have not personally tried these alternatives, but they seem reasonable.

  1. Identify the fuel pump power harness.  On the 1999 F-150, it goes to the middle-top of the tank, runs laterally to the driver's side, then up along the left frame beam to the engine compartment.  On my vehicle it can easily be seen by looking into the rear wheel well on the passenger side (but my truck is also 4x4 with 17" wheels, so the body sits up well from the undercarriage).  Install a few snap-on ferrite chokes (see Toolkit below!).  Remember that ferrite=iron and iron+water=rust, so do what you can to shield the chokes from the elements.
  2. Supposedly the primary problem with the fuel pump is that the ground lead runs the entire length of the body (it runs along the entire cable bundle to the engine compartment; the ground wire actually attaches at the very front end of the left frame beam, an easy 15' wire run)!  If you can manage to reground this wire much closer to the pump, that 15' "antenna" will be greatly diminished.  The TSB makes specific mention of this; if you do have someone do the filter install for you, make certain they follow the instructions regarding the ground wire.
  3. Filter Cons:  In Jan/Feb 2000 QEX, so-and-so has an article about vehicle noise suppression that mentions a mysterious device the author calls a "Filter Con".  I don't know if this is standard terminology, but I've been in electronics for 15+ years and have never heard of one...but basically what they are is small low-pass filters built into a solder-in or bolt-in package that looks very much like a feedthru capacitor.  Most manufacturers refer to them as "coaxial EMI filters" or something like that.  The specs are impressive:
Oh by the way:  Directions to the Fuel Pump power harness (on the '99 F-150, at least)::  Driver's side, about one foot aft of the front of the cargo bed.  Look up at the inside of the left frame beam.  There is an inline connector that is tacked to a lateral member.  Here is his mug shot!  In the picture, I am lying down on my back, driver's side, feet out, towards the front of the bed.  The fuel tank is on the top of the picture and the left frame beam is at the bottom.
 

Ignition Noise and "Grounding" your Vehicle parts

An interesting thing about the 1999 F-150 is that it is a distributed low-voltage ignition system.  There is no coil/distributor setup, but rather each cylinder has its own coil pack right on top (at least on the V-8's...the V-6's have one coil pack per cylinder pair).  This has the advantage of the system being +12VDC all the way up to the spark plug (practically); there is no point in changing high-voltage spark plug wires or distributor caps/points/rotors because there are none!

One nice thing to see also is that Ford has a "Radio Interference Capacitor" for both sides of all engines (one for each row of three or four cylinders) shunting the coil packs to the engine block.  This is factory standard installed equipment.  The capacitors are located way back in the engine compartment nearly to the firewall; they are very hard to get to.

I got curious one day and took one of the Radio Interference Capacitors off the block and onto my Boonton 160-A Q-meter (with standard inductances) to measure its impedance at RF.  I'm happy to report that the Radio Interference Capacitor's  RF impedance is <2 ohms from 3-30 MHz.  I'm not happy to report the ~12" small gauge pigtail it's integrated with...

With the low-voltage distributed ignition, fancy plug wires (Magnecore, etc.) probably won't do anything beneficial.  Utilizing 1/2" shield braid around the wires may still be of benefit.

I've read on the Usenet that some have had ignition noise problems specifically with "split-fire" style spark plugs.  I don't know what mine are but I'm told that almost all recent engines use them.  Could be that swapping out for conventional resistor plugs will help.

The general advise on Ignition noise is to bond everything...hood, doors, exhaust pipe, tailgate, bumper...anything not welded to the main chassis (that is, the chassis that is the primary return path for the ignition system.  In a pickup, then, the pickup bed should be added to the list as only the cab chassis is in the ignition return path).  Wide braid is best, since it can withstand the vibration and flexure in vehicle operation.

Inspect your vehicle closely.  On the 1999 F-150, there are several attempts at factory bonding:

Most of these bonds are pretty undersized from an RF point of view (and some even from a DC point of view...12AWG as a return for the charging circuit is pretty piss-poor!).  Note that only one side of the hood is bonded; none of the four doors, two bumpers, exhaust system, or any of the cargo bed is bonded to anything.  These spots would be a good place to start.

Don't be afraid to try strange stuff...anything that is metal should be bonded to the chassis.  One fellow had great success bonding his (metal) fuel line to chassis.  Many report significant improvements with exhaust system bonding or hood bonding.  Grab a bag of materials and have at it!

Grounding your Equipment

From my experience, the #1 everyday diagnostic tool you can have in your mobile shack is a Peak Reading wattmeter.  I heartily endorse my Autek WM-1.  Keep it inline and on Peak setting.  Why?  Read on...

My original HF-only install (after the SG-500 amplifier was added) had a "single-point" ground, from the amplifier chassis to vehicle chassis.  My radios and amplifier are all mounted in the center of the front seat (over the "transmission hump") and there is easy access to chassis ground right in front of the transmission hump (there is a small black plastic cover that is easily removed without tampering with the dash as a whole.  Even an "official" green-screw grounding point on the passenger side).  The "single-point" ground used 1" tinned braid, about a 5" length from the amplifier chassis to the ground screw.

Then I added all the VHF and satellite equipment (70cm preamp and filter; 2m brick amplifier, 6m preamp and filter), all underneath the rear bench seat, plus the IC-290H to the front console.  Ever since then, I would observe that on certain bands, and with varying frequency, the peak power on SSB would not show 500-600W, but appear "damped" to only around 100-150W.  If I whistled or hummed into the mic, the output would go up to full power.  This happened usually on 10m, always on 12m, sometimes on 15m, more often than not on 17m, and never on 20m or lower.  This "damped" response only happened with the amplifier on; with it off, I always got >90W peak in SSB.

Curious if the wattmeter just couldn't take the "heat", I pulled out my SM-220 station monitor from the home shack and hooked it up to monitor amplifier linearity (the "trapezoid" test).  The trapezoid showed the classic overdrive envelope, but (1) the amplifier was being driven with only 50W, well within its specifications, and (2) decreasing drive did nothing to the shape of the waveform (of course decreasing drive changed the size of the trapezoid).  Reconfiguring for a simple oscillogram, I monitored a string of dashes, and saw a most interesting waveform:  instead of nice squarish pulses, there was a very exaggerated logarithmic rise time.  The signal would make it to full power output, but only during the last 10% or so of the keyed dash.

Obviously something was damping the transient response of the entire system with the amplifier active.  Since the syllabic nature of SSB is much faster than CW, the SSB output was equivalently taking place well down the logarithmic rise time as displayed on CW.  That's why the peak-reading WM-1 read low on SSB, but not CW; and the meter averaging was long enough in Average mode for it to respond to the full power part of the output waveform.

Also, particularly when working Mode J satellites, I would experience plenty of "hash" on receive when I transmitted.  This is nothing new to Mode J (see the Mobile Satellite page), so I built and installed a 70cm narrow-bandpass filter.  While this helped, it didn't clean up all the trash.  It was hard to tell if what I heard was my transponded signal horribly distorted, or just crossband desense in the receiver.  And then suddenly he RX and audio would clean up and all was well, so I don't know even to this day if there was a real problem (that is, a problem that others could sense).

Solution:

I suspected that the lack of local grounding straps on the VHF and UHF equipment in the back might be contributing to some of the problem:

To address these issues, I installed additional short grounding straps for the VHF/UHF equipment in the back.  Some pictures to illustrate what was done are here.  Basically each deck was individually grounded to the vehicle chassis.  Additionally, each radio was individually grounded to vehicle chassis.  The result was phenomenal!  The crosstalk/hash on Mode J is almost completely gone, and the WM-1 wattmeter consistently kicks up to 500W peak output on all bands.

Isolating Your Accessory Runs

Here's a particularly interesting one that happened right after I performed the "Grounding your Equipment" just above.  After several minutes of operation on either 15m or 40m the HS-1500 antenna VSWR would suddenly skyrocket to between 4:1 and 5:1, and stay there.  No amount of antenna jostling or retuning would get the VSWR back below 4:1.  So I would cease operations, and upon returning to the radio after maybe a half hour it was fine!  Until the next several minutes of operation.  The problem seemed particularly bad in high duty cycle use (e.g., calling in large pileups, or slow CW on 40m to EU).  

Well, one time just on a whim I was back at the antenna jiggling and jostling and trying to find the "obviously intermittant connection" when I brushed against the "filter" on the DC motor drive line for the screwdriver antenna.  All screwdriver antennas require some sort of RF isolation of the DC lines that go inside to drive the motor; the HS-1500 came with a large-ish ferrite bead (maybe 5/8" diameter by 1-1/4" long) that was wrapped by the DC line twice thru.  Well, the damn thing was HOT, like too hot to keep my finger on it.  Hmm...ferrite has this property called "Curie Temperature", and when it gets heated to that temperature its magnetic/inductive properties go to zero...and this bead had gotten so hot that its inductive properties were long gone, so the DC line was a part of the antenna now...with very poor tuning characteristics!

Evidently the grounding exercise above changed the far-end RF impedance of the DC motor drive wire such that a current maximum occured at the ferrite "filter" on 40m and 15m...note how the two bands are harmonically related!  So this must be fixed...at first I decided I needed to keep as much RF away from the ferrite as possible, so I build a T-section low-pass filter (shunt-C, series-L, shunt-C) using the ferrite "filter" as the series-L element.  This didn't work; the shunt-C element, by putting a short circuit at the end of the wire pair coming out of the antenna, was putting a low impedance across the antenna terminals (oops!).  The second attempt was just to use a larger ferrite; more impedance=less current=less heat.  I used an FT-240 size (big) mix 43 toroid, wrapped 6 times.  That worked!  Now there is no discernable heat on the toroid even after extensive operation on either 15m or 40m.

Slick Hint  The easy way to implement this fix:  My HS-1500 uses a 2-prong trailer-type plug/jack to connect the DC pigtail coming from the base of the antenna to its power source.  So I went to AutoZone and got a 12" premade cable that had the 2-prong connector on either end.  The connectors are sexless so a cable section like that inserts between the existing connection between antenna and power.  Just wrapped the new 12" cable 'round the toroid, unplugged the existing connection, and inserted the new wrapped toroid.  No fuss!

Grounding Materials (or, the "Grounding Toolbox")

Which to use, strap or braid?

In my readings I have seen different parties state that (braid/strap) is better for grounding at RF.  Well the Q-meter needs more work so let's check it out.
Measurement samples:  13" long pieces of 1" wide braid, 4AWG wire, and 1" wide Cu strap at 28 MHz.

Interesting that the strap has the highest Q, but sure enough for those advocating braid, its inductance is quite a bit less.

Hardware

Tools Goop

Many recommend finishing off a bonding point with some sort of rubber or silicone sealant to further keep out weather.  Also, you should use a conductive anti-oxidizing compound within the joint.  There are different types, depending on if aluminum is involved (must be some chemistry there...).  RFConnection sells good copper-based goop (they also sell aluminum-based as well).  Aluminum goop is readily available at the hardware store as "NoAlOx" or similar--look in the electrical section as it's used in industry to prevent corrosion in conduit joints.

Ferrite Chokes

Know Your Ferrite Mix!  For 1-50MHz noise/interference suppression, you want to use Mix 31 toroids/beads.  It has been my experience that the majority of commonly-available surplus ferrite material is Mix 43 or 61.  Mix 43 and 61 are great for *tuned* HF circuits but are suboptimal (but usable) or useless, respectively,  for HF noise suppression.  The same applies for the cute "snap-together" beads--most of them are Mix 43.  The rectangular Radio Shack ones are Mix 61--utterly useless at HF!  If you're not sure, here's how you can tell:

Mix 31 will read a Q of about 1 (R=jX) at 20MHz.  Mix 43 will have a much higher Q (about 5-10) and Mix 61 will have a very high Q (>30).  Or, if your Impedance Analyzer only reads Z (upgrade!!), Mix 31 will have a peak in Z around 20MHz, while both Mix 43 and Mix 61 will be increasing through at least 30MHz.  Make sure your test wire is insulated...Mixes 31 and 43 are conductive and will short out bare wire turns!

If you're wrapping a toroid, be aware that distributed capacitance between windings is a factor.  Wrap no more than 3/4 of the toroid (if you wrap more, the two leads can be close enough together, and have enough shunt capacitance, that the toroid/coil is essentially out of the circuit), and maintain as much spacing between turns as possible.  Both R and X (or Z if you prefer) go up as the square of the number of turns, so it doesn't take many.  Again, use your Impedance Analyzer to assess the situation ahead of time.

 Amidon Inductive has good technical information and probably the best one-piece price for ferrite materials.  The one complaint I would have is their website has no mention/information of Mix 31, although they sell it.  Fair-Rite has extensive technical material on their website, and a very broad line of materials; I believe they are available via special order through Amidon.

Also, note that ferrite chokes are most effective in low impedance circuits.  See the Fair-Rite website above for a discussion.

Some Ways to Measure and Assess your noise issues

Instruments:

  1. Good old oscilloscope.  Doesn't have to be too fast (my Tek 485 definitely not put to the test here!).  Put your radio in AM mode (no filters, widest possible selectivity) and pipe the audio out to the 'scope.  Rev the engine, etc., and observe the waveform amplitude and period.
  2. Spectrum Analyzer.  Monitor the actual RF picked up by your antenna with the engine running.  This type of measurement requires a good understanding of how a spectrum analyzer works, though...it is not straightforward.  And it requires a "real" spectrum analyzer...not a $200 "kit conversion" or a service monitor!
  3. A computer with sound card!  Really, there are some excellent Audio Spectrum Analyzer applications available for sound cards.  Why not pipe your AM-demodulated audio right into the sound card and look at the spectrum?  If there's an RPM dependence you can relate it to frequency.  An added plus might be if you have multiple sources you're tracking down and you can separate them in frequency (maybe one whose frequency changes with engine RPM and one that doesn't).