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.
- 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.
- 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.
- 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:
- Left frame member to cab chassis (approx. 10AWG rubber moulded)
- Right frame member to cab chassis (two places, no less...one ~10AWG
rubber moulded, one 1/4" braid)
- Engine block to cab chassis (1/4" braid)
- Battery (-) to cab chassis (~#12AWG)
- (by default) alternator to engine block (through the metal bodies)
- Hood to cab chassis (1/4" braid, behind the hinge on the passenger
side...look WAY back there and you'll see it)
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:
- All three bands (6m, 2m, 70cm) have bandpass filters as the final
element before the antenna, but filters need a good ground reference to
perform their filtering function. That is, any common-mode pickup of
RF on the outside of any coax shield will pass right over the filter (chassis
or body) with no attenuation.
- Two bands (6m and 70cm) are connected to my HF radio, so any common-mode
pickup on HF transmit would find its way back to the HF radio (feedback
loop).
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.
- 4AWG 193pF to resonate
170nH X=30 ohms
Q=100
- strap
210pF to resonate 150nH
X=25 ohms Q=150
- braid
273pF to resonate 120nH
X=20 ohms Q=100
Interesting that the strap has the highest Q, but sure enough for those
advocating braid, its inductance is quite a bit less.
Hardware
- Always use stainless steel hardware (screws, washers, etc.) for
attachments to the vehicle body. Star washers too if available.
If the packaging doesn't say "stainless" then it isn't. Yes, stainless
is significantly more expensive. Ask for it!
- Stainless hose clamps in all sizes are handy for attaching braid
to tubing/pipes that you cannot drill (exhaust pipes, etc.)
- Plenty of braid or strap...braid is flexible, but absorbs water.
Strap has higher Q, but doesn't do nearly as well long-term under vibration
etc. Make your own strap out of flashing copper or brass--check your
local yellow pages under "Metals", "Surplus", or "Salvage"...or a hobby
shop or old-fashioned hardware store (Ace, True Value, etc.). Note
that new metal is significantly more expensive than salvage, and performs
no better...Braid you can get yourself from old coax (although that is also
very expensive, if the coax could be used instead as coax), or you can buy
braid from shops selling antenna supplies (e.g. cablexperts, RFConnection,
etc.).
Tools
- A small rotary tool (Dremel or equivalent) is exceptionally handy
at cleaning painted metal down to the shine.
- Your hands and wrists will appreciate an electric screwdriver
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:
- Break out your Impedance Analyzer (Autek, MFJ, AEA, whatever.
I personally endorse the Autek but it's also the only one I've used)
- Slip your BUT (bead under test) or TUT (toroid under test) onto
a small length (about 6-8") of insulated wire of moderate gauge
- Solder the wire into a small loop onto an SO-239 panel socket (i.e.,
one end to the center pin, the other end to the flange)
- Connect to your Impedance Analyzer and set the frequency to 20MHz
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:
- 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.
- 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!
- 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).