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wavesphere

wavesphere ( also known as ultrawavebubble, deafdumbblindnowdevice, Fn0rDpH0n3 )

wave sphere is an approch do increase the bandwith range, and with that increase the number of devices it affects of ladyada's wavebubble. ( ← the last sentence was no english. we are deeply sorry. )
in our english: we saw this nice thingie from ladyada called wavebubble, and we thouhgt, hmm maybe with some little ( which will hopefully get not major ) modifications ,a lot of effort and true zeal, we can b00st this baby up, to kill not only gsm, but also wlan, bluetooth and what not nice other stuffies, and call the whole devicythingie wavesphere.
… and this is the wiki to it, have phun.

credits :


xcept where otherwise noted, content on this wiki is licensed under the following license:CC Attribution-Noncommercial-Share Alike 3.0 Unported



overview

Each step of the project has a parts list, assorted assembly photos/videos and testing procedures. The parts list is as complete as possible, with suggested parts and cost. Many parts can be sampled for free or low cost, but this is starting to become harder and harder. Parts may have to be purchased in larger quantities than necessary, and I always suggest getting twice as many parts as you'll need in case something goes wrong.

Total cost should be ~$25 for PCBs and $100 for parts (if you sample chips) or $135 (buy all parts & use a nice lithium ion battery).

I would highly suggest getting a resistor kit in both 1206 and 0603 from Digikey which, if you dont have yet, will make doing SMT work less painful. Then you can skip on getting individual values.

Corrections, updates and suggestions are very welcome should be posted to the forum.

Tools

There are a few tools that are required for assembly. If you don't have them, now would be a good time to borrow or purchase them. They are very very handy whenever assembling/fixing/modifying electronic devices!

images_tools_wes50_t.jpg Soldering iron. Because of the many small parts, a WES-50/WES-51 and the other ~$100 Wellers is minimal equiptment. Get the finest pitch tip you can. Alternately you can use solderpaste and a hotplate. Although eventually you will need to solder something on the other side. A low quality (ahem, $15 radioshack) iron is not suitable.
images_tools_solderroll_t.jpg Solder. Rosin core 60/40 or 63/37 0.025”. Get high quality, fine solder. Silver solder is OK too but not necessary. (Kester 23-6337-0007)
Solder Paste. Good for soldering the TSSOP parts. Kester 57-3901-5403
images_tools_braid_t.jpg (De)solder braid. For fixing solder bridges. Techspray 1814-5F.
Power Supply
It can be a thousand dollar arbitrary waveform generator, or a 9V hooked up to an LM317 & potentiometer. Whatever, just make sure you can get ~3-4 V out of it, for testing.
images_tools_meter_t.jpg Multimeter/Oscilloscope A handheld meter, at least, is necessary. A scope will help you even more with debugging & analyzing the circuit. 10MHz is minimal. Most of the frequencies here are either 10MHz and lower or 1GHz and higher, so no point using something -really good-
images_tools_bk2650.jpg Spectrum Analyzer In theory, this is not necessary to construct, with the PLL. But still an incredibly useful tool for RF work. BK Precision 2650 3.3GHz is not a bad choice.
Needle-nose pliers. For bending leads, etc.
Tweezers. For holding fine components steady while soldering. Wiha #44501 from digikey is good.
images_tools_cooper170m_t.jpg Flush/diagonal cutters. Not needed that often, but handy anyways.
images_tools_panajr_t.jpg Board holder. The panavise jr. has been perfect.
images_tools_litworklamp_t.jpg Good light preferrably with Magnifying glass. Ideal for examining board for solder bridges, etc. Unicorn Electronics

PCBsDownload the gerbers and/or board files and generate the (tiled) gerbers you want. The files are in Eagle format and are small enough to be opened by the 'freeware' version (Mac/Win/Linux). Then send them off to your favorite board house. I have a seperate page all about this sort of thing.Inspect/Depanelize

In a week, the PCBs arrive. Hooray!

static.flickr.com_144_331274926_6a21e69918.jpg

static.flickr.com_143_331274794_8e814f0126.jpg

Depanelize them with tin snips, shears, band saw, etc.

static.flickr.com_158_331274970_3d0360d197.jpg

Print out the parts lists, placement diagrams, and schematic.

static.flickr.com_138_331275091_3d60ebe505.jpg

OK now you are ready to go!

Parts Listing

Parts Step 1 : Akku/Charger Pack

Part # & Datasheets Name Description Distributor Qty Cost Total Dist. Ger.
Battery 3.7V/1.2Ah Lithium Ion or Lithium Polymer battery Battery Space (for example) 1 ~$8 ~$8
Battery Protection Circuitry Circuitry to keep battery safe (optional but recommended) Battery Space 1 $1.30 $1.30
*LM3622M-4.2 IC1 Battery charger chip for 3.7V lithium battery Digikey
Sample
1 $2.64 $2.64 DigikeyDE
Hirose UX60-MB-5ST
or
*Molex 54819-0572
J1 Mini-B USB connector (SMT) Digikey
Mouser
Sample
1 $0.96 $0.96 DigikeyDE
163-2217 J2 1.7mm x 5.2mm SMT DC power jack Mouser 1 $0.77 $0.77
STN749 Q1 PNP 1A power transistor (SOT223) Digikey 1 $0.79 $0.79 DigikeyDE
FT232RL IC2 USB/ttl interface chip (optional) Mouser 1 $4.10 $4.10
SS14 (for example) D1 Schottky Diode (at least 1A/20V) Mouser
Digikey
1 $0.30 $0.30 DigikeyDE
LTST-S320GKT LED1 LED (1206) any really, but the recommended one is right-angle mount Digikey 1 $0.16 $0.16 DigikeyDE
UWX1C470MCL1GB C1 Input power filter capacitor (47uF/16V minimum) Mouser 1 $0.18 $0.18
B45197A1157K409 (tantalum)
UWT0J221MCL1GB (electrolytic)
C2 Battery filter capacitor (100uF/6.3V minimum) Digikey
Mouser
1 $0.28 $0.28 DigikeyDE tantal DigikeyDE electrolyt
0.1uF 1206 ceramic capacitor C3- C7 High frequency bypass capacitor (~.1uF 16V minimum) Mouser 5 $0.08 $0.40
0.22 1/4W resistor in 1206 pkg
R1 Changer current sense resistor 0.22ohm allows ~450mA charge current which is the USB max. Digikey
Mouser
1 $0.32 $0.32 DigikeyDE
2K 1/4W resistor in 1206 pkg R2 LED choke resistor (~1K depending on LED and brightness) Mouser 1 $0.08 $0.08
Total $12-$20

* Can be sampled for free at low quantitiesParts List - AAA Battery Pack

Parts Step 2 : Power supply

Part # & Datasheets Name Description Distributor Qty Cost Total Distr. Ger
J-188-1 SW1 Alternate action push button switch Digikey 1 $0.95 $0.95 DigikeyDE
*TPS79333 IC1 3.3V/200mA LDO regulator Digikey
Mouser
1 $0.53 $0.53
*LM2733x IC2 5 (or 7V) DC/DC converter Digikey 1 $2.58 $2.58
*LT1301CS8 IC3 12V DC/DC converter Digikey
Linear
1 $4.75 $4.75
*LT1173CS8 IC4 25V+ DC/DC converter Digikey
Linear
1 $4.88 $4.88
CDRH6D28NP-150NC L1 15uH power inductor Digikey 1 $1.03 $1.03 DigikeyDE
CDRH6D28NP-330NC L2, L3 33uH power inductor Digikey 2 $1.03 $2.06 DigikeyDE
0.1uF 1206 ceramic capacitor C2, C3 C7, C9, C11, C13, C16, C17 0.1uF ceramic filter capacitor Mouser 8 $0.08 $0.64
1.0uF 1206 ceramic capacitor C4, C6, C12, C15, C19 1.0uF ceramic filter capacitor Mouser 5 $0.18 $0.90
UWX0J101MCL1GB C1 100uF 6.3V input filter capacitor Mouser 1 $0.17 $0.17
UWX0G101MCL1GB C5 100uF/4V filter capacitor Mouser 1 $0.17 $0.17
TPSC107K010R0100 C10 100uF/10V low ESR tantalum capacitor Digikey 1 $1.18 $1.18 DigikeyDE
TPSC686K016R0200 C14 68uF/16V low ESR tantalum capacitor Digikey 1 $1.44 $1.44 DigikeyDE
B45197A6226K409 C18 22uF/35V low ESR tantalum capacitor Digikey 1 $1.40 $1.40 DigikeyDE
160pF 1206 ceramic capacitor C20 feed foward capacitor for 5V regulator (do not place) Digikey 1
1206 5% resistors R1, R2 Chosen value resistors for low battery detect: R1/(R1+R2)*Vlow = 1.1 Digikey/Mouser 2 $0.08 $0.16
120K 1206 5% resistor R3 Boost voltage reference resistor for 5V Digikey/Mouser 1 $0.08 $0.08
12K 1206 5% resistor R4 Boost voltage reference resistor for 5V Digikey/Mouser 1 $0.08 $0.08
~2K 5% resistor in 1206 pkg R5 LED choke resistor (~1-2K depending on LED and brightness) Digikey/Mouser 1 $0.08 $0.08 DigikeyDE
50K 1206 resistor R6 Boost voltage reference resistor for 24V Digikey/Mouser 1 $0.08 $0.08
1Meg 1206 resistor R7 Boost voltage reference resistor for 24V Digikey/Mouser 1 $0.08 $0.08 DigikeyDE
SS14 (for example) D1-D3 Schottky Diode (at least 1A/20V) Mouser
Digikey
3 $0.30 $0.90 DigikeyDE
Total $11-$26

* Can be sampled for free at low quantitiesPower supply assembly

Parts Step 3 : Tuning

Part # & Datasheets Name Description Distributor Qty Cost Total Dist. Ger.
*ATmega88-20AU IC5 8-bit microcontroller, an atmega48 is fine if take out the self-tuning stuff or dont want a bootloader. Atmega8 is probably OK too. Digikey
Sample
1 $3.76 $3.76 DigikeyDE
*AD8402ARZ10 IC6 Dual digital 10K potentiomenter Digikey
Sample
1 $3.78 $3.78 DigikeyDE
*LMC555 (or any CMOS 555 equiv) IC7 CMOS 555 Digikey
Mouser
Sample
1 $0.65 $0.65 DigikeyDE
*LM358D IC8, IC9 Dual rail/rail high voltage op-amp Digikey
Mouser\\ Sample
1 $0.22 $0.22 DigikeyDE
MMBT3906 Q1 PNP SOT-23 transistor Digikey
Mouser
1 $0.05 $0.05 DigikeyDE
JP2 2×3 male reprogramming header Digikey
Mouser
1
JP1 F/M matching header for serial comm Digikey
Mouser
1
LTST-S320GKT LED2 LED (1206) any really, but the recommended one is right-angle mount Digikey 1 $0.16 $0.16 DigikeyDE
0.1uF ceramic 1206 capacitor C21, C24, C25, C31, C32, C35 0.1uF Bypass cap Mouser 4 $0.08 $0.32
C1206C475Z4VAC7800 C22, C23, C33, C34 4.7uF 1206 ceramic capacitor Digikey\\ Mouser 4 $0.30 $1.20
68ohm 5% 1206 resistor R12 Current source set resistor, reduce for higher freq. Digikey 1 $0.08 $0.08 DigikeyDE
1K 5% 1206 resistor L5, L6 Use inductors to reduce PWM noise Digikey 2 $0.08 $0.16 DigikeyDE
10K 5% 1206 resistor R10, R14, R16, R17, R18 various 10K's Digikey 5 $0.08 $0.40 DigikeyDE
20K 5% 1206 resistor R11 Sets bias for current source Digikey 1 $0.08 $0.08 DigikeyDE
39K 5% 1206 resistor R13 Sets gain for VCO1 adjust as necessary Digikey 1 $0.08 $0.08
47K 5% 1206 resistor R15 Sets gain for VCO2 adjust as necessary Digikey 1 $0.08 $0.08
1206 resistor R8 placement optional: to set max gain for VCO1 Digikey 1 $0.08 $0.08
1206 resistor R9 placement optional: to set max gain for VCO2 Digikey 1 $0.08 $0.08
Total $3-$10

Parts Step 4: VCO

Part # & Datasheets Name Description Distributor Qty Cost Total Dist. Ger.
ROS-2500 VCO1 Voltage Controlled Oscillator (1.6-2.5GHz) Minicircuits
1 $22 $22
ROS-1700W VCO2 Voltage Controlled Oscillator (770MHz-1.7GHz) Minicircuits 1 $25 $25
SS14 (for example) D5, D6 optional Schottky Diode (at least 1A/20V) Mouser
Digikey
2 $0.30 $0.60 DigikeyDE
MIC2506 IC10 7V dual power switch Digikey 1 $3.11 $3.11 DigikeyDE
MIC2514 IC11, IC12 12V power switch Digikey 2 $2.23 $4.46 DigikeyDE
1206 Ferrite bead L9, L10, Noise reducing ferrites Digikey 2 $0.12 $0.24 DigikeyDE
0.1uF 1206 capacitor C51, C53 Bypass capacitors Mouser 2 $0.08 $0.16
1.0uF 1206 capacitor C50, C52 Bypass capacitors Mouser 2 $0.18 $0.36
Total ~$56

Parts Step 5: PLL

Part # & Datasheets Name Description Distributor Qty Cost Total Dist. Ger.
*LMX2433TM IC16 Dual 3.6/1.7GHz PLL Digikey\\ Sample 1 $4.20 $4.20 DigikeyDE
*LP2985IM5-2.5 IC15 2.5V regulator Digikey
Sample
1 $1.00 $1.00 DigikeyDE
ABMM-10.000MHZ-B2-T X1 10.000MHz Crystal Digikey
Mouser
1 $1.03 $1.03 DigikeyDE
3.9pF 0603 C60 Stabilizer for gain stage Digikey 1 $0.06 $0.06 DigikeyDE
5.6pF 0603 C61 Stabilizer for gain stage Digikey 1 $0.06 $0.06
20pF ceramic 0603 capacitor C81, C82 20pF crystal resonant capacitors (you can also use 22pF) Digikey
2 $0.10 $0.20 DigikeyDE
100pF 0603 C71, C72, C74, C78-C80 Filter capacitors Digikey 5 $0.06 $0.30 DigikeyDE
0.01uF 0603 C27, C70, C73, C75 Filter capacitors Digikey 4 $0.06 $0.24 DigikeyDE
0.1uF 1206 C25 Filter capacitors Mouser 1 $0.08 $0.08
0.1uF 0603 C76 Filter capacitors Digikey 1 $0.06 $0.06 DigikeyDE
1.0uF 1206 C26 Filter capacitors Mouser 1 $0.18 $0.18 DigikeyDE
1.0uF 0603 C50-C53, C63, C77 Filter capacitors Digikey 4 $0.05 $0.20 DigikeyDE
18ohm 0603 R20-R22, R29 Power supply filters Digikey
4 $0.08 $0.32 DigikeyDE
50 ohm 0603 R33, R34 PLL feed resistors Digikey 2 $0.08 $0.16 DigikeyDE
10K 0603 R40, R42 PLL output current sinks Digikey 2 $0.06 $0.12 DigikeyDE
10K 1206 R41, R43 PLL output current sinks Digikey 2 $0.06 $0.12 DigikeyDE
Total $3-$9

Parts Step 7: Gain Stage

Part # & Datasheets Name Description Distributor Qty Cost Total Dist. Ger.
*SXA-389B Q2, Q3 SOT89 MMIC gainstage RFMW\\ sample 2 $3.59 $7.18
22nH 0603 wirewound L7 RF choke for ~2GHz Digikey 1 $0.40 $0.40 DigikeyDE
33nH 0603 wirewound L8 RF choke for ~1GHz Digikey 1 $0.42 $0.42 DigikeyDE
1206 Ferrite bead R27, R28 Noise reducing ferrites Digikey 2 $0.12 $0.24
18 ohm 0603 resistor R23-R26 Tee network attenuator Digikey 4 $0.07 $0.28 DigikeyDE
68 ohm 0603 resistor R32 Tee attenuator (may have to adjust) Digikey 1 $0.07 $0.07
68pF 0603 capacitor C40, C42 Blocking capacitor for ~2Ghz Digikey 2 $0.03 $0.08 DigikeyDE
100pF 0603 capacitor C41, C43 Blocking capacitor for ~1GHz Digikey 2 $0.03 $0.08 DigikeyDE
1000pF 0603 capacitor C44, C47 Bypass capacitors Digikey 2 $0.03 $0.06 DigikeyDE
0.1uF 0603 capacitor C46, C49, Bypass capacitors Digikey 2 $0.15 $0.30 DigikeyDE
22pF 0603 capacitor C45 Filter capacitor for ~2GHz Digikey 1 $0.04 $0.04 DigikeyDE
68pf 0603 capacitor C48 Filter capacitor for ~1GHz Digikey 1 $0.03 $0.03 DigikeyDE
Total: $2-$10

Parts Step 8: Finishing

Part # & Datasheets Description Distributor Qty Cost Total Dist. Ger
SMA or RP-SMA edge launch If using external antennas Digikey
SparkFun
2 $2.00 $4.00 DigikeyDE
4-40 x 1/4” aluminium M/F standoff Assembly standoff McMaster-Carr 4 $0.73
4-40 x 3/8 ” aluminium F/F standoff Assembly standoff McMaster-Carr 4 $0.27
4-40 x 1/4” machine Assembly screws Digikey 8

Parts Step 8: Antennas

Part # & Datasheets Description Distributor Cost Dist. Ger.
ANT-868-CW- QW 1/4 wave whip antenna for GSM 850 band (RP-SMA, straight) Digikey $6.78 DigikeyDE
ANT-868-CW-HW 1/2 wave dipole whip antenna for GSM 850 band (RP-SMA, straight) Digikey $7.64
ANT-868-CW-HWR-RPS 1/2 wave dipole whip antenna for GSM 850 band (RP-SMA, rotating) Digikey $8.98
1/2 wave dipole antenna for 1.9GHz (RP-SMA, rotating) Hyperlinktech\\ Sharper Concepts $9.00
900 Mhz Helical antenna for 900mhz bands (SMA, straight) Saelig $8
Stubby 900Mhz Helical antenna for 900mhz bands (SMA, straight) Saelig $3
Dual 900/1800 Helical antenna for 900mhz and 1800Mhz bands (SMA, straight) Saelig $6
"Quad band antenna" Helical antenna for all GSM cell bands (SMA, right angle) SparkFun $4.95
1/4 wave 2.4GHz antenna Digikey
pretty much everywhere
~$5 DigikeyDE
 
home/wavesphere.txt · Last modified: 2009/06/15 20:08 (external edit)