This is only a preview of the June 2021 issue of Practical Electronics. You can view 0 of the 72 pages in the full issue. Articles in this series:
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Roadies’
by John Clarke
Test Signal
Generator
This test oscillator is ideal for testing balanced and unbalanced inputs on
professional sound equipment. It’s small, rugged, very portable and easy to
use. It’s powered by a single cell and is built to withstand use in a ‘roadie’
environment. Its frequency is fixed, but the output signal level is adjustable.
S
ound reinforcement systems in public venues
typically have a set of 3-pin XLR (eXtension Line
Return) sockets providing a connection point for
microphones. Instruments usually connect via a DI (Direct
Input) Box or using an unbalanced lead.
Over time, these connections can become unreliable or
go faulty. Problems that can occur include bad connecting
leads, poor XLR socket connections, broken wires or shorts.
Finding where the problem is located may be difficult.
That’s because the pathway from the XLR socket to a mixer
can be long and can pass through separate patch boxes before
finally making its way to a mixer.
There are many ways of tracing faults. You can simply use
a microphone or instrument as a signal source and test for
sound from the loudspeakers or headphones at the mixer.
But then you need to have somebody standing there speaking into the microphone or playing the instrument while
you trace the fault; not exactly ideal. It’s much easier to use
a test oscillator as the signal source.
This oscillator provides a signal level that is constant and
continuous. That makes it easier to get on with the job of
finding the trouble spot.
Our Roadies’ Test Signal Generator
is a small unit that’s powered from
a lithium button cell. The housing
is diecast aluminium so it can take
24
some punishment; the only exposed parts are the outlet socket
and a potentiometer knob for adjusting the signal level.
The oscillator output is around 440Hz (‘A’) – not so high
that it’s irritating, but high enough that it can be clearly
heard over background noise.
There is no on/off switch as such, since it is switched
on automatically when a jack is plugged in, as happens
in much professional audio equipment. This eliminates
the possibility that it can be accidentally left on after it is
unplugged, or accidentally switched on when it is jostled,
draining the cell of all its power.
Two versions
We have produced two versions of the Roadies’ Test Signal
Generator. One uses surface-mount components so that
the PCB is smaller and is housed in a more compact
enclosure.
If you prefer using throughhole components instead,
then you can
still build it;
but you will
need to use a
larger case.
Practical Electronics | June | 2021
Features and specifications
Rf
Rin
C1
C1
C1
• Generates 440Hz sinewave at 0-1.2V RMS (adjustable)
• Single-ended or impedance-balanced output via a 6.35mm jack socket
• Auto on/off switch
• Powered by a lithium button cell
• 60 hours of use from a single cell (3.5mA current draw when on)
• Compact and rugged
• Easy to build (two versions depending on constructor skill level)
IC1
R1
R1
R1
TRADITIONAL PHASE-SHIFT OSCILLATOR
Fig.1: a traditional phase-shift oscillator uses three
RC high-pass filters in the feedback loop of an op amp
(or similar amplification device) with sufficient gain
for oscillation to start up and then be maintained, but
not so much gain that the output becomes squared off.
Circuit basics
The circuit uses a simple phase-shift oscillator based on op
amps. These op amps can run from 1.8-6V and have a railto-rail output, so they are ideal for use with a 3V cell. They
can provide a sufficient output signal level of around 0.7V
RMS, even when the cell has discharged to 2V.
Fig.1 shows the configuration of a typical phase-shift oscillator. This often uses three identical resistor-capacitor (RC) highpass filters, in conjunction with an inverting amplifier IC1.
The gain of the inverting amplifier is made sufficient so
that oscillation will start at power-up and is maintained.
With the correct amount of gain, the op amp output signal
is a sinewave. Too much gain will cause the op amp to produce a squared-off waveform, with the tops of the sinewave
clamped at the op amp maximum output.
So these oscillators require the gain to be calibrated for
correct operation. That can be troublesome, especially when
the supply voltage changes, as can happen in a batterypowered oscillator.
The phase-shift oscillation frequency is given by:
1 / (√6 × 2 × R1 × C1)
Circuit details
The complete circuit is shown in Fig.2. The oscillator
section is the components around IC1a at upper-left. You
can see that this is a little different than what is shown in
Fig.1; we are using RC low-pass filters and the amplifier is
not set at a predetermined gain. Instead, it is operated in
open-loop mode, providing the maximum gain available
from the op amp.
This means that the gain is more than sufficient for oscillation to start and to be maintained. The op amp output
swings fully to the supply rails, so the waveform at IC1a’s
output is almost a square wave.
But there is a sinewave at the inverting input of op amp
IC1a (pin 2), as this is the output signal after passing through
the three low-pass filters. This is the reason for choosing
low-pass filters instead of high-pass.
Oscillation normally stabilises at a frequency when there
is a total phase shift of 180° through the three filter stages.
This, along with the 180° phase shift provided by inverting amplifier IC1a, gives the overall 360° shift required
for oscillation.
Anyway, that’s the theory; but in our circuit, the frequency
is lower than expected. For our circuit, the theoretical oscillation frequency is √6 / (2 × R × C), where R is 6.8kΩ
and C is 100nF. In this case, √6 is in the numerator and
not denominator due to our use of low-pass filters. This
works out to 573Hz. However, we measured the actual
oscillation frequency at 448Hz, and simulation shows that
S1
Vcc (3V)
470
10k
Vcc/2
100nF
6.8k
100nF
6.8k
100nF
6.8k
100nF
8
2
3
IC1a
1
4
D2
1N4148
Vcc/2
~440Hz
LED
K
10k
A
A
A
K
K
A
LED1
10k
6
3V
BATTERY
D1
1N4004
A
K
D3
1N4148
IC1b
7
S1: MICROSWITCH
OPERATED
VIA CON1
1 F
VR1
10k
LEVEL
3(5)
8
2(6)
IC2a
(IC2b)
1(7)
150
CON1
(6.5mm JACK SOCKET)
1nF
Vcc/2
1N4004
K
A
100nF
K
A
K
100 F
IC1, IC2: MCP6002 OR MCP6272
5
180k
1N4148
POWER
100 F
1k
POWER
NOTE: IC SECTIONS AND PIN NUMBERS IN BRACKETS
ARE FOR THROUGH-HOLE VERSION
10k
RING
10k
TIP
SLEEVE
5(3)
6(2)
IC2b
(IC2a)
7(1)
150
CHASSIS
4
SC ROADIES’
Roadies’
TestTEST
Signal
Generator
SIGNAL
GENERATOR
2020
Fig.2: our circuit uses a slightly unusual phase-shift oscillator with three low-pass filters in the feedback path and
diodes D2 and D3 to limit the output swing to around 1.4V peak-to-peak. The signal is taken from input pin 2 of IC1a, as
this is a sinewave, and amplified by op amp IC1b before being attenuated by VR1 and then fed to output socket CON1.
Practical Electronics | June | 2021
25
The XLR-to-6.35mm lead we made up to suit this project (see
Fig.8) also serves to turn it on and off: a tiny microswitch is
activated when ever the plug is inserted in the socket.
Scope1: this is the output waveform with VR1 adjusted so the
output just started clipping. It measures 448Hz and 1.0V RMS.
The waveform is a relatively clean, undistorted sinewave.
IC2b (IC2a in the through-hole version) provides a buffered
Vcc/2 output, also via a 150Ω resistor. This connects to the
ring terminal of the jack socket. When there is no signal,
with VR1 wound fully anticlockwise, both the tip and ring
are at Vcc/2.
Since the whole circuit is powered from a 3V cell, it floats
with respect to any outside reference voltage, so this voltage
can be grounded within the equipment being fed.
it is nominally 435Hz (the difference can be explained by
component variation). The LTspice circuit simulation file
we used to determine this is available for download from
the June 2021 page of the PE website.
The discrepancy between these figures and the calculated
573Hz value is due to IC1a switching into full output satuBalanced and unbalanced connections
ration, which slows down its low-to-high and high-to-low
Oscilloscope trace Scope1 shows the output waveform with
transitions, as it takes extra time for the op amp to come
VR1 adjusted so the output just started clipping. It measures
out of saturation.
448Hz and 1.0V RMS. The waveform is a relatively clean,
The signal level from IC1a is clamped to a nominal ±0.6V
undistorted sinewave.
about half supply (Vcc÷2) by back-to-back diodes D2 and D3.
The output is impedance-balanced, ie, the ring terminal
The 1kΩ resistor limits the current from the op amp output
impedance is the same as the tip output impedance. It is
when the diodes conduct.
not a true balanced output where the tip and ring have
This arrangement provides a relatively constant signal
complementary signal swings.
level regardless of changes in the supply voltage. That
However, the impedance-balanced output still provides
can vary from 3V with a new cell, down to 2V when it is
good common-mode signal rejection at receiving equipdischarged.
ment, cancelling noise and hum pickup that’s common in
The half-supply rail (Vcc/2) is formed by a 10kΩ/10kΩ
both balanced leads.
voltage divider across the supply, bypassed with a 100µF
For unbalanced lines, the ring connects to the sleeve and
capacitor. The non-inverting input to IC1a is also tied to this
so the signal is from the tip connection. More information
Vcc/2 supply. The signal therefore swings above and below
on this configuration is available at: http://bit.ly/pe-jun21-bal
this reference voltage.
For a balanced connection to the test signal oscillator,
With a nominal 1.2V peak-to-peak swing from pin 1 of IC1a,
ideally you should have a lead with a stereo jack plug at
after passing through the filters, we get a 78mV peak-to-peak
one end and an XLR at the other.
signal at pin 2 of IC1a. This is amplified
by a factor of 19 by op amp IC1b, giving
1.48V peak-to-peak, or 525mV RMS.
The signal is then AC-coupled to
level control potentiometer VR1. The
lower portion of VR1 connects to the
Vcc/2 reference, so that there is no DC
voltage across the potentiometer.
IC2a (IC2b in the through-hole version) amplifies this by a factor of two, so
the maximum output can be up to 1.2V
RMS, with just over 1V RMS available
before clipping. This signal goes to the
tip terminal of the jack socket.
Note IC2a’s (IC2b) output includes
a series 150Ω resistor for isolation, so
that the op amp isn’t prone to oscillation with capacitive loads. That’s extra
protection for the already stable op amp
(MCP6002), which has a typical 90°
phase margin with a resistive load and a The through-hole PCB mounts upside-down on the diecast case lid... which
45° phase margin with a 500pF capaci- becomes the base! Its power LED, output socket and level control all poke
tive load. If the MC6272 is used instead, through holes drilled in the side of the case. The panel label can be used as a
the resistive load phase margin is 65°. template for hole locations.
26
Practical Electronics | June | 2021
LED1
470
100 F
CR2032
10k
SILICON CHIP
BUTTON
CELL
HOLDER
100 F
CON1
01005201
C 2020
REV.B
10k
1
IC2
CUT OFF
+
150
150
S1
VR1
GND
TEST OSCILLATOR
A
k
TOP OF SMALL PCB
BOTTOM OF SMALL PCB
3x
100nF
10k
3x 6.8k
180k
10k
1k
4004
1
IC1
4148
2x
100nF
4148
10k
1 F D2
D3
D1
Fig.3: here’s the PCB overlay diagrams for both top
and bottom of the SMD version PCB, with a matching
photo (of the top side) which also shows the microswitch to
turn power on when the 6.35mm plug is inserted. Note the area
of the 6.35mm socket which must be shaved off to clear the button cell holder (in red).
Also shown is the case with the short ground lead in place – this is essential to prevent
hum when you touch the case. It connects to the ‘GND’ terminal on the PCB.
1nF
The jack tip should connect to pin 3
on the XLR, and the ring to pin 2. The
sleeve would connect to the pin 1 of
the XLR plug. Such cables are readily
available or you can make one up, as
per Fig.8.
For an unbalanced output, a mono
jack plug to mono jack plug lead can be
used. This automatically connects the
ring to the sleeve within the jack socket.
As mentioned earlier, power is from
a 3V button cell. Diode D1 provides
reverse polarity protection as the diode
will conduct with the cell inserted
backwards. This can usually only happen if the cell holder itself is fitted the
wrong way around on the PCB.
Construction
The smaller SMD version of the Roadies’ Test Signal Generator is built on a
PCB coded 01005201 which measures
47 × 47mm. This mounts in a 51 × 51
× 32mm diecast aluminium box.
The through-hole version is built on
a PCB coded 01005202 which measures
86.5 × 49.5mm. It fits in a diecast box
measuring 111 × 60 × 30mm. Figs.3 and
Reproduced by arrangement with
SILICON CHIP magazine 2021.
www.siliconchip.com.au
The smaller SMD version is held in place by its input socket and level control,
with a hole drilled through the case for the power LED to poke through. The
panel label can be used as a template for hole locations. Also shown here is the
card ‘insulator’ to ensure none of the components or solder joints can short out
to the case. Any type of card, or even thin plastic, is adequate.
Practical Electronics | June | 2021
4 are the PCB overlay diagrams for the
two versions.
Both boards are available from the
PE PCB Service
SMD version assembly
For the surface-mount version, many
of the parts are on the underside of the
PCB. In this case, begin construction
by installing the SMDs on both sides
of the PCB.
They are relatively large, so they
are not difficult to solder using a finetipped soldering iron. Good close-up
vision is necessary so you may need to
use a magnifying lens or glasses to see
well enough.
Be sure that the ICs are oriented correctly before soldering all their pins.
For each device, solder one pad first
and check alignment.
If necessary, adjust the component
position by reheating the solder joint
before soldering the remaining pins. If
any of the pins become shorted with
solder, solder wick can be used to remove the solder bridge.
The capacitors are usually unmarked
except on their packaging. The resistors
are marked with a code as shown in
the parts list.
Diodes D1-D3 are through-hole parts.
These are mounted and soldered form
the underside of the PCB, with the leads
trimmed flush on the top side. Take care
to orient each correctly before soldering. Now move on to the combined
assembly instructions below.
Through-hole assembly
For the through-hole PCB, start with
the resistors and diodes, then fit the
ICs, orientated as shown.
We don’t suggest that you use sockets
as the ICs could fall out if the unit is
27
SILICON CHIP
MCP6002
A
K
LED1
10kW
GND
TEST OSCILLATOR
180k
IC2
MCP6002
100nF
1
10kW
10kW
100mF
1mF NP
10kW
IC1
150W
S1
150W
470W
10k
6.8kW
1kW
6.8kW
100nF
C 2020
REV.B
01005202
D3
+
100mF
4148
6.8kW
CON1
D1
100nF
100nF
CELL1
CR2032
D2
4148
4004
BUTTON
CELL
HOLDER
1.0nF
100nF
1
VR1
10kW
Fig.4: and here’s the through-hole overlay and photo
for those who aren’t comfortable soldering SMDs!
dropped or kicked. Next, fit the MKT
capacitors, which are not polarised.
Combined assembly
Now mount the electrolytic capacitors.
Two of these are polarised, so they
must be installed with the longer leads
towards the + sign on the PCB.
Next, mount the cell holder with the
orientation shown, followed by potentiometer VR1 and jack socket CON1.
Note that for the surface-mount version, a small section of the plastic case
of the jack socket for CON1 needs to
be cut off, so that it does not foul the
cell holder. Fig.3 shows where to cut
at 45°; this can be done with a sharp
hobby knife.
Switch S1 is a microswitch, mounted
so that the lever is captured under the
front ring contact of jack socket CON1.
Before soldering it, check that the switch
is open-circuit between its two outside
pins when there is no jack plug inserted,
and closed when a plug is inserted. The
lever may require a little bending so that
the switch works reliably.
For the through-hole version, mount
LED1 so its body is horizontal and located so that the centre is in line with
the centre of the CON1 hole, as shown.
Make sure the leads are bent so the
anode (longer lead) is to the right. The
surface-mount PCB has LED1 arranged
vertically, with the top of the dome
21mm above the top of the board.
Case assembly
We are using the lid as the base of the
case for both versions. This gives a better
appearance and also means that we can
replace the lid screws with M4 nylon
screws (after tapping the holes to M4)
to act as feet.
Changing the cell requires removing
the PCB. That’s not too difficult, and we
don’t expect the cell will need changing
for years with intermittent use. Expect
over 60 hours of usage from a good cell.
We have provided front-panel artwork for both versions and many of
the drilling positions on the diecast
boxes. These are shown in Fig.6 and
Fig.7; they can also be downloaded as
a PDF file from the June 2021 page of
the PE website.
The hole for the 6.35mm jack socket
is 11mm, the potentiometer hole is 7mm
and the LED hole is 3mm in diameter.
The panel artworks show the positions.
3-PIN XLR PLUG
1
2
3
For the surface-mount version, the
LED hole is on the top of the case. With
this version, drill the holes at an angle
so that the pot shaft and jack socket
can be inserted more easily. The LED
will need to clear the box edge without
affecting its position.
Countersinking the inside of the LED
hole will make it easier to locate the
LED as the PCB is inserted into the case.
Both versions require a solder lug to
ground the case. For the through-hole
version, this is located on the lid but is
away from the underside of the PCB.
You need to drill a 3mm hole for this,
plus four for the PCB mounting posts.
The PCB is located centrally across
the width of the lid, but the front edge
is positioned so it is only 3mm back
from the lid edge, so that the pot and
jack socket are against the case edge
when assembled.
We used countersunk screws for the
standoffs and solder lug screws, and
if you do the same, these holes will
require countersinking on the outside
of the case. Add a star washer against
the solder lug before tightening the nut.
Then solder hookup wire to one end to
the solder lug and solder the other to
the GND terminal on the PCB.
The through-hole version uses a GND
PC stake fitted to the underside of the
board to connect this wire. On the surfacemount version, the wire solders to the
top of the PCB directly to the GND pad.
The surface-mount version should
have an insulator made from some stiff
card added between the PCB and case
lid (see Fig.5). This prevents possible
shorting between the two.
SLEEVE
Fig.8: if you don’t have a jack plug to XLR cable,
here
SC is how to make one. Use shielded stereo or
2020
balanced
microphone cable.
28
TIP
RING
6.3mm STEREO JACK PLUG
Practical Electronics | June | 2021
Parts list – Roadies’ Test Signal Generator
Parts common to both versions
Insulator
template
for surface
mount PCB
Fig.5: make this insulating panel from
thick card and insert it between the
SMD PCB and case lid.
As mentioned, M4 nylon screws are
ideal for mounting the lid. Tap each hole
with an M4 tap before securing the lid
with these screws.
Alternatively, you could use the
mounting screws supplied with the
case, and add small stick-on rubber feet.
Panel labels
The front panel labels can be made using overhead projector film with the
printing as a mirror image, so the print
will be between the enclosure and film
when affixed.
Use projector film that is suitable for
your printer (inkjet or laser) and glue
with clear neutral cure silicone sealant.
Squeegee out the lumps and air bubbles before the silicone cures. Once
cured, cut out the holes through the
film with a hobby or craft knife.
The potentiometer shaft is held in
place using its washer and nut, while
the 6.35mm jack socket is secured using the supplied washer, plastic dress
piece and dress nut.
Testing and modifications
You can test the oscillator using a
multimeter set to measure AC volts
and connected to the output between
the tip and ring connections of a stereo
jack plug. Note that the output can
produce clipping if the signal level is
near maximum, so bring the level back
a little for a clean sinewave.
The output frequency can be
changed by altering the values of the
three 6.8kΩ resistors in the low-pass
filters or changing the values of the
+
Power
(with jack plug inserted)
SILICON CHIP
Outlet
Parts for surface-mount version
1 double-sided PCB coded 01005201, 47 x 47mm from PE PCB Service
1 diecast aluminium case, 51 x 51 x 32mm [Jaycar HB5060]
1 M3 x 6mm countersunk screw (solder lug mounting)
1 M3 nut and star washer
Semiconductors
2 MCP6002-I/SN or MCP6272-E/MS op amps, SOIC-8 (IC1,IC2)
[RS Components Cat 6283598 or 6674492]
Capacitors (all 50V X7R SMD, 3216/1206 size)
1 1µF ceramic
5 100nF ceramic
1 1nF ceramic
Resistors (all 0.25W SMD, 1% 3216/1206 size)
1 180kΩ (code 1803)
5 10kΩ (code 1002)
1 1kΩ (code 1001)
1 470Ω (code 4700)
3 6.8kΩ (code 6801)
2 150Ω (code 1500)
Parts for through-hole version
1 double-sided PCB coded 01005202, 86.5 x 49.5mm from PE PCB Service
1 diecast aluminium box, 111 x 60 x 30mm [Jaycar HB5062]
4 M3 x 6mm pan head screws (PCB to standoffs)
5 M3 x 6mm countersunk screws (lid to standoffs and solder lug mount)
1 M3 nut and star washer
4 M3 tapped x 6.3mm standoffs
1 PC stake
Semiconductors
2 MCP6002-I/P or MCP6272-E/P op amps, DIP version
[RS Components Cat 403036 or 402813] (IC1,IC2)
Capacitors
1 1µF 16V NP PC electrolytic
5 100nF MKT polyester
1 1.0nF MKT polyester
Resistors (all 0.25W, 1%)
1 180kΩ 5 10kΩ
3 6.8kΩ
1 1kΩ
three associated 100nF capacitors.
Smaller values will provide a pro-
HOLE SIZES:
Power LED: .......3mm
Outlet Socket: ...11mm
Level pot: ...........7mm
SILICON CHIP
1 470Ω
2 150Ω
portionally higher frequency; larger
values, a lower frequency.
Roadies’ Test Signal Generator
..
Power +
(With jack plug
inserted)
Roadies’
Test Signal Generator
Level
1 panel label (see text)
1 CR2032 PCB-mount button cell holder
1 CR2032 cell
1 6.35mm stereo switched jack socket (CON1) [Jaycar PS0195, Altronics P0073]
1 C&K ZMA03A150L30PC microswitch or equivalent (S1) [eg Jaycar SM1036]
1 9mm 10kΩ linear pot (VR1)
1 knob to suit VR1
4 M4 x 12mm nylon screws (for mounting feet – replace supplied case screws)
1 solder lug
1 90mm length of green hookup wire
1 1N4004 diode (D1)
2 1N4148 diodes (D2,D3)
1 3mm LED (LED1)
2 100µF 16V PC electrolytic capacitors
+
Outlet
.
.
.
. .
.
.
. Level
.
+
.
.
min
max
Fig.6 and Fig.7: front-panel artwork for both versions of the Roadies’ Test Signal
Generator. As mentioned in the text, the artwork can be photocopied and used as a
drilling template. (Download from the June 2021 page of the PE website.)
Practical Electronics | June | 2021
29
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