PCB endplates

[Roger Critchlow]

DHL showed up a day earlier than promised.  The boards look good.  The 0.8mm thickness is very svelte.  The cutouts fit the hl2 and n2adr boards snugly.  But the four corner mounting holes don't align with the tapped holes in the corners of my case.

So, you remember how Steve mentioned that some enclosures are spec'ed at 105mm width while others are 106mm?  I think that my PCB endplates are cut for a 105mm wide case, so it doesn't quite align with my 106mm wide case.  I used f4grx's dxf files to set the edge cuts in kicad, but I had to rescale them because their units didn't make any sense when imported into kicad.  So it may also be that I just did a bad job of rescaling.

I enlarged the corner holes by hand deburring them with a larger drill bit, and it all fits together.  In the pictures you can see a little aluminum peeking out around the edges of the PCB endplates.

If anyone with a 105mm wide case could take measurements in mm of the endplate that came with the case, I can use width, height, inset width, corner hole diameter, shortest horizontal distance between corner hole edges, and shortest vertical distance between corner hole edges.  I figure I can make bigger corner mounting holes that satisfy both case sizes, and we keep the smaller endplate outline.

I'll also send a set of endplates, supplies permitting, anywhere US First Class postage reaches to anyone with a 105mm case who wants to see if they fit.

-- rec -- ad5dz --

[dick_...@hotmail.com]

Rodger

I have some mechanicals of a 106mm case form the web - attached.

Will you be willing to share your design files ? Either before or after the mechanical issues are resolved?

I also have a few extra PCB's from some of my projects that we could trade.

Dick K9IVB

[Roger Critchlow]

Thanks Dick -- 

Those are much easier to read than my columns of caliper readouts.  I'll add them to the kicad projects and other data that goes into the Hermes Lite github.  It should go up as soon as I sort this issue out, and they'll be freely available and freely reusable.

Now, who's got some mechanicals for the 105mm box?

-- rec -- ad5dz --

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[dick_...@hotmail.com]

I found this drawing on an ebay site that says it is selling the 105mm case.  The drawing indicates 106mm but it is different from the other drawings that I sent yesterday.

https://www.aliexpress.com/item/32922152354.html?spm=a2g0o.productlist.0.0.67804386aP75PJ&algo_pvid=f260c8f2-974f-46f4-86aa-d95df1d45e1b&algo_expid=f260c8f2-974f-46f4-86aa-d95df1d45e1b-4&btsid=68dd9db4-2c0f-4bc3-b1fb-56c429fbab0e&ws_ab_test=searchweb0_0%2Csearchweb201602_1%2Csearchweb201603_60

On Wednesday, July 17, 2019 at 7:14:38 PM UTC-7, Roger Critchlow wrote:

[Roger Critchlow]

This gets pretty funny.  

If you search for 55*105*150 mm boxes, you keep finding them from various sources, and they're all clearly labelled as 105mm width.  They also include variously watermarked versions of the appended mechanical drawing, which is clearly labelled as 106+/-0.2 mm width.  It's the same mechanical drawing that Dick Faust just posted.

If you print out that drawing it's a perfect fit to the mounting holes that I cut for the PCB endplates, the crosses on the mounting holes on the drawing are perfectly centered on the PCB mounting holes when the plate aligns to the drawing outline.  

But if you measure the widths on the printed drawing with your trusty electronic caliper, they're all a 1 mm smaller than the measurements written on the drawing.  Meanwhile, the measured heights are correct as written on the drawing.  So the 105mm case is in fact 105mm wide, the PCB slot is a 99.5mm wide, and the horizontal distance between the mounting hole centers is 95.5mm.

So I'm going to make the mounting holes 0.5mm larger and shift them 0.25mm horizontally edge-ward.  I'll make them plated through and leave a collar of copper exposed so the mounting screws can electrically connect the endplate copper pours to the case.  I'll keep the edge cut as is, because you don't want the edges of the end plate sticking out to get caught.  I should round off the corners, too, as they stick a little bit out past the corners of my 106mm case.  I'll make these changes and post the projects as soon as possible.

-- rec -- ad5dz --

[Steve Haynal]

Hi Roger,

I measured some end plates I have and their holes match the 96mm x 47.4mm in the SZOMK model number AK-C-C12 diagrams posted earlier. I'm not sure where I ordered them from.

The original enclosure is a bit on the tall side as the intent was to put two HL2 in the same enclosure. I have several of the shorter AK-C-C69 and like them also. 

What temperature does your HL2 run at with the end plates installed, especially during this heat wave? I am concerned about heat with a fully enclosed board. Maybe we will need some holes for a fan and ventilation?

73,

Steve

kf7o

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[Roger Critchlow]

I'm sure we're all a little vague about where the miscellaneous parts came from at this point.  Still, would like to hear from someone who knows they have a 55*105*150 case.

96mm, oh, that's not 1mm off from the 55*105*150 "mechanical", that's only 0.5mm off.  More operator error on my part, I was assuming a consistent error from the SZOMK, but it's a consistent error from some other extrusion.  All good, the mounting holes are ovals, so they become more circular ovals, and the displacement of the 106mm mounting hole is only 0.25mm outboard from the 105mm mounting hole.  My desire to make the mounting holes electrically connected to the ground pours on the end plates has already forced me to restart the design a few times, I now know how to edit the mounting hole footprint once so it propagates to all four mounting holes.

Good quesIion about temperature.  I'll fire it up and see what quisk says.  Though it's a relatively balmy 92F with 17% relative humidity here in Santa Fe.  Just running receive, I went from 30C to 35C in less than 30 minutes, and after an hour I'm at 36C.  I'll let it go a while to see if it's still climbing.  I'm not set up to do transmit or power amp testing as yet.

Something I discovered while screwing on the endplates: the case is very stable sitting on it's narrower end once the two halves of the clamshell are secure.  I'm curious if that has thermal benefits, too, which it should since it has larger exposed case surface area in that orientation.  The labelling of the end panels is also much easier in that orientation, too.

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[Roger Critchlow]

I've updated the PCB endcap designs, uploaded the files into the HermesLite2 repo at github, andsubmitted another order to jlcpcb.com to validate the design.  

The files are found at https://github.com/softerhardware/Hermes-Lite2/tree/master/hardware/enclosure/endcaps/ad5dz.  There is a Readme.org file in that directory which github formats and displays below the directory listing. 

I will consider this round of design probationary until I've fastened a set of endcaps onto my Hermes Lite, but I'm pretty sure they're going to work.  (Famous last words.)

[Steve Haynal]

Thanks Roger!

[Roger Critchlow]

You're very welcome.

My next set of boards is going through solder levelling.  Made the mistake of specifying ROHS for this set, which added $12 to the cost of the order.

More on the temperature question with the case buttoned up.  

I set the radio on edge and left the receiver running for days, and it generally stabilized a few degrees above ambient temperature.  My temperature records mostly say 34C.  That's with one receiver running at 48ksps. 

Then today I finally fired up the PA feeding a dummy load with a multimeter.  The watts measured on the dummy load agree with Quisk's reported power to 0.1W.  I'm getting 5.8W 160M, 5.4W 80M, 5.5W 60M, 4.8W 40M, 5.8W 30M, 5.3W 20M, 4.4W 18M, 4.1W 15M, 3.1W 12M, and 3.8W 10M.  Seems a little more wobbly than some of the curves I've seen posted here.

Continuously spotting on 160M I got up to 46C, then I decided that I needed a heftier dummy load before pushing on further.  That took less than a minute, but the rate of rise was so slow at that point that I suspected in might be minutes before the next degree ticked over.  What I found interesting was that the entire case was warm to the touch, that is the case was warm on the side where the PA is bolted down, but it was also warm on the opposite side.  So the warm air inside the enclosure is spreading the heat around.  Maybe attaching heatsinks to the inside walls of the enclosure will help transfer the heat from the air into the enclosure walls?  I put one of those IR thermometer guns into my Amazon shopping cart.

-- rec -- ad5dz --

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[Steve Haynal]

Hi Roger,

That is good news that it didn't heat up much past 46C. This is a little on the high side but I think we are okay to 55 or 60C. I also see the whole enclosure heat up, even without end plates.

Have you made any of the mods to increase power? Rewinding T3 makes the biggest difference. I see at least 5W on all bands.

73,

Steve

kf7o

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[Christopher KB3CS]

conduction generally moves/distributes much more heat energy than convection. esp. in copper and aluminum.

 - 37 (base 22) -

On Wednesday, July 24, 2019 at 11:50:40 PM UTC-4, Roger Critchlow wrote:

[...]

Continuously spotting on 160M I got up to 46C, then I decided that I needed a heftier dummy load before pushing on further.  That took less than a minute, but the rate of rise was so slow at that point that I suspected in might be minutes before the next degree ticked over.  What I found interesting was that the entire case was warm to the touch, that is the case was warm on the side where the PA is bolted down, but it was also warm on the opposite side.  So the warm air inside the enclosure is spreading the heat around.  Maybe attaching heatsinks to the inside walls of the enclosure will help transfer the heat from the air into the enclosure walls?  I put one of those IR thermometer guns into my Amazon shopping cart.

[...]

[Roger Critchlow]

Probationary was the right idea.  The latest attempt arrived this afternoon.  

The mounting holes are still not right.  I think that my manual enlargening to make the width work hid the fact that the height was a little off, too.  And perhaps making the holes plated through stole a bit of diameter, too.  Then the SMA connectors on the back ended up a little snugger than the last.  Nothing that a little more manual enlargening doesn't fix, but nearly crossthreaded a few mounting screws.  And for my final trick, I laid out the labels on the back panel upside down.

So, back to kicad and hope third time's a charm.

-- rec -- ad5dz --

[Steve Haynal]

Hi Roger,

I like the black color. I received the two samples you sent today. I look forward to trying them out.

73,

Steve

kf7o

[Roger Critchlow]

Steve --

The black does look very amateur, which is to say professional.  I have a set of horizontal red endplates arriving today, too.

The rewind kit arrived yesterday, too.  Thanks, added to my to do list.

-- rec -- ad5dz --

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[Steve Haynal]

Hi Roger and Group,

Below is a picture of the latest end plate PCB Roger sent me. It fits pretty well. I like the vertical orientation. I am thinking about having end plate PCBs included with build9. Here is what I am considering:

** Add fan option and any fan control logic on inside of front panel. We can have traces and components on the inside of these panels as they are PCBs. This is kind of neat for people who want to make small enhancements to the HL2. I would probably borrow JI1UDD fan setup as it is controlled with just one output. I didn't find the schematic or BOM for this on JI1UDD's links. Can someone point me to any schematic and BOM?

** Enlarge holes slightly to handle more build/assembly variation.

** May only include front panel to reduce costs. There are only 3 holes in the back panel. I am thinking we can provide a drill template for the back panel. People would print this out and drill the three holes. A panel is included whenever you purchase an enclosure. It fits well and is sturdy. What do people think?

73,

Steve

kf7o

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[dick_...@hotmail.com]

Does this mean that the files and Gerbers are now correct for ordering?

I have some AD0412HS-G70 40mm square x10mm fans made by ADDA that I would like to incorporate.  Pix attached.  These were found at a local hamfest and have filter covers.  I do not know if these fans are still available.  Similar ones are still found in some hot swap SATA drive enclosures.

I also found the JI1UDD schematic on pg 4 [attached]

Dick K9IVB

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[Walter Holmes]

The end plate looks really nice indeed.

I can't tell if this is for the normal or the low profile case though.

It would be nice to have the option for both, that may add too much administration to the orders. :)

I currently have the 3d printable end plates that work very well for the normal size case, but would like to find the same details for the lower profile version if they exist anywhere. As the lower profile case is much nicer to me.

Walter/K5WH

[Roger Critchlow]

I'm glad they're looking good.  

The git repo is still one of the older designs.  The new design is on a computer at home and I am away from home for a week.  And I have a family reunion arriving the week after I get home, so it may take a little more time before I get the updated designs uploaded.  The delta between getting a design to JLCPCB and updating the additional information posted to the git is enough that I only want to do it once more.

Enlargening holes a bit to tolerate more dimensional variation is prudent.  I had to back off the first three screws on one endplate to get the fourth started cleanly.

Shortening the short dimension to fit a low profile case should be no problem if all the extra length is coming out of the middle of the case profile where the two halves meet.

Adding a circuit for fan control sounds like a good add on.  Probably want vent holes in both endplates if you really need the cooling air, maybe even fans on both endplates, one blowing in and one blowing out.  Seems like the problem with air cooling might be that the space between the board and the case wall is isolated from cooling air circulation.

-- rec -- ad5dz --

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[Steve Haynal]

Hi Group,

I have added another version of end plates to github:

 https://github.com/softerhardware/Hermes-Lite2/tree/master/hardware/enclosure/endcaps/kf7o/hl2_55fb

This has:

** Common library with single basic front and back component so that it is easy to create new end plates.

** End plate uses oval corner holes to handle variation in enclosures where some units have 96.5mm others 96mm hole spacing.

** Position of connector holes match exactly component position on HL2 PCB. This corrects some slight error I was seeing in the length dimension.

** Holes are slightly larger to handle build variations.

This first end plate is a combined end plate. It can be used for both the front and back of a 106mm X 150mm X 55mm enclosure. It is easy to convert this to a front or back only end plate by removing one of the basic components.

This end place also has a drill diagram for those who want to modify the end plates included with the enclosure to work with the HL2. Just print out the attached PDF, line up the corner holes with the corner targets (note the two variations, inner target for 96mm spacing, outer target for 96.5mm spacing), then use a hole punch to make divets where all the holes should be drilled. Pick a drill bit that when laid on the paper matches the diameter of the printed hole. For the rectangular ethernet hole, drill the from small to large bits, and then file or clip the metal to make more rectangular. Please let me know how this goes if you try it.

I have asked makerfabs what the cost will be to include 2 of the same universal end plates, or 2 different end plates. Once I hear from them, we can discuss what should be included in build9.

For my end plates, I am planning on the following additions:

** Optional electronics for fan control. This is just a few surface mount components on the inside of the end plate. Some wires will have to be soldered directly to the end plate. The most inexpensive small fans are 40mm X 40mm. Unfortunately that size will not fit in a universal end plate so there will be some front or back only end plates. This will also include a fan mount component with ventilation holes. I don't think a fan is needed as my tests with the enclosed unit were fine even after 6 minutes continuous transmit of WSPR. But a fan is still a nice option since maybe in very hot operation locations a fan can help.

** Low profile end plates. I also like the low profile (40mm) AK-C-C69 enclosures listed on the wiki page and have three of them. Unfortunately a 40mm x 40mm can't be used if mounted to the end plate. 

73,

Steve

kf7o

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[Steve Haynal]

Hi Group,

Makerfabs responded and the cost for two different end plates included with each order is well under a dollar, so I will submit separate front and back panels to them. I am considering where the optional fan should be. The least expensive small fans commonly available appear to be 40mmX40mmX10mm. Three possible locations are:

** Front panel above the LEDs. There is just barely room. One side of the fan would be about flush with the top half of the enclosure.

** Back panel above the two SMA connectors. Again, just barely room. In fact the same amount of room assuming the optional SMA connectors on the front may be installed as well.

** On the top clam of the enclosure, right above the PA. This would require a paper template and kit buyers to manually drill vent and mounting holes in the aluminum.

All of the above assume the taller 55mm enclosure and only one HL2 board installed in the enclosure. Another possibility, which I don't like as much, is to mount the fan external to the enclosure. Any thoughts or comments?

73,

Steve

kf7o

 on Mouser or Digikey are 

[Sid Boyce]

Hi Steve,
I have some fans to hand originally as spares for some +12V 55A
IBM/Emerson server power supplies that have been modded to supply +13.8V
50A.
They are 40mmx40mmx25mm and I have one fitted to the front panel of my
HL2Beta8.

With heatsinks n the FPGA and the AD9866 temperature sits at +28 degs C
rising to +40 degs C on TX reported by quisk.
73 ... Sid.

On 20/08/2019 04:58, Steve Haynal wrote:
> Hi Group,
>

> Makerfabs responded and the cost for two different end plates included
> with each order is well under a dollar, so I will submit separate
> front and back panels to them. I am considering where the optional fan
> should be. The least expensive small fans commonly available appear to
> be 40mmX40mmX10mm. Three possible locations are:
>
> ** Front panel above the LEDs. There is just barely room. One side of
> the fan would be about flush with the top half of the enclosure.
> ** Back panel above the two SMA connectors. Again, just barely room.
> In fact the same amount of room assuming the optional SMA connectors
> on the front may be installed as well.
> ** On the top clam of the enclosure, right above the PA. This would
> require a paper template and kit buyers to manually drill vent and
> mounting holes in the aluminum.
>
> All of the above assume the taller 55mm enclosure and only one HL2
> board installed in the enclosure. Another possibility, which I don't
> like as much, is to mount the fan external to the enclosure. Any
> thoughts or comments?
>
> 73,
>
> Steve
> kf7o
>
>
>
>
>
>
>

>  on Mouser or Digikey areÂ

>
>
>
> On Sunday, August 18, 2019 at 2:24:39 PM UTC-7, Steve Haynal wrote:
>
> Hi Group,
>
> I have added another version of end plates to github:

> Â
> https://github.com/softerhardware/Hermes-Lite2/tree/master/hardware/enclosure/endcaps/kf7o/hl2_55fb

> end plate.Â
>
> 73,
>
> Steve
> kf7o
>  Â

>
>
>
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--
Sid Boyce ... Hamradio License G3VBV, Licensed Private Pilot
Emeritus IBM/Amdahl Mainframes and Sun/Fujitsu Servers Tech Support
Senior Staff Specialist, Cricket Coach
Microsoft Windows Free Zone - Linux used for all Computing Tasks

[ROBERT ENTWISTLE]

The only input I would like to suggest is that if at all possible, please keep the DB1 and DB12 connectors the same size and location. I am currently designing a new JI1UDD AK4951 codec companion board which will mate to HL2B8 (and hopefully future) versions of the HL2.

I can share which IO's are being used for what on the companion board if coordination in gateware development going forward is considered worthy.

73,

Robert, WA2T

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[Martyn 5B4AMO]

Hi Steve,

You asked "This end place also has a drill diagram for those who want to modify the end plates included with the enclosure to work with the HL2. Just print out the attached PDF, line up the corner holes with the corner targets (note the two variations, inner target for 96mm spacing, outer target for 96.5mm spacing), then use a hole punch to make divets where all the holes should be drilled. Pick a drill bit that when laid on the paper matches the diameter of the printed hole. For the rectangular ethernet hole, drill the from small to large bits, and then file or clip the metal to make more rectangular. Please let me know how this goes if you try it."

Well I have the HL2 build 8 which came with blank end plates. This morning I printed out the .pdf (the trick is to remove any printer scaling so it comes out the right size, I found!) then I cut it out and stuck it on the end plate in the right position with bluetack. Used the centre punch to get the hole positions, then removed the paper and drilled the holes. All went well! The most difficult bit was making the rectangular hole for the ethernet - not so difficult - but a bit of filing required. The metal is soft, and easy to file. I did all the holes with my trusty hand-held power drill, if I had a bench drill it would have been more precise.

The only problem I had is that when I put the screw in for heat sinking the PCB to the case, I ended up with the board a little further out than it should be. So the PCB is very slightly extended beyond of the end of the lower clamshell case. This didn't stop the end plate going on.

Anyway, your .pdf idea of drilling template is a good one, and it works! Many thanks.

Best Regards, Martyn.

[Steve Haynal]

Hi Sid,

This is very close to what I see without a fan. How much difference does the fan make for you? What is your top temperature after 5-6 minutes of keydown with and without the fan?

73,

Steve

kf7o

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[Steve Haynal]

Hi Robert,

There are no plans to change the size and location of DB1 or DB12. Which pin are you using for the fan control? Maybe we can have that in common.

Please note that having a codec on the HL2 or any other openhpsdr radio does not eliminate latency for RX audio. The data is still sent to the PC, processed there, and then passed back to the HL2. It amounts to a ethernet soundcard on the radio. There are many inexpensive USB soundcard options which won't use FPGA resources.

73,

Steve

kf7o

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[Steve Haynal]

Hi Martyn,

Thanks for the update. It is good to have confirmation that the holes are aligned. I have also seen the problem of the board slightly sticking out on one end. Usually I can make the mounting hole slightly larger so that I can nudge the board. In build 9, I have also decreased the length of the filter board by .1mm the help here. Would your problem be fixed by a slightly larger or positioned mounting hole, or is the length of your two boards actually slightly longer than 150mm?

73,

Steve

kf7o

[ROBERT ENTWISTLE]

Hi Steve,

Okay on the DB1 and DB12, thanks.

No plans for a fan in what I am working on.

My main interest in the codec is for the CW sidetone, the local mic input and RX audio outputs are bonus for me. I cannot speak to the codec latency for RX audio, perhaps Taka-san will chime in.

73,

Robert, WA2T

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[Takashi K]

Hi Robert-san,

> I cannot speak to the codec latency for RX audio, perhaps Taka-san will chime in.

Steve is right. Rx audio latency exists.

It's not serious for me. It might be effect that my HL2 is connected to RPi2 directly.

I recommend to check wether the latency is acceptable or not by yourself.

73,

Taka,  ji1udd

[Sid Boyce]

Hi Steve,
I'll have to make measurements tomorrow.
For fan power I am using a DC-DC convertor set at +6.5V.
73 ... Sid.

> >  on Mouser or Digikey areÂ

> >
> >
> >
> > On Sunday, August 18, 2019 at 2:24:39 PM UTC-7, Steve Haynal wrote:
> >

> >     Hi Group,
> >
> >     I have added another version of end plates to github:
> >     Â
> >   Â
> https://github.com/softerhardware/Hermes-Lite2/tree/master/hardware/enclosure/endcaps/kf7o/hl2_55fb
> <https://github.com/softerhardware/Hermes-Lite2/tree/master/hardware/enclosure/endcaps/kf7o/hl2_55fb>
>
> >    
> <https://github.com/softerhardware/Hermes-Lite2/tree/master/hardware/enclosure/endcaps/kf7o/hl2_55fb
> <https://github.com/softerhardware/Hermes-Lite2/tree/master/hardware/enclosure/endcaps/kf7o/hl2_55fb>>
>
> >
> >     This has:
> >
> >     ** Common library with single basic front and back
> component so
> >     that it is easy to create new end plates.
> >     ** End plate uses oval corner holes to handle variation in
> >     enclosures where some units have 96.5mm others 96mm hole
> spacing.
> >     ** Position of connector holes match exactly component
> position on
> >     HL2 PCB. This corrects some slight error I was seeing in the
> >     length dimension.
> >     ** Holes are slightly larger to handle build variations.
> >
> >     This first end plate is a combined end plate. It can be
> used for
> >     both the front and back of a 106mm X 150mm X 55mm
> enclosure. It is
> >     easy to convert this to a front or back only end plate by
> removing
> >     one of the basic components.
> >
> >     This end place also has a drill diagram for those who want to
> >     modify the end plates included with the enclosure to work
> with the
> >     HL2. Just print out the attached PDF, line up the corner
> holes
> >     with the corner targets (note the two variations, inner
> target for
> >     96mm spacing, outer target for 96.5mm spacing), then use a
> hole
> >     punch to make divets where all the holes should be
> drilled. Pick a
> >     drill bit that when laid on the paper matches the diameter
> of the
> >     printed hole. For the rectangular ethernet hole, drill the
> from
> >     small to large bits, and then file or clip the metal to
> make more
> >     rectangular. Please let me know how this goes if you try it.
> >
> >     I have asked makerfabs what the cost will be to include 2
> of the
> >     same universal end plates, or 2 different end plates. Once
> I hear
> >     from them, we can discuss what should be included in build9.
> >
> >     For my end plates, I am planning on the following additions:
> >
> >     ** Optional electronics for fan control. This is just a few
> >     surface mount components on the inside of the end plate. Some
> >     wires will have to be soldered directly to the end plate.
> The most
> >     inexpensive small fans are 40mm X 40mm. Unfortunately that
> size
> >     will not fit in a universal end plate so there will be
> some front
> >     or back only end plates. This will also include a fan mount
> >     component with ventilation holes. I don't think a fan is
> needed as
> >     my tests with the enclosed unit were fine even after 6
> minutes
> >     continuous transmit of WSPR. But a fan is still a nice option
> >     since maybe in very hot operation locations a fan can help.
> >
> >     ** Low profile end plates. I also like the low profile (40mm)
> >     AK-C-C69 enclosures listed on the wiki page and have three of
> >     them. Unfortunately a 40mm x 40mm can't be used if mounted
> to the
> >     end plate.Â
> >
> >     73,
> >
> >     Steve
> >     kf7o
> >      Â

> >
> >
> >
> > --
> > You received this message because you are subscribed to the Google
> > Groups "Hermes-Lite" group.
> > To unsubscribe from this group and stop receiving emails from
> it, send

> > an email to hermes-lite...@googlegroups.com
> <mailto:hermes-lite%2Bunsu...@googlegroups.com>
> > <mailto:hermes-lite...@googlegroups.com
> <mailto:hermes-lite%2Bunsu...@googlegroups.com>>.

> > To view this discussion on the web visit
> >
> https://groups.google.com/d/msgid/hermes-lite/bb76ccf3-ebf3-43e5-8f50-54793f755999%40googlegroups.com
> <https://groups.google.com/d/msgid/hermes-lite/bb76ccf3-ebf3-43e5-8f50-54793f755999%40googlegroups.com>
>
> >

> <https://groups.google.com/d/msgid/hermes-lite/bb76ccf3-ebf3-43e5-8f50-54793f755999%40googlegroups.com?utm_medium=email&utm_source=footer

> <https://groups.google.com/d/msgid/hermes-lite/bb76ccf3-ebf3-43e5-8f50-54793f755999%40googlegroups.com?utm_medium=email&utm_source=footer>>.
>
>
>
> --
> Sid Boyce ... Hamradio License G3VBV, Licensed Private Pilot
> Emeritus IBM/Amdahl Mainframes and Sun/Fujitsu Servers Tech Support
> Senior Staff Specialist, Cricket Coach
> Microsoft Windows Free Zone - Linux used for all Computing Tasks
>

> --
> You received this message because you are subscribed to the Google
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> <mailto:hermes-lite...@googlegroups.com>.

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[K Jones]

Steve:

 

Awesome thumbs on the end plates from Marketfabs  ... count me in some sets for my:

HL2 build7

Hermes-Lite 2.0 Build8

Hermes-Lite 2.0 Build (X) to come

Kyle

KJ4QAL

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[Steve Haynal]

Hi Robert,

For CW sidetone there should be very little latency as the sidetone can be generated on the FPGA. Only the audio processed on the host will experience the latency. If all you want is a sidetone, PWM to create a sine wave may be easier:

 http://www.ti.com/lit/an/spna217/spna217.pdf  The link is an example. You wouldn't have to use the N2HET but could create similar counters in the FPGA.

73,

Steve

kf7o

[Amogh Desai]

Hi Steve,

I recent bought this type of speed controller for a dc motor.  The heatsink on it may be of interest to us:

https://www.banggood.in/Geekcreit-PWM-DC-Motor-Speed-Controller-Speed-Switch-Module-6V12V24V28V-3A-1203B-p-1043383.html?rmmds=buy&cur_warehouse=CN

I have not tried this yet, however using this type of heatsink with a thermal pad might save us from drilling a hole in the cabinet.

Amogh

VU3DES

[Sid Boyce]

Hi Steve,

I'll have to open up the enclosure and unsolder the fan to check the
temperature and report on that later.

With the fan it starts at +28C from cold and stabilises at +41C with key
down for 5+ minutes (20m 4.x Watts), returning to a settled +30C after
10 minutes on RX.

73 ... Sid.

On 20/08/2019 16:40, Steve Haynal wrote:

> >  on Mouser or Digikey areÂ

> >
> >
> >
> > On Sunday, August 18, 2019 at 2:24:39 PM UTC-7, Steve Haynal wrote:
> >

> >     Hi Group,
> >
> >     I have added another version of end plates to github:
> >     Â
> >   Â
> https://github.com/softerhardware/Hermes-Lite2/tree/master/hardware/enclosure/endcaps/kf7o/hl2_55fb
> <https://github.com/softerhardware/Hermes-Lite2/tree/master/hardware/enclosure/endcaps/kf7o/hl2_55fb>
>
> >   Â
> <https://github.com/softerhardware/Hermes-Lite2/tree/master/hardware/enclosure/endcaps/kf7o/hl2_55fb
> <https://github.com/softerhardware/Hermes-Lite2/tree/master/hardware/enclosure/endcaps/kf7o/hl2_55fb>>
>
> >
> >     This has:
> >
> >     ** Common library with single basic front and back
> component so
> >     that it is easy to create new end plates.
> >     ** End plate uses oval corner holes to handle variation in
> >     enclosures where some units have 96.5mm others 96mm hole
> spacing.
> >     ** Position of connector holes match exactly component
> position on
> >     HL2 PCB. This corrects some slight error I was seeing in the
> >     length dimension.
> >     ** Holes are slightly larger to handle build variations.
> >
> >     This first end plate is a combined end plate. It can be
> used for
> >     both the front and back of a 106mm X 150mm X 55mm
> enclosure. It is
> >     easy to convert this to a front or back only end plate by
> removing
> >     one of the basic components.
> >
> >     This end place also has a drill diagram for those who want to
> >     modify the end plates included with the enclosure to work
> with the
> >     HL2. Just print out the attached PDF, line up the corner
> holes
> >     with the corner targets (note the two variations, inner
> target for
> >     96mm spacing, outer target for 96.5mm spacing), then use a
> hole
> >     punch to make divets where all the holes should be
> drilled. Pick a
> >     drill bit that when laid on the paper matches the diameter
> of the
> >     printed hole. For the rectangular ethernet hole, drill the
> from
> >     small to large bits, and then file or clip the metal to
> make more
> >     rectangular. Please let me know how this goes if you try it.
> >
> >     I have asked makerfabs what the cost will be to include 2
> of the
> >     same universal end plates, or 2 different end plates. Once
> I hear
> >     from them, we can discuss what should be included in build9.
> >
> >     For my end plates, I am planning on the following additions:
> >
> >     ** Optional electronics for fan control. This is just a few
> >     surface mount components on the inside of the end plate. Some
> >     wires will have to be soldered directly to the end plate.
> The most
> >     inexpensive small fans are 40mm X 40mm. Unfortunately that
> size
> >     will not fit in a universal end plate so there will be
> some front
> >     or back only end plates. This will also include a fan mount
> >     component with ventilation holes. I don't think a fan is
> needed as
> >     my tests with the enclosed unit were fine even after 6
> minutes
> >     continuous transmit of WSPR. But a fan is still a nice option
> >     since maybe in very hot operation locations a fan can help.
> >
> >     ** Low profile end plates. I also like the low profile (40mm)
> >     AK-C-C69 enclosures listed on the wiki page and have three of
> >     them. Unfortunately a 40mm x 40mm can't be used if mounted
> to the

> >     end plate.Â
> >
> >     73,
> >
> >     Steve
> >     kf7o
> >      Â
> >
> >
> >

> > --
> > You received this message because you are subscribed to the Google
> > Groups "Hermes-Lite" group.
> > To unsubscribe from this group and stop receiving emails from
> it, send

> > an email to hermes-lite...@googlegroups.com
> <mailto:hermes-lite%2Bunsu...@googlegroups.com>
> > <mailto:hermes-lite...@googlegroups.com

> <mailto:hermes-lite%2Bunsu...@googlegroups.com>>.

> > To view this discussion on the web visit
> >
> https://groups.google.com/d/msgid/hermes-lite/bb76ccf3-ebf3-43e5-8f50-54793f755999%40googlegroups.com
> <https://groups.google.com/d/msgid/hermes-lite/bb76ccf3-ebf3-43e5-8f50-54793f755999%40googlegroups.com>
>
> >

> <https://groups.google.com/d/msgid/hermes-lite/bb76ccf3-ebf3-43e5-8f50-54793f755999%40googlegroups.com?utm_medium=email&utm_source=footer

> <https://groups.google.com/d/msgid/hermes-lite/bb76ccf3-ebf3-43e5-8f50-54793f755999%40googlegroups.com?utm_medium=email&utm_source=footer>>.
>
>
>
> -- Sid Boyce ... Hamradio License G3VBV, Licensed Private Pilot
> Emeritus IBM/Amdahl Mainframes and Sun/Fujitsu Servers Tech Support
> Senior Staff Specialist, Cricket Coach
> Microsoft Windows Free Zone - Linux used for all Computing Tasks
>

> -- You received this message because you are subscribed to the Google
> Groups "Hermes-Lite" group.
> To unsubscribe from this group and stop receiving emails from it, send

> an email to hermes-lite...@googlegroups.com
> <mailto:hermes-lite...@googlegroups.com>.

> To view this discussion on the web visit

> https://groups.google.com/d/msgid/hermes-lite/1d4c4fa5-c269-4975-860c-5087b7517ab5%40googlegroups.com
> <https://groups.google.com/d/msgid/hermes-lite/1d4c4fa5-c269-4975-860c-5087b7517ab5%40googlegroups.com?utm_medium=email&utm_source=footer>.

[Sid Boyce]

Hi Steve,

10 degs C increase with fan disconnected.

With the fan it starts at +28C from cold and stabilises at +41C with key
down for 5+ minutes (20m 4.x Watts), returning to a settled +30C after
10 minutes on RX.

Disconnecting the fan +5.1W out on 20m after a similar period
temperature reached +51C.

After 5 minutes cools down to +34C and stays at +34C 12 minutes back on RX.

73 ... Sid.

On 20/08/2019 16:40, Steve Haynal wrote:

> >  on Mouser or Digikey areÂ

> >
> >
> >
> > On Sunday, August 18, 2019 at 2:24:39 PM UTC-7, Steve Haynal wrote:
> >

> >     Hi Group,
> >
> >     I have added another version of end plates to github:
> >     Â
> >   Â
> https://github.com/softerhardware/Hermes-Lite2/tree/master/hardware/enclosure/endcaps/kf7o/hl2_55fb
> <https://github.com/softerhardware/Hermes-Lite2/tree/master/hardware/enclosure/endcaps/kf7o/hl2_55fb>
>
> >   Â
> <https://github.com/softerhardware/Hermes-Lite2/tree/master/hardware/enclosure/endcaps/kf7o/hl2_55fb
> <https://github.com/softerhardware/Hermes-Lite2/tree/master/hardware/enclosure/endcaps/kf7o/hl2_55fb>>
>
> >
> >     This has:
> >
> >     ** Common library with single basic front and back
> component so
> >     that it is easy to create new end plates.
> >     ** End plate uses oval corner holes to handle variation in
> >     enclosures where some units have 96.5mm others 96mm hole
> spacing.
> >     ** Position of connector holes match exactly component
> position on

> >     HL2 PCB. This corrects some slight error I was seeing in the
> >     length dimension.

> >     ** Holes are slightly larger to handle build variations.
> >
> >     This first end plate is a combined end plate. It can be
> used for
> >     both the front and back of a 106mm X 150mm X 55mm
> enclosure. It is
> >     easy to convert this to a front or back only end plate by
> removing
> >     one of the basic components.
> >
> >     This end place also has a drill diagram for those who want to
> >     modify the end plates included with the enclosure to work
> with the
> >     HL2. Just print out the attached PDF, line up the corner
> holes
> >     with the corner targets (note the two variations, inner
> target for
> >     96mm spacing, outer target for 96.5mm spacing), then use a
> hole
> >     punch to make divets where all the holes should be
> drilled. Pick a
> >     drill bit that when laid on the paper matches the diameter
> of the
> >     printed hole. For the rectangular ethernet hole, drill the
> from
> >     small to large bits, and then file or clip the metal to
> make more
> >     rectangular. Please let me know how this goes if you try it.
> >
> >     I have asked makerfabs what the cost will be to include 2
> of the
> >     same universal end plates, or 2 different end plates. Once
> I hear
> >     from them, we can discuss what should be included in build9.
> >
> >     For my end plates, I am planning on the following additions:
> >
> >     ** Optional electronics for fan control. This is just a few
> >     surface mount components on the inside of the end plate. Some
> >     wires will have to be soldered directly to the end plate.
> The most
> >     inexpensive small fans are 40mm X 40mm. Unfortunately that
> size
> >     will not fit in a universal end plate so there will be
> some front
> >     or back only end plates. This will also include a fan mount
> >     component with ventilation holes. I don't think a fan is
> needed as
> >     my tests with the enclosed unit were fine even after 6
> minutes
> >     continuous transmit of WSPR. But a fan is still a nice option
> >     since maybe in very hot operation locations a fan can help.
> >
> >     ** Low profile end plates. I also like the low profile (40mm)
> >     AK-C-C69 enclosures listed on the wiki page and have three of
> >     them. Unfortunately a 40mm x 40mm can't be used if mounted
> to the

> >     end plate.Â
> >
> >     73,
> >
> >     Steve
> >     kf7o
> >      Â
> >
> >
> >

> > --
> > You received this message because you are subscribed to the Google
> > Groups "Hermes-Lite" group.
> > To unsubscribe from this group and stop receiving emails from
> it, send

> > an email to hermes-lite...@googlegroups.com
> <mailto:hermes-lite%2Bunsu...@googlegroups.com>
> > <mailto:hermes-lite...@googlegroups.com

> <mailto:hermes-lite%2Bunsu...@googlegroups.com>>.

> > To view this discussion on the web visit
> >
> https://groups.google.com/d/msgid/hermes-lite/bb76ccf3-ebf3-43e5-8f50-54793f755999%40googlegroups.com
> <https://groups.google.com/d/msgid/hermes-lite/bb76ccf3-ebf3-43e5-8f50-54793f755999%40googlegroups.com>
>
> >

> <https://groups.google.com/d/msgid/hermes-lite/bb76ccf3-ebf3-43e5-8f50-54793f755999%40googlegroups.com?utm_medium=email&utm_source=footer

> <https://groups.google.com/d/msgid/hermes-lite/bb76ccf3-ebf3-43e5-8f50-54793f755999%40googlegroups.com?utm_medium=email&utm_source=footer>>.
>
>
>
> -- Sid Boyce ... Hamradio License G3VBV, Licensed Private Pilot
> Emeritus IBM/Amdahl Mainframes and Sun/Fujitsu Servers Tech Support
> Senior Staff Specialist, Cricket Coach
> Microsoft Windows Free Zone - Linux used for all Computing Tasks
>

> -- You received this message because you are subscribed to the Google
> Groups "Hermes-Lite" group.
> To unsubscribe from this group and stop receiving emails from it, send

> an email to hermes-lite...@googlegroups.com
> <mailto:hermes-lite...@googlegroups.com>.

> To view this discussion on the web visit

> https://groups.google.com/d/msgid/hermes-lite/1d4c4fa5-c269-4975-860c-5087b7517ab5%40googlegroups.com
> <https://groups.google.com/d/msgid/hermes-lite/1d4c4fa5-c269-4975-860c-5087b7517ab5%40googlegroups.com?utm_medium=email&utm_source=footer>.

[Christopher KB3CS]

a couple of sneaky "REF**"s crept into the endcap in the repo.

i cleaned those up.

may i propose some changes to the labelling?

 - 0x49 -

On Sunday, August 18, 2019 at 5:24:39 PM UTC-4, Steve Haynal wrote:

Hi Group,

I have added another version of end plates to github:

 https://github.com/softerhardware/Hermes-Lite2/tree/master/hardware/enclosure/endcaps/kf7o/hl2_55fb

This has:

** Common library with single basic front and back component so that it is easy to create new end plates.

** End plate uses oval corner holes to handle variation in enclosures where some units have 96.5mm others 96mm hole spacing.

** Position of connector holes match exactly component position on HL2 PCB. This corrects some slight error I was seeing in the length dimension.

** Holes are slightly larger to handle build variations.

This first end plate is a combined end plate. It can be used for both the front and back of a 106mm X 150mm X 55mm enclosure. It is easy to convert this to a front or back only end plate by removing one of the basic components.

[...]

[Steve Haynal]

Hi Chris,

Fortunately, the REF**s don't show up on the gerber output. Take a look at the LED description on the wiki:

https://github.com/softerhardware/Hermes-Lite2/wiki/LEDs

The DHCP and ADC CLK is not clear to me. I debated putting both modes on the silkscreen but thought just the run mode would be clearer. I am open to better labels. Any other ideas out there?

73,

Steve

kf7o

[Steve Haynal]

Hi Sid,

Thanks for the data. I have added a place for an optional fan on the back panel.

73,

Steve

kf7o

> > an email to hermes-lite+unsubscribe@googlegroups.com
> <mailto:hermes-lite%2Bunsu...@googlegroups.com>
> > <mailto:hermes-lite+unsub...@googlegroups.com

> <mailto:hermes-lite%2Bunsu...@googlegroups.com>>.
> > To view this discussion on the web visit
> >
> https://groups.google.com/d/msgid/hermes-lite/bb76ccf3-ebf3-43e5-8f50-54793f755999%40googlegroups.com
> <https://groups.google.com/d/msgid/hermes-lite/bb76ccf3-ebf3-43e5-8f50-54793f755999%40googlegroups.com>
>
> >
> <https://groups.google.com/d/msgid/hermes-lite/bb76ccf3-ebf3-43e5-8f50-54793f755999%40googlegroups.com?utm_medium=email&utm_source=footer
> <https://groups.google.com/d/msgid/hermes-lite/bb76ccf3-ebf3-43e5-8f50-54793f755999%40googlegroups.com?utm_medium=email&utm_source=footer>>.
>
>
>
> -- Sid Boyce ... Hamradio License G3VBV, Licensed Private Pilot
> Emeritus IBM/Amdahl Mainframes and Sun/Fujitsu Servers Tech Support
> Senior Staff Specialist, Cricket Coach
> Microsoft Windows Free Zone - Linux used for all Computing Tasks
>
> -- You received this message because you are subscribed to the Google
> Groups "Hermes-Lite" group.
> To unsubscribe from this group and stop receiving emails from it, send

> an email to hermes-lite+unsubscribe@googlegroups.com
> <mailto:hermes-lite+unsub...@googlegroups.com>.

[Steve Haynal]

Hi Amogh,

It would be interesting to see if that heatsink works and also how well. I opted for an optional fan on the back panel. It doesn't need to be used and can be considered ventilation holes if not used. There is no requirement to drill holes.

73,

Steve

kf7o

[rentwist]

Hi Steve,

Think you have seen this already but here is what I came up with for labels on my CNC endplates:

73,

Robert, WA2T

[Christopher KB3CS]

okay!  i wanted first to demonstrate i could extract part of the git repo (both endcaplib and hl2_55fb directories) and examine the endcap design in KiCad. took the path of least resistance in running the 3D rendering and using the provided snapshot facility to visualize the design. labels were done from my faulty memory instead of reference first to the complete LED indicator documentation.

i believe there are more than 8 items and in fact at least 10 items in the LED status indication matrix. hmm.
each item is important in its own way, of course. should one be able to interpret the indicators at every phase of operation? i think so, yes.

i intend to try out some designs over the weekend and post another rendering.

  - 1 (base 73) -

On Saturday, August 24, 2019 at 12:28:09 AM UTC-4, Steve Haynal wrote:

Hi Chris,

Fortunately, the REF**s don't show up on the gerber output. Take a look at the LED description on the wiki:

https://github.com/softerhardware/Hermes-Lite2/wiki/LEDs

The DHCP and ADC CLK is not clear to me. I debated putting both modes on the silkscreen but thought just the run mode would be clearer. I am open to better labels. Any other ideas out there?

73,

Steve

kf7o

[...]

[Sid Boyce]

Hi Steve,
Another fan option is a tangential blower like
https://www.ebay.co.uk/itm/1pcs-5015S-5V-0-1-0-3A-Black-Brushless-DC-Cooling-Blower-Fan-50x15mm/312708984589?hash=item48cee86f0d:g:SUMAAOSwjT5dNeh0
mounted on the top cover with an exhaust cut out on the side -- draws up
air from the board and exhausts it through the side vent.

It's more work to make side the cut out but I've done this for the HL2
Btea5, the fan sitting over the FPGA/AD9866.
The example pictures show a similar arrangement for the LimeSDR.
73 ... Sid.

On 17/08/2019 21:35, Steve Haynal wrote:
> Hi Roger and Group,
>
> Below is a picture of the latest end plate PCB Roger sent me. It fits
> pretty well. I like the vertical orientation. I am thinking about
> having end plate PCBs included with build9. Here is what I am considering:
>
> ** Add fan option and any fan control logic on inside of front panel.
> We can have traces and components on the inside of these panels as
> they are PCBs. This is kind of neat for people who want to make small
> enhancements to the HL2. I would probably borrow JI1UDD fan setup as
> it is controlled with just one output. I didn't find the schematic or
> BOM for this on JI1UDD's links. Can someone point me to any schematic
> and BOM?
>
> ** Enlarge holes slightly to handle more build/assembly variation.
>
> ** May only include front panel to reduce costs. There are only 3
> holes in the back panel. I am thinking we can provide a drill template
> for the back panel. People would print this out and drill the three
> holes. A panel is included whenever you purchase an enclosure. It fits
> well and is sturdy. What do people think?
>
> 73,
>
> Steve
> kf7o
>

> hl2frontpanel.jpg
>
>
>
> On Tuesday, July 30, 2019 at 1:45:29 PM UTC-7, Roger Critchlow wrote:
>
> Steve --
>

> The black does look very amateur, which is to say professional. 

> I have a set of horizontal red endplates arriving today, too.
>

> The rewind kit arrived yesterday, too.  Thanks, added to my to do

> list.
>
> -- rec -- ad5dz --
>
> On Mon, Jul 29, 2019 at 10:55 PM Steve Haynal
> <softerh...@gmail.com <mailto:softerh...@gmail.com>> wrote:
>
> Hi Roger,
>
> I like the black color. I received the two samples you sent
> today. I look forward to trying them out.
>
> 73,
>
> Steve
> kf7o
>
>
> On Monday, July 29, 2019 at 4:35:09 PM UTC-7, Roger Critchlow
> wrote:
>

> Probationary was the right idea. The latest attempt
> arrived this afternoon. Â
>
> The mounting holes are still not right.  I think that my

> manual enlargening to make the width work hid the fact

> that the height was a little off, too.  And perhaps

> making the holes plated through stole a bit of diameter,

> too.  Then the SMA connectors on the back ended up a
> little snugger than the last. Nothing that a little more

> manual enlargening doesn't fix, but nearly crossthreaded a

> few mounting screws.  And for my final trick, I laid out

> the labels on the back panel upside down.
>
> So, back to kicad and hope third time's a charm.
>
> -- rec -- ad5dz --
>
> On Tue, Jul 23, 2019 at 6:13 PM Roger Critchlow
> <r...@elf.org <mailto:r...@elf.org>> wrote:
>
> I've updated the PCB endcap designs, uploaded the
> files into the HermesLite2 repo at github,
> andsubmitted another order to jlcpcb.com

> <http://jlcpcb.com> to validate the design. Â
>
> The files are found atÂ
> https://github.com/softerhardware/Hermes-Lite2/tree/master/hardware/enclosure/endcaps/ad5dz
> <https://github.com/softerhardware/Hermes-Lite2/tree/master/hardware/enclosure/endcaps/ad5dz>. Â

> There is a Readme.org file in that directory which

> github formats and displays below the directory listing.Â

>
> I will consider this round of design probationary
> until I've fastened a set of endcaps onto my Hermes

> Lite, but I'm pretty sure they're going to work.Â

> (Famous last words.)
>
> -- rec -- ad5dz --
>

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[Steve Haynal]

Hi Robert,

Very nice. I do remember seeing this before. Would you be willing to send me your CNC files to post on github? We do not have any files for CNC. I would add them here:

https://github.com/softerhardware/Hermes-Lite2/tree/master/hardware/enclosure/endcaps

73,

Steve

kf7o

[Steve Haynal]

Hi Group,

I have posted beta versions of the 55mm front and back end plates. I'd appreciate review and feedback.

The front panel includes optional electronics on the inside for a PWM audio output. This is for an optional CW sine sidetone to a cheap cell phone speaker. The schematic is untested. I'd appreciate review. The schematic is at:

https://github.com/softerhardware/Hermes-Lite2/raw/master/hardware/enclosure/endcaps/kf7o/hl2_55f/endcap.pdf

The labeling has been updated. The design includes two layers, one for horizontal and another for vertical labeling. Please let me know which orientation you prefer. Templates that show the labeling are below.

https://github.com/softerhardware/Hermes-Lite2/raw/master/hardware/enclosure/endcaps/kf7o/hl2_55f/gerber/endcap_h.pdf

https://github.com/softerhardware/Hermes-Lite2/raw/master/hardware/enclosure/endcaps/kf7o/hl2_55f/gerber/endcap_v.pdf

The front panel includes two additional holes for CL1 and CL2. These are system clock 1 and 2 and are used to synchronize multiple radios. Build9 will start including these connectors. Build5 through build8 users can add SMA connectors here, but should use circular SMA connectors such as part number CONSMA003.062. Also, older builds may need to drill these two holes slightly larger for the round base of these SMA connectors to fit through. There is room and no silkscreen should be destroyed. It is easy to drill PCB. Build9 has the SMA connectors inset so the larger holes are not needed. See the attached 3D view. The 3D view is green but black will be fabricated.

The front panel now includes ventilation holes. There are 3 groups. 1 group can optionally be used for the cell phone speaker which must be glued to the inside of the panel. See the attached 3D view.

The front panel now includes a cut out on the left side when oriented vertically. Small wire clippers can be used to cut this out. The purpose is to allow ribbon cable or other wires to connect to DB12. These are used to daisy chain several synchronized HL2s together.

The back panel includes optional electronics for fan control. This circuit is borrowed from the JI1UIDD/VU2ZAZ companion board. I have not tested it. Review is appreciated. The schematic is:

https://github.com/softerhardware/Hermes-Lite2/raw/master/hardware/enclosure/endcaps/kf7o/hl2_55b/endcap.pdf

See the 3D view below for the fan mounting location. This supports commonly available 40mmX40mmX10mm 12V fans.

The labeling has been updated. The design includes two layers, one for horizontal and another for vertical labeling. Please let me know which orientation you prefer. Templates that show the labeling are below.

https://github.com/softerhardware/Hermes-Lite2/raw/master/hardware/enclosure/endcaps/kf7o/hl2_55b/gerber/endcap_h.pdf

https://github.com/softerhardware/Hermes-Lite2/raw/master/hardware/enclosure/endcaps/kf7o/hl2_55b/gerber/endcap_v.pdf

I plan to request 20-50 extra copies of these panels from Makerfabs. I will sell this on Tindie for pretty much shipping. This is so build5-build8 have easy access to panels. 

These panels are designed to easily convert to 40mm high. I will add 4mm versions soon.

Best Regards,

Steve Haynal

[rentwist]

Hi Steve,

I will upload the files soon.

73,

Robert, WA2T

[Amogh Desai]

Hi Steve,

I tested the before mentioned heatsink today.

Before installing the heatsink, I tried transmitting into a dipole on 14Mhz. At start the temp on SparkSdr was 30 DegC at room temp of 24 DegC. With key down and 6 watts showing on a Diamond dx-200, the temperature  gradually reached to 50 DegC in just about 1.5 minutes and some distortion started showing around the signal in Sparksdr spectrum display.  The distortion products were getting thicker with each degree temperature increase.  I stopped at around 53 DegC as I don't have much test equipment for digging it further.

I then installed the heatsink with some rubber padding between the FETs. It just needed some filing and it sits flush with a very good contact with the case:

Before filing:

After Filing:

And the results are really good. It took almost 5 minutes full key down for reaching 50 DegC.  The distortion I was talking about started showing up at around 51 DegC as below:

Regards,  

Amogh

VU3DES

[Sid Boyce]

Hi Steve,
Another fan option is a tangential blower like
https://www.ebay.co.uk/itm/1pcs-5015S-5V-0-1-0-3A-Black-Brushless-DC-Cooling-Blower-Fan-50x15mm/312708984589?hash=item48cee86f0d:g:SUMAAOSwjT5dNeh0
mounted on the top cover with an exhaust cut out on the side -- draws up
air from the board and exhausts it through the side vent.

It's more work to make side the cut out but I've done this for the HL2
Btea5, the fan sitting over the FPGA/AD9866.

The example pictures show a similar arrangement for the LimeSDR.

I just thought --- cutting the hole in the end plate  is far easier than
cutting the enclosure.

[Christopher KB3CS]

stayed up late to work on the endcaps, eh?  :-D

starting with this new revision, i've made what might be suitable improvements.  vertically oriented front endcap only (for now). see photo.

On Sunday, August 25, 2019 at 1:48:35 AM UTC-4, Steve Haynal wrote:

Hi Group,

I have posted beta versions of the 55mm front and back end plates. I'd appreciate review and feedback.

[...]

[Bob A. Booey]

Two comments:

Shouldn't "11-18V" be "11-16V"?

"Run" should not be italicized.

73,

Robert, WA2T

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[Steve Haynal]

Hi Amogh,

Thanks for the data. Do you have any thermal compound between the rail and slot? Is the enclosure's slot slightly sanded to remove any coating and improve heat transfer? I see slower heating without heatsink than you, so just checking.

The distortion products are something new. I will have to check if I see them too.

73,

Steve

kf7o

[Steve Haynal]

Hi Chris,

Run is a historic term from openhpsdr. I prefer it over CON. Also, that LED is a CLK rather than PHY in my opinion when in IDLE mode. I think the italics and text size are enough to distinguish between the two modes.

73,

Steve

kf7o

[Steve Haynal]

Hi Robert,

Thanks. I've updated the files to be 11-16V. 

73,

Steve

kf7o

On Sunday, August 25, 2019 at 5:04:39 PM UTC-7, Bob A. Booey wrote:

Two comments:

Shouldn't "11-18V" be "11-16V"?

"Run" should not be italicized.

73,

Robert, WA2T

On 8/25/2019 7:32 PM, Christopher KB3CS wrote:

stayed up late to work on the endcaps, eh?  :-D

starting with this new revision, i've made what might be suitable improvements.  vertically oriented front endcap only (for now). see photo.

On Sunday, August 25, 2019 at 1:48:35 AM UTC-4, Steve Haynal wrote:

Hi Group,

I have posted beta versions of the 55mm front and back end plates. I'd appreciate review and feedback.

[...]

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[Amogh Desai]

Hi Steve,

No, I haven't used any thermal compound as it wasn't possible to apply it. HL2 PCB  alone slides in the case freely, but after adding the heatink, had to push it with little force and couldn't apply any compound due to this sliding part.  It's not very tight but makes a good contact. Have used thermal pads between the heatsink just to avoid any shorting with components around the FETs.  Also, my setup doesn't have any heatsinks for AD9866 or FPGA yet.

My Aluminium Case is not anodised so thought I dont need to sand it, but you can correct me on this. 

-

Regards, 
Amogh
VU3DES

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[dick_...@hotmail.com]

Steve

I would prefer the horizontal configuration but I could live with the vertical.

Do you plan to order some of each or just the vertical for build 9

Dick K9IVB

[gerry kavanagh]

Looks great Steve. I note there are no drill files in the repository... are they not required?

/ Gery

[Christopher KB3CS]

i hear you. the LED documentation refers to two major modes: Run and Idle. 

in Run mode, the steady light indicates a connection made to a controller.

so, following the documentation over precedent, this leads to a specific place in the matrix of indications called 'connected'.

it seems redundant to have the indication named 'Run' in the major mode 'Run' column.

i suggested PHY over CLK because it is not clear which clock is referenced by the name. 

there appears to be three indicators related to clocks in Idle mode. 

i suppose ETH or NET may be more specific and acceptable.

  - 1u (base 43) -

On Monday, August 26, 2019 at 1:00:02 AM UTC-4, Steve Haynal wrote:

Hi Chris,

Run is a historic term from openhpsdr. I prefer it over CON. Also, that LED is a CLK rather than PHY in my opinion when in IDLE mode. I think the italics and text size are enough to distinguish between the two modes.

73,

Steve

kf7o

[...] 

[rentwist]

Taka-san, Steve and group,

At the risk of being off topic (which this is, sorry), RX latency is nearly imperceptable when comparing the HL2 with Taka-san's companion board and/or PiHPSDR on Rock64Pro with a more traditional TRX (Elecraft KX3 in my case).  I would estimate the latency (without measuring it) in the few tenths of seconds range.  This should not be a problem for all but the very fastest QRQ operators working QSK (which is not the way QRQ CW is typically operated).

73,

Robert, WA2T

On Tuesday, August 20, 2019 at 5:57:40 PM UTC-4, Takashi K wrote:

Hi Robert-san,

> I cannot speak to the codec latency for RX audio, perhaps Taka-san will chime in.

Steve is right. Rx audio latency exists.

It's not serious for me. It might be effect that my HL2 is connected to RPi2 directly.

I recommend to check wether the latency is acceptable or not by yourself.

73,

Taka,  ji1udd

[Steve Haynal]

Hi Group,

I've released the end plates. This includes both horizontal and vertical text orientation. This includes variations for 40 and 55 mm height enclosures. Drill files are included as .TXT. 

https://github.com/softerhardware/Hermes-Lite2/tree/master/hardware/enclosure/endcaps/kf7o/releases/20190901

The KiCAD source files are on github if you wish to make any changes

https://github.com/softerhardware/Hermes-Lite2/tree/master/hardware/enclosure/endcaps/kf7o/

These end plates have yet to be fabricated, but have been verified with print outs. The *.zip files are ready to be sent to a PCB maker. You can find PCB makers at pcbshopper.com

73,

Steve

kf7o

On Saturday, August 24, 2019 at 10:48:35 PM UTC-7, Steve Haynal wrote:

[Christopher KB3CS]

looking at kf7o/releases/20190901/

the 55mm endplates say "11-18V" when they should say "11-16V", right?  the 40mm endplates say "11-16V".

  - 2f (base 29) -

On Sunday, September 1, 2019 at 4:13:52 PM UTC-4, Steve Haynal wrote:

Hi Group,

I've released the end plates. This includes both horizontal and vertical text orientation. This includes variations for 40 and 55 mm height enclosures. Drill files are included as .TXT. 

https://github.com/softerhardware/Hermes-Lite2/tree/master/hardware/enclosure/endcaps/kf7o/releases/20190901

The KiCAD source files are on github if you wish to make any changes

https://github.com/softerhardware/Hermes-Lite2/tree/master/hardware/enclosure/endcaps/kf7o/

These end plates have yet to be fabricated, but have been verified with print outs. The *.zip files are ready to be sent to a PCB maker. You can find PCB makers at pcbshopper.com

73,

Steve

kf7o

[...]

[Graeme Jury]

The 40mm end plates are smaller and can only take 16V :-)

73 de Graeme ZL2APV

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[Steve Haynal]

Hi Chris,

Thanks for the check. I think only the .pdf templates had the old lettering. The gerber files were correct. I regenerated the 2 .pdf template files for the 55mm front.

73,

Steve

kf7o

[gerry kavanagh]

Thanks for all thw work on this Steve. I have ordered a batch of 55mm Horizontal text in matte black. Should look good.

I will likely have spares if anyone is interested.

/ Gerry

[Steve Haynal]

Hi Group,

I received a test batch of the end plates today. I'm really happy with them. Below are a few pictures. Since this was a build8 without CL1 and CL2 inset, I had to drill the holes slightly larger. I drilled from front to back and that turned out not to be best. If you drill, do it back to front and it should be neater with less burrs on the front. On the back of the 40mm height unit, I needed to drill the holes larger as this one used an older N2ADR board without inset SMA connectors. Here I drilled back to front and it is a bit neater. No drilling is necessary for build9 units which will ship with the 55mm vertical oriented end plates. One picture below shows where electrical components can be installed for an optional and experimental simple CW sidetone from PWM. 

All the end plates are available for 55mm and 40mm enclosures, vertical or horizontal lettering for either. See this link:  
https://groups.google.com/d/msg/hermes-lite/k7rjvgeqTuE/8k_nYNLpAwAJ

I will eventually sell some end plates on Tindie for the price of the end plates plus shipping.

73,

Steve

kf7o

[gerry kavanagh]

Very neat!

[Jim Ancona]

They look great Steve! I'm looking forward to ordering a set when they're available.

Jim

N1ADJ

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[Brian Machesney]

I have the end plates Steve sent to me for distribution.

All of the 55mm end plates are gone.

I have six (6) pairs of 40mm end plates available.

Please use the "Reply privately to author" facility and I will send you the payment details.

73 -- Brian K1LI

[bagmouse7]

Please sign me up for a set and send me the details.

Thanks!

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[Chris Moore]

Hi Steve -

I'd like to get a set of the 40mm plates made - in addition to sending the gerber files to a fab shop, wondering how I specify the material as per the 55mm plates that came with the build 9 units?

Cheers - Chris AG5RR

[Steve Haynal]

Hi Chris,

The build 9 end plates are 0.8mm thick versus the standard 1.6mm. They are 2 layer with black finish. You may want to wait a few days to order as I am getting ready to make a new end plate release.

73,

Steve

kf7o