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17, 19 & 20 April 2007 - Lattice Crystal Filter

One of the areas I wish to modify in any new panadapter design is the crystal filter. The four crystal Gaussian ladder design in the Z90 performs well, but widening the 1 KHz bandpass results in an asymmetrical stopband, as the holder capacitance distorts the response.

There are several approaches to restoring a symmetrical passband. One I've tried with some success is that suggested in Experimental Methods in RF Design by Wes Hayward W7ZOI, et al., canceling the holder capacitance by parallel inductance. The inductance is selected to be resonant with the crystal holder capacitance at the filter center frequency. Since holder capacitance is commonly in the 3 - 5 pF range, the resulting inductance value is often impractical, as the self-resonant frequency of the required inductor is generally below the crystal filter center frequency. The solution to this is to add padding capacitors across the crystals to bring the inductance down to practical values. And, to achieve resonance, either the paralleled inductors must be adjustable or the padding capacitance must include trimmers. Then, each individual LC "neutralizing" networks must be sequentially tuned by shorting out the other networks.

This approach works, but requires a lot of work and, preferably, reasonably sophisticated test equipment, to align. And, the resulting filter is much more complicated, which adds cost.

An alternative approach to a wideband filter is a lattice design, as illustrated below.
 

L1, L2 and L3 are a transformer, given separate identifiers for the purpose of SPICE analysis.

This circuit should cause you to think that you've seen it before, but in a different context. Perhaps redrawn it will look more familiar.

Yes, this is a classic Wheatstone bridge. If the transformer secondary is balanced (voltage and stray capacitance) and if X1 and X2 are identical, the voltage at point B equals the voltage at Point A, i.e., zero.

(I'm not going to use mathematical analysis in this discussion, substituting hand waving, computer simulation and measured results.)

A crystal filter that always gives zero output is not terribly useful, but suppose X1 and X2 are not exactly equal. Suppose, in fact that they have different series resonant frequencies, perhaps two or three KHz different, but are otherwise the same. Assuming the crystals have the same physical holder style, and since the resonant frequencies are so close, the holder capacitance will be essentially identical. At frequencies significantly away from resonance, the response of this circuit should be close to zero, as once we move away from X1 and X2's resonance points, they look similar. Thus the bridge is in balance and point B's voltage equals point A's voltage, and there is no output. Thus, the holder capacitance is effectively cancelled.

As we approach the resonance frequencies, the impedances are no longer equal and the bridge becomes unbalanced and hence an output voltage is developed at point B, proportional to the unbalance. This is exactly how a bandpass filter behaves—maximum output at the center frequency and reduced output outside the passband. 

Andy, G4OEP and M0AYF have done some work with simplified lattice filters that may be seen at http://g4oep.atspace.com/sfxf/sfxf.htm. and http://www.qrss.thersgb.net/QRSS-Band-Pass-Filters.html. Building on their work, I simulated and then built a two-crystal 8 MHz lattice filter.  For information on lattice crystal filter design beyond those two sites, you may with to consult the standard reference on passive filters, Zverev's Handbook of Filter Synthesis. (If you do not already own this book, ask your library to obtain a copy on inter-library loan as the current list price is nearing $300.). Also, Kinsman's Crystal Filters: Design, Manufacture and Application is good on lattice filter design. It is also expensive, at $175 and should be obtained via inter-library loan.  (Zverev works out to about $0.50 per page, but Kinsman's book is closer to $1.00 per page.)

In July, 2007, Brad, AL4T, wrote to say that Zverev is now available in a lower cost paperback edition. Indeed, Amazon carries it for $58, which is only about twice what I paid for the hardbound edition in 1975. To repeat—this book belongs in your personal library if you are interested in filter design.  If you are not an engineer, don't be put off by all the equations. There are plenty of tables and discussions you can use to design filters without delving deeply into the mathematics. But, if you take the time and wade through the math, you will have an even better understanding of filter design.

Since the two crystals should be close in resonant frequency, but not exactly matched, I used an 8 MHz series resonant crystal and an 8 MHz 20 pF parallel resonant frequency crystal. Using an HP 87510A VNA,  I first measured the parameters of these crystals, taking a sample of 10 parallel resonant crystals and using data developed for 65 series resonant crystals when working on the Z90 filters. These are inexpensive crystals used for microprocessor clock oscillators.

 
Xtal Type C0 (pf) C1 (fF) L1 (mH) R1 (Ω) Fseries (KHz) Mouser PN Comments
8 MHz Series 3.83 18.59 21.30 14.0 8000.071 520-HCA800-SX Mean of 65 samples
8 MHz 20pF Parallel 3.8 18.641 21.336 14.33 7997.062 73-XT49U 800-20 Mean of 10 samples

The quick and dirty design is not much different than our initial design. The input transformer (L1, L2 and L3) is wound on a ferrite toroidal core, FT50-43, with a primary of 5 turns no. 30 AWG, and the secondary windings bifilar wound with 7 turns of no. 30 AWG,  twisted together before winding.  (Note the phasing dots - the secondary windings must be connected as shown.) The output transformer is 5 turns (50 ohm side) and 10 turns (crystal side) of no. 30 AWG on a FT50-43 core. The filter elements thus work at 200 ohm impedance level.

The capacitor identified as C3/Cx is a 5-30 pF trimmer. C5 is a 15 pF NP0 ceramic. The two crystals are identified as C1 and C2 because that's the way LTSpice models crystals. The input and output 50 ohm resistors represent the impedance of the test equipment used to measure the filter.

To simulate varying the trimmer capacitor C3, the SPICE model steps by 1 pF steps. As the results show below, the filter response is quite sensitive to the this value. As we expect from looking at this circuit as a Wheatstone bridge, when the trimmer is adjusted to match the capacitance across C2, the null will be maximum. This corresponds to the magenta trace in the simulation results below.

However, we note other changes, in that "wings" develop on the filter at certain capacitance settings, and the ultimate rejection varies considerably with the degree of circuit balance the trimmer is able to achieve.
 

 

I breadboarded the filter using one of the PCB holders I developed. These are discussed at my Prototyping page. I measured the filter's response using an HP87510A VNA.

 

 

Let's see how the filter performs.

50 KHz span, after adjusting the trimmer for best response without wings appearing. The response looks quite good. Bandwidth is about 3 KHz and the stopband asymmetry is not too bad. At ±25 KHz, the flanks are down about 40 dB.

 

 
100 KHz span, after adjusting the trimmer for maximum ultimate rejection, accepting the "wings." Ultimate rejection is about 40 dB and the notch depth approaches 70 dB. Some stopband asymmetry is seen, but it's not too bad. We also see some spurious response on the right hand flank.

So far, the filter looks good. However, we should look at the filter response over a wider range than just 100 KHz.

 

1 MHz span. Note the large number of spurious responses on the high side of the filter. The worst of the unwanted responses is only down about 20 dB from the desired bandpass.


Although the passband out to ± 100 KHz is acceptable, the spurious responses make this filter unusable for the intended purpose of an IF passband filter for a spectrum analyzer. There are too many spurious responses and the responses are just too strong.

All crystals exhibit spurious resonance modes, although some care in crystal production by shaping the blank edges (think increased cost) can reduce their number and intensity. However, spurious responses are not of significant concern for a microcontroller time base oscillator and hence they are not controlled.

One possible fix for at least the far outlying spurious responses would be to back up the crystal lattice with a high quality LC bandpass filter, perhaps 50 KHz wide. This is at the edge of achievable at 8 MHz with powdered iron toroidal inductors. Another fix would be to discard our inexpensive microprocessor crystals and purchase custom designed crystals, intended for crystal filter use. This would increase the filter cost many fold, of course, and would probably still exhibit spurious responses, just not as many as seen with the microprocessor crystals.

We also may ask why these spurious responses show up in the lattice filter but are not present in the Z90's Gaussian ladder filter, which uses the same crystals. As the plot below shows, the Z90's filter is free of spurious signals. (The plot is only 25 KHz span, as I don't have a wider data set at hand. However, the wider studies show similar spurious-free response.)

The answer resides in the filter topology. If we look out 100 or 200 KHz from resonance, where the spurious responses lie, the lattice filter resembles a bridge in balance. Its passband rejection relies upon the two crystals having identical responses, in this case the holder capacitance, plus the padding/trimmer caps. Unless both crystals have identical spurious responses--which is exceedingly unlikely--spurious responses in either crystal result in bridge unbalance and hence output. One might think of the lattice design as placing the spurious responses of the crystals in parallel, i.e., all spurious responses of both crystals appear in the output.

Consider, in contrast, the ladder filter used in the Z90, as presented below.

The crystals are effectively in series. Hence in order for a spurious response seriously compromise the filter, the spurious must be coincident in more than one crystal, which is unlikely as the spurious frequencies depend on more or less random effects in the crystal blank . Otherwise, the selectivity of the remaining three crystals damps out spurious responses of any single crystal. (When building an analog panadapter a few years  ago, I found that a three-crystal ladder had unacceptable spurious problems, as the attenuation of just two series crystals was not enough to control spurious levels. A four-crystal filter performs much better.)

 

Z90 1 KHz Gaussian Crystal filter (typical) amplitude and group delay response.

After looking at the spurious response in the simple lattice filter, I decided to try an 8 MHz bandpass filter to be used in series with the lattice filter. The bandpass filter would be narrow enough to knock down the worst of the crystal filter's spurious responses.

Using AADE Filter Design software, I designed a 50 KHz wide 4th order coupled resonator Butterworth bandpass filter, with the resulting schematic below. I assumed the inductors were wound with 12 turns on a T50-2 core, with a Q of 150. (The actual inductors I wound have measured Q at 7.9 MHz between 230 and 240.)


Although the resulting design has a decent appearance, note the insertion loss—26 dB at the design frequency. Ouch! This high insertion loss is due to inadequate inductor Q. If we rerun the filter design software with infinite resonator Q, the loss is, as expected, 0 dB. However, even an inductor Q of 500 results in 11.5 dB insertion loss. And, my parts box is fresh out of powdered iron cores that will yield a Q of 500 at 7.9 MHz. 

AADE Predicted response.

The as-built filter. Measured insertion loss is 26 dB, excellent agreement with the design software. The filter flank is lumpy, and would need investigation if this were a design to be used for any serious purpose. The flanks also do not show the expected attenuation versus frequency.

This data is taken with an HP8752B vector network analyzer.

The filter is built on a spare Z10010 bandpass filter board. The inductors are 12 turns no. 26 AWG magnet wire wound on T50-2 powdered iron cores.

The measured inductance value ranged from 0.90 μH to 0.865 μH at 7.9 MHz using an HP 4342A Q-meter. The measured Q values ran between 230 and 240.


The next step is to connect the two filters in series to see how much improvement there is in spurious crystal filter response.

I'll display the two measured responses side-by-side. Note that the data sweeps have different vertical reference (-70 dB versus -40 dB) and span values (500 KHz versus 1 MHz). The data is taken with an HP8752B vector network analyzer
.

Lattice crystal filter and 4 section  coupled resonator filter in series Crystal lattice filter only

 


The coupled resonator filter knocks down many of the spurious responses, but not all of them. And, with the 25 dB insertion loss of the coupled resonator filter, the net is a very lossy filter indeed.

It would, of course, be possible to build an LC filter with less insertion loss, even with T50-2 inductors. If we increase the filter bandwidth to, say, 200 KHz, we expect the insertion loss to be in the 3 or 4 dB range. Of course, increasing the coupled resonator filter bandwidth will allow more spurious signals from the crystal filter to leak through.

 

Andy, G4OEP, suggested that I might have used two crystals that were particularly spurious-laden in my filter. A thought I had was that the spurious level was increased due to overdrive, as the 8752B VNA default drive level is -10 dBm. I've looked at both possibilities.

First, reducing the drive level to first -22 dBm, and then -42 dBm shows no change in the spurious level. So much for the overdrive theory.

Checking Andy's theory required a bit more work.

First, I measured the spurious levels in an assortment of 8 MHz crystals of the types used in the experimental filter, and selected the two (one with 8 MHz series resonance and one with 8 MHz 20 pF parallel resonance) with the fewest visible spurious responses. To measure spurious responses, I inserted the crystals in a home made IEC 12.5 ohm Pi test fixture and swept the amplitude response from 7.5 to 8.5 MHz with an HP8752B vector network analyzer.
 

8 MHz series resonant crystal with my ID number 229. This crystal shows relatively few spurious responses, at least down to the -30 dB level.
 
8 MHz parallel resonant crystal with my ID number of 2. This crystal shows few spurious responses, at least down to the - 30 dB level.

I then removed the two original crystals from the filter and measured the lattice response with no crystals installed. This essentially measures the bridge balance, with the most important source of potential unbalance likely being the transformer. After bringing the bridge into balance, I found remarkably good balance, with about -80 dB loss.
 
Filter circuit with both crystals removed. Trimmer capacitor adjusted for minimum signal transmission.

I then installed the two selected crystals, no. 2 and no. 229, into the filter test bed. Here's the result. For convenience, I'll show both the original filter (which uses crystals no. 8 and 237, and the new version, side-by-side. (I did not adjust the balance capacitor after installing the crystals.)
 

 

Revised Filter with Crystals no. 229 and 2

 

Original Filter with Crystals no. 8 and 229

 


Clearly selecting crystals for minimum spurious helps. There are fewer spurious responses and those spurious responses found have lower amplitude. But, it's still unacceptable for the intended purpose as a panadapter IF filter.

What is needed is a pair of crystals optimized for low spurious levels, likely backed up by one or more LC filter stages on the input and output.

One further point is that we should remember that the Wheatstone bridge circuit was originally developed to magnify differences between the two bridge arms. Hence we should not be surprised that even small differences between the two arm crystals cause disproportionate increases in bridge output. (See simulation results below to see how much loss in rejection even a tiny difference in bridge legs causes.)

The last test I ran was to tweak the balance trimmer with crystals 229 and 2 installed. It was possible to achieve close to 80 dB balance, although this was difficult to maintain. Temperature changes would unbalance the bridge by 10 or 20 dB. It also required the fingers of a safe cracker to achieve 80 dB null, as the slightest tweak to the balance trimmer would shift the null by 10 dB or more. A better design would use a series capacitor to reduce the effective trimmer range to a few pF centered about the desired value, instead of relying upon the trimmer alone to provide all the balancing capacitance.
 

Filter Response with crystals selected for minimum spurious response


To obtain a feel for how sensitive the bridge is to differences between the two crystals, I ran a SPICE simulation with identical crystals in both legs, varying the balance capacitor by 0.1 pF steps from 1 pF below balance to 1 pF above balance. (At balance, the simulated output is not meaningful as it is a function of SPICE's rounding error in dealing with identical component values. It shows -330 dB for this circuit.)

 

SPICE simulation of bridge unbalance. 0.1 pF steps.

About 0.5% error in capacitance between the two bridge arms corresponds to about 6 dB difference in the worst case, as the bridge approaches balance.

If we look at the bridge sensitivity as we move even closer to perfect balance, we see a major output shift for tiny changes in one of the legs. The run below takes one leg from 17.8 pF to 18.2 pF in 0.02 pF steps, with 18 pF representing perfect balance. We see about 7 dB change for 0.02 pF shift in capacitance at the closest point to bridge balance.

 
SPICE simulation of bridge closer to balance. Steps are 0.02 pF.