HF High power combiner

By David Sudry 4X4WN

This article describes the construction, and provides the performance of a
two-way power combiner with 2KW power capability. Material cost is
about $25.
A detailed construction information with complete test data is provided.
The high power combiner is a part of a 1KW solid state amplifier being
built by the author.
The amplifier uses two EB104 kits purchased from CCI communications.
Each of the two modules delivers 500-600 watts. Each module uses 4
MRF150 FETs with 48V supply.
A 1000W PEP commercial combiner ( CCI ) purchased for the amplifier
showed 0.5db insertion loss. This means that 122W out of the amplifier
1000W output power will be dissipated in the combiner itself.
The main objective was to build a combiner with much lower insertion
loss and higher power capability.
Table 1 shows the effect of combiner insertion loss on the output power.
With 0.5db insertion loss 122W will be lost in the combiner.

Insertion loss db
0.05
0.1
0.2
0.3
0.4
0.5

Power loss at 1000W

12W
23W
47W
72W
96W
122W

Output power
988W
977W
953W
928W
904W
878W

Table 1: Output power vs. combiner insertion loss

The high power combiner developed shows insertion loss of 0.05 to 0.1
dB from 1.8MHz to 30MHz.

Combiner description:
An In-Phase combiner architecture is used (Ref.1). Input impedance is 50
ohms and output impedance is 25 ohms.
A Unun (Unbalanced to unbalanced) transformer transforms the combiner
25 ohms to the required 50 ohms (Ref. 3).
The combiner and the UNUN schematics are shown below.

Fig. 1 Basic In Phase combiner/divider.

Rin = RL = 50 ohms
Rout = RL/2 = 25 ohms
Rb = 2RL = 100 ohms

Figure 2 Combiner construction

Figure 2 shows the transmission line transformer core, the Teflon wires
that are inserted through the brass tubes, the100 ohm balancing resistor
and the 100pf terminating capacitor.
The transmission line transformer dimensions are 2.4x 11/4 x 5/8.

Fig 3 25 ohms to 50 ohms Unun transformer

Fig. 3 shows the Unun ( Unbalanced-to-Unbalanced transformer.

Terminals 3&6 form the 25 ohm input port, and the tap (A) forms the 50
ohms output port.

Combiner construction:
The combiner core was purchased from CCI. Ferrite material is 61, with
permeability of 125. Higher permeability will enhance performance at
1.8MHz.
This combiner core is built out of 4 cylindrical ferrites, two in series at
each port.
A brass tube is inserted inside the series ferrite pair. The brass tubes are
soldered to two small rectangular glass epoxy boards.
One board (At the near end) shorts both tubes and forms the output port.
Both brass tubes are soldered to the other board at the far end. There is no
connection between the tubes at this end.
The combiner core is mounted on a 4 by 5 PCB. Soldering pads on the
copper clad of this PCB are cut to form mounting pads for the combiner
core and the Unun.
A 31/2 long (8.8cm) AWG 16 Teflon insulated wire is inserted inside
each brass tube. The Teflon wires are crossed at the far end and soldered
to the brass tubes (On the main PCB). The wires length is identical, and
the construction is symmetrical.
The two rectangular boards are soldered to pads on the 4x5 PCB that
holds all the combiner parts together.
The assembled transformer core can be purchased from CCI. It contains
the ferrites, the brass tubes and the two terminating boards (cost is $12).
The wires at the near end are connected to PCB pads, the balancing 100
ohms resistor, made out of four parallel 390 ohm resistors can be
connected to these pads as well. These are the input ports.
The brass tubes are shorted at the near end by the terminating PCB (Part
of the combiner core) to form the output port.
This is a typical wideband RF transmission line transformer construction
(Ref 2).

Unun Construction:
The 25 to 50 ohms transformer uses a FT-240-61 toroid. This toroid has
2.4 outer diameter, permeability is 125.
The toroid core and the AWG 14 Thermaleze wire can be purchased from
Amidon Associates AB240-125 Balun Kit.
This kit is also available from Alltronics for $10.
Use 3M Scotch No 27 (Or equivalent) high temperature tape to cover the
bare ferrite core. The tape is available from Techni-Tools cost is $11.30
for a 66ft roll.
Six trifilar turns of #14 Thermaleze wire are evenly wounded on the
toroid.
The center winding (See Figure 2) is tapped 5 turns from terminal 3, to
provide 2:1 ratio. Terminal 4 is left unconnected.
Terminals 3 & 6 are connected together to form the 25 ohms port, and the
tap (A) is the 50 ohms port.
Assembly Technique:
1. Mount the transformer core on the 4x5 PCB. Mark rectangular areas
for the transformer core soldering (Size not critical). With a sharp
knife remove copper clad around these rectangular areas, use a hot
iron tip to peel off the copper clad strips.
The transformer core will be placed on the top of the 4x5 PCB and will
be soldered to the rectangular pads.
2. Insert the AWG18, Teflon insulated wire 31/2 long, to each brass
tube.
Cross the wires at the far end and solder to the rectangular pads.
The other wire edge will be connected to a PCB mounted connectors
(UHF, N) or to pads on the PCB.
Make sure wire length is identical, and routing is symmetrical.
3. Connect the four 390 ohms, 3W resistors in parallel between the input
ports, keep leads short.
4. Apply the high temperature tape around the bare torrid core.
Wound the toroid with six trifilar windings, connected as shown in

Fig.2
Keep windings tight and symmetric.
Mount the toroid on the 4x5 PCB. Add insulation between the toroid
bottom and the PCB.
Connect terminal 1 to ground, connect terminals 2 and 5 together.
Connect terminals 3& 6 to the transformer output ( 25 ohms ).
Connect the two 200pF capacitors in series from terminal 6 to ground.
Connect a PCB mounted connector (UHF, N) with a short lead to
the 5th turn from terminal 3.
The combiner can be mounted in any metal or plastic box with the
connectors mounted on the box.

Pictures:

Picture 1 Combiner top view

Four parallel 390 ohms, 3W, resistors provide a 12W, 100 ohms balancing resistor.

Picture 2 Combiner bottom view

The two Unelco 200pF 350V capacitors form a 100pF 700V capacitor

Combiner Performance Summary:

Frequency Insertion loss
Input ports
(MHz)
(dB)
Isolation (dB)
1.8
0.05
13
3.5
0.05
18
7.0
0.05
24
10.1
0.05
28
14.0
0.05
31
18.1
0.06
33
21.0
0.07
34
24.9
0.08
35
28.0
0.08
35
30.0
0.10
35
50.0
0.25
29

Port 1 VSWR

Port 2 VSWR

Output VSWR

1.67
1.32
1.14
1.08
1.03
1.01
1.02
1.05
1.06
1.07
1.22

1.67
1.32
1.14
1.08
1.04
1.01
1.02
1.04
1.06
1.07
1.22

1.13
1.09
1.08
1.08
1,08
1.08
1.09
1.10
1.11
1.12
1.34

Table 2: High power combiner performance summary

Performance review:
Combiner swept insertion loss, and port to port isolation are provided below:
Insertion loss is less than 0.1db from 160 to 10 meters (1.8-30 MHz). Only
mere 23W is dissipated in the combiner with 1000W input under good load
VSWR.
With varying antenna VSWR more power will be reflected and dissipated in
the combiner. Cores size can easily handle 200-400W of dissipated power.
Any solid state amplifier should be provided with VSWR protection, usually
reducing exciter power with output VSWR greater than 2:1, and bypassing the
amplifier with output VSWR greater than 3:1.
Worst case port to port isolation is 13db at 1.8 MHz. 18db isolation at 3.5MHz,
and excellent 24-35 dB from 7-30 MHz.

Combiner Parts list:

Item
Transformer core
16 AWG Teflon wire
Capacitor (2)
200pF, 350V
Resistors (4)
390 ohms, 3W
Toroid ( Amidon )
5x4 PCB
3M # 27 Tape

Vendor
CCI Comm.
(937) 426-8600
RF Parts
(800) 737-2787
RF Parts

P/N
RF2061-0

Cost ($)
11.95

TEF16

0.45/ft

J101-200

1.60

Digi-Key
(800) 344-4539
Alltronics
(408) 943-9773
Build your own
Technitool
(610) 941-2400

P-390W-ND

0.49

AB240-125

10.0

105AD027

11.30/roll

References:
1. Single Sideband System and circuits, By William E. Sabin & Edgar O.
Schoenike, McGraw Hill 1987.
2. Motorola AN749, Broadband Transformers and Power Combining
Techniques.
3. Transmission line transformers, by Jerry Sevick, ARRL.