CONSTRUCTION AND USE of BROADBAND TRANSFORMERS

Broadband transformers are not difficult to understand. They are commonplace

in today's amateur technology. Most broadband transformers are wound on ferrite
toroids or rods. Some are wound on powdered-iron cores, while others are formed
on pot or cup cores. We will confine our discussion to transformers that are
wound on ferrite toroids or balun cores (sometimes called "binocular" cores.
Basic information on toroids and how to wind them is available in the Oak
Hills Research application note No- T-IA. Therefore, I shall not repeat the
fundamental information about toroids in this note.

Basics of Broadband Transformers

A broadband RF transformer is designed to operate over a wide range of freq-

uencies with minimum XL or Xc occurring at one or more frequencies within
the design range of the transformer. This requires that we use high permeability
cores with relatively small windings for the MF and HF spectrum. As the operat-
ing frequency is increased the core becomes less and less evident to the circuit
Only the winding on the core is effective at the upper range of operation.
At the lower end of the frequency range the core is "seen" by the circuit,
and it enables the winding to exhibit the necessary inductance for the low-
frequency portion of the operating range. Most HF broadband transformers are
wound on ferrite cores that have a u . ( initial permeability or mu) of 125
or 850. The latter type is the most common for coverage from 1.8 to 30 MHz.
The 125 mu cores have the suffix "61" for Amidon or Fair-Rite products. No.
43 material has a mu of 850. No. 63 and 68 material is generally used for
VHF broadband transformers (mu = 40 and 20, respectively).

There are two kinds of broadband transformers. One is known as a "conventional"

type, which has separate primary and secondary windings, as do power and audio
transformers. The other type is called a "transmission-line" transformer.
It is believed that the latter variety is the most efficient of the two. In
any event, all transformers must have some loss, however small. W2FMI has
developed broadband transformers that have efficiencies in the high 90% range.
This is discussed in his ARRL book, Transmission Line Transformers. I recommend
this book to those who want to learn more about broadband-transformer design
and application.

Transmission-line transformers are wound with twisted or parallel windings

and produce specific integers of impedance transformation, such as 4:1, 9:I
and 16:I. Conventional transformers permit you to obtain any transformation
ratio you need. The windings on a transmission-line transformer exhibit a
characteristic impedance of roughly 2 5 ohms. Some designers use teflon insulated
miniature 25-ohm coaxial cable for the windings. Parallel-wire windings are
laid on the core with the wires for a given turn adjacent to one another.
Twisted-wire windings generally contain 6 to 8 twists per inch.
2 broadband

A bifilar winding has two parallel wires that are wound on the core at the
same time. A trifilar winding has three such wires, and a quadrifilar winding
has four wires. Fig. 1 illustrates in schematic form how a conventional and
transmission-line transformer compare.

2 C}"~ L---0 4 HI-Z LO-Z

CONVENTIONAL TRANSMISSION
LINE

Fig. 1 -- A conventional broadband transformer is shown at the left.

The example at the right illustrates a bifilar-wound transmission-line
transformer. The pictorial drawings show how the windings relate to
the schematic diagrams. The large black dots near leads 1 and 2 of the
transmission-line transformer indicate the polarity or phase of the
windings.

Determining - the - Minimum - Number - of - Turns

Once we know the required impedance transformation ratio for our circuit we
can calculate the turns or voltage r atio of the transformer. The turns ratio
is the square root of the impedance ratio. Thus, for a 4:1 Z ratio we have
a 2:1 turns ratio. For example, we might have 10 turns of wire for the hi-
Z winding, and 5 turns of wire for the low-Z winding. This 2:1 turns ratio
equates to a 4:1 Z ratio.

The question now arises concerning the required inductance of the transformer
windings. Most industrial designers follow a rule that dictates the XL (induct-
ive reactance) of the smallest winding must be X4 or greater the load impedance
of the winding. Therefore, if the smaller winding looks into a 50-ohm load,
the XL of that winding must be 200 ohms or greater. I use the X4 rule for
all of my design work. The inductance of the winding may now be found from
L(uH) = XL/(6.28 X f(MHz). We can now look up the A L for the toroid core we
plan to use and learn how many turns are needed to obtain the required induct-
ance. Once we learn the number of turns for the small winding we will be able
to wind the larger winding in accordance with the already determined turns
ratio.

If there is too little inductance in the transformer winding we will experience

losses and SWR problems because of the to-Z transformer winding placing a
low value XL in parallel with the resistive load.
 broadband

Transformers on Balun Cores

Many designers prefer to use balun or binocular cores for broadband transform-
ers that must accomodate RF power For the most part, these transformers are
of the conventional type shown in Fig. 1. Balun cores are made from ferrite.
The permeability of the core material i s 850 to 900 for applications from
1 . 8 to 30 MHz.

You may create your own balun cores by using two rows of ferrite toroids,
side by side. For example, you want to build a 50-W broadband RF amplifier.
You can use two rows of 6 each FT-50-43 ferrite toroids. The cores are glued
together by means of quick-setting epoxy cement to form two separate tubes
of toroids. When the glue has dried, cement the two rows together (side by
side) with epoxy. This results in a binocular type of core assembly. Additional
toroids can be added to the two rows if higher power is anticipated. Fig.
2 shows an example of a one-piece balun core and one that has been fashioned
from two rows of toroids.

( ferrite) are formed by gluing the toroids to

vs of cores are then glued together, side by s
an at the right. It can be an Amidon Associates BN-43-7501 or
unit. The low-Z winding is generally a single, U-shaped turn
.. The larger winding has as many turns as are needed to provide

The transformers in Fig. 2 are configured for unbalanced circuits. If a push-

pull amplifier is used, merely place a center tap on the U-shaped, one-turn
winding. Locate it at the center of the U bend of the winding, as shown above.
The 1-turn primary winding should be made from heavy-gauge wire or small copper
or brass tubing since it must carry considerable do and RF current for the
transistor or transistors in the power amplifier. The larger winding, which
feeds the harmonic filter, may be fashioned from smaller wire. Use the largest
wire gauge practicable, consistent with fitting the winding in the holes of
the core. The larger the wire diameter the lower the losses.

Broadband Balun Transformers

Balun (balanced to unbalanced) transformers are used in test equipment, mixers,

receivers, transmitters and antenna circuits. Circuits and wiring information
concerning baluns is available in The ARRL Electronics Data Book and The Radio
4 broadband

Amateur's Handbook, plus the W1FB book, Ferromagnetic Core Design 8 Applicat-
ions Handbook (1). Therefore, that information will not be repeated here.

Baluns are transmission-line transformers. The greatest common misuse of balun

transformers is when they are used in antenna systems. A balun is designed
to interface between specific impedances. It cannot accommodate a wide range
of impedances, irrespective of its transformation ratio. For example, a 4 . -1
balun transformer is normally used between a 50-ohm unbalanced line and a
200-ohm balanced line or termination. It may be used also for joining a 75-
ohm unbalanced line to a 300-ohm balanced one. The importance of balun design
and application is clearly explained in the W2FMI book, Transmission Line
Transformers (ARRL). Broadband transformers are not effective at impedances
above approximately 600 ohms. Therefore, when they are included in the circuit
of an Transmatch (antenna tuner) for use with "any impedance," they can't
perform properly -- especially at high impedances. The phase becomes question-
able and they can saturate and burn up easily under certain conditions. An
ideal environment for a balun is one that presents input and output impedances
that are suitable for the transformer design. These impedances should remain
constant over the operating-frequency range of the balun. A worst-case example
of a balun in an improper environment is one that is used at the teed point
of a dipole that is meant for muItiband use. If sufficient RF power is fed
through the balun, it will saturate or burn up on some frequencies. This is
because the antenna impedance may be several thousands of ohms at some freq-
uencies. This results in extremely high RF voltages within the balun. Core
saturation is dependent upon the cross-sectional area of the core, the number
of turns on the windings and the current (ac and dc) flowing through the wind-
ings. Add to this the peak-peak voltage in the windings. High values of RF
voltage can also cause arcing between the windings and the transformer core. A
situation of this type is common also when a balun is used at the feed point
of a single-band dipole, where the SWR is low at the design frequency, but
high above and below the design frequency. Should you attempt to use the antenna
at a frequency where the SWR is high (1.5:1 or greater), the balun finds it-
self in a very hostile environment. Not only is there a mismatched condition
at the balun, but high RF voltage will be present at the feed point. Evidence
of core saturation is noted when the transformer becomes hot to the touch.
This assumes that the wire used for the windings is large enough to prevent
heating of the windings. Core saturation also causes the generation of square
waves, and these are rich in harmonic energy. Therefore, a saturated core
can cause TVI and RFI Equations for calculating the core size versus saturat-
ion are given in the books listed at the end of page 3 and the start of this
page.
Practical Examples of Broadband-Transformer Use

Fig. 3 shows examples of some common uses for broadband transformers. Circuit
A illustrates the use of a broadband transformer at the output of an active
mixer. The resistor bridged across the transformer primary helps to establish
a constant impedance. This makes it less difficult to calculate the turns
ratio when the load impedance is known. Another advantage of R1 is that it
helps to improve the IMD characteristic of the mixer. Typical R1 values are
from 4700 to 12,000 ohms for IMD improvement.

Fig. 3B shows how you can use a broadband transformer for matching a 50-ohm
antenna to a grounded gate RF amplifier in a receiver or converter. The input
impedance (source) of the JFET is on the order of 200 ohms, which calls for
 broadband

1
I I I 2n4416

+12V

RF POWER AMP

TO 50-OHM
HARMONIC
FILTER

+12V

Fig. 3 -- Examples of how to use broadband RF transformers. An untuned

mixer output circuit (Tl) is seen at A. RI improves the IMD performance
and helps establish the T1 primary load impedance. The 10:1 Z ratio
permits the use of a 500-ohm IF filter. A typical transformer for the
mixer might have a primary with 25 turns of no. 28 enam. wire on an
an FT-50-43 toroid. A 10 turn secondary would be used for a 500-ohm
load. Circuit B shows a common-gate JFET RF amplifier. T1 provides a
match between a 50-ohm antenna and the 200-ohm input Z of Q1. Amplifier
C is a push-pull Class C type for RF power service. T1 matches the 50-
ohm input line to the bases of Q1 and Q2. Balun cores of the type in
Fig. 2 may be used at TI and T2 of this circuit. T2 matches the collector
impedance to a 50-ohm harmonic filter.
a T1 impedance ratio of 4:1. Fig. 3C shows a push-pull RF power amplifier
that uses two broadband transformers of the type in Fig. 2. T1 matches 50
ohms to the Q1/Q2 base impedance (generally less that 10 ohms). T2 is wound
to transform the Q1/Q2 collector impedance to a 50-ohm harmonic filter. The
center tapped windings of 11 and T2 are shown at the center of Fig. 2. Numerous
practical examples of broadband transformers and associated circuits are found
in The WIFB QRP Notebook, The ARRL Handbook and Solid State Design for the
Radio Amateur.

Toro idaI transformers may be used in place of 11 and T2 in Fig. 3C. The major
disadvantage of using a toroidal transformer in a push-pull circuit is that
it is difficult to provide a precise electrical center for the tapped winding.
6 broadband

Physical and electrical symmetry are important for any balanced circuit. The
transformers in Fig. 2 lend themselves more readily to effective balance.

Bits and Pieces of Information

- Check
your December annual indices in QST for articles about toroids A number of
good articles on the subject have been published in QST during the past 20
years.

Use caution when winding ferrite cores. They break easily if dropped on a
hard surface. Also, many ferrite cores have not been tumbled to provide smooth
edges. These sharp surfaces can easily strip the enamel insulation from the
wire used for the windings. This can cause shorted turns that ruin the trans-
former performance. It is wise to wrap large ferrite cores with 3M glass tape
or plumber's Teflon tape before applying the windings. This helps to protect
the wire from abrasion.

A broken ferrite core may be repaired and used again if the halves are glued
firmly together with epoxy cement. I once shattered a huge 20-kW toroid (used
as a balun core for commercial broadcast) by applying too much power in a
situation of high RF voltage. It broke into flour pieces. It was glued and
used successfully in a high-power application.

In order to avoid confusion when building transformers with multifilar windings

you can spray paint the wires with different colors before putting the winding
on the core. Also, be on the lookout for magnet wire with different colors
of enamel insulation (green red, brown and gold, which are standard colors).

Ferrite is not a perfect insulator. Rather, it is a semiconductor type of

ceramic. Bare wire should not, therefore, be used on an untaped ferrite core.

If you have ferrite or powdered-iron cores of unknown characteristics you

may learn the A factor by winding a few turns on the core, measuring the
winding inductance and applying this equation: A L = (L(uh) X 10 4 1 /N 2 where
N is the number of turns on the core.