Improved remote station audio link
With the Flex 5000 up and running in my remote station over the phone patch, I wanted to be able to get stereo sound from the Flex to my operating position. The Flex uses both audio channels to provide binaural audio or to feed the audio from each receiver (I have the second receiver installed) to separate channels.
I started looking at a number of low delay solutions for digitizing audio channels and moving them over the Ethernet that provides remote control of the PC driving the Flex. There are commercial solutions that provide audio over Ethernet for recording studios but they are expensive! I started thinking about building a custom solution using a micro-controller when one of my friends suggested using a balanced audio link as a much lower tech solution.
The remote station is located about 500 feet from the house. The Ethernet run is all Cat 6 twisted pair cable in three spans – each span interconnects via an Ethernet switch running at 100 MBps. Fortunately, when the cable was installed I had dual cables pulled to each drop (cable is inexpensive) so I had a spare cable on each span. Each span connects to the next with a short Ethernet cable.
There is probably 700 feet of cable between the three spans – driving unbalanced audio over this length of cable was a sure recipe for hum pickup and disappointment. Balanced audio was a slam-dunk choice for the link.
Cat 6 has four twisted pairs so for my configuration I decided on the following:
- Two pairs for stereo audio from the Flex
- One pair for microphone audio to the Flex
- One pair for PTT control of the Flex
To make sure I had enough audio to drive the microphone pair back to the Flex, I added an audio preamplifier based on an LM386. Here is a link to the schematic – it's very simple!
Design Notes
- The electrolytic capacitor on pin 7 of the LM386 provides decoupling of any low frequency noise on the power supply. The National Semiconductor data sheet does not show a rejection ratio for the 330uF capacitor used in this design. I tried a 50uF (the largest value for which the data sheet plots a rejection response) but it was not enough to completely nail the hum – the 330uF removed all hum.
- The 0.1uF capacitor across the input provides a path to ground for strong AM signals picked up by the microphone cable. Some of the AM stations in the Bay Area put -15 dBm signals into my receivers – as a result, this capacitor is critical! Without it, there was low-level pickup of KGO AM 810. Note that even in the configuration shown; the LM386 has at least 26 dB gain – more than enough to render a good imitation of a crystal set!
- The 16-ohm resistor (R3) in the schematic serves as the load for the LM386.
- All the transformers are 1:1 ratio with 600-ohm impedance. Radio Shack carries a suitable transformer (PN: 273-1374 ). A typical Radio Shack store only carries a couple of these in inventory so you will likely have to visit a couple of stores – call ahead and ask them to check the inventory system to tell you which stores have the transformers in stock.
- I built the link in two units – local and remote – separated by the twisted pairs of the CAT6 cable.
- I couldn't find bulkhead mount RJ-45 connectors (if indeed they are made!). Instead, I used a wall plate with a modular jack insert. This dictated a larger box than I would have liked but it made for a much simpler mechanical construction.
- Local and remote units have separate power supplies – this avoided having to deal with resistive losses in the cable – this is typically about 28-ohm per 1000 feet for CAT6 cable.
- The PTT switch on the microphone provides the bias to the base of the transistor controlling the relay in the remote unit. Only 5 mA flows on the PTT line with little voltage drop due to IR losses in the cable.
The remote audio link works well and provides full stereo from the Flex to the operating position in the house. The stereo link goes into a pair of Logitech powered speakers and sounds great!