ZoZo 1W Upgrade
Posted: Mon Sep 29, 2025 6:50 pm
Hey everyone!
I've been working on a complete redesign of the ZOZO 1W FM PLL transmitter circuit, and I wanted to share my findings with the community. After analyzing the original design, I identified several areas where modern components and improved design techniques could deliver significant performance improvements.
What's Changed? Nearly everything - from the PLL synthesizer to the power supply, with a focus on professional-grade performance while maintaining builder-friendly construction.
This redesign delivers 25dB better phase noise, 4x better frequency stability, 20dB lower spurious emissions, and adds full digital control with LCD display and computer interface.

upload
Section 1: PLL Synthesizer Upgrade
THE BIG ONE: Replace the old PLL IC with Analog Devices ADF4351
Original: Discrete PLL IC with external VCO
New: ADF4351 integrated wideband synthesizer
The ADF4351 is a game-changer.
1. Integrated VCO Eliminates Design Headaches
You had to design, tune, and stabilize an external VCO (Variable Frequency Oscillator)
The ADF4351 has a built-in VCO covering 35MHz to 4.4GHz
No more fiddling with coils, no temperature drift from external VCO, consistent performance unit-to-unit
ADF4351 Key Advantages
Integrated VCO: Eliminates external VCO design complexity and variability
Fractional-N: Allows 1Hz resolution vs typical 25kHz with integer-N
Low Phase Noise: -110 dBc/Hz @ 10kHz vs -85 dBc/Hz typical
Wide Range: 35MHz to 4.4GHz covers all FM applications
Digital Control: SPI interface allows full programmability
2. Phase Noise Performance That Actually Matters
Original: -85 dBc/Hz @ 10kHz offset (typical for basic PLLs)
New: -110 dBc/Hz @ 10kHz offset
Real-world impact: Your FM signal will be 25dB cleaner. This means:
Less interference to adjacent channels
Cleaner received audio
Better compliance with regulations
Professional broadcast quality
Phase noise is the "fuzz" around your carrier frequency. Bad phase noise makes your signal spread into nearby channels and causes that characteristic "hiss" on weak signals. The ADF4351's low phase noise comes from its advanced charge pump design and integrated VCO topology that minimizes jitter.
Fractional-N Synthesis = Insane Frequency Resolution
Integer-N PLL gives you 25kHz steps (or whatever your reference frequency divides to)
Fractional-N would give 1Hz resolution
Instead of dividing by whole numbers only, fractional-N uses a sigma-delta modulator to average between division ratios. This lets you synthesize frequencies that would be impossible with integer division, all while maintaining low phase noise.
4. Digital Control via SPI = Future-Proof
Full digital control via 3-wire SPI interface

RF Power Chain & Protection
This deserves special attention because the RF chain is where hobby builds often fail.
Stage 1: RF Buffer Amplifier (BFP420)
The ADF4351 outputs about 0dBm (1mW). So the PA needs around 10-20mW for 1W output. You need amplification in between, but not just any amplifier BFP42 The perfect buffer choice
fT (Transition Frequency): 25 GHz
Noise Figure: 0.9 dB @ 900MHz
Gain: 12-15 dB @ 100MHz
Package: SOT-343 (4-pin, easy to solder)
Input Matching:
C20 (10nF) - DC blocking, AC coupling from ADF4351
Direct 50ฮฉ match (BFP420 has high input impedance at 100MHz)
Bias Network:
R20 (220ฮฉ) - Base bias resistor from +12V through RFC
Provides ~2mA base current for Class A operation
Q-point: Vce โ 6V, Ic โ 15mA
Emitter Degeneration:
R21 (68ฮฉ) + C22 (bypass)
- Stabilizes bias point
- Improves linearity
- Reduces temperature sensitivity
- Increases input/output impedance (easier matching)
RF Choke (L4):
10ยตH provides high impedance at RF, low DC resistance
Isolates RF from power supply
Prevents oscillation through supply lines
Performance:
Input: 0dBm (1mW) from ADF4351
Output: +12dBm (16mW)
Gain: 12dB
Drives PA to full output
The BFP420's high fT eliminates all these issues for just cheap cost.

Multi-Rail Design: Separate analog/digital supplies reduce noise coupling
Low-Dropout Regulators: Excellent PSRR (65dB) for clean analog supplies
High-Efficiency Pre-reg: 85% efficiency reduces heat generation
Comprehensive Protection: Fuse, TVS, thermal shutdown, current limiting
PA Boost Supply: Optimized 28V for LDMOS efficienc

32-bit ARM Cortex-M4: 168MHz clock, DSP instructions, floating-point unit
Memory Storage: 100 frequency presets in flash memory
Real-time Display: Frequency, power, VSWR, temperature monitoring
Multiple Interfaces: USB, RS-232, SPI for computer control
Advanced Features: Frequency sweeping, automatic protection, remote control

Layer Stack-up (1.6mm total thickness):
Layer 1 (Top): Signal routing + Component placement 35ยตm copper
Layer 2: Ground plane (solid) 35ยตm copper
โ 0.2mm prepreg (ฮตr = 4.3)
Layer 3: Power planes (+3.3V, +5V, +12V split) 35ยตm copper
โ 1.2mm core (ฮตr = 4.3)
Layer 4 (Bottom): Signal routing + Ground returns 35ยตm copper
Impedance Control:
- Single-ended 50ฮฉ: 1.2mm trace width over Layer 2 ground
- Differential 100ฮฉ: 0.8mm traces, 0.2mm spacing
- Via specifications: 0.2mm drill, 0.45mm pad
6.3 Critical Trace Routing & Impedance Control
High-Speed Digital Traces:
SPI Bus (ADF4351 Control):
MCU_MOSI โโโโโโโโโโโโโโโโโโโโโโโโโโโโโโโโโโโ ADF4351_SDATA
โ 33ฮฉ series termination โ
MCU_SCK โโโโโโโโโโโโโโโโโโโโโโโโโโโโโโโโโโโ ADF4351_SCLK
โ 33ฮฉ series termination โ
MCU_CS โโโโโโโโโโโโโโโโโโโโโโโโโโโโโโโโโโโ ADF4351_LE
โ 33ฮฉ series termination โ
โ
โโโ Via to Layer 4 ground return plane
Clock Distribution (Length Matched ยฑ0.1mm):
TCXO_25MHz โโโโโโโโโโโโโโโโโโโโโโโโโโโโโโโ ADF4351_REFIN
โ 50ฮฉ impedance controlled โ
โ Guard ring: GND trace โ
โ Via fence every 2mm โ
โโโ Kelvin ground connection
RF Signal Path (50ฮฉ Impedance):
ADF4351_RFOUT โโโโโโโโโโโโโโโโโโโโโโโโโโโ BUFFER_INPUT
โ W=1.2mm, Layer 1 โ
โ Ground via every 5mm โ
โโโ Coplanar waveguide
BUFFER_OUT โโโโโโโโโโโโโโโโโโโโโโโโโโโโโโโ PA_INPUT
โ Minimize length <10mm โ
โ Direct connection โ
โโโ Impedance matched
PA_OUTPUT โโโโโโโโโโโโโโโโโโโโโโโโโโโโโโโ FILTER_INPUT
โ High current path โ
โ W=2.0mm for current โ
โโโ Low inductance layout
Audio Signals (Shielded):
AUDIO_L/R โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ PREAMP_INPUT
โ Twisted pair routing โ
โ GND guard traces โ
โโโ Isolated from digital
Power Distribution Network:
+28V_PA: 4mm wide trace, 70ยตm copper
+12V: 2mm wide trace, multiple vias
+5V: 1.5mm wide trace, plane connection
+3.3V: 1mm wide trace, separate analog/digital
Via Stitching Pattern (RF Return Current):
Layer 1 GND โโ Layer 2 GND plane
โ โ โ โ โ
โ โ โ โ โ โ โ
โ โ โ โ โ
Spacing: 5mm maximum for 100MHz signals
Via size: 0.2mm drill, 0.45mm pad
Signal Integrity: Controlled impedance, minimal crosstalk, proper termination
EMC Compliance: RF shielding, ground plane integrity, filtered supplies
Thermal Management: Thermal vias, copper pour, component placement
Manufacturing: DFM rules, standard processes, reliable assembly

RF Chain Improvements
BFP420 Buffer: High fT (25GHz) ensures stable gain to 1GHz
LDMOS PA: 60% efficiency vs 30% for bipolar, better linearity
5th Order Filter: >40dB harmonic suppression vs typical 20dB
Directional Coupler: Real-time VSWR monitoring and protection
Temperature Monitoring: Thermal shutdown prevents damage
I have made a small HTML document with all the info in it still work in progress but any feedback or ideas are welcome!

I've been working on a complete redesign of the ZOZO 1W FM PLL transmitter circuit, and I wanted to share my findings with the community. After analyzing the original design, I identified several areas where modern components and improved design techniques could deliver significant performance improvements.
What's Changed? Nearly everything - from the PLL synthesizer to the power supply, with a focus on professional-grade performance while maintaining builder-friendly construction.
This redesign delivers 25dB better phase noise, 4x better frequency stability, 20dB lower spurious emissions, and adds full digital control with LCD display and computer interface.

upload
THE BIG ONE: Replace the old PLL IC with Analog Devices ADF4351
Original: Discrete PLL IC with external VCO
New: ADF4351 integrated wideband synthesizer
The ADF4351 is a game-changer.
1. Integrated VCO Eliminates Design Headaches
You had to design, tune, and stabilize an external VCO (Variable Frequency Oscillator)
The ADF4351 has a built-in VCO covering 35MHz to 4.4GHz
No more fiddling with coils, no temperature drift from external VCO, consistent performance unit-to-unit
ADF4351 Key Advantages
Integrated VCO: Eliminates external VCO design complexity and variability
Fractional-N: Allows 1Hz resolution vs typical 25kHz with integer-N
Low Phase Noise: -110 dBc/Hz @ 10kHz vs -85 dBc/Hz typical
Wide Range: 35MHz to 4.4GHz covers all FM applications
Digital Control: SPI interface allows full programmability
2. Phase Noise Performance That Actually Matters
Original: -85 dBc/Hz @ 10kHz offset (typical for basic PLLs)
New: -110 dBc/Hz @ 10kHz offset
Real-world impact: Your FM signal will be 25dB cleaner. This means:
Less interference to adjacent channels
Cleaner received audio
Better compliance with regulations
Professional broadcast quality
Phase noise is the "fuzz" around your carrier frequency. Bad phase noise makes your signal spread into nearby channels and causes that characteristic "hiss" on weak signals. The ADF4351's low phase noise comes from its advanced charge pump design and integrated VCO topology that minimizes jitter.
Fractional-N Synthesis = Insane Frequency Resolution
Integer-N PLL gives you 25kHz steps (or whatever your reference frequency divides to)
Fractional-N would give 1Hz resolution
Instead of dividing by whole numbers only, fractional-N uses a sigma-delta modulator to average between division ratios. This lets you synthesize frequencies that would be impossible with integer division, all while maintaining low phase noise.
4. Digital Control via SPI = Future-Proof
Full digital control via 3-wire SPI interface

RF Power Chain & Protection
This deserves special attention because the RF chain is where hobby builds often fail.
The ADF4351 outputs about 0dBm (1mW). So the PA needs around 10-20mW for 1W output. You need amplification in between, but not just any amplifier BFP42 The perfect buffer choice
fT (Transition Frequency): 25 GHz
Noise Figure: 0.9 dB @ 900MHz
Gain: 12-15 dB @ 100MHz
Package: SOT-343 (4-pin, easy to solder)
Input Matching:
C20 (10nF) - DC blocking, AC coupling from ADF4351
Direct 50ฮฉ match (BFP420 has high input impedance at 100MHz)
Bias Network:
R20 (220ฮฉ) - Base bias resistor from +12V through RFC
Provides ~2mA base current for Class A operation
Q-point: Vce โ 6V, Ic โ 15mA
Emitter Degeneration:
R21 (68ฮฉ) + C22 (bypass)
- Stabilizes bias point
- Improves linearity
- Reduces temperature sensitivity
- Increases input/output impedance (easier matching)
RF Choke (L4):
10ยตH provides high impedance at RF, low DC resistance
Isolates RF from power supply
Prevents oscillation through supply lines
Performance:
Input: 0dBm (1mW) from ADF4351
Output: +12dBm (16mW)
Gain: 12dB
Drives PA to full output
The BFP420's high fT eliminates all these issues for just cheap cost.

Multi-Rail Design: Separate analog/digital supplies reduce noise coupling
Low-Dropout Regulators: Excellent PSRR (65dB) for clean analog supplies
High-Efficiency Pre-reg: 85% efficiency reduces heat generation
Comprehensive Protection: Fuse, TVS, thermal shutdown, current limiting
PA Boost Supply: Optimized 28V for LDMOS efficienc

32-bit ARM Cortex-M4: 168MHz clock, DSP instructions, floating-point unit
Memory Storage: 100 frequency presets in flash memory
Real-time Display: Frequency, power, VSWR, temperature monitoring
Multiple Interfaces: USB, RS-232, SPI for computer control
Advanced Features: Frequency sweeping, automatic protection, remote control

Layer Stack-up (1.6mm total thickness):
Layer 1 (Top): Signal routing + Component placement 35ยตm copper
Layer 2: Ground plane (solid) 35ยตm copper
โ 0.2mm prepreg (ฮตr = 4.3)
Layer 3: Power planes (+3.3V, +5V, +12V split) 35ยตm copper
โ 1.2mm core (ฮตr = 4.3)
Layer 4 (Bottom): Signal routing + Ground returns 35ยตm copper
Impedance Control:
- Single-ended 50ฮฉ: 1.2mm trace width over Layer 2 ground
- Differential 100ฮฉ: 0.8mm traces, 0.2mm spacing
- Via specifications: 0.2mm drill, 0.45mm pad
6.3 Critical Trace Routing & Impedance Control
High-Speed Digital Traces:
SPI Bus (ADF4351 Control):
MCU_MOSI โโโโโโโโโโโโโโโโโโโโโโโโโโโโโโโโโโโ ADF4351_SDATA
โ 33ฮฉ series termination โ
MCU_SCK โโโโโโโโโโโโโโโโโโโโโโโโโโโโโโโโโโโ ADF4351_SCLK
โ 33ฮฉ series termination โ
MCU_CS โโโโโโโโโโโโโโโโโโโโโโโโโโโโโโโโโโโ ADF4351_LE
โ 33ฮฉ series termination โ
โ
โโโ Via to Layer 4 ground return plane
Clock Distribution (Length Matched ยฑ0.1mm):
TCXO_25MHz โโโโโโโโโโโโโโโโโโโโโโโโโโโโโโโ ADF4351_REFIN
โ 50ฮฉ impedance controlled โ
โ Guard ring: GND trace โ
โ Via fence every 2mm โ
โโโ Kelvin ground connection
RF Signal Path (50ฮฉ Impedance):
ADF4351_RFOUT โโโโโโโโโโโโโโโโโโโโโโโโโโโ BUFFER_INPUT
โ W=1.2mm, Layer 1 โ
โ Ground via every 5mm โ
โโโ Coplanar waveguide
BUFFER_OUT โโโโโโโโโโโโโโโโโโโโโโโโโโโโโโโ PA_INPUT
โ Minimize length <10mm โ
โ Direct connection โ
โโโ Impedance matched
PA_OUTPUT โโโโโโโโโโโโโโโโโโโโโโโโโโโโโโโ FILTER_INPUT
โ High current path โ
โ W=2.0mm for current โ
โโโ Low inductance layout
Audio Signals (Shielded):
AUDIO_L/R โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ PREAMP_INPUT
โ Twisted pair routing โ
โ GND guard traces โ
โโโ Isolated from digital
Power Distribution Network:
+28V_PA: 4mm wide trace, 70ยตm copper
+12V: 2mm wide trace, multiple vias
+5V: 1.5mm wide trace, plane connection
+3.3V: 1mm wide trace, separate analog/digital
Via Stitching Pattern (RF Return Current):
Layer 1 GND โโ Layer 2 GND plane
โ โ โ โ โ
โ โ โ โ โ โ โ
โ โ โ โ โ
Spacing: 5mm maximum for 100MHz signals
Via size: 0.2mm drill, 0.45mm pad
Signal Integrity: Controlled impedance, minimal crosstalk, proper termination
EMC Compliance: RF shielding, ground plane integrity, filtered supplies
Thermal Management: Thermal vias, copper pour, component placement
Manufacturing: DFM rules, standard processes, reliable assembly

RF Chain Improvements
BFP420 Buffer: High fT (25GHz) ensures stable gain to 1GHz
LDMOS PA: 60% efficiency vs 30% for bipolar, better linearity
5th Order Filter: >40dB harmonic suppression vs typical 20dB
Directional Coupler: Real-time VSWR monitoring and protection
Temperature Monitoring: Thermal shutdown prevents damage
I have made a small HTML document with all the info in it still work in progress but any feedback or ideas are welcome!
