Directional coupler 144 and 432 MHz http://www.ok2kkw.com/00003016/komparator/smerova_odbocnice_pcb/smerova_odbocnice_en.

htm

PCB directional coupler for SWR protection of SSPA up to 1 kW level.

When I needed to buy somewhere some similar direction coupler for lower VHF bands PA up to 500W, I was not
successful.  The only simple solution was to develop such device at home. Maybe the below description will be useful
for someone, who want to construct SSPA with all protections in his home shack as well as.

In the Czech republic are quite regularly used professional directional couplers by Kathrein, dismounted from obsolete
GSM base stations of 1st generation. This device is mechanicaly perfect, but the coupling attenuation on 2m is to high
to be able use it for stable SWR measurment. As well as the 7/16 DIN connectors are not very often use in regular level
ham radio practise. The other, commercialy available directional couplers are not usable for RF power in the range 300
to 800W. Due to it, I set the task for such part (144 & 432MHz):

simple, cheap and repeatable construction even in ham radio environment

power limit 800W by the maximum PWR level for good N connectors

good matching for 50Ω impedance – at least -26dB reflections

built in detectors, delivering about 10V DC in case of 500W RF power.

directivity (isolation between forward and a reverse path) at least 20dB

The very first idea was to draw such coupler lines on single, double plated PCB. However: when the ordinary, 1.5 mm
thick FR4 laminate is used, the width of stripline is less, than 3mm, what is not enough to transfer the above
mentioned RF power (particularly, when operate the FSK mode, like for EME and a MS). When 500W RF is applied, RF
current 3,2A warming up the stripline and due to that the RF current is above limit for such mictrostrip width. To
transfer the above mentioned power (up to 800W) is necessary increase width of line and it (for 1.5mm thick material) 
is needed to use PCB with lower dielectric constant, than FR4 have (for example Rogers 3000 family PCBs). However
such RF PCB material is not well accessible for home radio shack. Due to that I decided to use rather sandwich
construction of directional coupler using two regular FR4 1.5mm thick and only one of them has one side plated lines,
which gives 3mm dielectric below the microstrip. It allowed me to increase width of power line. Now the power is not
limited even up to 1kW RF. Both single sided boards (the above with microstrip, the bottom one with ground plane) are
interconnected by small brass rivets (2.5mm dia, 5mm long). Finally I made two versions – one for 144 (and 70MHz) up
to 800W RF and the second one for 432MHz RF, as well as up to 800W. Of course the 144MHz version of stripline is
usable for 70cm as well, but due to tight coupling the power on 70cm shall be limited to abt. 150W RF. But it‘s not a
fault, because this directional coupler is designed for installation INTO a SSPA, and such QRO PA can’t be commonly
used for more bands (due to 2nd. harmonics cutting off  by for each band separately tailored LPF).

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Directional coupler 144 and 432 MHz http://www.ok2kkw.com/00003016/komparator/smerova_odbocnice_pcb/smerova_odbocnice_en.htm

                                   

The bord A49 is a directional coupler with more tight coupling, Coupler A49 A50 note
primarily designed for 2m PAs with 100 to 800W RF out. A50 PCB reflections
has desidned for 70cm for the same power range. Both of these 30dB 30dB SWR 1,06 / 1,06
144MHz
couplers are not suitable for 23cm. For this band I will publish reflections
27dB 30dB SWR 1,09 / 1,06
soon another board for home brewing. 432MHz
limit. PWR
750 W 800 W
When you intend use these coupler, také a care to the connection 144MHz
of cox cables. For 2 m and the PWR up to 500W is good enough limit. PWR
150 W 800 W
simply solder teflon cable (similar size like RG58) , but for higher 432MHz
PWR and for 70cm is better to use install the PCB into a suitable coupl.att. see the RF
30 44
144MHz (50R) connection: pic
box and use good N connectors.
coupl.att. see the RF
20 33
SMD components are 1206 size detection diode is a RF Schottky 432MHz (50R) connection: pic
directivity
low signal rectifier with capacity below 1pF and at least 20V see the RF
A/B 144MHz 25 26
reverse voltage. I have there obsolete KAS34 by Tesla, but any (50R)
connection: pic
similar type is OK.   The key component is suitable terminating directivity
resistor of the decoupling microstrip. PCB has designed for see the RF
A/B 432MHz 23 27
connection: pic
parallel combinationof two SMD resistors 150 Ω of 1206 size, (50R)
however soldered resistors have to high parazitic capacity. After detected DC
some experiments was as a terminator used ordinary 1/4W voltage
1,43 n.a. *)
metalized resistor 82 Ω with wire connections, which is placed 70MHz (FWD,
20W) A
there as shown on the pics. Body of the resistor is about 2mm
detected DC
above the PCB plane and the grounded point is inside the coupling
voltage
loop. (pic) Legth of resistor wires have some inductance, which 70MHz (FWD,
0,3 n.a. *)
compensates resistor capacity. 20W) B
detected DC
Detector blocking capacitors are standard ceramic 2.2nF, seriál voltage
resistor 3.3kΩ. If you want to use the directional coupler for SWR 5,4 1,14 *)
144MHz
protection, you may reverse the diode polarity and use for (FWD, 50W) A
example this comparator. If you prefer use external detector, detected DC
connect the coupling microstrip directly to the SMA connector, voltage
0,7 0,06 *)
placed on the side wall of the box. 144MHz
(FWD, 50W) B

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Directional coupler 144 and 432 MHz http://www.ok2kkw.com/00003016/komparator/smerova_odbocnice_pcb/smerova_odbocnice_en.htm

Measured average performance (4 pcs were measured) is in the detected DC

table. voltage
14,7 3,4 *)
432MHz
(FWD, 50W) A
detected DC
Let me wish to all, who will try to do this directional coupler, voltage
2,9 0,29 *)
successful construction and lot of fun on VHF bands! 432MHz
(FWD, 50W) B
73 de OKVPZ detected DC
voltage
4,4 n.a. *) **)
Check the pics below: 70MHz (FWD,
100W)
detected DC
voltage
21,5 5,1 *) **)
144MHz
(FWD, 800W) 
detected DC
voltage
n.a. 13,6 *) **)
432MHz
(FWD, 800W)

Note:     *)  measured by high impedance voltmete

**)  estimated by calculation              
A / B - detectors voltage direction forward and reverse

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