Re: [Repeater-Builder] IOTA Switched Power Supply and Noise?

2005-07-19 Thread Gran Clark




Joe
Carefully consider expanding into switchers. The designs are quite
varied. To repair them you really need a good high frequency scope,
shielded isolation transformer, 0.18 ohm 1000 watt resistor load,
and most of all a good schematic. Switcher parts are hard to find
especially the low ESR capacitors (a common failure). Fixing an
analog supply is a slam dunk compared to a switcher. I would not put one
at a repeater site unless the site happens to be my home.
Gran K6RIF
At 16:49 7/17/2005, you wrote:
Does anybody have a web site to
look at IOTA power supply? I need to find 
some to replace my power supplies in the future. Bruce
KD4BOH.- 
Original Message - 
From: Joe Montierth [EMAIL PROTECTED]
To: Repeater-Builder@yahoogroups.com
Sent: Wednesday, May 25, 2005 2:22 PM
Subject: Re: [Repeater-Builder] IOTA Switched Power Supply and
Noise?

I have one of the 75 amp supplies working at a remote
 site. We have not seen any noise from the unit, but
 our equipment is all VHF and UHF, haven't checked it
 down in HF, but at UHF we have seen no problems. We
 have 20 UHF RX's and 6 VHF and have not seen any
 degradation.

 These IOTA's run much cooler than the analog Astron's,
 and are much smaller. I will probably be changing out
 all of the Astrons to these in the next few years, as
 conditions warrant.

 Joe

 --- Nick Papadonis [EMAIL PROTECTED] wrote:
 Hi Folks,

 I'm considering purchasing a 45A IOTA Switched Power
 supply to power a UHF Micor and am concerned about
 switch PS noise.

 Has anyone tried these supplies with UHF radios? Is
 noise experienced?

 Insight greatly appreciated. Thanks.

 --
 Nick KB1GZN Boston, MA








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Re: [Repeater-Builder] IOTA Switched Power Supply and Noise?

2005-07-19 Thread Dave VanHorn
At 09:43 AM 7/19/2005, Gran Clark wrote:
Joe

Carefully consider expanding into switchers.  The designs are quite 
varied.  To repair them you really need a good high frequency scope, 
shielded isolation transformer,  0.18 ohm 1000 watt resistor load, 
and most of all a good schematic.  Switcher parts are hard to find 
especially the low ESR capacitors (a common failure).  Fixing an 
analog supply is a slam dunk compared to a switcher. I would not put 
one at a repeater site unless the site happens to be my home.

On the other hand, a well designed switcher can easily outlast a linear.

Heat kills, and a switcher dissipates a LOT less heat on any given 
load, than a linear supply.
Jim Williams of Analog Devices, published a formula for predicting 
capacitor life in a given design. There are a number of factors that 
go into it, but the temperature term decreases the projected life of 
the caps by half, for every 10C rise in ambient temperature. This is 
true wether the cap is used in a switcher, or a linear supply.

Without the formula, you can simply predict a cap's life in a 
moderate application, by using it's rated lifetime and the 
application temperature.
If you look at Digi-Key's site, you'll see that each type of cap has 
a rating in so many hours, and so many degrees C.
A cap rated for 2000 hours at 85C is going to fail roughly 4x faster 
than one rated at 2000 hours at 105C.
Both will last twice as long if you run them 10C under their ratings.

For the large electrolytics in a switcher, you can estimate ripple 
current requirements by the output current and the number of caps in parallel.
Say an output cap in my IOTA died.  I would replace the output caps, 
output diode, and probably the switching transistor as well, before 
even turning on the supply.
To pick a new cap, I would look up the ratings on the existing ones 
in Digi-Key, and pick a similar, but higher lifetime unit.

But, let's say that I couldn't find the ratings..  Ok, so it's a 55A 
output, and maybe there are three caps in parallel across the output. 
(I haven't opened it up)
I divide 55A by 2 ( N-1 to be conservative) and look for caps rated 
at 25V and 27A, of roughly the same uF rating. Then I take what I 
find, and use the lowest ESR and longest lifetime ratings that will 
fit the case. If I can't satisfy that, then I use 55A/3 and try 
again. It's very unlikely that you can't find a similar or better cap 
to replace it with.  If the original design used 16V parts on the 
output, I could stick with that, but I prefer more margin 
there.  Always remember, the original manufacturer was cost 
constrained, and you really aren't. Adding another $1 to the cost is 
really not an issue to you, but adding another $0.05 may have been a 
real battle for the designer.

The waste heat may also be affecting other devices in your system, 
depending on how you deal with removing it.

Replacement caps do need to be chosen properly, but as time goes on, 
caps get better and better. Today's so-so caps have roughly the 
same ratings for ripple current and ESR as the exceptionally good 
caps of a few years ago.  Similar for transistors and diodes.  By the 
time yours fail, odds are that if they used state-of-the-art parts in 
the design, those parts are now good or average.

Switcher parts are generally available through Digi-Key, or other 
similar sources.

As to what you need to repair them, I disagree.  Just plain common 
sense, and an understanding of how switchers work is enough.
If you see a failed component, there is a reason that it failed, and 
there are other things that this failure will have overstressed.
Fix all three, if possible.   Sometimes the reason for failure is a 
design problem though, and that is a more difficult fix usually.
A copy of Art of Electronics would be a better investment, IMHO :)

Then again, the IOTA units are very reasonably priced, and you might 
just prefer to replace it with the then current models.


Fixing an analog supply is probably easier, if we define fixing 
as replacing the blown parts. Otherwise, it's the same as a switcher, 
determine what failed, determine why it failed, and determine what 
else probably took some stress, and repair all three.  If the 
fundamental cause is excessive heat though, you're pretty much stuck 
since linear supplies are by nature, wasteful and that waste ends up 
as heat, and heat kills.


A final note on electrolytic caps, their failure modes are not 
limited to splattering their guts all over the inside of the box. Far 
more often, they go leaky, or they go open. I've seen 1000uF caps 
that read as 1uF on a cap meter, after a few years in service.   Bad 
caps may or may not cause problems in your system, but the problems 
that they cause can be really difficult to find, if you don't 
approach with a suspicious eye.   Caps are one of the few electronic 
components that really do have a finite lifetime, and a definite 
wear-out.  An open cap does not filter like it 

Re: [Repeater-Builder] IOTA Switched Power Supply and Noise?

2005-07-19 Thread Joe Montierth
Dave's points are good, I'd like to point out a couple
of other things.

We have used Astron supplies for years, and overall
have been happy with them. There are some drawbacks,
mainly the analog design is very wasteful of power,
and the units get very warm (hot). I have done some
measurements, and a RM-50 will waste as heat about 480
watts when putting out 40 amps at 13.5 volts. An IOTA
DLS-45 will waste about 136 watts as heat under the
same conditions. Note that the RM-50 is only rated at
37 amps continuous, while the DLS-45 will put out 45
amps all day long.

If you do the calculations on wasted heat, this comes
to an additional 4147 KWh per year on the Astron, and
an additional 1175 KWh/ year on the IOTA. If you live
in an area with 10 cents/KHh power (typical) then your
power savings in one year will be almost $300.

Many of you do not run this kind of power
continuously, but we do. Even at lower duty cycles you
will probably realize these savings within 5 years, if
you are paying for power out of your pocket.

Even if I could not fix these power supplies, and even
if I had to change it once a year, I would still be
money ahead with the IOTA. Also, we do not use ours on
commercial power, we use it at a generator site where
our cost to generate power is about 30 cents/KWh.

Did I mention that the Astron weighs 50 lbs and the
Iota weighs 5.5?

Joe




--- Dave VanHorn [EMAIL PROTECTED] wrote:

 At 09:43 AM 7/19/2005, Gran Clark wrote:
 Joe
 
 Carefully consider expanding into switchers.  The
 designs are quite 
 varied.  To repair them you really need a good high
 frequency scope, 
 shielded isolation transformer,  0.18 ohm 1000 watt
 resistor load, 
 and most of all a good schematic.  Switcher parts
 are hard to find 
 especially the low ESR capacitors (a common
 failure).  Fixing an 
 analog supply is a slam dunk compared to a
 switcher. I would not put 
 one at a repeater site unless the site happens to
 be my home.
 
 On the other hand, a well designed switcher can
 easily outlast a linear.
 
 Heat kills, and a switcher dissipates a LOT less
 heat on any given 
 load, than a linear supply.
 Jim Williams of Analog Devices, published a formula
 for predicting 
 capacitor life in a given design. There are a number
 of factors that 
 go into it, but the temperature term decreases the
 projected life of 
 the caps by half, for every 10C rise in ambient
 temperature. This is 
 true wether the cap is used in a switcher, or a
 linear supply.
 
 Without the formula, you can simply predict a cap's
 life in a 
 moderate application, by using it's rated lifetime
 and the 
 application temperature.
 If you look at Digi-Key's site, you'll see that each
 type of cap has 
 a rating in so many hours, and so many degrees C.
 A cap rated for 2000 hours at 85C is going to fail
 roughly 4x faster 
 than one rated at 2000 hours at 105C.
 Both will last twice as long if you run them 10C
 under their ratings.
 
 For the large electrolytics in a switcher, you can
 estimate ripple 
 current requirements by the output current and the
 number of caps in parallel.
 Say an output cap in my IOTA died.  I would replace
 the output caps, 
 output diode, and probably the switching transistor
 as well, before 
 even turning on the supply.
 To pick a new cap, I would look up the ratings on
 the existing ones 
 in Digi-Key, and pick a similar, but higher lifetime
 unit.
 
 But, let's say that I couldn't find the ratings.. 
 Ok, so it's a 55A 
 output, and maybe there are three caps in parallel
 across the output. 
 (I haven't opened it up)
 I divide 55A by 2 ( N-1 to be conservative) and look
 for caps rated 
 at 25V and 27A, of roughly the same uF rating. Then
 I take what I 
 find, and use the lowest ESR and longest lifetime
 ratings that will 
 fit the case. If I can't satisfy that, then I use
 55A/3 and try 
 again. It's very unlikely that you can't find a
 similar or better cap 
 to replace it with.  If the original design used 16V
 parts on the 
 output, I could stick with that, but I prefer more
 margin 
 there.  Always remember, the original manufacturer
 was cost 
 constrained, and you really aren't. Adding another
 $1 to the cost is 
 really not an issue to you, but adding another $0.05
 may have been a 
 real battle for the designer.
 
 The waste heat may also be affecting other devices
 in your system, 
 depending on how you deal with removing it.
 
 Replacement caps do need to be chosen properly, but
 as time goes on, 
 caps get better and better. Today's so-so caps
 have roughly the 
 same ratings for ripple current and ESR as the
 exceptionally good 
 caps of a few years ago.  Similar for transistors
 and diodes.  By the 
 time yours fail, odds are that if they used
 state-of-the-art parts in 
 the design, those parts are now good or average.
 
 Switcher parts are generally available through
 Digi-Key, or other 
 similar sources.
 
 As to what you need to repair them, I disagree. 
 Just plain common 
 sense, and an 

Re: [Repeater-Builder] IOTA Switched Power Supply and Noise?

2005-07-19 Thread Dave VanHorn


If you do the calculations on wasted heat, this comes
to an additional 4147 KWh per year on the Astron, and
an additional 1175 KWh/ year on the IOTA. If you live
in an area with 10 cents/KHh power (typical) then your
power savings in one year will be almost $300.

We don't pay the power bill at our sites, but that is an angle I 
hadn't considered.
Amusing, because I routinely design battery powered equipment, where 
every milliwatt is considered.

Power factor is another issue that goes under the radar. The power 
factor on those Astrons is going to be pretty bad, and if you hang 
larger or better caps inside the case, it just gets worse. With a 
switcher design, the power factor can easily approach 90%.

One of these days, I need to measure the astron that powers the 
club's machines.
It would be interesting to know what temperature it's running at 
nominally, but from calibrated thumb, I know it's pretty hot.
The club didn't want to get a switcher, because switchers are 
noisy.   I've put many switchers through FCC part 15 testing, and 
have yet to have anything even show up on the spectrum plots from the 
switcher, either radiated or conducted.

I haven't got the harness made yet for the new machine, but when I 
do, I'll be making the same measurements and more on this system.
One that I plan to do, is to set up the SA, and have a look at 
exactly what noise the Iota outputs.

When I'm working on the club's machines, I have to do what they 
want.  On my own machines, I have no such constraints. :)





 
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Re: [Repeater-Builder] IOTA Switched Power Supply and Noise?

2005-07-19 Thread Dexter McIntyre W4DEX
Anyone have an idea how much power would be saved by running a MSF-5000 
that is idle most of the time from a switcher instead of the stock heavy 
iron power supply?.  The transformers produce a lot of heat just in 
standby mode.  I have several of these machines on line and also a GE 
repeater with a big transformer.

Dex,
W4DEX




 
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Re: [Repeater-Builder] IOTA Switched Power Supply and Noise?

2005-07-19 Thread Joe Montierth
The easiest way to tell would be to measure the AC
current draw in idle. Then measure the DC current draw
in idle.

You can get a pretty close watt figure by multiplying
the amps times the voltage (115v) on the input side,
and doing the same thing on the DC side. The
difference between the two is your wasted heat. If you
convert the watts to kilowatts (divide by 1000), then
multiply your results by 8760, that will tell you the
number of wasted KWH in one year.

Example: .72 amps draw at 115 volts, 1.3 amps draw at
13.5 volts.  .72 x 115 = 83 watts in. 1.3 x 13.5 =
17.5 watts delivered. This means 65.5 watts are
wasted, or about 574 KWh/year.

Joe



--- Dexter McIntyre W4DEX [EMAIL PROTECTED] wrote:

 Anyone have an idea how much power would be saved by
 running a MSF-5000 
 that is idle most of the time from a switcher
 instead of the stock heavy 
 iron power supply?.  The transformers produce a lot
 of heat just in 
 standby mode.  I have several of these machines on
 line and also a GE 
 repeater with a big transformer.
 
 Dex,
 W4DEX
 





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Re: [Repeater-Builder] IOTA Switched Power Supply and Noise?

2005-07-19 Thread Mike Morris WA6ILQ
One nit-pick: measure the actual AC line voltage and use it
where Joe has 115v.  Locally it's 118-123v, depending on
the local load (i.e. lower on a summer day, highest during
a winter night).

And sometime when you have a free hour, wander around
the house and count how many wall warts you have in use,
and feel each one and see just how warm it is.  Then if
you want to see an interesting number, unplug each one,
and take it and it's load and plug it into a power strip, or
some strips that are daisy chained...

I did this at a friend house and we ended up with about 20
plugged into a half-dozen power strips and totalling about
2 and a half amps of AC... He's got 112-114v of AC at his
house so using 113 we get 255.2w ... divide by 1000 and
times 8760=2235.5, or 2.2kw just in wall wart wastage.

Think how many houses have that exact same situation.

Might be worth putting a switch on an idle wall wart

Or plugging the modem, inkjet printer and USB hub wallwarts
into a power strip, and using the strip's switch to power down
the entire computer system when it's not in actual use.

Mike WA6ILQ

At 11:24 AM 7/19/05, you wrote:

The easiest way to tell would be to measure the AC
current draw in idle. Then measure the DC current draw
in idle.

You can get a pretty close watt figure by multiplying
the amps times the voltage (115v) on the input side,
and doing the same thing on the DC side. The
difference between the two is your wasted heat. If you
convert the watts to kilowatts (divide by 1000), then
multiply your results by 8760, that will tell you the
number of wasted KWH in one year.

Example: .72 amps draw at 115 volts, 1.3 amps draw at
13.5 volts.  .72 x 115 = 83 watts in. 1.3 x 13.5 =
17.5 watts delivered. This means 65.5 watts are
wasted, or about 574 KWh/year.

Joe


--- Dexter McIntyre W4DEX [EMAIL PROTECTED] wrote:

  Anyone have an idea how much power would be saved by
  running a MSF-5000
  that is idle most of the time from a switcher
  instead of the stock heavy
  iron power supply?.  The transformers produce a lot
  of heat just in
  standby mode.  I have several of these machines on
  line and also a GE
  repeater with a big transformer.
 
  Dex,
  W4DEX
 





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Re: [Repeater-Builder] IOTA Switched Power Supply and Noise?

2005-07-19 Thread Dave VanHorn


Think how many houses have that exact same situation.

I know I suffer from this big-time.
Lots of wall wart devices.
They are going to switchers though, it's finally come to the place 
where the switcher is cheaper than the iron and shipping from China.
Last year, I needed a new wart for something, and was surprised by a 
lighter than air 1A wart for $15, with adjustable output voltage, 
that is a switcher.
It's still going, so acceptable quality I guess.

Lots of devices plugged in at my place, and the devils that design 
them love to stick in digital clocks, so you don't want to unplug them.






 
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Re: [Repeater-Builder] IOTA Switched Power Supply and Noise?

2005-07-19 Thread Joe Montierth


--- Mike Morris WA6ILQ [EMAIL PROTECTED] wrote:


 I did this at a friend house and we ended up with
 about 20
 plugged into a half-dozen power strips and totalling
 about
 2 and a half amps of AC... He's got 112-114v of AC
 at his
 house so using 113 we get 255.2w ... divide by 1000
 and
 times 8760=2235.5, or 2.2kw just in wall wart
 wastage.
 

Except that the formula is already in KWh, IOW not 2.2
but 2235 KWh per year! If he's burning that much juice
(255 watts) then he's using a KWh every four hours!
That's 60 cents a day just to run wall warts.

Joe




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Re: [Repeater-Builder] IOTA Switched Power Supply and Noise?

2005-07-19 Thread Dave VanHorn
At 05:18 PM 7/19/2005, Tony King, W4ZT wrote:
One caution about these switchers. Many of the cheap switchers being
made today both as chargers and supplies generate tremendous amounts of
RFI.  A number of my ham friends have experienced unbearable
interference from these devices.  Note that they have no part 15
certification and you can never locate the actual manufacturer to have
problems corrected. It gets even worse when your NEIGHBOR has these devices.

I'm sure it happens, but I haven't been hit with it.
I have receivers that cover 0.1-2GHz, and haven't noticed anything.





 
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Re: [Repeater-Builder] IOTA Switched Power Supply and Noise?

2005-07-19 Thread Mark A. Holman
If I did that my XYL would string me by a wall wart ! :)  

shes tolerable to my hobby and I have to put up with cats ! 

- Original Message - 
From: Dave VanHorn [EMAIL PROTECTED]
To: Repeater-Builder@yahoogroups.com
Sent: Tuesday, July 19, 2005 5:03 PM
Subject: Re: [Repeater-Builder] IOTA Switched Power Supply and Noise?


 

Think how many houses have that exact same situation.
 
 I know I suffer from this big-time.
 Lots of wall wart devices.
 They are going to switchers though, it's finally come to the place 
 where the switcher is cheaper than the iron and shipping from China.
 Last year, I needed a new wart for something, and was surprised by a 
 lighter than air 1A wart for $15, with adjustable output voltage, 
 that is a switcher.
 It's still going, so acceptable quality I guess.
 
 Lots of devices plugged in at my place, and the devils that design 
 them love to stick in digital clocks, so you don't want to unplug them.
 
 
 
 
 
 
 
 Yahoo! Groups Links
 
 
 
 
 
 





 
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Re: [Repeater-Builder] IOTA Switched Power Supply and Noise?

2005-07-17 Thread Bruce Nanney
Does anybody have a web site to look at IOTA power supply? I need to find 
some to replace my power supplies in the future.  Bruce KD4BOH.-  
Original Message - 
From: Joe Montierth [EMAIL PROTECTED]
To: Repeater-Builder@yahoogroups.com
Sent: Wednesday, May 25, 2005 2:22 PM
Subject: Re: [Repeater-Builder] IOTA Switched Power Supply and Noise?


I have one of the 75 amp supplies working at a remote
 site. We have not seen any noise from the unit, but
 our equipment is all VHF and UHF, haven't checked it
 down in HF, but at UHF we have seen no problems. We
 have 20 UHF RX's and 6 VHF and have not seen any
 degradation.

 These IOTA's run much cooler than the analog Astron's,
 and are much smaller. I will probably be changing out
 all of the Astrons to these in the next few years, as
 conditions warrant.

 Joe

 --- Nick Papadonis [EMAIL PROTECTED] wrote:
 Hi Folks,

 I'm considering purchasing a 45A IOTA Switched Power
 supply to power a UHF Micor and am concerned about
 switch PS noise.

 Has anyone tried these supplies with UHF radios?  Is
 noise experienced?

 Insight greatly appreciated.  Thanks.

 --
 Nick KB1GZN  Boston, MA








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Re: [Repeater-Builder] IOTA Switched Power Supply and Noise?

2005-07-17 Thread Dave VanHorn
At 06:49 PM 7/17/2005, Bruce Nanney wrote:
Does anybody have a web site to look at IOTA power supply? I need to find
some to replace my power supplies in the future.  Bruce KD4BOH.-

I picked up one on ebay recently, very competitive pricing.





 
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RE: [Repeater-Builder] IOTA Switched Power Supply and Noise?

2005-07-17 Thread Richard
I bought one about six months or so ago, but I don't remember where. Google
should turn something up for you, that's how I found it.

Richard, N7TGB

-Original Message-
From: Repeater-Builder@yahoogroups.com
[mailto:[EMAIL PROTECTED] Behalf Of Bruce Nanney
Sent: Sunday, July 17, 2005 4:49 PM
To: Repeater-Builder@yahoogroups.com
Subject: Re: [Repeater-Builder] IOTA Switched Power Supply and Noise?


Does anybody have a web site to look at IOTA power supply? I need to find
some to replace my power supplies in the future.  Bruce KD4BOH.-
Original Message -
From: Joe Montierth [EMAIL PROTECTED]
To: Repeater-Builder@yahoogroups.com
Sent: Wednesday, May 25, 2005 2:22 PM
Subject: Re: [Repeater-Builder] IOTA Switched Power Supply and Noise?


I have one of the 75 amp supplies working at a remote
 site. We have not seen any noise from the unit, but
 our equipment is all VHF and UHF, haven't checked it
 down in HF, but at UHF we have seen no problems. We
 have 20 UHF RX's and 6 VHF and have not seen any
 degradation.

 These IOTA's run much cooler than the analog Astron's,
 and are much smaller. I will probably be changing out
 all of the Astrons to these in the next few years, as
 conditions warrant.

 Joe

 --- Nick Papadonis [EMAIL PROTECTED] wrote:
 Hi Folks,

 I'm considering purchasing a 45A IOTA Switched Power
 supply to power a UHF Micor and am concerned about
 switch PS noise.

 Has anyone tried these supplies with UHF radios?  Is
 noise experienced?

 Insight greatly appreciated.  Thanks.

 --
 Nick KB1GZN  Boston, MA








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Re: [Repeater-Builder] IOTA Switched Power Supply and Noise?

2005-05-25 Thread Joe Montierth
I have one of the 75 amp supplies working at a remote
site. We have not seen any noise from the unit, but
our equipment is all VHF and UHF, haven't checked it
down in HF, but at UHF we have seen no problems. We
have 20 UHF RX's and 6 VHF and have not seen any
degradation.

These IOTA's run much cooler than the analog Astron's,
and are much smaller. I will probably be changing out
all of the Astrons to these in the next few years, as
conditions warrant.

Joe

--- Nick Papadonis [EMAIL PROTECTED] wrote:
 Hi Folks,
 
 I'm considering purchasing a 45A IOTA Switched Power
 supply to power a UHF Micor and am concerned about
 switch PS noise.
 
 Has anyone tried these supplies with UHF radios?  Is
 noise experienced?
 
 Insight greatly appreciated.  Thanks.
 
 --
 Nick KB1GZN  Boston, MA
 
 
 
 




__ 
Do you Yahoo!? 
Yahoo! Small Business - Try our new Resources site
http://smallbusiness.yahoo.com/resources/




 
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