Cirrus Logic AN168 User Manual

AN168
Application Note
ACOUSTIC PATH DESIGN FOR FULL-DUPLEX CELLULAR
HANDS-FREE CAR KITS
This application note describes a design procedure coupled with some testing procedures to enable a system designer to implement a low cost full-duplex cellular hands-free system for cars using the CS6422 Enhanced Echo Cancelling IC. This application note focuses on the design of the acoustic path, that is, the path between the acoustic output (AO) and the acoustic input (APO) of the CS6422. The acoustic path contains the speaker driver, the speaker, the air path between the speaker and the microphone, the microphone, and the microphone preamp.
Additionally, a suggested set of CS6422 configuration parameters is presented as well as some system-level tests that can be used to optimize the parameters for a particular environment.

1. DESIGN PROCESS AND CONSIDERATIONS

There are four parts to the hands-free design process: mechanical design, electrical design, echo
canceler coefficient optimization, and testing. This note will investigate all four.

1.1 Design Flow

The design flow for full-duplex systems is as follows:
1) Design the mechanical and electrical systems for low distortion, specifically less than 2% THD across frequency.
2) Install the equipment in the target test system, usually a car.
3) Tweak the mic preamp gain to achieve -9 dB acoustic coupling.
4) Load the starting point example CS6422 regis­ter configuration.
5) Perform parameter optimization tweaking tests.
6) Test under actual driving conditions. If neces­sary, modify speaker/mic placement and test again.
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Copyright © Cirrus Logic, Inc. 2006
(All Rights Reserved)
MAR ‘06
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TABLE OF CONTENTS

1. DESIGN PROCESS AND CONSIDERATIONS ........................................................................1
1.1 Design Flow ........................................................ .... ... ... ... .................................................. 1
1.2 Mechanical Design ............................................................................................................. 4
1.2.1 Selecting the Acoustic Components .....................................................................4
1.2.1.1 Speaker Requirements ................................................. ... .....................4
1.2.1.2 Microphone Requirements ......................................................... ... ... .... . 4
1.2.1.3 Speaker Housing Requirements ......................... .... ... ... ... .... ... ... ... ... .... . 5
1.2.2 Placing the Speaker and Microphone ................................................................... 5
1.3 Electrical Design ........................................... ... ... .... ... ... ... .... .............................................. 5
1.3.1 Selecting the Speaker Driver ................................................................................ 5
1.3.2 Setting the Speaker Driver Gain ........................................................................... 6
1.3.3 Volume Control ...... ... .... ... ... ... ... .... ... ... ..................................................................7
1.3.4 Acoustic Coupling .. ... .... ... ... ... ... .... ... ... .......................................... ... .... ... ... ... ... .... . 8
1.3.5 Setting the Mic Preamp Gain ........................................ ... ... .... .............................. 8
1.3.6 Acoustic Sidetone .. .......................................... ... .... ... ... ... ... ................................ 11
1.4 Echo Canceler Parameter Optimization ...........................................................................11
1.4.1 Starting Example .................................... .... ... ... ............................................. ... ... 11
1.4.2 Tweaking the Parameters ...................................................................................12
1.4.3 Network Sidetone ............................. ... ... .... ... ... ... .... ... ... ... ................................... 13
1.4.4 Loop Gain .................. .... .......................................... ... ... ... ... ................................ 14
1.5 Tests ................................................ ... ... .... ... ... ... .......................................... .... ... ............ 14
1.5.1 Acoustic Coupling .. ... .... ... ... ... ... .... ... ... .......................................... ... .... ... ... ... ... ... 15
1.5.1.1 Loop Gain Method ...................... ................... ................... ................... 15
1.5.1.2 Frequency Response Method .............................................................17
1.5.2 Acoustic Distortion ..................................................... ......................................... 17
1.5.2.1 Frequency Sweep Test .......................................................................18
1.5.2.2 Buzz Test ......................... ... ... .... ... .......................................... ... ... ... ... 18
1.5.3 Acoustic ERLE ....................... ... .... ... ... .......................................... ... .... ... ... .........19
1.5.3.1 White Noise RMS Method .......................... ......................................... 19
1.5.3.2 Loop Gain Method ...................... ................... ................... ................... 20
1.5.4 Call Testing and Coefficient Optimization ........................................................... 23
1.5.4.1 Far-end single-talk counting ................................................................23
1.5.4.1.1 Subtest A, EC Convergence Test .............................................. 23
1.5.4.1.2 Subtest B, Half-Duplex to Full-Duplex transition time ................ 24
1.5.4.1.3 Subtest C, Transmit Suppression test .......................................24
1.5.4.2 Double-talk .......................................................... ................................ 24
1.5.4.3 Half-duplex alternate counting ................................................ ... ... ... ... 25
1.6 Layout Guidelines ................................................... ... ... ... .... ... ... ... ................................... 25
1.6.1 CS6422-specific guidelines ........................ ... ... ... .... ... ......................................... 25
1.6.2 Car-Kit guidelines ............................. ... ... .... .......................................... ... ... ... ... ... 26
1.6.2.1 +5VA/AGND Components ............. ... ... .... ......................................... ... 26
1.6.2.2 +5VD/DGND Components ............................... ... .... ............................ 26
1.6.2.3 +12VBATT/BATTGND Components ................................................... 27
1.7 Quick list of important points: .................................. ... ... ... .... ... ... ...................................... 27
1.7.1 Reset and configuration timing ............................................................................ 27
1.7.2 Distortion .................................................................... ... ...................................... 27
1.7.3 Speaker/mic placement ................. ... ... ... .... ... ... ............................................. ... ... 27
1.7.4 Acoustic coupling ................................... .... ... .......................................... ... ... ... ... 28
1.7.5 Training sequence ......................... ............. ......... ............. ............. ............. ......... 28
2. APPENDIX - EXAMPLE SPEAKER DRIVER CIRCUITS ...................................................... 29
2.1 Example 1: TDA1519A -- 15 Watts into 4 W ................................................................. ... 29
2.2 Example 2: TDA2003 -- 3 Watts into 4 W ........................................................................29
2.3 Example 3: TDA1905 -- 2.5 Watts into 4 W .....................................................................33
2.4 Example 4: LM1877-- 2 Watts into 4 W ...........................................................................34
2.5 Example 5: LM4861-- 1 Watt into 4 W .............................................................................34
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LIST OF FIGURES

Figure 1. Speaker Distortion.................................................................................................................... 4
Figure 2. Speaker Driver Distortion......................................................................................................... 6
Figure 3. Generic Speaker Driver Configuration.....................................................................................7
Figure 4. Using RVol to Implement Volume Control................................................................................7
Figure 5. Three Common Sources of Acoustic Path Distortion............................................................... 9
Figure 6. Acoustic Coupling Design Target.............................................................................................9
Figure 7. Example Acoustic Coupling Frequency Response..................................................................9
Figure 8. Setting the Acoustic Coupling................................................................................................10
Figure 9. Loop Gain with Network Sidetone..........................................................................................13
Figure 10. Loop Gain Diagram.............................................................................................................. 15
Figure 11. Acoustic Coupling Measurement Method ............................................................................ 16
Figure 12. Example Acoustic Coupling Frequency Response.............................................................. 17
Figure 13. Relative THD+N................................................................................................................... 18
Figure 14. Coupling-Weighted THD+N..................................................................................................19
Figure 15. Acoustic ERLE Measurement -- Train the AEC................................................................... 21
Figure 16. Acoustic ERLE Measurement -- Freeze AEC...................................................................... 22
Figure 17. Acoustic ERLE Measurement -- Clear AEC......................................................................... 22
Figure 18. Suggested CS6422 Layout..................................................................................................25
Figure 19. Speaker Driver Implementation............................................................................................ 26
Figure 20. CS6422 Reset and Configuration Timing............................................................................. 27
Figure 21. Example 4 kHz, 3-Pole Butterworth Low-Pass Filter ........................................................... 30
Figure 22. TDA 1519A Schematic.........................................................................................................31
Figure 23. TDA 2003 Schematic...........................................................................................................32
Figure 24. TDA 1905 Schematic...........................................................................................................33
Figure 25. LM 1877 Schematic ............................................................................................................. 35
Figure 26. LM 4861 Schematic ............................................................................................................. 36
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1.2 Mechanical Design

The performance of full-duplex hands-free designs is strongly influenced by the mechanical hardware, far more so than comparable half-duplex systems. Upgrading a half-duplex design by adding a full-duplex echo controller without changing the half-duplex mechanical hardware typically results in a system whose performance is unacceptable. This section describes the critical parameters of the mechanical design that ensure quality full-duplex operation.
The mechanical design consists of speaker and microphone component selection, speaker housing and mounting, and speaker and microphone placement in the car..

1.2.1 Selecting the Acoustic Components

1.2.1.1 Speaker Requirements
The quality of the speaker in a full-duplex system is critical to system performance because echo cancelers are sensitive to signal distortion. Because the echo canceler uses a linear filter to model the acoustic path, the acoustic path to be modeled must be linear in order for the echo canceler to work well. The total worst-case distortion in the acoustic path, which includes the speaker driver, the speaker, the microphone, and the microphone preamp, should be less than 2% THD across frequency.
The speakers in automotive hands-free systems are typically driven with a maximum RMS power between 0.5 and 5 Watts. In order to maintain 2% THD or less, it is necessary to install a speaker whose RATED power is at least twice as large as the maximum power to be driven. For example, if we wish to drive 2 Watts into the speaker, then the speaker's RATED power should be 4 Watts or greater. The RATED power of a speaker is the power at which the distortion performance is specified. The typical distortion specification for a speaker operating at its RATED power is either 5% or 10% THD, depending on how the manufacturer specifies distortion.
Speakers are also specified with a MAX power rating. The MAX power is the power level above which the speaker can be damaged. The RATED power, if it is given, is typically about half as large as the MAX power. Thus if the RATED power is not given, a good rule is to assume that the RATED power is about half of the MAX power.
NOTE: The above RATED power/MAX power generalization does not hold for new generation ultra-thin Mylar speakers. The poor distortion performance of these thin speakers makes them unsuitable for full-duplex car designs. Thick speakers exhibit a more linear behavior than thin speakers of equal diameter and are preferred in full-duplex designs.
1.2.1.2 Microphone Requirements
Less care is needed in microphone selection than in
Speaker
Figure 1. Speaker Distortion
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speaker selection. Almost any standard inexpensive electret microphone will work because microphones are inherently fairly linear devices. Microphones that cancel background noise due to their mechanical construction are preferred over those that do not. Microphones that are omnidirectional are preferred over those that are directional.
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1.2.1.3 Speaker Housing Requirements
The quality of the speaker housing affects the performance of the system because the speaker can induce vibrations in its housing if it is not properly mounted. These vibrations tend to create “buzzing” artifacts which are not linear and result in poor echo canceler performance.
Speakers that are supplied after-market in a housing and speakers that are part of the car's radio system generally do not present problems. It is the speakers that are glued or otherwise rigidly affixed to their plastics that create nonlinear buzzing artifacts.
Speakers should be soft-mounted to their housings by using soft pliable acoustic foam. Care should be taken to minimize any physical means by which the speaker can induce vibrations in the plastics.
The Test section contains a test procedure for testing and eliminating buzzing artifacts.
1.2.2 Placing the Speaker and Micro­phone
The placement of the speaker and the microphone affects the gain selection portion of the electrical design of the system which will be covered shortly. The microphone should be placed as close as feasible to the talker's mouth. This maximizes the signal-to-noise ratio (SNR) of the talker's speech. In a car, the optimal place for the microphone is near the rear view mirror, usually attached to the driver’s visor.
There are two considerations for the speaker placement. The more important of the two is that the speaker be placed such that there is a minimum of movement in the air space between the speaker and the microphone. This will minimize the number of updates and corrections that the adaptive filter makes during the call, resulting in the transmission of very little residual echo to the
far-end listener. The second consideration is that the speaker should be placed as far from the microphone as possible. This minimizes the acoustic coupling between the speaker and mic and allows the mic preamp gain and speaker driver gain to be maximized.
The optimum placement for the speaker in a car is the top of the dashboard. Whereas this does not minimize the distance between the speaker and the mic, it does limit the changes in the acoustic path, allowing the adaptive filter to update less often, resulting in less residual echo transmission. Other placement options, below the dash, driver's side door, and passenger's side door, favorably decrease the acoustic coupling, but result in the driver or the passengers being positioned directly in the path between the speaker and the microphone.

1.3 Electrical Design

The electrical design process consists of the component selection of the speaker driver, the gain selections of the speaker driver and the mic preamp, and the implementation of an acoustic sidetone. The primary design consideration of the electrical design process is to limit the distortion in the acoustic path to less than 2% THD.

1.3.1 Selecting the Speaker Driver

Many system designers overestimate the quality of their speaker drivers. For example, a speaker driver that claims to be “5 Watts” on the cover of its data sheet is not suitable to drive 5 Watts of power into the speaker of a full-duplex echo cancelling system. The reasons are two-fold:
1) The “5 Watts” number is usually a Typical number, not a Maximum or a Minimum speci­fication
2) “5 Watts” is specified with a THD of 10%, not the 2% number that we are designing to.
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Speaker Driver
Vout
Rx Out
VCC
GND
Figure 2. Speaker Driver Distortion
The Appendix lists five example speaker driver circuits that are suitable for full-duplex hands-free systems.

1.3.2 Setting the Speaker Driver Gain

V
Gain
-------- -
=
Vin
where Vin = full-scale voltage at the AO pin of the CS6422, which is 1 Vrms, or 0 dBV.
Additionally, the gain can be expressed in dB using the following relationship:
Gain dB() 20 Gain()log×=
The following example shows how to derive the gain required to drive 2 Watts of RMS power into a 4 speaker. Keep in mind that the RATED power for this speaker should be 4 Watts or greater, and the MAX power should be 8 Watts or greater.
2
V
PIV×
==
----- -
R
The speaker’s RATED power and the power driven into the speaker are RMS powers. The RMS power is given by the product of the RMS current and the RMS voltage, or the square of the RMS voltage over the speaker resistance.
The maximum speaker driver gain is determined by the square root of the product of the RMS power and the speaker driver resistance:
2
V
PVI×
==
----- -
R
VPR×=
where P = RMS power delivered to speaker, V = RMS voltage across speaker terminals, I = RMS current through speaker, and R = resistance of speaker in Ohms.
VPR× 24× 8 2.828====
Gain
V
-------- -
Vin
2.828
------------­1
2.828== =
Gain dB() 20 2.828()log× 9dB==
Many speaker drivers suitable for hands-free full-duplex design have fixed gains of 20 dB or more, or are not stable for gains less than 20 dB. Adding 20 dB of gain to the full-scale output of the CS6422 (=1 Vrms, =0 dBV, =2.8 Vpp) results in a huge signal at the speaker terminals (=10 Vrms, =20dBV, =28Vpp). Because of this, the speaker driver gain is implemented in two stages, an attenuator stage followed by a gain stage. The attenuator can be implemented using a simple resistor voltage divider network as shown in Figure 3.
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CS6422
A0
R
+
1
R
2
Attenuation Gain
+20 dB
+
Figure 3. Generic Speaker Driver Configuration
CS6422
RVol
TVol
Acoustic
Echo
Canceler
-
Σ
+
D/A
A/D
Speaker
Driver
Mic
Preamp
3
Microcontroller
Figure 4. Using RVol to Implement Volume Control

1.3.3 Volume Control

In most half-duplex systems, volume control is implemented by changing the gain of the speaker driver. In a full-duplex system, this is undesirable because gain changes in the acoustic path require the echo canceler to readapt, resulting in elevated levels of residual echo during the training process or a temporary drop to half-duplex operation.
In CS6422 systems, it is best to implement volume changes by using the RVol control. The RVol control provides up to +30 dB of AGC'ed gain to the receive path, and because the output of the
RVol control is fed both to the echo canceler and to the DAC driving the speaker, changes in RVol do not cause changes in the acoustic path, which keeps the echo canceler from having to readapt. This portion of the signal flow diagram is shown in Figure 4.
In general, the RVol control should be set to a value between +6 dB and +30 dB. In systems which have a network sidetone (a coupling path between NO and NI supplied by the phone), the maximum RVol value may need to be limited due to loop gain concerns. See the sections entitled Network Sidetone and Loop Gain for more information.
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1.3.4 Acoustic Coupling

Figure 5 shows the three most common places for distortion to be introduced into the acoustic path. These are the speaker driver, the speaker, and clipping at the A/D converter after the mic preamp. With careful choice of the speaker and speaker driver gain, we can eliminate the first two by using the techniques previously discussed. The third distortion source, clipping at the A/D converter, is controlled by limiting the amount of acoustic coupling.
The acoustic coupling is defined as the gain (or loss) between the AO pin and the APO pin on the CS6422, with TGain set to 0 dB. If TGain is set to a non-zero value, then the TGain value is added to the AO/APO gain number to compute the amount of acoustic coupling.
The acoustic coupling is determined by 5 factors: the speaker driver gain, the speaker efficiency, the air coupling between the speaker and the microphone, the microphone sensitivity, and the mic preamp gain. Assuming the speaker and mic have been chosen, the remaining design variables are the speaker driver gain, the mic preamp gain, and the speaker and mic position.
Usually, the speaker driver gain is chosen based on the linearity requirements previously described. The speaker and mic placement are determined by ergonomic factors and the desired acoustic path stability described above. The remaining variable is the mic preamp gain, which is typically set such that the worst-case acoustic coupling is between
-9 dB and -15 dB, the first number being the preferred design target, as shown in Figure 6.
The acoustic path response is highly frequency dependent. The contributions of the speaker driver and the mic preamp to the frequency response are essentially negligible since both of these amplifiers typically have a stable and well-behaved frequency response. The dominant factors in the frequency response of the acoustic path are the speaker's
inherent frequency response, the microphone's inherent frequency response, and the frequency response of the path between the speaker and the mic which is strongly affected by the speaker's housing. The flatter the frequency response, the better the echo cancellation.
Figure 7 shows an example acoustic path frequency response for a speaker and microphone separated by approximately one meter.
The signal at APO will visibly clip for signals greater than +5 dBV (5 Vpp). Keep in mind that the acoustic A/D converter clips at 0 dBV (2.8 Vpp) when TGain is set to 0 dB.

1.3.5 Setting the Mic Preamp Gain

As stated above, the design goal is to have the worst-case value for the acoustic coupling, the highest value across the frequency band of interest, less than or equal to -9 dB. Strictly speaking, it need only be less than 0 dB to avoid clipping at the acoustic A/D converter. The additional 9 dB provides margin for component tolerance variation (dominated by speaker variation), component installation (dominated by speaker/mic placement), and acoustic path variation (dominated by the position of the driver, passengers, and objects in the car). The mic preamp gain is adjusted to achieve the desired level of acoustic coupling.
There are two methods that can be used to set the acoustic coupling: the frequency response method and the loop gain method. The frequency response method is good because it provides frequency response information that can be used to increase the quality of the system (flat frequency response is desired). The loop gain method is quick, easy, and requires no additional test hardware beyond the ability to configure the CS6422's registers.
In the frequency response method, the acoustic path frequency response, the gain between the AO and the APO pins on the CS6422, is measured by automated test equipment and plotted. The
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Speaker Driver
Speaker
AO
DAC
1
2
Air
CS6422
Coupling
3
APO
ADC
Mic Preamp
Microphone
Figure 5. Three Common Sources of Acoustic Path Distortion
Speaker Driver
AO
DAC
Speaker
CS6422
ADC
Acoustic Path = -9dB
APO
Mic Preamp
Microphone
Figure 6. Acoustic Coupling Design Target
Acoustic Coupling (dB)
0 500 1000 1500 2000 2500 3000 3500 4000
0
-10
-20
-30
-40
-50
-60
-70
-80
Frequency (Hz)
Air
Coupling
Figure 7. Example Acoustic Coupling Frequency Response
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maximum value of this curve is then noted, and gain is added or subtracted at the mic preamp in order to set this maximum value to -9 dBV (with TGain set to 0 dB). This procedure is further described in the Tests section of this note.
The loop gain method uses howling to determine the optimum mic preamp gain. In short, the phone network is disconnected from the CS6422, and TVol, RVol and NSdt are used to create a +9 dB path between APO and AO inside the CS6422. The system will howl, go into regenerative feedback, at the point that the total loop gain reaches a factor of '1', or 0 dB. This happens whenever the gain between AO and APO outside the CS6422 reaches
-9 dB. The frequency of the howl is the frequency of the maximum loop gain, which is dominated by the speaker, microphone, and the air path between the two. Figure 8 illustrates.
The loop gain procedure is as follows:
1) Configure the CS6422 with its default configu­ration, with the exception of the following:
a) Mic = ‘1’ or ‘0’, depending on whether the
internal mic preamp is used or not
b) TSD = RSD = HDD = ‘1’, transmit and re-
ceive suppressors and half-duplex mode are disabled
c) ACC = NCC = 'cleared', echo cancelers are
forced to a cleared state to prevent updates
d) AECD = NECD = ‘1’, echo cancelers are
disabled e) TVol = +12 dB f) NSdt = -12 dB g) RVol = +9 dB
2) Adjust the mic preamp gain (or the speaker driver gain) until the system is just on the verge of howling. At this point the gain between AO and APO will be the desired -9 dB.
Disconnect
Network
CS6422
-12dB
NSdt - Network
Sidetone
+9dB
RVol - Receive
Volume
TVol - Transmit
Volume
12dB
Figure 8. Setting the Acoustic Coupling
Goal is -
9dB
A
O
APO
0dB
Speaker
Driver
Adjust
?dB
Mic
Preamp
Air Coupling
-?dB
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The register settings to accomplish the above are as follows:
reg 0: 47a0 (or c7a0 if internal mic preamp is used)
reg 1: 26a2 reg 2: 0004 (default) reg 3: 0006 (default) reg 4: 0008 (default) reg 5: 033a
Note: If the mic preamp gain is not easily adjustable in the test circuit, coarse amounts of gain can be added by using the TGain control, which can be set to 0 dB, +6 dB, +9.5 dB, or +12 dB.

1.3.6 Acoustic Sidetone

When the coupling path between the speaker and the microphone is relatively consistent, linear, and has a high signal-to-noise ratio (SNR), the CS6422 provides good echo cancellation and makes good training decisions. In the car environment, the SNR of the acoustic path can be degraded significantly by road and engine noise and the separation between the speaker and the mic. In these systems, it is often useful to introduce a strong, linear, predictable coupling path electrically by using an acoustic sidetone.
The acoustic sidetone provides 3 main benefits:
1) The presence of a strong path decreases conver­gence time, meaning it decreases the time the CS6422 spends in half-duplex.
2) The linear path enhances stability in systems in which the strongest real (air) path is distorted. Note that even though the echo canceller will not cancel the nonlinear elements of the acous­tic echo, it will make better decisions regarding when to engage the supplementary suppression algorithms to mask such echo. This results in improved performance during far-end sin­gle-talk.
3) The consistent path provides an echo path that is independent of the acoustic environment, making the system less sensitive to path chang­es and noise. This enhances full-duplex perfor­mance by reducing the tendency of the CS6422 to drop to half-duplex when the driver moves.
The amount of sidetone required depends on several factors. Typically, a good number is between -24 dB and -12 dB. To be useful, the electrical coupling should be about as strong as the strongest typical air coupling, but not much stronger. A good starting point for systems whose peak acoustic coupling is -9 dB is -18 dB of acoustic sidetone. The acoustic sidetone can be implemented in CS6422 systems by using the ASdt control, which is configurable to none, -24 dB,
-18 dB, or -12 dB.
1.4 Echo Canceler Parameter
Optimization
One of the benefits of the CS6422 is its high degree of configurability. Whereas the number of parameters may seem daunting at first, there are only a few that need to be tweaked to optimize performance. The rest can be set once and left alone.

1.4.1 Starting Example

The following is an example register configuration that is useful as a starting point for cellular car hands-free systems.
Note: Actual performance testing should be performed in a car, not a lab. This is because the car and the lab present different acoustic environments to the echo canceler, and the goal is to optimize the parameters for the target environment, which requires testing in that target environment.
The following parameter set assumes that there is no coupling on the network interface to the phone. If there is a network coupling path, see the Network Sidetone and Loop Gain sections below.
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