rc2103_0assembly 762KB Aug 31 2006 05
Contents
1. Arcom Communications 24035 NE Butteville Rd Aurora Oregon 97002 503 678 6182 arcom ah6le net RC 210 Repeater Controller Assembly Manual Hardware Version 3 0 Original Release Date September 13 2004 Reproduction or translation of any part of this manual beyond that permitted by sections 107 or 108 of the 1976 United States Copyright Act or its legal successor without the express written permission of Arcom Communications is unlawful as noted below Requests for permission to copy or for further information should be addressed to Arcom Communications Except as noted above permission is hereby granted for any non profit group or individual to reproduce any portion of this document provided that the reproduction is not sold for profit the intent of reproduction is to further disseminate information on the RC 210 Repeater Controller kit the reproduction is not used for advertising or otherwise promoting any specific commercial product other than the RC 210 and full credit is given to Arcom Communications as the original source of information The information contained in the manual has been carefully checked for accuracy and is believed to be entirely reliable However no responsibility is assumed for inaccuracies Arcom Communications reserves the right to make changes in the RC 210 Repeater Controller kit to improve reliability function or design without obligation to purchasers of previous equipment Arcom Communications does not as2. connectors for J2 J3 and J4 either DB9 or RJ45 modular jacks You must now decide which you prefer to use You may want to read the Choosing Your Connector section at the end of this manual before proceeding with this step J6 RJ45 or DB9 female right angle PC mount J7 RJ45 or DB9 female right angle PC mount J8 RJ45 or DB9 female right angle PC mount Install the Phoenix PC mount 4 pin jack at the location on the PC board marked Power It should be installed so it fits inside the outline marked on the PC board Power 4 pin green Voltage Regulators IC 1 is installed upright on the PC board with the metal tab lined up with the dark line on the silkscreened outline on the PC board and should be spaced 1 4 above the surface IC1 78M05 LM340T5 Install the heatsink onto the metal tab of IC1 with the 4 40 hardware provided Then cut off the excess length of the screw IC7 looks like a transistor It should be installed just like the transistors IC7 78L033 CZ 3 3 Inductor L1 looks like a 1 watt resistor Bend one lead over and install it vertically on the board 1 L1 silver black black red silver Crystals Install the following 2 crystals with the body 1 8 inch above the surface of the PC board Caution Make sure you space the crystal as stated to avoid shorting traces on the PC board Y1 3 579 Mhz crystal Y2 16 00 Mhz crystal 3 57ECSV 160ECSV Crystal X1 looks dif
3. 4 C43 10uf Diodes Diodes are polarized devices with the cathode end being banded Observe polarity when installing the following diodes D1 D2 D3 D5 1N4001 Install the following 22 ea 1N4148 diodes D11 D12 D13 D14 D15 D16 D17 D18 D20 D21 D22 D23 D24 D25 D26 D27 D33 D34 D35 D36 D37 D38 LEDs Install the LEDs 1 2 above the board to allow them to be bent over later Note that one side is flat this is the cathode Be sure the flat side of the LED lines up with the flat side on the PC board P1Key P2Key P3Key Red LED P1Cos P2Cos P3Cos Green LED P1Ctcss P2Ctcss P3Ctcss Yellow LED P1Dtmf Red Led P2Dtmf Green LED P3Dtmf Yellow LED Transistors All transistors should be installed with the body not more than 1 4 above the PC board Match the body of the transistor with the outline on the board and carefully bend the leads to match the hole pattern on the PC board All transistors are 2N3904 Q1 Q6 Connectors Carefully install J1 taking care that no pins are bent over as you insert them Holding J1 flush against the PC board solder two opposite pins in order to the hold it in place Then solder the remaining pins taking care to avoid solder bridges Solder the two larger holes one on each end to the pads on the PC board Use lots of solder to make a mechanically secure connection J3 25 pin female right angle PC mount Your RC 210 kit comes with 2 types of
4. 64 pin TQFP 1 ISD4003 04MP VoiceCorder 28 pin DIP 32 ULN2003A 16 pin DIP 1 MT8806 Crosspoint Switch 24 pin DIP 3 MT8870 DTMF Decoder 18 pin DIP 1 1232 Level Translator 16 pin DIP 2 TLO64 Operational Amp 14 pin DIP 2 74HC595 Shift Register 16 pin DIP Sockets 33 18 pin DIP Socket 1 24 pin DIP Socket 1 28 pin DIP Socket 32 14 pin DIP Socket 5 16 pin DIP Socket Voltage Regulators 1 5 0 volt LM340T5 TO 220 case 1 3 3 volt 78L33 TO 92 case with piece of tape on leads Connectors 3 9 pin female right angle PC mount 25 pin female right angle PC mount RJ45 modular jack 4 pin power female PCB power 4 pin power male plug 36 pin single row header PC mount 10 pin dual row header PC mount AN SE AAA NO GQ Misc Heatsink 4 39 screw and nut assembly 3 579 Mhz crystal 3 57ECSV 16 Mhz crystal 160ECSV 32768 Khz crystal small cylindrical 10 uh choke silver black black red silver Self resetting Fuse X030 3 Push on jumpers PC Board revision 2 8 Assembly Manual User Manual VLC a ara AA wee ON ee ee ee NA em et do doo do Ce Construction You are now ready to begin construction of the RC 210 Use a temperature controlled fine tipped soldering iron and good quality 60 40 rosin core solder for construction Follow standard construction practices when building the unit You will also need small fl
5. C19 C20 L1 o o gu 2 E 1 lolo 017 OHO D16 OHO 015 OHO D140 D13 D12 Dit 012 OBO Program OO 027 028 OO 026 OO 025 OBO p24 OO 023 OO 022 D21 8 6409660660666 DTMF CTCSS cts cTt s cos J5 1 C0000000 1 0 Expand Sad JP3 1 aaada Dela Beara 1 IC5 16 00000000 00000000 8 9 00000000 1 IC6 16 00000000 9 RC 210 Rev 3 0 Copyright Arcom 2003 2004 o o 107 oO 2 o a nie AB o of res Jo o o ap io HAH cis o Flo olko go o offoce a O m oles JO o No O Ol Rez YO S 3 Romke orzo 3 lo Js 20 E lo offoca Arto 8 lo Olbecw c27 0 Lo o a o nag cos odo o o Le le o 90 2 2 Ao o 5 o o o 55 Ak 2 o c o 9 cascas 037 O o C26 Record c43 O00000 haio E o res AH of nas Jo IIL pond JP6 TP3 JP9 of R55 Jo ol o 4 OO OX ofp jo o so O E cso o ofo 9 olmo F wl 9 a al Slo al 50 oslo J 38 ommo 88 omo y p 28 oL R32 O og lo O R3s o Dx o lo CS E c2140Jkh oO O or O o OLRs2 jo mo aj Ba ON Duo On O O Rei jo JP 1 JP18 1 JPii JP12 JP13 au ads 009 COO C41 A 3 05 ae C48 200 Ez TO Sci omo 036 omo 038 ees oe oe Port2 Discts4
6. P2 JP3 and JP4 This completes the audio path for the receiver amplifiers when the audio delay board is not installed JP2 JP3 JP4 Install a push on jumper on each of the 3 de emphasis jumpers You can skip this step if you plan on using flat audio on your repeater JP5 JP6 JP9 Install a push on jumper on JP1 This enables the LED s you can remove it later if you wish to reduce current draw JP1 Check Your Work Double check your work All solder connections are bright and shiny No solder bridges between IC socket pins All components installed in their correct positions Diodes transistors voltage regulators and electrolitic capacitors installed with their proper polarity The pc board modifications are done correctly Congratulations At this point your RC 210 is completely assembled except for the integrated circuits These will be installed after you run some voltage checks Checking Voltages For these tests you will need to connect power to the RC 210 It is suggested that you use a power supply with current limiting just in case Locate the green 4 pin power plug and connect it as follows Pin 1 11 5 to 15 Vdc Pins 3 amp 4 Ground both of these pins MUST be connected to the power supply s negative leads Meter Plus Lead Meter Minus Lead Result IC2 pin 16 Ground 5 5 U6 pin 24 Ground Vcc 5 U5 pin 4 U5 pin 11 Vcc 5 U5 pin 12 U5 p
7. ferently from the other 2 crystals it is a small cylindrical type with close spaced leads X1 should be mounted 1 4 above the PC board then bent over so it lays flat against the board away from the Mega128 X1 32768 Khz crystal Fuse The RC 210 uses a special self resetting fuse It looks like a yellow ceramic capacitor and is marked X030 F1 Fuse Resistor Network The resistor network is a 10 pin single in line package colored black There is a white dot on one end which indicates pin 1 Line pin 1 up with 1 marking silkscreened on the PC board at RN1 RN1 470 ohm resistor network Jumper Headers Locate the 2 32 pin jumper header connectors Carefully cut them between pins in the notches in the plastic to create the following 10 pin 3 pin 5 pin 6 pin 8 pin 2 pin gt A o e e e Ne SY A gt UON Install the following pin headers you just created JP1 2 pin JP2 JP3 JP4 5 pin JP5 JP6 JP9 2 pin JP7 JP8 JP10 JP11 3 pin JP12 JP13 3 pin J1 10 pin J2 3 pin J5 8 pin J9 6 pin Now install J5 the 10 pin dual row header gt J4 Locate the push on jumpers and slide them over pins 1 amp 2 or 2 8 3 of the jumper headers depending on your COS polarity requirements Don t worry if you don t know which you need right now as you can easily change them later JP7 JP8 JP10 JP11 JP12 JP13 Install push on jumpers over pins 2 amp 3 of J
8. in 11 1 2 Vcc 5 U7 pin 27 U7 pin 12 3 3v 5 Vcc refers to the voltage supplied to the RC 210 If you do not obtain the results above carefully check the PC board for cold solder joints bridges or unsoldered connections If all is well remove power You re now ready to install the socketed integrated circuits U1 U2 U3 MT CM 8870 Ic2 MAX232 IC3 IC5 74HC595 IC4 IC6 ULN2003A U4 U5 TLO64 U6 MT8806 U7 ISD4003 M4 Your RC 210 is now ready for installation and programming Please consult the Operations Manual If You Need Assistance We offer several ways you can obtain assistance with your RC 210 Our Website http www ah6le net arcom help html Our email list it s a good idea for all RC 210 owners Send an email to mailto rc210 subscribe yahoogroups com Or you may contact us directly at Arcom Communications 24035 NE Butteville Rd Aurora Oregon 97002 503 678 6182 email arcom ah6le net 6 JP1 othe of Ar 2 ry C17 a ry C16 C15 IC4 6 ole jo eto Focs a 000000000 U1 O cs odo MT8878 S 9000000009 O O Rr2 jo 9 cz Afo 000000000 o Ar a o mree7a U2 00000000 O O 1 c8 DTMF ang 000000000 Expand ts ifo nteaza U3 900000000 qe C13 Oa v0 Oa wl Oa o ZO o poo m a Slo a Doo o lo o oo o bo obo o bo obo o bo obo Olo o Olw noO Ojo 00000000 9 cia Fo Garo olfoca 600555005 Megal28 xt
9. ket before proceeding to the next one If you find a socket is difficult to install remove it and check for bent pins Install the following IC sockets U6 24 pin U1 U2 U3 18 pin U4 U5 14 pin U7 28 pin IC2 IC3 IC4 16 pin IC5 IC6 16 pin Now check all your work All leads should be soldered with no solder bridges or cold solder joints Resistors Resistors lie flat on the PC board and have a lead spacing of 0 5 You may wish to use a lead former to preform the resistor leads for the neatest appearance Install the following resistors 10K brown black orange gold resistors R26 R27 R31 R32 R38 R44 R45 R51 R54 R59 R60 R61 R62 R63 R65 Install the following 47K yellow violet orange gold resistors R50 R52 R53 Install the following 22K red red orange gold resistors R34 R55 R67 R66 In the following 47 ohm yellow violet black gold R29 R43 R49 Install the following 470K yellow violet yellow gold resistors R10 R11 R12 Install the following 110K brown brown yellow gold R28 R30 R36 Install the following 33K orange orange orange gold resistors R35 R40 R58 Install the following 100K brown black yellow gold resistors R1 R2 R3 R4 R5 RY R46 R47 R48 Install the following 470 ohm yellow violet brown gold resistors R6 R7 R8 R15 R16 R17 R18 R19 R20 R21 R22 R23 R37 R57 Resist
10. ors R13 and R14 are not included See Hardware Manual for details Potentiometers Carefully bend the three leads of each trim pot over 90 degrees so the leads face the back of the trim pot body Then insert the leads through the holes in the PC board with the body closest to the edge of the board it is flush against the board Then solder the connections note the pots should lay down against the board with the adjustment slot facing up 10K ohm C103 Port1 Disc Port2 Disc Port3 Disc Record Play Tone 500K ohm C504 P1 Tx P2 Tx P3 Tx Capacitors The following capacitors are 1uf 104 and should be mounted as close to the board as possible without stressing the leads C1 C3 C5 C6 C9 C14 C15 C16 C17 C19 C20 C22 C27 C31 C32 C35 C36 C37 C38 C39 C45 C46 C47 Install the 0068 uf 682 capacitors C24 C25 C30 Install the following capacitors C18 C21 C7 C8 22pf 220 33pf 330 Electrolitic Capacitors These capacitors are polarized so care should be taken to orient them properly Note that at the installation positions for these capacitors the PC board is marked with a plus Note that the capacitors have the minus lead marked Install accordingly The following are all 2 2uf C23 C26 C29 C34 C41 C44 C48 Install the remaining electrolytic capacitors C11 C12 C13 C60 1uf C10 47uf C28 C33 C40 C42 22uf C
11. sume any liability arising out of the application or use of any product or circuit described herein neither does it convey license under its patent rights or the rights of others Parts List Check off the part in the space provided as you locate and verify against this list Resistors 1 4 watt 15 10k ohm brown black orange gold 22k ohm red red orange gold 47k ohm yellow violet orange gold 100k ohm brown black yellow gold 470k ohm yellow violet yellow gold 110k onm brown brown yellow gold 33k ohm orange orange orange gold 470 ohm yellow violet brown gold 47 ohm yellow violet black gold DE IA 4 14 3 AN AN AR ATRIO N OA SO Resistor Network 1 470 ohm network 10 pin SIP Potentiometers 6 10k ohm C103 3 500k ohm C504 Capacitors Capacitors may be marked in various ways The typical markings are given but may vary 23 Auf 104 2 33pf 330 2 22pf 220 3 O068uf 682 Electrolytic Capacitors 4 1 uf 7 2 2 uf 4 22 uf 1 47 uf 2 10 uf 4 1N4001 Rectifier might be 1N4002 or 1N4004 22 1N4148 Silicon Diode 4 Red LED 4 Green LED 34 Yellow LED Transistors 6 2N3904 NPN Integrated Circuits Do not handle the IC s unnecessarily Carefully remove the IC tubes from the anti static bag and check each one against the parts Then return the tubes with the ICs to the bag 1 ATMega128 mounted on PCB
12. ush or semi flush cutting pliers and small tipped needle nosed pliers A magnifying glass may prove useful for identifying the values of small parts Keep the tip of the soldering iron bright and clean wiping it frequently on a wet sponge or rag Make solder joints carefully but swiftly Prolonged heat on a PC board pad can be disastrous and ruining this PC board can be expensive Two or three seconds should be enough time to apply heat to any joint Follow the order of construction as they have been developed to make installation of parts as easy as possible The microprocessor ATMega128 has already been soldered on the board Great care should be taken when assembling the RC 210 to ensure there are no static discharge issues The use of a grounding wrist strap and grounded tip soldering iron is highly recommended Note DAMAGE DUE TO STATIC DISCHARGE IS NOT COVERED UNDER WARRANTY IC Sockets Note If any sockets are bent carefully straighten them with a pair of needle nose pliers When installing IC sockets double check to ensure that the socket is seated properly against the board with the notch beveled corner or 1 towards the silkscreened reference U1 IC2 etc Be sure all IC socket pins are showing on the solder side of the board While making certain the IC socket is tight against the PC board tack solder two diagonally opposite corners Such as pins 1 and 14 ona 14 pin socket Then solder the remaining pins of that soc
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