Arcom RC210 User manual

Arcom Communications
24035 NE Butteville Rd
Aurora, Oregon 97002
[phone]
[email protected]t
http://www.arcomcontrollers.com/
RC210 Repeater Controller
Assembly Manual
Hardware Version 3.3
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 RC210 Repeater Controller kit; the reproduction is not used for advertising or otherwise promoting any specific commercial product other than the
RC210; 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 RC210 Repeater Controller kit to improve reliability, function
or design without obligation to purchasers of previous equipment. Arcom Communications does not assume 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.
RC210 Repeater Controller
Assembly Manual
Hardware Version 3.3

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RC210 Repeater Controller
Assembly Manual
Hardware Version 3.3

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Parts List
Check off the part in the space provided as you locate
and verify against this list.
Resistors, 1/4 watt
( ) 12 10k ohm (brown-black-orange-gold)
( ) 3 22k ohm (red-red-orange-gold)
( ) 4 47k ohm (yellow-violet-orange-gold)
( ) 10 100k ohm (brown-black-yellow-gold)
( ) 3 470k ohm (yellow-violet-yellow-gold)
( ) 3 110k ohm (brown-brown-yellow-gold)
( ) 3 33k ohm (orange-orange-orange-gold)
( ) 23 470 ohm (yellow-violet-brown-gold)
( ) 2 47ohm (yellow-violet-black-gold)
Resistor Networks
( ) 1 470 ohm network (471 or 470)
( ) 1 10K ohm network (103G)
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.
( ) 28 .1 uf (104)
( ) 2 33pf (might be 30pf) (33 or 30)
( ) 2 22pf (22)
( ) 3 .0068uf (682)
( ) 1 .001uf (102 and has paper on each lead)
Electrolytic Capacitors
( ) 7 2.2 uf
( ) 3 22 uf
( ) 1 47 uf
( ) 2 10 uf
Diodes
( ) 2 1N4001 Rectifier (might be 1N4002 or 1N4004)
( ) 6 1N914 Silicon Diode
( ) 13 1N5231B Zener Diode (taped together)
( ) 4 Red LED
( ) 4 Green LED
( ) 4 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) (64 pin TQFP)
( ) 1 ISD4003-04MP VoiceCorder (28 pin DIP)
( ) 2 ULN2003A (or MC1413P) (16 pin DIP)
( ) 1 MT8806 Crosspoint Switch (24 pin DIP)
( ) 3 MT8870 DTMF Decoder (18 pin DIP)
( ) 1 ST232 Level Translator (16 pin DIP)
( ) 2 TL064 Operational Amp (14 pin DIP)
( ) 2 74HC595 Shift Register (16 pin DIP)
Sockets
( ) 3 18-pin DIP Socket
( ) 1 24-pin DIP Socket
( ) 1 28-pin DIP Socket
( ) 2 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)
Connectors
( ) 3 9-pin female right-angle PC mount
( ) 1 25-pin female right-angle PC mount
( ) 3 RJ45 modular jack
( ) 1 4 pin power female PCB power
( ) 1 4 pin power male plug
( ) 2 36 - pin single row header PC mount
( ) 1 10 pin dual row header PC mount
Misc.
( ) 1 Heatsink
( ) 1 4-40 screw and nut assembly
( ) 1 3.579 Mhz crystal (3.57ECSV)
( ) 1 16 Mhz crystal (160ECSV)
( ) 1 32768 Khz crystal (small cylindrical)
( ) 1 10 uh choke (silver-black-black-red-silver)
( ) 1 Self-resetting Fuse (X050)
( ) 13 Push-on jumpers
( ) 1 PC Board (Revision 3.3) w/ CPU
( ) 1 Assembly Manual
( ) 1 User Manual
RC210 Repeater Controller
Assembly Manual
Hardware Version 3.3

4
Construction
You are now ready to begin construction of the RC210. 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 flush 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
RC210 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 on a 14
pin socket). Then solder the remaining pins of that socket 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
( ) U2, U3 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:
( ) R32, R55, R58
( ) R65, R66, R67
( ) R36, R37, R49
( ) R50, R63, R64
Install the following 47K (yellow-violet-orange-gold) resistors:
( ) R28, R54, R56, R57
Install the following 22K (red-red-orange-gold) resistors:
( ) R39, R59, R70
In the following 47ohm resistors (yellow-violet-black-gold)
( ) R34, R48
Install the following 470K (yellow-violet-yellow-gold) resistors:
( ) R10, R11, R12
Install the following 110K (brown-brown-yellow-gold)
( ) R33, R35, R41
Install the following 33K (orange-orange-orange-gold) resistors:
( ) R42, R45, R62
Install the following 100K (brown-black-yellow-gold) resistors:
( ) R1, R2, R3, R4, R5, R9, R51, R52, R53, R74
Install the following 470 ohm, (yellow-violet-brown-gold) resistors:
( ) R6, R7, R8, R15, R16, R17, R18, R19, R20
( ) R21, R22, R23, R24, R25, R26, R27, R29
( ) R40, R43, R61, R69, R71, R72
(Resistors R13 and R14 are not included. See Hardware Manual
for details)
RC210 Repeater Controller
Assembly Manual
Hardware Version 3.3

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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.
( ) C2, C3, C5, C6, C9, C10, C11, C12, C13, C14
( ) C15, C16, C17, C19, C20, C22, C24, C32, C33
( ) C34, C37, C38, C39, C40, C41, C46, C47, C48
Install the .0068 uf (682) capacitors
( ) C25, C26, C30
Install the following capacitors:
( ) C18, C21 22pf (220)
( ) C7, C8 33pf (330) (may be 30pf, marked 30)
( ) C31 .001uf (102)
Electrolytic 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 2.2 uf.
( ) C23, C27, C29, C36, C42, C45, C49
Install the remaining electrolytic capacitors:
( ) C1 47uf
( ) C28, C35, C43 22uf
( ) C4, C44 10uf
Diodes
Diodes are polarized devices, with the cathode end being banded.
Observe polarity when installing the following diodes.
( ) D1, D2 1N4001 (may be 1N4004)
Install the following 6 ea. 1N914 diodes:
( ) D16, D17, D18, D19, D20, D21
Install the following 13 ea. 1N5231B zener diodes
( ) D3, D4, D5, D6, D7, D8, D9
( ) D10, D11, D12, D13, D14, D15
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 J4 taking care that no pins are bent over as you
insert them. Holding J4 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.
( ) J4 25-pin female right-angle PC mount
Your RC210 kit comes with 2 types of connectors for J2, J3 and J4
- either DB9 or RJ45 modular jacks. You must now decide which
you prefer to use.
( ) J1 RJ45 or DB9 female right angle PC mount
( ) J2 RJ45 or DB9 female right angle PC mount
( ) J3 RJ45 or DB9 female right angle PC mount
RC210 Repeater Controller
Assembly Manual
Hardware Version 3.3

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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
IC1 is installed laying down on the PC board with the heatsink
between it and the PC board . Carefully bend IC1’s leads 90
degrees and insert into the appropriate holes in the board. Slide the
heatsink in place and use the supplied 4/40 screw and nut to
secure the assembly through the hole in the board.
( ) IC1 78M05 (LM340T5)
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 so it is standing up.
( ) 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 (3.57ECSV)
( ) Y2 16.00 Mhz crystal (160ECSV)
Crystal X1 looks differently 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 RC210 uses a special, self-resetting fuse. It looks like a yellow
ceramic capacitor and is marked "X050"
( ) F1 Fuse
Resistor Networks
The resistor networks are a 10 pin single in-line package. 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 and RN2.
( ) RN1 470 ohm resistor network
( ) RN2 10K 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:
( ) 7 3 pin
( ) 3 5 pin
( ) 1 6 pin
( ) 1 8 pin
( ) 4 2 pin
You may add the leftover to your junkbox!
Install the following pin headers you just created, being careful to
keep them perpendicular to the pc board
( ) JP1, JP2, JP3 3 pin
( ) JP4, JP5, JP6 3 pin
( ) JP7, JP8, JP9, JP13 2 pin
( ) JP10, JP11, JP12 5 pin
( ) J6 3 pin
( ) J7 8 pin
( ) J9 6 pin
Now install J5, the 10 pin dual row header
( ) J5
Locate the push-on jumpers and slide them over pins 1 & 2 or 2 & 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.
( ) JP1, JP2, JP3, JP4, JP5, JP6
Install push-on jumpers over pins 2 & 3 of JP10, JP11 and JP12.
This completes the audio path for the receiver amplifiers when the
audio delay board is not installed:
( ) JP10, JP11, JP12
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.
( ) JP7, JP8, JP9
Install a push-on jumper on JP13. This enables the LED's (you can
remove it later if you wish to reduce current draw)
( ) JP13
RC210 Repeater Controller
Assembly Manual
Hardware Version 3.3

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Check Your Work
Double check your work.
( ) All solder connections are bright and shiny.
( ) No solder bridges between IC socket pins.
( ) All components are installed in their correct positions.
( ) Diodes, transistors, voltage regulators and electrolytic capacitors are installed with their proper polarity.
( ) The pc board modifications are done correctly.
Congratulations! At this point your RC210 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 RC210. 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
Pin 3 or 4 Ground
Meter Plus Lead Meter Minus Lead Result
( ) IC2, pin 16 Ground +5 ± 5%
( ) U6, pin 24 Ground Vcc ± 10% *
( ) U5, pin 4 U5, pin 11 Vcc ± 10% *
( ) U5, pin 12 U5, pin 11 1/2 Vcc ± 10%
( ) U7, pin 27 U7, pin 12 3.3v ± 5%
* Vcc refers to the voltage supplied to the RC210.
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 MT8870DE1
( ) IC2 MAX232 (ST232)
( ) IC3, IC5 74HC595
( ) IC4, IC6 ULN2003A (or MC1413P)
( ) U4, U5 TL064
( ) U6 MT8806AE
( ) U7 ISD4003-04MP
Your RC210 is now ready for installation and programming. Please consult the Operations Manual.
RC210 Repeater Controller
Assembly Manual
Hardware Version 3.3

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If You Need Assistance
We offer several ways you can obtain assistance with your RC210:
Our email list (it's a good idea for all RC210 owners):
Send an email to: mailto:rc210-[email protected]
Or you may contact us directly at:
Arcom Communications
24035 NE Butteville Rd.
Aurora, Oregon 97002
[phone]
email: [e-mail]
RC210 Repeater Controller
Assembly Manual
Hardware Version 3.3