Timewave PK-232SC Assembly instructions

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PK-232SC Upgrade
Hardware Installation
Manual
for
Upgrade Kit p/n A.06140
Revision 2.1a
Note:
This manual covers installation of the features added with the SC version of
the PK-232.
The PK-232SC Operating Manual covers description and operation of the
features added with the SC version of the PK-232
The main PK-232 manual describes the modes and features found in the
original PK-232 and PK-232MBX.
The DSP manual supplement describes the DSP board features.

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WARRANTY TIMEWAVE TECHNOLOGY INC.
LIMITED ONE YEAR WARRANTY
WHO IS COVERED This warranty is extended only to the original purchaser of the A.06140.
WHAT WE WILL DO If your A.06140 fails in normal use because of a defect in workmanship or materials
within one year of the date of purchase, we will repair or replace (at our option) the
equipment at our factory without charge to you. Timewave will pay for the return of the
warranty-repaired unit to you.
WHAT YOU MUST DO First, double check your connections and operating procedure. If you're certain that the
unit is faulty, notify Timewave Customer Service immediately. If Timewave is unable to
resolve the problem by telephone or email, we will give you an RMA number and ask
you to return the unit. You must pay all shipping and insurance charges for returning the
unit to our factory.
WHAT IS NOT
COVERED We cannot be responsible for damage caused by accidents, abuse, misuse, improper
installation, or unauthorized attempts to repair the unit. This warranty does not cover any
parts of the PK-232 except the A.06140.
SERVICE WARRANTY Timewave service work performed in connection with this warranty is warranted to be
free from defects in materials and workmanship for 30 days from the date of repair. All
other terms of the limited warranty apply to the service warranty.
HOW TO CONTACT TIMEWAVE
Contact Timewave Customer Service by telephone at [phone] or by FAX at (651)
489-5066.
Mailing and shipping address is: 27 Empire Drive, Suite 110, St. Paul, MN 55103
email: [email protected]m
[e-mail]
[e-mail]
web: www.timewave.com
TIMEWAVE MAKES NO OTHER WARRANTY, EXPRESSED OR IMPLIED, INCLUDING BUT NOT LIMITED TO THE
IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
©2001, 2005, 2011, 2012 by Timewave Technology Inc., St. Paul, MN USA

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Table of Contents
Introduction..................................................................................................................................... 5
Contents of the SC upgrade kit........................................................................................................ 6
Required Tools................................................................................................................................. 7
PK-232 Disassembly......................................................................................................................... 8
PK-232SC Assembly Instructions ................................................................................................... 11
Wired connections to main board............................................................................................. 11
Power Connections................................................................................................................ 11
PK-232 Serial interface Connections ..................................................................................... 13
New DSP Board Installation................................................................................................... 16
Receive Audio Connections ................................................................................................... 17
Transmit Audio Connections ................................................................................................. 20
Sound Card / TNC Software Switch Connections .................................................................. 21
Reset Switch Connections ..................................................................................................... 22
Main Board Re-install ................................................................................................................ 24
SC Board Installation ................................................................................................................. 25
Units with MBX daughter board............................................................................................ 25
Units without MBX daughterboard ....................................................................................... 27
Table 1: SC Board Connections.............................................................................................. 30
SC Board Settings........................................................................................................................... 31
Jumper settings ......................................................................................................................... 31
DSP Jumper............................................................................................................................ 31
Sound Card Audio Jumpers ................................................................................................... 31
USB power Jumpers............................................................................................................... 31
Rig control serial port Jumpers.............................................................................................. 31
Trimpot settings ........................................................................................................................ 32
SC Board Parts Layout ................................................................................................................... 33
DTR PTT option for the PK-232SC.................................................................................................. 36

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Introduction
Thank you for purchasing the PK-232SC upgrade kit for the PK-
232. The Timewave part number of this kit is A.06140.
Please carefully install the SC upgrade kit according to the
following instructions. The best way to have a successful
installation is to preview this manual completely before starting.
Please read before installing this upgrade kit.
1. Be sure to download the latest upgrade for
ModemSwitch™ from http://www.timewave.com
2. Check your radio cable to be certain the black wire
(Squelch) is NOT connected to pin 3 of the Radio 1 or
Radio 2 connector on the back of the PK-232).
When you have completed assembly of your PK-232SC upgrade
kit, please refer to the PK-232SC Operating Manual for USB
driver installation information and description of the new
features you have added.

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Contents of the SC upgrade kit
•SC board assembly
•1 PK-232SC housing top assembly with SC/TNC switch &
LED assemblies
•6 Black 6-32x0.5 phillips head screws
•Zinc 6-32x0.375 phillips head screws
•1 Zinc 6-32x0.50 phillips head screws
•0.75x0.25 hex M-F standoffs
•1 0.1875 round spacer
•1 5 pin IDC connector – red, black, white & black wire
assembly
(attached to SC/TNC switch & LED on top housing)
•4 pin IDC connector – white & violet assembly
•3 pin IDC connector – blue & orange assembly
•1 2 pin IDC connector – red & black wire assembly
•1 2 pin IDC connector – grey wire assembly
•2 pin IDC connector - brown wire attached to reset switch
•2 pin IDC connector - 2 white wires attached to reset
switch
•1 Reset switch with red wire, brown wire, and 2 white wires
•9 pin IDC connector to 14 pin DIP IC plug – red, violet,
green, orange & yellow assembly
•2 pin IDC connector to 3 pin IDC connector with 1 orange
wire
•1 2 Pin locking header for JP1 (replacement for bottom-
mounted JP1)
•14 pin IC sockets for older PK-232
•2 pin Jumpers for various headers and loopback test
•1 USB cable – USB A to mini B
•1 3.5 mm to 3.5 mm audio cable -
•PK-232SC installation manual
•PK-223SC CD w/ all PK-232 manuals
•Warranty card

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Required Tools
You will need the following tools to complete this upgrade:
•Solder pencil and solder
•Needle nose pliers
•Small side cutters
•#2 Phillips Screw driver
•small straight-blade screwdriver
•Solder removal tools (de-soldering braid, de-soldering
vacuum pump, etc.)

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PK-232 Disassembly
Complete all disassembly steps before starting the new
assembly steps!
____ 1) Remove all cables and power from unit.
____ 2) Remove the six screws holding the top cover on the unit.
____ 3) Remove the top cover.
____ 4) If you have a PK-232MBX with a daughter board,
temporarily remove the MBX board. Do not bend the pins
on the bottom of the MBX board.
____ 5) If a DSP board is installed, you may leave the DSP board
in place.
____ 5B) If you have a OVL LED assembly installed, unplug the
IDC connector from the header next to the red LED on the
DSP board.
____ 6) Remove the threshold control knob from the front panel.
Carefully remove the nut and washer from the bushing of
the threshold control.
____ 7) If your unit has a panel-mounted power connector and/or
reset switch, carefully remove the nut and washer from the
bushing of each.
____ 8) Remove all the screws from the bottom of the PK-232
housing that hold the main board in place. There may be 6
or 7 screws, depending upon the model of the PK-232. Do
not remove the screws that hold the standoffs to the main
PC board.

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____ 9) Remove the main PCB board assembly by lifting it up
and out from the back of the PK-232. Try not to bend the
leds on the led board.
____ 10) If your PK-232 is equipped with a 2400-baud modem or
other modification that uses the external modem port, it
must be removed.
____ 11) If your PK-232 is equipped with a 3rd party modification
such as a TAPR kit, it must be removed.
____ 12) If your PK-232 is equipped with a Timewave
PSK/Soundcard interface, it must be removed. If your PK-
232MBX main board has headers on JP4, JP5, and JP6, be
sure to replace the jumpers on pins 2 & 3 of those headers.
If you have jumpers in place on JP4, JP5, & JP6, you
should not remove them. If you do not have jumpers on
JP4, JP5, & JP6, do not install them (older AEA models.)
____ 13) If your PK-232 is equipped with a Timewave reset
switch, it must be removed.
____ 14) Remove resistor R28 - 10 Ohm -(brown-black-black.)
You can just clip the leads near the body of the resistor.
You do not need to unsolder the leads from the board.
____ 15) If your PK-232 has the JP1 battery jumper connector
mounted on the bottom of the main board, it must be
removed. A new connector is provided with the SC
upgrade kit to place on the top of the board in the same
holes. Use care in removing the JP1 from the bottom of
the board so you do not damage the pads or vias.
____ 16) If you removed JP1 from the bottom of the main PK-
232 board in the previous step, install the replacement JP1
connector on the top of the board. To avoid melting the

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plastic part of the connector, do not use excess heat when
soldering the connector.
Be very careful in the following steps if you do not
have experience de-soldering multi-pin
connectors from PC boards!
____ 17) If the DB-25 25-pin connector on the left rear corner of
the PK-232 main PC board is installed, carefully de-solder
and remove it. Do not burn the PC board with excess heat!
Do not damage the vias or traces on the PC board! Use
care when removing this part so you do not burn the
board. The holes will not be used again so you can clip
those leads which may be accessible from the rear of the
connector on the top of the board. Note some connector
styles have no exposed leads.
____ 18) Clean all excess solder from the vias for the DB-25
connector. Do not burn the PC board with excess heat! Do
not damage the vias or traces on the PC board!
____ 19) If you have a Timewave USB adapter module installed
in place of the 25 pin DB RS-232 connector, remove the
USB module. Do not burn the PC board with excess heat!
Do not damage the vias or traces on the PC board!

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PK-232SC Assembly Instructions
Wired connections to main board
Power Connections
13.8 VDC
Ground
____ 1) If your PK-232 has no power jack mounted directly on
the board, solder JP6 (Black) to ground pad.

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___ 2) If your PK-232 Board has a power jack installed on the
board, solder the black wire to the lug on the top of the
jack as shown below:
___ 3) Solder JP6 (Red) to front side of D10

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PK-232 Serial interface Connections
These connections are near the left back corner of the PK-232SC
main board.
There are two different configurations of the PK-232 serial
connections:
Configuration 1: U19 and U20 ICs are plugged into sockets. Some
AEA PK-232 models and some AEA PK-232MBX models with MBX
daughter boards have this configuration. See Fig. 1 & 1A..
Figure 1: U19 & U20 location

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Figure 1A
–
Serial connections -
SC cable plugged into sockets
____ 1) Plug cable assembly 1 (white and blue wires) into the
U20 socket with the white wire toward the left edge of the
main PK-232 circuit board.
____ 2) Plug cable assembly 2 (violet, red, green, orange and
yellow wires) into the U19 socket with the violet wire
toward the left edge of the main PK-232 circuit board.
____ 3) Skip the rest of this section and go to Receive Audio
Connections

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Configuration 2: U19 and U20 ICs are soldered directly onto the
main board (no sockets). Original AEA PK-232 models and some
AEA PK-232MBX models with MBX daughter boards have this
configuration. See Fig. 1 & 1A.
____ 1) Remove U19 ( 14 pin IC) from the main PC board
Do not burn the PC board with excess heat! Do not
damage the vias or traces on the PC board!
____ 2) Remove U20 (14 pin IC) from the main PC board
Do not burn the PC board with excess heat! Do not
damage the vias or traces on the PC board!
____ 3) Insert a 14 pin DIP IC socket into the U19 holes and
solder all 14 pins.
____ 4) Insert a 14 pin DIP IC socket into the U20 holes and
solder all 14 pins.
____ 5) Plug cable assembly 1 (white and blue wires) into the
U20 socket with the white wire toward the left edge of the
main PK-232 circuit board.
____ 6) Plug cable assembly 2 (violet, red, green, orange and
yellow wires) into the U19 socket with the violet wire
toward the left edge of the main PK-232 circuit board.

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New DSP Board Installation
If you have a new DSP Board Upgrade Kit that you have not
installed yet, install the DSP board according to the DSP Board
installation instructions. Exception: Do not install the wire
connected to the DSP IN pin of the DSP board. It will be
installed in the next section of the SC Board installation.

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Receive Audio Connections
Figure 4 -RX audio without DSP
____ 1) If your PK232 has a DSP board go to step 6.
____ 2) If your PK232 has no DSP board, remove C-54 located
near the fuse.
____ 3) If your PK232 has no DSP board, solder the orange wire
of cable assembly RX-audio to the C54 back pad (located
by the fuse).
____ 4) If your PK232 has no DSP board, solder the blue wire of
cable assembly RX-audio to the C54 front pad (located by
the fuse).
____ 5) Go directly to Transmit Audio connections

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Figure 5 -RX audio with DSP

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C54
Figure 6 -RX audio with DSP - detail
____ 6) If your PK-232 has a DSP board remove the wire from the
DSP IN to the main board (C54).
____ 7) Solder the orange wire of cable assembly RX-audio to
the C54 back pad (located by the fuse).
____ 8) Solder the blue wire of cable assembly RX-audio to the
“IN” pad on the DSP board.
____ 9) If your PK-232 has a DSP board do not remove the wire
from the DSP OUT connection.
____ 10) Go directly to Transmit Audio connections

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Transmit Audio Connections
R160
Figure 7
____ 1) If R-160 is in installed, continue to Step 2). If R-160 is
not installed, go to Step 3).
____ 2) Remove resistor R-160 (orange-orange-red) located
behind the front panel just below Q10 (Use needle nose
pliers to avoid burning your fingers!)
____ 3) Solder the white wire of cable assembly TX-audio to the
R160 front pad.
____ 4) Solder the violet wire of cable assembly TX-audio to the
R160 back pad.