Zares ZTrak User manual

ZTrak
Zares OpenTracker Kit
USER GUIDE
Version: 1.1
Date: 16/05/2006

© Copyright 2006 - ZARES (ZL1CVD Amateur Radio Equipment Supplies) – all rights reserved
Page 2
Contents
INTRODUCTION....................................................... 3
F EATURES ................................................................3
A CKNOWLEDGEMENTS ................................................3
APRS OVERVIEW.....................................................4
C APABILITIES ............................................................4
H OW IT WORKS ..........................................................4
T ECHNICAL I NFORMATION ...........................................4
ZT RAK U SES .............................................................5
Data ....................................................................5
Tracker.................................................................5
Weather................................................................5
ASSEMBLY NOTES................................................... 6
T OOLS R EQUIRED ......................................................6
P ARTS LIST ...............................................................6
A SSEMBLY ................................................................6
CONNECTING IT ALL UP.........................................9
T HE R ADIO P ORT .......................................................9
T HE S ERIAL P ORT ......................................................9
D ELUO GPS RECEIVER ................................................9
1-W IRE W EATHER S TATION ....................................... 10
E XPANSION P ORT ..................................................... 10
T HEORY OF O PERATION ............................................ 11
TX & RX ADJUSTMENTS........................................ 12
T RANSMIT A DJUSTMENT ........................................... 12
R ECEIVE A DJUSTMENT .............................................. 12
LED I NDICATOR ...................................................... 12
CONFIGURATION................................................... 13
P ROFILES ................................................................ 13
Setting ProfileConditions...................................... 13
How Conditions AreTested.................................... 14
C ONFIGURATION O PTIONS ......................................... 14
Callsign ............................................................. 14
Frequency........................................................... 14
Path................................................................... 14
TX Delay............................................................ 14
TX Interval.......................................................... 14
Symbol Table and Symbol Code .............................. 14
Temp. Adjust....................................................... 15
Quiet Time.......................................................... 15
Text ................................................................... 15
Altitude, Course/Speed, Timestamp.......................... 15
GPS Quality........................................................ 15
Temperature........................................................ 15
Voltage............................................................... 15
Protocol ............................................................. 15
Copy from Config n.............................................. 15
SmartBeaconing™................................................ 15
Power Control..................................................... 15
Timeslot ............................................................. 15
PTB2 Output....................................................... 15
Enable Counter.................................................... 16
Reset Counter on Transmit..................................... 16
Counter Rearm.................................................... 16
Invert Carrier Detect............................................. 16
Suppress PTT Out on PTT In.................................. 16
Disable Transmit on Low Voltage............................ 16
Allow Transmit Without GPS Lock........................... 16
Send Telemetry Packet........................................... 16
L OADINGAND S AVING S ETTINGS ................................ 16
RECEIVING AND DECODING APRS DATA............. 17
W HAT YOU WILL NEED .............................................. 17
D OWNLOAD AND INSTALL AGWPE............................. 17
D OWNLOAD AND INSTALL AGWT RACKER .................... 17
FIRMWARE............................................................. 18
F IRMWARE V ERSIONS A VAILABLE ............................... 18
L OCATING N EW F IRMWARE ....................................... 18
U PLOADING N EW F IRMWARE ..................................... 19
A BOUT FIRMWARE FILES ............................................ 19
APPENDIX A - TELEMETRY OPERATION.............. 20
APPENDIX B – APRS SYMBOL TABLES.................. 21
APPENDIX C – NZ APRS FREQ UENCIES ................ 25
APPENDIX D – ZTRAK CIRCUIT & LAYOUT .......... 26
APPENDIX F – RADIO PORT CABLE WIRING ........ 27
Y AESU FT-411, FT-470, FT-530, ADI AT-201, R ADIO
S HACK HTX-202, ETC . ............................................. 27
I COM T2H, IC-2AT, IC-V8, ETC & Z ARES . ................... 27
Y AESU VX-150, VX-2R, VX-5R & I COM ..................... 27
K ENWOOD TH-78A, TH-D7A, ETC .............................. 28
K ENWOOD WITH 8- PIN RJ-45...................................... 28
K ENWOOD WITH 8- PIN RJ-45 AND 1/8" S PEAKER J ACK .... 28
Y AESU WITH 6- PIN RJ-11 AND 1/8" S PEAKER J ACK ......... 29
I COM WITH 8- PIN RJ-45 AND 1/8" S PEAKER J ACK ........... 29
K ENWOOD AND A LINCO WITH 8- PIN ROUND M IC J ACK ..... 29
Y AESU WITH 8- PIN ROUND M IC J ACK ........................... 30
I COM WITH 8- PIN ROUND M IC J ACK ............................. 30
6-P IN M INI DIN DATA J ACK ( USES C ARRIER DETECT LINE )30
6-P IN M INI DIN DATA & 1/8" S PEAKER J ACKS ............... 31

Introduction
The ZTrak is an amateur radio data encoder capable of generating1200 or 300 baud AX.25 packets using both APRS™
and OpenTRAC protocols, as well as PSK31 text beacons. It can be connected to a GPS receiver to report position,
course, speed, time, altitude. It will also report telemetry from itsonboard temperature and voltage sensors. With its
expansion connector and ease of reprogramming, the device can be adaptedto a wide variety of tasks.
Features
•Cost effective APRS kit with case
•100% compatible with (and based on) OpenTracker APRS kit from N1VG
•Supports two APRS profiles that can report altitude, course/speed, timestamp, GPS quality, temperature, voltage,
telemetry)
•Configuration options include call, path, symbol table & symbol code, a text message, optional fixed position,
SmartBeaconing & Compression
•Profiles can switch when trigged by a change in altitude, speed, temperature, voltage, an analogue input, a switch
input, GPS fix/no-fix
•Firmware updates are free and easy to install.
•Easy to connect with a wide range of transceivers.
Quite a few configuration options are available that allow you to expand on the basic functionality. Please carefully read
through this guide to gain a clear understanding of your ZTrak.
Acknowledgements
The Zares ZTrak utilizes the same software and firmware as that used in the OpenTracker APRS project. Many thanks to
Scott Miller (N1VG) for his support. For more information on the OpenTracker project, please visit Scott’s project page at
http://n1vg.net/opentracker/

© Copyright 2006 - ZARES (ZL1CVD Amateur Radio Equipm ent Supplies) – all rights reserved
Page 4
APRS Overview
Automatic Position Reporting System (APRS) is an amateur radio based automatic position reporting system for tracking
and digital communications, and was developed by Bob Bruninga (WB4APR) at the United States Naval Academy.
Capabilities
In its simplest implementation, APRS is used to transmit real-time reports of the exact location of a person or object via a
data signal sent over radio frequencies. In addition to real-time position reporting capabilities using the Global Positioning
System, APRS is also capable of transmitting a wide variety of data, including weather reports, short text messages, radio
direction finding bearings, telemetry data, and storm forecasts. Once transmitted, these reports can be combined with a
computer and mapping software to show the transmitted data superimposed with great precision upon a map display.
How it works
At the sender’s end, data from various sensors (GPS, temperature, etc) is collected and encoded into the APRS format
then transmitted to another station. At the receiving end, the APRS data is then decoded and displayed on a map or it is
retransmitted on to the APRS radio network or sent to the Internet.
APRS network example APRS weather station example
Technical Information
In its most widely used form, APRS is transported over the AX.25 protocol using 1200 baud Bell 202 audio frequency-shift
keying. Amateur radio operators use frequencies located within the amateur 2-meter band - usually 144.390 MHz in North
America, 145.175 MHz in Australia, 144.575 MHz in New Zealand, 144.930 MHz in Argentina, 145.570 in Brazil and
144.80 MHz throughout Europe. An extensive digital repeater, or "digipeater" network provides transport for APRS
packets on these frequencies. Internet gateway stations (i-Gates) connect the on-air APRS network to the APRS Internet
System (APRS-IS), which serves as a worldwide, high-bandwidth backbone for APRS data. Stations can tap into this
stream directly, and a number of databases connected to the APRS-IS allow web-based access to the data as well as
more advanced data mining capabilities. A number of low-earth orbiting satellites and the International Space Station are
also capable of relaying APRS data.

© Copyright 2007 - ZARES (ZL1CVD Amateur Radio Equipm ent Supplies) – all rights reserved
Page 5
ZTrak Uses
The ZTrak connects to a transceiver to make it transmit APRS packets. In broad terms, it can be set up for sending data,
used to track a mobile object or report weather.
Data
Uses..
•Beacon
•Monitoring equipment
APRS data it sends..
•Station name or callsign
•The station type or identifier
•Short message text
•Digipeater path
•Fixed position
•Temperature
•Voltage
•ADC value
You will need..
•ZTrak
•Zares transceiver
Tracker
Uses..
•Beacon
•Monitoring equipment
•Tracking an object
APRS data it sends..
•Station name or callsign
•The station type or identifier
•Short message text
•Digipeater path
•Current position
•Temperature
•Voltage
•ADC value
•Altitude
•Time
You will need..
•ZTrak
•Zares transceiver
•GPS receiver
Weather
Uses..
•Beacon
•Monitoring equipment
•Report the weather
APRS data it sends..
•Station name or callsign
•The station type or identifier
•Short message text
•Digipeater path
•Fixed position
•Temperature
•Voltage
•Wind speed
•Wind direction
•Outside temperature
You will need..
•ZTrak
•Zares transceiver
•1-Wire weather instrument
X
C
V
R
Z
T
R
A
K
X
C
V
R
Z
T
R
A
K
G
P
S
X
C
V
R
Z
T
R
A
K
W
X

© Copyright 2006 - ZARES (ZL1CVD Amateur Radio Equipm ent Supplies) – all rights reserved
Page 6
Assembly Notes
Tools Required
This kit requires basic to intermediate level soldering & construction skills. You will need:
•low-wattage fine tipped soldering iron & Solder (rosin core solder – never use acid core solder for electronics)
•Screwdriver
•Wire cutters
•Hacksaw
•Sharp hobby knife
•Hobby files
•Adjustable spanner
•Flat nose pliers
•Drill & 3mm drill bit
Parts list
Review the parts list and identify the components you have received. If any are missing or damaged, contact
[e-mail] for replacements. Don’t worry if your kit includes extra resistors or other parts not listed above – these
may be provided for modifications and or an alternate versions of the kit.
Part Value Description Notes
C1 0.33 CAPACITOR Marked: 334
C2, C3, C 4 0.1 CAPACITOR Marked: 104
C5, C6 18p CAPACITOR Marked: BC 18J – remove from paper carrier and straiten leads
D1, D2 1N914 DIODE Marked: 1N4148
D3 LED3MM LED Installed with the short lead facing IC2 ( LM335); long lead facing up
IC1 LM7805 Voltage R egulator Marked: L7805CV
IC2 LM335 Temp Sensor Marked: LM335
IC3 68HC908KX8 Microcontroller Marked: MC908KX8CPE
Q1, Q2 2N7000 FET Marked: 2N7000
R12, R13 680 RESISTOR Colour bands: Blue – Gray – Brown – Gol d
R1, R7 10k RESISTOR Colour bands: Brown – Black – Orange – Gold
R11 20k RESISTOR Colour bands: Red – Black – Orange – Gol d
R2 220k RESISTOR Colour bands: Red – Red – Yellow – Gold
R3 2.2k RESISTOR Colour bands: Red – Red – Red – Gol d
R4 1k RESISTOR Colour bands: Brown – Black – Red – Gold
R5 3.3k RESISTOR Colour bands: Orange – Orange – Red – Gold
R6 6.2k RESISTOR Colour bands: Blue – Red – Red – Gold
R10 10m RESISTOR Colour bands: Brown – Black- blue – Gold
R8, R9 10k POTENTIOMETER Marked: 103
Y1 TC38H CRYSTAL Marked: 29.4C64
P1 F09D Radio port connector With PCB positioned as per the overlayi mage, this is the LHS connector
P2 M09D Serial port connector With PCB positioned as per the overlayi mage, this is the RHS connector
PCB1 - Double sided PCB
CSE1 H1551K Hammond Case + screws
Assembly
If you plan to install just the zTrak PCB inside a rig, may wish to skip this stage.
Attach the D c onnectors to
the PCB & layit on top of
the case. Use it as a
template to mar kthe cuts
you will need to make with
the hacksaw
Remove the PCB & make the
cuts stopping about 3~5mm
from the bottom. Using a hobby
knife, scribe a line between
them. Using a small adj ustable
spanner as pictured, slowly
appl y pressure toward the
inside of the case
You mayneed to wor kthe
spanner back and forth a
few times. Eventually the
plastic will come away
leaving a fairlyclean line
where you scribed
Use the hobby knife to
trim it up and r emove
any excess plastic
swarf. Check the socket
will clear the slot OK
and continue to trim as
required
The PCB is close fit to the
case and mayrequire filing
on both bevels. M ake sure
the PCB sits square in the
case and the sol der
terminals for the connectors
sit in the center of their
corresponding solder pads

© Copyright 2007 - ZARES (ZL1CVD Amateur Radio Equipm ent Supplies) – all rights reserved
Page 7
The DB9 connectors should now be soldered into place - male on the right, the female on the left.
With the board in the case as pictured, solder the connectors in pl ace
making sur e the connector pins are centered within the solder pads Remove the assembl y from the case, turn it over and sol der the other side
Referring to the overlay pictured, install the components in the sequence described.
Resistors mount flush with the
board Leads slightly bent at back to hol d the components in place while
soldering
Its likely this kit will be used in close pr oximityto RF. Its important to keep
component lead length as short as possible so we don’t end up with allot
of little antennas! Trim leads as close to board as practical
Some c apacitors are supplied on paper tape and
will need their leads straitened Diodes are polarized and will onl y work correctly when i nstalled one way. Make sur e the black
band on the diode matches the board layout
All resistors, capacitors & di odes now installed

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Page 8
Install the semiconductors, crystal & GPS power link (if required)..
Regulator IC1 lays flat agai nst
the PCB so its leads must be
bent
Install all semiconductors (except IC 3) and the cr ystal.
Again make sure all lead lengths are kept as short as
possible
If you intend to power a GPS recei ver directl yfrom
zTrak, you will need to add a link between pin 9 & 10 of
the feature connector. A resistor lead cut-off is ideal for
this
If you want the LED to be visible through the case, now is a good time to drill the hole in the lid.
You need to drill a 3mm hole
approxi matel y35mm from the left
side and 8mm down
To position the LED correctly,
bend the legs over and place the
board backin the case. Attach
the lid and move the LED into
best position. If you wish, it can
sit proud of the lid hole for a
wider vi ewi ng angle
The final lead length of the LED
which sits flush with the lid hole is
about 5-6mm from top of board to
bottom of LED lens
If zTrakis being used in a highly
visible situation, the flashing LED can
become annoyi ng. Mounting it flush
with the lid ensures limited viewing
angle. You can also increase the value
of R4 to dim the LED
This would also be a good time to drill holes to access the TX & RX level pots R8 & R9. However in practice these tend to
be set-and-forget so it’s not necessary as they can be easily adjusted with the lid off.
The microcontroller IC3 is static sensitive so
make sure you handl e it as little as possible.
Preferably only handl e while wearing an
antistatic wrist strap or ensure you are grounded
Due to the manufacturing technique, the legs of
DIL ICs tend to be slightly wider than required.
To straighten them prior to insertion place one
row of pi ns on a hard, flat surface. Hold IC3
body bythe edges and gentlyroll it until the pins
reach the correct angle. Repeat for the other
row, and insert the IC into the board gentl y,
making sur e that each pi n is aligned with its hole
When soldering IC3, solder the ground pin1st
(as pictured) and then the other pi ns.
Assembly is now complete. You may wish to further secure the ZTrak board to the case at the screw mounting points and or install D
socket standoffs. Silicone sealer could also be used to fill the gap at the top of the D sockets. These optional items are not supplied
with the basic kit as the final installation will vary from customer to customer.

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Page 9
Connecting it all up
The Radio Port
The pin out of the ZTrak radio connector is identical to that used by the OpenTracker, Kantronics KPC-3 and Byonics
TinyTrak3. Any cable that was made to interface a radio to these devices should work with ZTrak. BUX Comm provides
detailed wiring diagrams and pre-assembled cables for a wide variety of radios at http://www.packetradio.com/wiring.htm.
Pin no Description
1 Audio out
2 COR / Squelch input
3 PTT
4 No connection
5 Audio in
6 Ground
7 Power in
8 PTT input
9 No connection
The Serial Port
The serial port is wired as a RS-232 DTE device so standard serial GPS receivers can be directly connected. To connect
to a PC, a null-modem cable oradapter will be required. By default, the OpenTracker processor expects GPS data to be
in NMEA-0183 format at 4800 baud.
Pin no Description
1 No connection
2 RX data (from PC or GPS recei ver)
3 TX Data (to PC)
4 V(ext). +5V @ appx 450mA max bydefault. Can be
set to supply voltage bychanging an internal
jumper.
5 Ground
6 No connection
7 1-wire weather station for AAG wind instrument
8 No connection
9 No connection
Typical null-modem wiring
Deluo GPS receiver
The Deluo GPS receiver is supplied with a 6 pin round mini-din plug. Most users will choose to cut off this connectorand
wire up their own DB-9 female plug. The following table outlines the connections.
Deluo Pin Deluo wire colour Deluo Signal name Connect to ZTrak pin
1 Green GPSData Out 2
2 Blue Noconnection Noconnection
3 Red Power in 4
4 Black Ground 5
5 White GPSData in Noconnection
6 Yellow TTL GPS Data Out Noconnection

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Page 10
1-Wire Weather Station
The ZTrak is capable of connecting to the AAG TAI8515 1-Wire Weather Instrument. This weather station provides wind
speed, wind direction, and temperature readings.
The weather instrument uses a RJ11 connector. Common 2-conductor
telephone line cord can be used to carry the 1-Wire signal from the instrumant
to the zTrak.
Pictured here are the pin assignments on the end that connects to the weather
instrument.
On the ZTrak end terminate the cable with a DB9 connector. The data line
should be connected to pin 7 and ground to pin 5.
Be sure to leave the supplied loopback device installed in the wind instrument’s
second port.
You then need to load the 1-wire weather station firmware into the ZTrak. Refer
to the Firmware section of this guide formore details.
Expansion Port
The expansion port allows you to interface directly with the OpenTracker
processor.
Pin No Description
1 Transcei ver power control
2 Ground
3 ‘Jumper’ switch input – usuall y used to switch between OpenTracker
profiles. Refer to the Configuration section of this manual for more details.
4 IRQ – if pulled to ground will force an immedi ate transmission
5 ADC0 – on board temperature sensor
6 ADC1 – on-board voltage di vider provides 1/3 Vin
7 ADC2 – Spar e ADC input – also used for 1-wire data bus
8 Connects to Vin
9 Vext – connected to pi n 4 of D B-9 – a jumper wired between JP9 & JP10
provides + 5V on pin 4 of the serial port to power a GPS receiver.
10 regulated +5V DC
•Pin 1 can be used for either PTT input formic encoder operation, or as
a relay control output if power control is enabled. When used as a relay
output, the pin can provide no more than 15 ma current.
•Pin 4 pulled momentarily to ground will force an immediate transmit.
•If Pin 8 and Pin 9 are jumpered together, pin 4 on the serial connector
can be used to supply raw voltage (Vin) to an external device such as a
GPS receiver, or to receive power via a specially wired cable assembly.
•If Pin 9 and Pin 10 are jumpered together, pin 4 on the serial connector
will be supplied with regulated +5V.
•Most handheld radios (with the notable exception of those made by
Kenwood) assert PTT by grounding the microphone input. Resistor R3 is
used for this purpose.
R3 should be omitted if ZTrak is used with mobile radios
or with handhelds that do not use this method of PTT keying. If the tracker
will be used with both mobile and handheld radios, R3 can be installed in
the cable used to connect the handheld to ZTrak.
1…………………….10