ARES 2 Tone Sequential Tone Decoder Kit Assembly Instructions

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1 Tools Required: ARES Tone Sequential Tone Decoder Kit Assembly nstructions 3/8 Electric Drill Soldering ron Wire Strippers Needle Nose Pliers Wire Cutters Ruler 60/40 Solder Phillips Screw Driver /8, 5/64, 9/3 and 5/6 Drill Bits Masking/Scotch Tape Exacto Knife or Dremel Tool Note: Examine all parts for correct part number and/or polarity markings prior to assembly. Some parts look similar but are not interchangeable and will cause the decoder to fail to operate correctly. Check twice, solder once!! Part : Printed Circuit Board Assembly.. 3. Verify all of the parts received in the kit with the parts list. Using a /8 drill bit, drill and enlarge the 4 corner pads/holes of the circuit board. Locate Resistors R through R0. nsert the resistors into the circuit board at their locations as indicated by the component notations. Solder the 0 connections and trim the leads flush with the board. See ig.. R0 0 ohm Brn-Red-Brn-old R5 330 ohm Org-Org-Brn-old R, R6, R7 K ohm Brn-Blk-Red-old R9 0K ohm Brn-Blk-Org-old R8 0K ohm Red-Blk-Org-old R,R3 00K ohm Brn-Blk-Yel- old R4 M ohm Brn-Blk-rn-old 4. Locate Jumpers JP & JP. The jumpers look like /4W resistors with one black band. nsert the jumpers into the circuit board at their locations as indicated by the component notations. Solder the 4 connections and trim the leads flush with the board. See ig.. 5. Locate Capacitors C, C, C3, C6, and C8. nsert the capacitors into the circuit board at their locations as indicated by the component notations. Solder the 0 connections and trim the leads flush with the board. See ig. 3. JP, JP Blk Band C, C, C3, C6, C8-0. uf (04 Marking)

2 6. Locate Capacitors C4 and C5. nsert the capacitors into the circuit board at their locations as indicated by the component notations. Solder the 4 connections and trim the leads flush with the board. See ig Locate Tantalum Capacitor C7. nsert the capacitor into the circuit board paying attention to the correct polarity component notation. Solder the leads and trim the leads flush with the board. See ig. 5. C4, C5 - pf (J Marking) 8. Locate Diode D. nsert the diode into the circuit board paying attention to the correct polarity component notation. Solder the leads and trim the leads flush with the board. See ig. 6. C7-4.7 uf (Observe + Marking) D - N Locate the two 8 pin DP Sockets. Place the at U and U locations. Locate the notch of the socket as indicated on the circuit board. Solder the 6 connections. Do not trim leads. See ig Locate Transistors Q and Q. Locate the flat of the transistor according to the flat as indicated on the component notations. Solder the 6 connections and trim the leads flush with the board. See ig. 8. Q, Q N3904. Locate SCR SCR. nsert the SCR into the circuit board at their locations as indicated by the component notations. Locate the flat of the SCR according to the flat as indicated on the circuit board. Solder the 3 connections and trim the leads flush with the board. See ig. 9. SCR N506. Locate Crystal X. nsert the crystal into the circuit board at the location indicated by the component notation. Solder the connections and trim the leads flush with the board. See ig. 0. X 4 MHz 3. Locate the 3 Terminal 5V Regulator U3. Place in the circuit board at location U3. Orient the tab as indicated by the thick bar on the board notation. Solder the 3 connections and trim the leads flush to the board. See ig.. U3 7805T

3 4. Locate DP Relay RLY. Place the relay in the circuit board and solder the 6 connections. Do not trim the leads. See ig.. RLY - 5. Locate Power Resistor R. Place the resistor in the circuit board and solder the connections. Trim the leads flush with the boards. See ig. 3. R 8. Ohms 5W 6. Locate LEDs D and D3. Locate the flat on the bottom diameter of the LED body. Hold the LED in your left fingers, small flat facing you, and bend the two leads 90 degrees downward approximately /4 from the bottom of the LED body. nsert the LEDs into the circuit board at their locations as indicated by the component notations. Locate the lead nearest the small flat on the LED body as indicated. Space the LEDs approximately 5/8 above the board and solder the 4 connections. Trim the leads flush with the board. When you are done, the two LEDs should face away from the board at a right angle about 5/8 above the board. See ig. 4. Double check to be sure the LEDs are properly located by the small flat on the flange of the LED body. D reen D3 Red (Clear Body) 7. Measure and cut the following wires. Strip each end /8, twist tightly, and tin each end lightly with solder. Solder each wire into the circuit board as described. Refer to ig Red AW at +V pad. 3 Black AW at -V pad. 3 Black 6 AW at -V pad. 3-/ Black 6 AW at SW pad. 3-/ Black 6 AW at SW pad. Blue 6 AW at SW- pad. Yellow 6 AW at SW- pad. -/ Red 6 AW at SW-5 pad. 3-/ White 6 AW at AUD N pad. 3-/ reen 6 AW at AUD OUT pad. 8. This completes the circuit board assembly except for the sound buzzer. Set the board aside for now.

4 Part : Project Box Drilling Locate the drilling template enclosed. Place the plastic box upside down on the center area of the template. Using a pencil, mark the center line point on each of the 5.3 long sides. Refer to ig. 6. Cut out the template around the perimeter of the drawing. Align one side of the template with the top edge of the box and tape in place. Be sure to align the pencil center mark with the center line of the template. Wrap the template around the bottom and bring it up flush with the top edge of opposite side of the box. Align the center line with the pencil center mark and tape in place. Refer to ig. 7. Using a center punch or awl, mark the center of each hole location on the box. Do not hammer as you may crack the box. Remove the template and save for reference. Drill the holes indicated on the template. Drill bits needed are /8, 5/64, 9/3 and 5/6. t s best to drill all of the holes with the /8 bit and follow with the larger bit to complete the proper hole size. f using the Piezo Sound enerator, mark and drill the two mounting holes and wire entry hole in the side panel using the piezo generator as a template. Drill the 3 holes with a /8 drill bit. Refer to ig. 8. Part 3: inal Assembly. Locate the DC Power Jack. Solder the Black and Red ga. wires from the +V and -V connections on the pc board to the jack terminals as shown in ig Locate the DPDT Toggle Switch (SW). Solder the Red, Yellow and Blue 6 ga. wires from the SW connections on the pc board to the switch terminals as shown in ig. 0. Refer to the schematic for terminal number locations. Cut and strip a 3- / Black 6 ga. wire and solder to terminal 6 of the switch. Be careful not to overheat the connections and melt the switch. Locate the Push Button Switch (SW). Solder the two Black 6 ga. wires connected to the SW locations on the circuit board to the switch. t does not matter which switch terminal is used. Refer to ig.. Note: The following two steps require close examination of the jack terminals. Be sure that the tip connector is the audio hot lead (reen or White Leads) and that the ground terminal is use for the black wires. The third shorting terminal is not used. Jacks can come in different orientations as compared to the picture, so examine the jack for the correct connections. ailure to connect to the correct terminal may short the audio output.

5 4. 5. Locate a 3.5 mm jack. Solder the white 6 ga. wire from the Audio n connection on the pc board to the tip connection as shown in ig. Cut and strip a Black 6 ga. wire. Twist this wire together with the Black 6 ga. wire from the switch. Solder both wires to the ground connection of the jack. Refer to ig.. Be sure that you examine the jack for the correct hot & ground connection tabs. ently bend the terminals outward to clear the center area if needed. Be sure wires don t protrude into the plug area. Locate the second 3.5 mm jack. Solder the reen 6 ga. wire from the Audio Out connection on the pc board to the tip connection of the second 3.5 mm jack. Twist together the Black 6 ga. wire from the first 3.5mm jack and the Black 6 ga. wire from the -V connection on the pc board. Note: ig. depends on type of Jack purchased. Be sure to verify correct hot and round terminals. Solder these wires to the ground connection of the 3.5mm jack. Refer to ig.. ently bend the terminals outward to clear the center area if needed. Be sure wires don t protrude into the plug area. Note: The project box has internal ribs. f the drill holes are in the area of the ribs, use an Exacto Knife or Dremel Tool to remove the ribs flush to the wall of the box. This makes the LEDs and jacks mount flat and easily. Do not try to mount on a rib as the jack will come loose or rotate. 6. Mount the sound buzzer on the side panel using two 4-40 x 5/8 screws, lock washers and nuts. eed the two wires through the panel to the inside of the box. Refer to ig Retrieve pc board assembly. Solder the Red sound buzzer lead to the SA pad on the pc board. Solder the Black sound buzzer lead to the SA- pad on the pc board. Refer to ig. 4. (f you purchased a 5V sound buzzer, connect the positive lead to SA5 pad on the circuit board) Locate four 4-40 x 5/8 screws and insert from the bottom panel of the box. Hold the screws in place by placing a piece of tape over the screw heads. Refer to ig Turn the box over and place four ¼ spacers on the screws. Refer to ig Place the pc board on the spacers and carefully feed the two LEDs into the bezels in the front panel. Be sure the leads do not touch each other. Secure the pc board with four 4-40 lock washers and nuts. Refer to ig. 7.. Mount the two switches and the 3 jacks into the holes in the box. Tighten the nuts securely. Refer to ig. 7 for the orientation of the toggle switch.. Place the front and back labels on the box as shown in igs. 8 and 9. Place the 4 Vinyl oot Pads at the corners of the box just inside of the round molded pads in the bottom of the box.

6 Part 4: Test & Checkout Make a V DC power cable using the.5mm DC Plug provided and your user supplied wire (not part of the kit). Make an Audio Jumper for the radio to decoder audio connection using the two 3.5mm mono plugs provided and your user supplied wire (not part of the kit). Plug the V DC cable into the V nput Jack on the back of the box. Connect the negative test lead of a DC Voltmeter to the black wire on the DC Jack. Check for voltages at the following points: U Pin 8: +5VDC U Pin : +5VDC Note: f you do not measure the correct voltage or have voltage at an incorrect level, DO NOT PROCEED until the problem is corrected. Damage to the chips will occur if voltages are not correct! Place the front audio toggle switch in the On position. Using an Ohmmeter, check for continuity between the white and green wires on the two audio jacks. Place the front audio toggle switch in the Mute position. Using an Ohmmeter, check for 8. ohms between the black and white wires of the audio input jack. Make a short wire jumper from any of the remaining wires in the kit. Using this jumper, connect U Pin to the following pins: a. U-Pin 5: Relay should click. b. U-Pin 6: Piezo Tone enerator should sound and Red LED should begin to flash. Remove jumper, and Red LED should continue to flash and Piezo Tone enerator should stop sounding. f the Red LED does not continue to blink, add the remaining K resistor to the RX location on the circuit board (RX not shown in pictures) to keep the SCR latched and the LED blinking. (Note: There will be a low level tone until reset.) Press the front Reset push button and Red LED should turn off. c. U-Pin 7: reen LED should turn on. Remove jumper and reen LED should turn off. 8. Remove VDC cable from the unit. This completes the initial checkout of the unit.

7 9. This part is static sensitive. Be sure you are not full of static electricity before handling the part. Carefully align the pins of the LM358 Op Amp to the U socket and push the C into the socket. Be sure that Pin (Dot/Notch) of the C matches the notch in the end of the socket. Refer to ig. 30. ailure to insert the C correctly can damage the C. Check to be sure the 8 leads are properly inserted and not bent over or under the C or socket. 0. This part is static sensitive. Be sure you are not full of static electricity before handling the part. Carefully align the pins of the 609 PC Microprocessor to the U socket and push the C into the socket. Be sure to Pin Dot/Notch) of the C matches the notch in the socket. Refer to ig. 3. ailure to insert the C correctly can damage the C. Check to be sure the 8 leads are properly inserted and are not bent over or under the C or socket.. Place the plastic lid on the box and attach with the 4 screws provided with the box. This completes the assembly and test of the ARES Two Tone Sequential Decoder. Using the Two Tone Sequential Decoder Locate the decoder near your transceiver. Plug one end of the audio patch cable you constructed to the Speaker Output jack on your transceiver. Connect the other end of the cable to the Audio nput jack on the Decoder. Plug an external speaker into the audio output jack. Place the Audio toggle switch in the On position and check for audio from the transceiver by opening the squelch. f squelch noise is heard in the speaker, you have a good audio connection. Adjust the volume control for comfortable listening level. Do not over drive the audio level. The Mute position of the audio toggle switch will turn off the audio from the radio until an alert is received. You can use the decoder in either switch position. Connect the VDC cable to your station power supply and plug the cable into the VDC jack on the rear of the box. The reen LED should turn on signifying that the unit is ready to decode an alert. When an alert is received, the RED LED will begin to flash, the Piezo Tone enerator will sound for a 6 seconds, and the speaker audio will turn on if the audio switch is in the Mute position for approximately 60 seconds. This will allow you to listen to the alert instructions. After 60 seconds, the audio will mute. The Red LED will continue to flash to show an alert was received. Press the Reset push button to turn off the Red LED after an alert. Caution: This decoder has the audio output referenced to ground. f you have a radio that has an isolated audio output (not referenced to ground), you must use an audio isolation transformer. Connecting the decoder directly to that type of radio will damage the radio!

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16 ARES Tone Sequential Decoder Parts List Designation QTY Part Value C,C,C3,C6,C8 5 Capacitor. u C4, C5 Capacitor p C7 Capacitor, Tant 4.7 u D Diode N4004 Q,Q Transistor N3904 JP, JP Jumper 0 Ohms R0 Resistor 0 Ohms R5 Resistor 330 Ohms R, R6, R7, RX 4 Resistor K Ohm R9 Resistor 0K Ohm R8 Resistor 0K Ohm R, R3 Resistor 00K Ohm R4 Resistor M Ohm R Resistor 8. Ohms 5W SCR SCR N506 U Op Amp LM358AN U Microprocessor 609 U3 Voltage Regulator LM7805T X Crystal 4MHz D3 LED RED T-3/4 D LED RN T-3/4 SW Push Button N.C. SW Toggle Switch DPDT SA Tone enerator SONALERT RLY Relay Relay SPDT Relay (Alternate) Relay SPDT LED Mount T-3/4 Dip Socket 8 Pin J3 DC Jack V Coaxial P3 DC Plug V Coaxial Plug J, J Jack 3.5 mm Mono P, P Plug 3.5mm Mono Enclosure 6"x3"x" 4 eet Stickon PC Board Rev. 4 Spacers Nylon #4 Hole 6 Screw 4-40x5/8" 6 Nuts Lock Washer a. Wires Blk, Red, Yel, rn, Blu, Wht a Wires Blk, Red Labels

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18 ARES Tone Sequential Decoder Parts List Designation QTY Part Value Source Part No. C,C,C3,C6,C8 5 Capacitor. u DigiKey ND C4, C5 Capacitor p DigiKey BC005CT-ND C7 Capacitor, Tant 4.7 u uturlec C0047UT D Diode N4004 All Electronics N4004 Q,Q Transistor N3904 uturlec N3904 JP, JP Jumper 0 Ohms DigiKey 0.0QBK-ND R0 Resistor 0 Ohms DigiKey 0QBK-ND R5 Resistor 330 Ohms DigiKey 330QBK-ND R, R6, R7, RX 4 Resistor K Ohm DigiKey.0KQBK-ND R9 Resistor 0K Ohm DigiKey 0KQBK-ND R8 Resistor 0K Ohm DigiKey 0KQBK-ND R, R3 Resistor 00K Ohm DigiKey 00KQBK-ND R4 Resistor M Ohm DigiKey.0MQBK-ND R Resistor 8. Ohms 5W DigiKey TWW5J8RE-ND SCR SCR N506 DigiKey N506OS-ND U Op Amp LM358AN DigiKey LM358ANS-ND U Microprocessor 609 DigiKey PC609-/P-ND U3 Voltage Regulator LM7805T uturlec 7805T X Crystal 4MHz DigiKey X97-ND D3 LED RED T-3/4 uturlec LED5RL D LED RN T-3/4 uturlec LED5 SW Push Button N.C. All Electronics MPB-5 SW Toggle Switch DPDT uturlec DPDT SA Tone enerator SONALERT DigiKey ND RLY Relay Relay SPDT uturlec JRC-3-05 Relay (Alternate) Relay SPDT DigiKey PB07-ND LED Mount T-3/4 All Electronics HLED-4 Dip Socket 8 Pin uturlec CS8 J3 DC Jack V Coaxial uturlec DCCHM4 P3 DC Plug V Coaxial Plug uturlec DCPWR004 J, J Jack 3.5 mm Mono uturlec P035SCK00 P, P Plug 3.5mm Mono uturlec P035MB Enclosure 6"x3"x" All Electronics MB-3 4 eet Stickon DigiKey SJ ND PC Board Rev. uturlec Custom Design 4 Spacers Nylon #4 Hole DigiKey 876K-ND 6 Screw 4-40x5/8" DigiKey H348-ND 6 Nuts 4-40 DigiKey H6-ND 6 Lock Washer 4-40 DigiKey H36-ND 6 a. Wires Blk, Red, Yel, rn, Blu, Wht a Wires Blk, Red Labels Rev. September 009

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