------------------------------------------------------------------------------ FaxCon (c) Michael Klingel - construction guidance - ------------------------------------------------------------------------------ Contents ======== 0 preparations 1 notes for construction 1.1 placing the parts on the board 1.2 first test 1.3 test of the serial interface 1.4 further construction 2 connectors and components 2.1 connectors and jumpers on the board 2.2 parts list Appendix A pinning of the serial (PC-)port / standby switch B suggestions for the case C wiring of the change over switch as standby switch D view of the DSUB connectors in the case 0 preparations ============== Before beginning the construction please print and read this text, as well as the plans in the following files: SCHALT.* circuit diagram BESTUECK.* board place plan LAYOUT.* board layout ANSCHLUS.* board connection diagram UMSCHALT.* wiring of standby switch Possible modifications/supplements of the hardware can be found in the file: HWFIX.TXT 1 notes for construction ========================= (a board connection diagram is shown in the file "ANSCHLUS.*") 1.1 board --------- !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! Handle the components with care, in particular do not touch the pins of the integrated circuits and absolutely avoid electrostatic discharges. !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! - Solder all components with exception of the integrated circuits, use sockets for the integrated circuits, attach jumpers (link plugs) depending upon available EPROM size (standard 32K-Eprom: J11, J12 each on pin 1+2) Special: -------- C4 (100uF): solder a little horizontal ('+' longer) to provide enough space to the 25pin connector when fitting into the case. R14 (1k5): bend the wire that points to the microcontroller (U1) before soldering to get a connection-pin ("HWFIX.TXT"). sketch: ++ !! +--------+ !! +--! R14 !-+! ! +--------+ ! =======!==============!======= board ! ! Hints: ------ Voltage regulator: ------------------ The voltage regulator U10 has the following pinning: +-----+ ! O ! +-----+ ! 7806! Viewed from ! ! inscribed side +-----+ ! ! ! ! ! ! 1 2 3 Position of pin 1: ------------------ Observe orientation: To identify the position of pin 1, see the notch or a point at the component case. The board place plan likewise identifies pin 1 with a notch in the case, additionally in each case a angular solder pad is shown. - Visual inspection on incorrectly placed parts, solder joints, wrong polarized capacitors and diodes - Apply voltage at J1 and J2 - Check the voltage (approx. 5.5V) at the supply voltage pins of the integrated circuits - Disconnect voltage - Place the integrated circuits in their sockets !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! Please read the operating instructions before doing the following tests and before using FaxCon. Among other things the instructions contain information to the supported baud rates and show the meaning of the light-emitting diode displays, the function of the push-buttons, the configuration as well as the test of the finished device. !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! 1.2 first test (can be skipped) ------------------------------- - connect leds and push-buttons - apply voltage -> both leds are on -> memory test (some seconds) -> green led remains on, red led turns off - press red push-button briefly (max. 1 second) -> green led turns off, red led turns on - disconnect voltage 1.3 test of the serial interface (can be skipped) ------------------------------------------------- This test can be skipped and done after finishing the device. Then the two connectors for connecting into the serial connection between modem and computer are available anyway. 1.3.1 with the aid of a terminal program: - make serial connection to the computer (TxD, RxD, GND, connect CTS to RTS of computer) Hint: ----- 25pin female connectors are available in the data switch box. Simply use one of them to provisionally connect the computer with a serial cable (pin allocation see appendix). - apply voltage - wait till memory test is done (both leds light up) - start terminal program on the computer - push and hold green push-button -> press red push-button briefly -> release green push-button (with older firmware versions (up to 2.10) instead: press green push-button long (approx. 5sec)) -> both leds turn off - enter 'ATFAXCON' at the terminal -> configuration is output - disconnect voltage 1.3.2 with the aid of a fax software: - make serial connection to the computer (TxD, RxD, GND, connect CTS to RTS of computer) - push and hold red push-button - apply voltage - release red push-button -> red led is off, green led flashes briefly (during the memory test both leds light up) - press green push-button briefly (max. 1sec) -> green led flashes rapidly - start fax software and receice fax -> test fax is received (after about 15sec) - disconnect voltage 1.4 further construction ------------------------ - installation into a suitable (metal-)case (e.g. normal manual serial data switch box with 25pin conectors, this contains also a change over switch, which can be wired as standby switch; only some holes must be drilled additionally) Hint: ----- when installing the board, use spacing bolts: 4 pieces as well as screw/nut/washers; 1 piece in addition glued under the EPROM (between U3, J11 and the resistor). - wiring of the push-buttons, leds, the power switch (fuse between switch and connector), the current supply connector (isolated from the case!), the serial connectors, as well as - if necessary - the standby switch Hints: ------ Push-buttons: ------------- Insure short soldering time, otherwise they get to hot and are possibly mechanically damaged. Leds: ----- The anode of the led is often identified by the longer connector. The leds can be glued to the hole in the case. Better these are installed with led clips (the small black things) without glue. Therefore only the clip must be shifted over the led and then pressed into the hole (not to big) in the case. The clip locks then. Current supply connector: ------------------------- This mostly has 3 pins, by which however only 2 are used. The correct ones can be found by plugging the connector to the power pack and measuring, which pins are right. The polarity for connecting J1 and J2 does not matter, since a rectifier is on the board. Thus one continues to connect first one pin of the connector directly to J1. Then the other pin is connected to the switch by the fuse and from the switch to J2. The switch is 2way, 2position (each 3 pin in a series). One way is used for the switching of the power supply, the other one switches the back up battery. In each case only 2 pins are required for on/off, thus the middle (usually longer) and e.g. the lower one (in this case FaxCon is switched on, if the switch lever shows upward). Here comes a small sketch for the wiring of the switch (with connection of the back up battery): Switch (from the rear, solder side) o o + - O---------Fuse---------o o--------Battery-------\ Connector ! O---------\ o o ! ! ! ! ! ! ! ! ! J1 J2 J10 J7 to FaxCon board Standby switch -------------- (see appendix) - if necessary connection of the back up battery (switched with the 2way 2position switch, which is also used for power on/off) Hint: ----- The battery holder can be installed in the case in different ways. E.g. most plastic holders can be glued into the cover of the case. In each case make sure that nothing is short circuited. For savety reasons place a tape an top of the batteries. - check of the construction. Absolutely guarantee with the fact that no connection insists in particular between the standby switch and the components on the board! - further actions as described in the operating instruction under "line-up". With first power-up keep pressed both push-buttons, so that the EEPROM is loaded with the factory-configuration. 2 connectors and components =========================== 2.1 connectors and jumpers on the board --------------------------------------- Current supply J1, J2 9V DC or 7V AC, 300mA Backup (supply with power failure) J10 + backup battery 6V (e.g. 4 AAA or AA batteries) J7 GND Serial interface J3.1 modem RxD J3.2 n.c. J3.3 modem TxD J3.4 GND J3.5 GND J3.6 computer RxD J3.7 +10V (normally not used) J3.8 computer TxD Light emitting diodes J5.1 led green (kathode) J5.2 +5VLED (anodes of the two leds) J5.3 led red (kathode) Push-buttons J8.1 push-button green J8.2 GND (both push-buttons) J8.3 push-button red I2C-Bus (for extensions) J4.1 SDA J4.2 SCL J4.3 GND J4.4 n.c. J4.5 +5V Selection of the ROM size (normally 32K) +------------------+-----+-----+ ! Firmware EPROM ! J12 ! J11 ! +------------------+-----------! ! 32K or 64K high ! 1-2 ! 1-2 ! ! 64K low ! 1-2 ! 2-3 ! ! 64K ! 2-3 ! 2-3 ! +------------------+-----+-----+ (64K high/low: Selection of the firmware version with two 32K-firmwares in a 64K-EPROM) Others J13 signal for receive/transmit (output) 2.2 parts list -------------- Qty part name part description RM Reichelt(approx.DM each) 1 U1 80C32 5,-- 80C32-25 (Segor) 1 U2 74HCT573 1,-- 74HCT573 1 U3 27C256 (Firmware) 5,-- 1 U4 628128 (128 KByte) 10,-- 628128ALP-07(Seg.) optional... 628512 (512 KByte) 35,-- 628512LP-07(Segor) 3 U5,8,9 74HCT00 -,50 74HCT00 1 U6 PCF8582E-2 2,-- PCF8582AP 1 U7 MAX232 2,-- MAX232CPE 1 U10 7806 -,50 uA7806 9 D1-9 1N4001 10 -,05 1N4001 2 R1,16 10k 1/4W 10 (not available seperately, 4 R2-5 330 1/4W 10 10 pieces/value: 3 R6,7,10 3k3 1/4W 10 0,10 each 3 R12-14 1k5 1/4W 10 Order.nr.: 1 R15 4k7 1/4W 10 1/4W value) 2 C1,2 22p cer. 2,5 -,10 Kerko 22p 7 C3,5,7-11 10u/16V el. capacitor rad. 2,5 -,15 SM 10/16 rad 1 C4 100u/35V el. capacitor rad. 5 -,15 rad 100/35 8 C6,12-16,18,19 100n cer. 5 -,25 Sibatit 100n 1 X1 Quartz 11,0592 MHz 5 1,-- 11,0592-HC18 6 J1,2,6,7,9,10 SIP 1pin 2,5 = 1 J3 SIP 8pin 2,5 = 1 J4 SIP 5pin 2,5 = 4 J5,8,11,12 SIP 3pin 2,5 = -,40 Stiftl. 36G (1x) 1 *1 Led low-current, red -,20 TLLR 4400 1 *1 Led low-current, green -,20 TLLG 4400 1 *1 Push-button red -,25 T250A rot 1 *1 Push-button green -,25 T250A gruen 1 *1 Switch 2way 2position 3,-- MS245 1 *1 DC-connector (isolated) 1,30 DCBU-2.1Z (Segor) 1 *1 D-SUB connector female 25pin *3 1 *1 D-SUB connector male 25pin -,50 D-SUB ST25 1 *1 Switch 16way 2position *3 1 *1 Fuse 0,4A T -,70 MINI-TRAEGE 0,4A 1 *2 Case *3 1 *2 Printed circuit board 2 *2 Jumper 2,5 -,15 Jumper rot 13 *2 Zero ohms resistor or wire 10 -,05 0-Ohm 0207 (100 pieces Segor) *1 not placed on board *2 not numbered *3 serial cross over switch 25pin manuel 9,-- COM707 Additional parts: 1 IC-socket precision 8pin -,20 GS 8P 3 IC-socket precision 14pin -,35 GS 14P 1 IC-socket precision 16pin -,40 GS 16P 1 IC-socket precision 20pin -,50 GS 20P 1 IC-socket precision 28pin -,70 GS 28P 1 IC-socket precision 32pin -,80 GS 32P 1 IC-socket precision 40pin -,90 GS 40P 5 Distance rolls plastic 5mm -,10 DK 5mm 5 Screws M3 x 12 mm (100 pieces up) -,03 SZK M3,0x12mm 5 Nuts M3 (100 pieces up) -,02 SK M3,0 5 Washers M3 (100 pieces up) -,02 SKU M3,0 5 Zahnscheiben M3 (100 pieces up) -,03 SKZ M3,0 1 Batterie-holder flat 4 x AA 1,20 BH 3-4F (Segor) 1 Batterie clip (for batterie holder) -,20 CLIP 9V 1 Universal power supply 300mA 7,-- MW 88-GS/6 Part sources (Germany, please ask for international p&p costs): Reichelt Elektronik Segor-Electronics Elektronikring 1 Kaiserin-Augusta-Allee 94 26452 Sande 10589 Berlin Tel: 04422-955-0 Tel: 030-3449794 Fax: 04422-955-111 Fax: 030-3453968 p&p (max. 10kg) p&p (max. 3kg) Nachnahme DM 7,90 Post Vorkasse DM 6,80 Bankeinzug DM 5,80 Post Nachnahme DM 9,90 " ab 100,- DM 6,60 minimum order: DM 10,- no minimum order Status: March 1999 Appendix ======== A Pinning of the serial (PC-)port / standby switch -------------------------------------------------- (the switching position 'operation' is drawn, a nicer view can be found in the file "UMSCHALT.*") Modem Computer 25pin 9pin GND ---------------------x-- GND 7 5 +-----------------------> FaxCon o----------o RI --o - o o - o-- RI 22 9 o----------o DCD --o - o o - o-- DCD 8 1 o----------o DSR --o - o-+ o - o-- DSR 6 6 ! o----------o DTR --o - o-+ o - o-- DTR 20 4 o----------o CTS --o - o-+ +-o - o-- CTS 5 8 ! ! o----------o RTS --o - o-+ +-o - o-- RTS 4 7 o----------o RxD --o - o---+ +---o - o-- RxD 3 2 ! ! o----------o TxD --o - o-+ ! ! +-o - o-- TxD 2 3 ! ! ! ! ! ! ! ! V V V V FaxCon Operating position: RxD and TxD of modem and computer are connected to FaxCon, RTS connected to CTS at the modem and the computer, DSR connected to DTR at the modem all other signals are disconnected Position Standby: Modem and computer 1:1 interconnected GND is ground through in both operating modes and is connected to GND on the board. Some notes to the usage of the change over switch from a serial interface switch-box can be found further below in the text. B Suggestions for the case -------------------------- A normal 25pin manual serial data transfer switch can be used. Additionally this contains the required standby switch, three DSUB connectors and enough wires needed for the wiring. The two DSUB connectors fortunately already find their place in this case. A third one remains unused at the moment. Only the holes for the leds, the push-buttons, the power switch, the current supply connector and the board mounting holes must additionally be drilled. Because of the material of the case, sharp drills should be used, in order to get exact drillings. In order to install the board the change over switch must be dismounted. However, for the wiring as standby switch it is anyway practical to have both, the switch and the two connectors openly accessible. Note: ----- Indicated in parentheses () are the required hole diameters in mm for the parts used by me. Please check before drilling. Front view: +----------------------------------------------------------+ ! ! ! +----------------+-------------+ ! ! ! stand ! r g ! G ! ! +-- -by -----+-------------+ ! ! ! switch ! ! R ! ! +----------------+-------------+ ! ! ! +---+----+----------------------------------------+----+---+ +----+ +----+ r (4,4) = led red (with tie-clip) g (4,4) = led green (with tie-clip) R (7,0) = push-button red G (7,0) = push-button green Back view: +----------------------------------------------------------+ ! +--------------------+ ! ! ! 25pin female ! DC S ! ! +--------------------+ ! ! ! ! +--------------------+ +--------------------+ ! ! ! 25pin female compu.! VR ! 25pin male modem ! ! ! +--------------------+ +--------------------+ ! +---+----+----------------------------------------+----+---+ +----+ +----+ S (5,0) = on/off switch DC (approx. 12) = current supply connector VR (3,5) = voltage regulator (cooling, normally not required) Bottom view from inside the case: +----+--------------------+------+--------------------+----+ ! +--------------------+ +--------------------+ ! ! o 25pin male modem 25pin female comput. o ! ! ! ! ! ! MAX 80C32 EPROM RAM ! ! 232 ! ! ! ! +-------------+ ! ! ! ! ! ! ! standby ! ! ! o ! switch ! o ! +-----------+-------------+--------------------------------+ o (3,5) = drillings for board mounting (attach board in such a way that it closes up with the front of the case so that in the rear there remains sufficient space for the connectors) C Wiring of the change over switch as standby switch ---------------------------------------------------- First of all, a small advice: Before the later installation of the standby switch and DSUB connectors in the case, all other wirings should be done, since it becomes somewhat closer after the installation in the case. It is practical to unsolder all wires first, after dismounting of the change over switch and the DSUB connectors. These wires are normally long enough, in order to be used for the new wiring. Afterwards the wires (coloured alternating) are soldered to the required pins of the DSUB connectors with one end. Subsequently, at the change over switch the connections for the position 'Standby' are built. This can be done most simply with silver wire, which interconnects in each case two neighbouring connectors of the change over switch. Now the free ends of the DSUB connectors are connected in each case alternating (modem - computer) with the change over switch. Finally the connections for the position 'operation' are made and the four wires to the board are soldered to the appropriate pins. The two GND pins of the DSUB connectors are connected directly to the suitable pins of the board. The four so far only one sided soldered wires are interconnected, at the best before the installation of the change over switch, with the suitable pins of the board. Sketch of the change over switch with example wiring: (a nicer figure can be found in "UMSCHALT.*") +--------+ DTR RI TxD RxD ! RTS ! CTS 20 22 O 2 ## O 3 ! 4 ! 5 i I I i I I I I I ## I I I I I I I I I computer X X X ## X X X I I I i I I I I I ## I I I I I I I I I modem +-+ O ## O +--------+ ! ## ! i i i i i i i i i ## i i i i I I i I I computer ! ## X X ! i i i i i i i i i ## i i i I I I i I I modem ! #### ! 6 8 ! screw -> #### ! DSR DCD +---------------------------------------+ vvvvvvvvv rotary knob I = used ports i = not used ports X = silver cable links for position 'standby' +-! = bridges for position 'operation' O = connections to the board (TxD/RxD, modem/computer) numbers = connections to the 25pin DSUB connector (computer / modem) In each case three pins next to another represent a single 2position switch. Caution: Only the originally used single switches should be used. The others are often missing at all! The change over switch can also look somewhat differently. What to do with a change over switch of other design: First of all: The change over switches used in the switch boxes differ from week to week. Important is nevertheless only, that the required 16 single switches are available. Normally all single switches originally used function as disired. So if all were connected, also all switches are available. A change over switch could have e.g. 3 times 24 connectors, thus 3 planes with in each case 8 (24:3) single switches. For FaxCon thus 2 of these planes would be sufficient (2*8=16). Most suitably the 2 foremost planes (next at the rotary knob) should be used, the third stays unused. Use my plan respectively. E.g. for DSR and DCD, use the 2 switches beside the others, thus so: DTR RI TxD RxD RTS CTS DSR DCD instead of with the version described in the plan: DTR RI TxD RxD RTS CTS DSR DCD For each signal always two single switches (= 1 pair) are used. In order to be able to use the cable link for the standby position as easily as possible, in each case a pair of single switches next to each other is best, thus like that: - - - - - - - - - - - - ! ! ! ... ! - - - - - - - - - - - - \_______/\_______/\_______/ \_______/ 1. 2. 3. 8. (as with the above Umschalter-Paar sample cross-over switch) (- solder pins, ! wires) Finally is it however insignificant, which contacts are used, importantly is only that the wiring is correct. Watch out with the installation in the case that the solder points do not cause a short-circuit to the board. D View of the DSUB connectors in the case ----------------------------------------- Modem (male) Computer (female) ... x 8 7 6 5 4 3 2 x x 2 3 4 5 6 7 8 x ... ... 22 x 20 20 x 22 ... Only the required connectors are numbered, view from solder side. (x = unused pins, ... = further unused pins) ------------------------------------------------------------------------------ FaxCon (c) Michael Klingel - construction guidance - ------------------------------------------------------------------------------