boatman

The minijack on the front is in parallel with the headset connector on the back panel. As there wasn't space for two separate jacks, it is a 4-way 3.5mm jack with the following connections: Tip: Headphone - R1: Headphone + R2: Mic input Sleeve: GND I don't have a PC headset to test it but I have put a scope on the pins to check the signals are present. Note that the headphone drive on this beltpack is a bridge amplifier and doesn't need a GND connection. There is a considerably higher level of drive compared to a conventional Tecpro or Stonewood (Granite Audio) box. One feature which was requested is the ability to modify the headphone volume control so that it cannot be turned down to zero. Resistor R37 (currently 10R in the parts list) should be increased appropriately to achieve this. A value around 1k to 2k should be sufficient. The four-way DIL switch on the back panel has two functions: SW1 turns on the 12V bias for electret mics and SW2-SW4 adjust the mic amp gain according to the following table: Switches ON dB gain None 31.9 4 33.0 3 34.3 3 & 4 35.9 2 38.0 2 & 4 40.5 2 & 3 44.0 All 49.9

Very good. Is there a prize for being the first to mention it? ;) One other random question - what's the logo/symbol just to the right of the empty screw hole? Have a look at this close-up then have a look at my forum user name. http://mydesk.myzen.co.uk/_Useful/BlueCom/Boatman.jpg

I wondered how long it would take someone to notice! I actually only had seven M3 screws of the appropriate length (with matching heads) in my box. I should have moved one from the front to the back before taking the second set of shots. The ideal fixing into the case would be this M3 x 8mm taptite screw from Farnell (it could also be used to mount the connectors to the back panel), but I didn't have those handy either, so had to run an M3 tap a short way down the holes.

The beltpack panels are here and fit perfectly! A small design change means that they are considerably more handsome than the first set of power unit panels. A few pictures. http://mydesk.myzen.co.uk/_Useful/BlueCom/BeltpackPanels.jpg http://mydesk.myzen.co.uk/_Useful/BlueCom/BeltpackFront1.jpg http://mydesk.myzen.co.uk/_Useful/BlueCom/BeltpackFront2.jpg http://mydesk.myzen.co.uk/_Useful/BlueCom/BeltpackBack1.jpg http://mydesk.myzen.co.uk/_Useful/BlueCom/BeltpackBack2.jpg

Thanks to BR member Hieronymus for spotting an error in the parts list. The correct part number for VR2 should be RE06773 (CPC) or 1191736 (Farnell). Correct parts list version 1.2b is below: BluecomBeltpackPartsList_V1_2b.pdf

It was quite some time ago when I ordered these from CPC and when they arrived they were in Farnell packaging. I've just checked against the data sheet and they are actually the Alps 29 0006 that I have (6.5mm above the PCB to the centre of the shaft, so both the panels and your part number are correct! I will update the parts list.

Someone has pointed out a couple of minor errors in the parts list for the beltpack. The quantities were wrong for resistors R1 & R2 and resistors R21 & R28 were missing. I hope it's right now! BluecomBeltpackPartsList_V1_2a.pdf

Reservoirs to remove any switcher noise from wall-wart style power supplies. Two are needed as the power lines to the separate loops are isolated by diodes.

Here are the technical documents for the Bluecom Beltpack: Schematic: BluecomBeltpackSchematic_V1_2.pdf Component placement: BluecomBeltpackPlacement_V1_2.pdf Parts list: BluecomBeltpackPartsList_V1_2.pdf Gerber files: BluecomBeltpackGerbers_V1_2.zip Front and back panels are currently being laid out and will be available here in a couple of weeks once prototype boards have been received and fitted.

Initially, we plan to have part numbers for the major UK and European suppliers (Farnell, CPC, RS Components & Rapid Electronics). Someone will need to translate these to Mouser or whatever other US suppliers. We have a few BR members on that side of the pond who may be willing to do this. Edited to add: Extended Hogmanay celebrations, ferry cancellations, floods and of course Bridge parties (the game sort not the civil engineering sort) not withstanding, I have two complete working and tested beltpack boards! They have been tested with the Bluecom Power Unit and a Tecpro BP111 all in circuit. As a result of this testing a couple of component values have changed and the 6-pin KK connector, which gives access to various points on the circuit, has been changed to an 8-pin so that the common bus is also available. Revised schematic, placement, parts list and Gerber files for version 1.2 will be available in the documentation thread very soon. A few pictures: http://mydesk.myzen.co.uk/_Useful/BlueCom/BluecomTesting1.jpg http://mydesk.myzen.co.uk/_Useful/BlueCom/BluecomTesting2.jpg http://mydesk.myzen.co.uk/_Useful/BlueCom/BluecomTesting3.jpg http://mydesk.myzen.co.uk/_Useful/BlueCom/BluecomTesting4.jpg

The whole project has two aims; firstly to provide an open-source DIY comms system which will be compatible with Tecpro and Stonewood (now known as Granite) systems but at a much lower cost and secondly to provide a source of funds to keep the Blue-Room going. To that end, bare boards will be definitely be available for both the beltpack and power unit. We have yet to decide on what level of kits or finished boards we will support as that requires considerable investment in stock. We'll let you know as soon as possible. Anyway my soldering iron is cooling and I have two completed second prototype boards for testing. You will see in the second photograph that some components are on stand-offs; this is to make it easier to set up the gain structure correctly. I intend have some results before Hogmanay so that we can declare the project "Almost Ready" by the time the Bells ring out! http://mydesk.myzen.co.uk/_Useful/BlueCom/BeltpackBuilt1_1A.jpg http://mydesk.myzen.co.uk/_Useful/BlueCom/BeltpackBuilt1_1B.jpg

So, what would you do with your time if your dog got sick and you had to cancel Christmas with the family? Well, I chose to get out the soldering iron and make a start with the beltpack board which arrived this morning. I've fitted most of the major components which control the layout of the front and back panels (just the LED to be fitted) and I will complete the panel layout in the next couple of days. As soon as I have the modified parts list I will complete a couple of boards and then they can be tested. http://mydesk.myzen.co.uk/_Useful/BlueCom/BluecomBeltpackV1_1.jpg Oh, and have a good Christmas and New Year.

Here are the 1.0 release Gerbers for the Power Unit panels. I have modified the solder mask layer so that the text and graphics will now be plated. There are three files; two are for separate front and back panels and the third is for combined panels. The combined panels file has both a silkscreen layer and a V-groove layer. If your PCB manufacturer can rout a 0.9mm wide v-groove then use the latter otherwise use the silkscreen layer and separate the panels with a hacksaw and fine file. PsuPanelFront1_0.zip PsuPanelBack1_0.zip PsuPanels1_0.zip

I'm not quite sure what you mean by "Ferrule Kit". If you mean a "Bezel Kit" like this, then, 'Yes' it will fit OK and 'No' I don't know if you need one or two for each case. However, the webpage implies they are sold as single items so you probably need two. Thanks. The actual cutting line is just a guide. The limits are the two solid silk-screen lines and it's very easy to cut with a standard hacksaw and finish with a file down to the silk-screen lines. As I wrote in an earlier post these are prototype boards made cheaply in China and the manufacturer doesn't support routing grooves for separation. The production Gerber files will have a V-groove layer for routing out between the panels. There will also be Gerbers for two separate front and back panels which will be machined to the correct profile. The production boards will probably be manufactured in the UK and may be significantly more expensive!

Front and back panels for the Power Unit are now available and they fit perfectly. These are the prototype panels made to check that they fit and I thought the text would show through the solder mask a little better than it does. I have decided that the production panels will have the text plated through the solder mask to make it more visible. I still don't have any production beltpack PCBs. Once I have a completed one I will make PCB panels for that as well. It will also have the text plated through the solder mask. http://mydesk.myzen.co.uk/_Useful/BlueCom/BluecomPanels1.jpg http://mydesk.myzen.co.uk/_Useful/BlueCom/BluecomPanels2.jpg http://mydesk.myzen.co.uk/_Useful/BlueCom/BluecomPanels3.jpg http://mydesk.myzen.co.uk/_Useful/BlueCom/BluecomPanels4.jpg http://mydesk.myzen.co.uk/_Useful/BlueCom/BluecomPanels5.jpg http://mydesk.myzen.co.uk/_Useful/BlueCom/BluecomPanels6.jpg I have five available (one is already allocated) and the price will be £8.50 each (that's both front and back panels). I also still have six power unit PCBs at the same price. Carriage will be £1.50 within the UK. If you wish to purchase a pair of boards please send me a PM.

It depends on how many stations you intend to have on the system. Each output loop is separately fused with a 2.5A polyswitch, so the maximum load can be 5A. Starting with the most expensive here's a few to choose from: http://cpc.farnell.com/ideal-power/5211202b-24-3a/psu-desktop-24v-5-0a-2-pin-iec/dp/PW02434 http://cpc.farnell.com/ideal-power/5210952-24-3a/psu-desktop-24v-3-75a-2-pin-iec/dp/PW02431 http://cpc.farnell.com/ideal-power/521060b-24-3a-1/psu-desktop-24v-2-5a-2-pin-iec/dp/PW02428 http://cpc.farnell.com/ideal-power/25hk-ph40-a24/psu-desktop-24v-1-66a-2-pin-iec/dp/PW03347 As soon as I have a working beltpack board, I'll measure the current it consumes and then I can give an indication of what current capacity a typical system will need.

The Gerber files for the base unit front and back panels are here. There are three zip files; for the separate panels and a combined layout for both panels. Also, a placement picture and, due to the wonders of laser printer & Pizza-box prototyping, a couple of pictures of the panels in place. PsuPanelsBoth.zip PsuPanelFront.zip PsuPanelBack.zip I will be getting five panels made so there will be some for sale in a week or so. I still have seven base unit bare boards available.

Are you adding snap-apart routed channels in between the fascia PCBs? That would provide a much neater finish than having to physically saw a PCB in half. Most manufacturers will add routed channels anyway if you give the separate PCBs separate outlines. Sawing PCB material is messy and tends to leave a rather rough edge, hence why most PCB material is chopped by guillotine or panelised as snap apart boards. As all of the prototype boards are being made at my own personal expense, I am currently using a cheaper PCB manufacturer based in China. Unfortunately, they don't support partially routed or drilled breakaways, only silk screen cutting lines. The designs can easily be transferred to a manufacturer who will produce such boards but they are a lot more expensive.

Yes, it this one (click on the picture for a link to the Farnell page): http://uk.farnell.com/productimages/farnell/standard/1549965-40.jpg You can get blank metal panels and seals, but I am designing PCB front and back panels. The panels will come on as a pair on a common PCB which will have to be sawn in half as that's a much cheaper manufacturing option. Once the beltpack board is finished there will be PCB panels for it too.

Hmmmm, (® Ynot) I think it's time to start ordering from Farnell in Holland! Although, you have omitted the fact that the CPC prices are for packs of 5, whereas the Farnell prices are for individual components, so there's not quite as much difference as it first appears. The original Tecpro power unit had three circuits capable of being commoned, with a single male connector on each circuit. To increase flexibility, we decided to offer a male and female on each circuit, but restrict it to two circuits. The other difference being that you need an external 24V power supply for the Bluecom base unit. Something like this would be fine for most systems. For a large installation you may need to go to this one.

This thread has been created to hold the technical documents for Bluecom. I'll start with the schematic, placement diagram, parts list and Gerber files for the base unit. Documents for the beltpack will be posted here as soon as they become available. BluecomPsuSchematic1_1.pdf BluecomPsuPlacementx2.pdf BluecomPsuPartsList.pdf BluecomPsuGerbers1_1.zip

EasyPC version 17. The problem only appears occasionally when the Gerber resolution is set to 3 decimal places. I've now set it to 5 and all seems to be OK. Their support person is aware of the problem and there's a discussion about it on the EasyPC forum here. I've always used the 2.3 setting for Gerber files in previous versions (I've been using EasyPC since the DOS version from about 20 years ago!) and never had a problem until the Windoze release 17.

No the height was right, but they collided with an internal web on the case in version 1.0 and had to be moved slightly towards the centre of the board. That was when the Gerber file error crept in. I have been in touch with the PCB layout software vendors and they are now aware of the problem and have offered a solution which seems to work OK. I have nine bare boards here and you are welcome to a couple. They will be £8.50 each plus carriage @ £3.50 to the Republic of Ireland (1, 2 or 3 boards will all be the same on a 5-day delivery). There are no front or back panels yet, but they are in the pipeline and the bill of materials will be available in the next day or two. Someone else is dealing with the beltpack boards and I don't have any of those available yet.

We have working base station boards. There was a small issue with component locations in version 1.0 where the large reservoir capacitors touched the case; so version 1.1 was quickly produced. Unfortunately the PCB layout package created an error in the manufacturing files which caused a short between one of the power rails and the ground plane (the layout was perfect, but the Gerber files had a problem which I didn't pick up before ordering the PCBs). Anyway it's sorted now and the first ten boards are available with a minor correction by scalpel (see the last picture). In case anyone wants to get their own base unit boards manufactured, the Gerber files are also fixed. Now I have a completed board, I will lay out the front and back panels for the base unit in the next few days. In the meantime here's some pictures: http://mydesk.myzen.co.uk/_Useful/BlueCom/BluecomPowerUnit0.jpg http://mydesk.myzen.co.uk/_Useful/BlueCom/BluecomPowerUnit1.jpg http://mydesk.myzen.co.uk/_Useful/BlueCom/BluecomPowerUnit2.jpg http://mydesk.myzen.co.uk/_Useful/BlueCom/BluecomPowerUnit3.jpg http://mydesk.myzen.co.uk/_Useful/BlueCom/BluecomPowerUnit4.jpg

The power unit PCBs arrived from China this morning. I am waiting on 3-pin XLR male connectors as I have run out, but everything else is to hand and I will build the first one tomorrow. http://mydesk.myzen.co.uk/_Useful/BlueCom/PowerUnitPcb.jpg