BlueClone - The Blue Room's Own Comms System

[boatman]

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.

[boatman]

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.

[bigclive]

Very neat. When I used PCB laminate for front panels myself I used the white screenprint on the front for the graphics. It's actually quite tough.

 

I'm squirming at that ultra-thin cutting line. No problem if you have a guillotine, but quite tricky to saw accurately. A channel routed out there would have made it a lot easier to cut or snap the panel into the two halves with little edge cleaning required.

 

But the design is progressing very nicely. Good job!

[Rob_P]

A quick one - I see that Farnell sell a ferrule kit for this case. It does look like it would tidy things up a lot. 2 questions therefore:

1) Has this kit and the belt back been designed with the ferrule kit in mind?

2) Does anyone know if the ferrule kit comes as a pair of parts or as individual bits? Basically, if I want to order a set of 6 cases do I need 6 or 12 ferrules?

 

Thanks,

Rob

Edited December 12, 2013 by Rob_P

[boatman]

A quick one - I see that Farnell sell a ferrule kit for this case. It does look like it would tidy things up a lot. 2 questions therefore:

1) Has this kit and the belt back been designed with the ferrule kit in mind?

2) Does anyone know if the ferrule kit comes as a pair of parts or as individual bits? Basically, if I want to order a set of 6 cases do I need 6 or 12 ferrules?

 

Thanks,

Rob

 

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.

 

Very neat. When I used PCB laminate for front panels myself I used the white screenprint on the front for the graphics. It's actually quite tough.

 

I'm squirming at that ultra-thin cutting line. No problem if you have a guillotine, but quite tricky to saw accurately. A channel routed out there would have made it a lot easier to cut or snap the panel into the two halves with little edge cleaning required.

 

But the design is progressing very nicely. Good job!

 

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!

[boatman]

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.

Edited December 24, 2013 by boatman

[dmxlights]

So, what would you do with your time if your dog got sick and you had to cancel Christmas with the family?

 

Good for some that has something to play with over Christmas. Well I do have sick dog and he is not great.

 

Happy Christmas and a happy new year to you

 

PS I cant wait to order some belt packs boards from you

[Hieronymus]

Looks good! I greatly appriciate all your effort.

 

It's a good thing to know that in 2014 we'll have a proper comm system, that has all the good stuff, yet is homemade for a more then reasonable price. (you wouldn't say that with those coverplates :-) ). The offer to help still stands.

Best whishes to all

 

 

 

[antlear]

Hi guys just saw this, are these going to be sold as kits or prebuilt.

Thanks

[boatman]

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

[NewChris]

Will you have supplier codes for us in the united States?

[boatman]

Will you have supplier codes for us in the united States?

 

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

Edited January 4, 2014 by boatman

[Hieronymus]

*applause please!!!*

 

:notworthy:

 

Great work!

 

I'll update my excel calculations this weekend. It will be easy to identify total costs of the parts!

Edited January 4, 2014 by Hieronymus

[Hieronymus]

Hi Boatman!

 

I've updated the BOM calculation sheet to include the CPC codes for the beltpack. There are a few things that need be clearer I think.

 

- Could you check that I chose the correct induction for L1 (I thought they had similar specs and size, maybe I'm overlooking something)

- J175 has a four options on farnell for a TO-92 package. Could you check that, which one is needed?

- Also for the NE5534 and TL072 I chose the option with the highest slew rate. And the highest hFE for the BC547. Is that correct?

 

This is a list for the CPC order codes. Without a few connectors, case and resistors. I will do the farnell list later this week.

 

Here is the download: BOM-0.3.xlsx

[NewChris]

Hi Boatman!

 

I've updated the BOM calculation sheet to include the CPC codes for the beltpack. There are a few things that need be clearer I think.

 

- Could you check that I chose the correct induction for L1 (I thought they had similar specs and size, maybe I'm overlooking something)

- J175 has a four options on farnell for a TO-92 package. Could you check that, which one is needed?

- Also for the NE5534 and TL072 I chose the option with the highest slew rate. And the highest hFE for the BC547. Is that correct?

 

This is a list for the CPC order codes. Without a few connectors, case and resistors. I will do the farnell list later this week.

 

Here is the download: BOM-0.3.xlsx

 

WOW! this spreadsheet is excellent. I am currently making my own for the United States. Yours have manufactures and their codes so it will make my life easier. I will post mine once I finish them. I don;t know when that will be given I have to go back to school.