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----------------------- How to build a BLUE BOX ----------------------- We all know that the touch tone frequencies are composed of 2 tones (2 different frequencies) so that is the reason why we have 2 VCO's (Voltage Controlled Oscilators). We will call then VCO#1 and VCO#2. If you have noticed VCO#1 and VCO#2 are exactly the same type of circuits. That is why only 1 was drawn. But remember that whatever goes for VCO#1 also goes for VCO#2. Both VCO'S are composed of a handfull of part. One chip, two capacitors, 2 resistors and five potentiometers. All of this will give you (when properly calibrated) one of the freqencies necessary (the other one will come from VCO#2) for the operation of the Blue Box. Both of these freqs. will be mixed in the speaker to form the required tone. This is one of the most sophisticated designs I have ever made. Why? Because other designs will drain the battery after 10 calls. This design will make them last 10 months!!!!! But never the less, don't forget to put in a switch for on and off. Ok let's build the two VCO'S and calibrate the unit before we get to the keyboard construction. VCO CONSTRUCTION: ---------------- TOOLS REQUIRED 1 ocilliscope(optional but not req) 1 Freq. counter (REQUIRED) 1 Volt meter " " " Electronics tools (Pliers,drll, screwdrivers, etc.) ===================================== PARTS R1 1.5K RESISTOR 5% R2 1K RESISTOR 5% C1 .1uf ELECTROLYTIC CAPACITOR 16VDC C2 .01uf " " (MYLQR)16VDC IC1 2207 VCO CHIP BY EXAR ELECTRONICS Remember the above only says VCO#1 but the same is for VCO#2 R3-R4 150 OHM RESISTORS 5% C3-C4 .1 uf ELECTROLITIC CAPACITOR 10VDC P1-P10 200K TRIMMER POT - 20 TURNS DIODES USED IN THE KEYBOARD ARE 1N914 TYPE (40 OF THEM) & 13 SWITCHES FOR THE KEYBOARD SPST MOMENTARY. SPKR=YOU CAN USE A TELEPHONE SPEAKER FOR THIS (IT WORKS BEST) BUT REMEMBER TO TAKE OUT THE DIODE THAT IS CONNECTED ACCROSS IT. ======================================= IMPORTANT NOTES 1. DO NOT USE ANYTHING ELSE OTHER THAN A MYLAR CAPACITOR FOR C2. 2. PINS 10,9,8 SHOULD BE TIED TOGETHER AND BE LEFT FLOATING. 3. ALL RESISTORS SHOULD BE 5%! NOTHING ELSE! 4. A TELEPHONE SPEAKER GIVES THE BEST RESULTS. ======================================= TROUBLE SHOOTING By now you should have constructed the two VCO'S on a bread board or anything that pleases you. Check for cold solder joints, broken wires, polarity of the battery, etc. Before we apply power to the VCO'S we have to adjust the pots for their half way travel point. This is done by turning them 21 turns to the right and then 10 turns to the left. Do the same for all ten of them. Now apply power to the unit check to see that you have power in the chips by putting the positive lead of your volt meter on pin 7 and the negative lead on pin 12. If you do not have anything there turn off the unit and RECHECK THE WIRING. When you get the right voltages on the chips, connect a diode to a piece of wire (look at fig. 2 for the orientation of the diode) from ground to any pot at point T (look carefully at the schematic for point T it is labeled T1-T10 for all pots). You should be able to hear a tone, if not disconnect the lead and place the speaker close to your ear and if you hear a chirp-like sound, this means that the two VCO'S are working if you don't, it means that either one or both of the VCO'S are dead. So in this case it is always good to have an ocilloscope on hand. Disconnect the speaker from the circuit and hook the ocilliscope to 1 of the leads of the speaker & the ground from the scope to the ground of the battery. Connect again the ground lead with the diode connected to it from ground to any pot on the VCO that you are checking and you should see a triangle wave if not turn the pot in which you are applying the ground to until you see it. When you do see it do the the same for the other VCO to make sure it is working. (amplitude is about 2VAC). When you get the two VCO's working you are set for the adjustment of the individuals pots. Adjustment ---------- Disconnect the speaker from the circuit and connect a freq. counter (the positive lead of the counter to one of the speakers leads that belongs to VCO#1 or connect it to pin 14). Connect the negative lead to the battery negative and connect the jumper lead with the diode from ground to pot number 1.T1. ( the first pot number 1 point T1) if you got it working you should hear a tone and get a reading on the counter. Adjust the pot for a freq. of 1700HZ and continue doing the same for pots 2-5 except that they get differents freqs. which are: $$$$$$$ $ P1= 1700hz $ $ P2= 1300hz $ $ P3= 1100hz $ $ P4= 900hz $ $ P5= 1500hz $ $$$$$$$ Now disconnect the freq. counter from the speaker lead of VCO#1 or from pin 14 (which ever you had it attached to at the beginning) and connect it to the speaker lead of VCO#2 or to pin 14 of VCO#2 and make the same adjustments to P6-10. $$$$$$$$ $ P6= 1100hz $ $ P7= 700hz $ $ P8= 900hz $ $ P9= 2600hz $ $ P10= 1500hz $ $$$$$$$$ When you finish doing all of the pots go back and re-check them. Keyboard -------- If you look at FIG-2 you will see that the keys are simple switches. Connected to a ground and two diodes on the other end. these diodes are used to simplify the construction of the keyboard because otherwise the distribution of the ground signal for both VCO'S would have been done mechanically. The diode will go to VCO#1 and the other will go to VCO#2. FIG-3 shows the arrangement of the keys on the keyboard. Below is a table that will help you connect the keys to the required VCO's pots. (-FIG 2-) -----!-----!--------!--------!------- ! ! ! ! TO ! TO ! FREQ ! FREQ ! KEY POT ! POT ! OUT: ! OUT: ! ON ! ON ! ! ! VCO1! VCO2! ! ! -----!-----!--------!-------%!------- 1 ! 06 ! 1700hz ! 1100hz ! C 2 ! 10 ! 1300hz ! 1500hz ! 0 1 ! 10 ! 1700hz ! 1100hz ! E 4 ! 07 ! 0900hz ! 0700hz ! 1 3 ! 07 ! 1100hz ! 0700hz ! 2 3 ! 08 ! 1100hz ! 0900hz ! 3 2 ! 07 ! 1300hz ! 0700hz ! 4 2 ! 08 ! 1300hz ! 0900hz ! 5 2 ! 06 ! 1300hz ! 1100hz ! 6 5 ! 07 ! 1500hz ! 0700hz ! 7 5 ! 08 ! 1500hz ! 0900hz ! 8 5 ! 06 ! 1500hz ! 1100hz ! 9 - ! 09 ! ------ ! 2600hz ! X Remember that in FIG-2 it's the same for each key except the "X" key, which only takes one diode. few KEYS to the diagram: Cx is capacitor #x Denoted by: ---| | --- Px is Pot or Variable resistor #x Deno ted by :/ \ /<-- \ Rx is resistor #x Denoted by /\/\/\/\ SCHEMATICS The XR-2207 chip is a Voltage-Controlled Oscillator and a 14 pin device thus you must be very careful when soldering the parts to this device. It is a little dificult to actually draw a schematic on an 80 character screen using limited graphics, but I will give it a try. TO GND_____________ | ___ C2 C3 ___ _||_ | | | _____|__9v+ | | | | ` ` ` ` ` ` ` | ------------------------------- | 7 6 5 4 3 2 1 | | | < | |8 9 10 11 12 13 14| | ------------------------------- | ` ` ` ` ` ` ` | | | | --| |--------| | | |C1 R2 | R1 | GND ______|___/\/\/\/\______|_____/\/\/\/\______| is is a diagram of how to locate the different pins on the chip. Please notice that pin one (1) is the closest to the notch on top of the chip. The first thing we'll do is to connect power to the chip (remember that you need to build two (2) of these to get a complete system) this is accomplished by connecting the positive wire of the battery lead to pin#1 one leg of R1 and R2 is soldered to pin#11. The other leg of R1 goes to pin 1 or to the d. C1 goes between pin 10 and ground. The timing capacitor or C2 goes between pins 2 and 3 of the chip. Pins 8 and 9 should be grounded to ground. Pin 14 is the output and this is where one leg of C4 (C3 goes on the other VCO) in series with R3 (the same goes for the other VCO) and to one lead of the speaker. The trimmer pots P1 to P10 should be grouped in groups of 5 pots each. The way you group it is by soldering one end of the pot to each other leaving the wiper and the other end free. | This end goes to pin 6 of the chip | _____________|_____________ / / / / / \ \ \ \ \ /<- /<- /<- /<- /<- \ | \ | \ | \ | \ | / | / | / | / | / | | | | | | | | | | | P1 P2 P3 P4 P5 And finally this is the way each key should be wired. diode he contact of the |--------- \------ key to Px ------>|-----| | diode | ----- --- Ground