AOR AR8000 Scanning Receiver Modifications

These mods were done some years ago now, I find it's a rewarding challenge to try and squeeze extra circuits into and performance out of, a piece of equipment.
While modifying equipment that uses surface mount technology, I strongly recommend that you use a small-tipped soldering iron (1mm or less), and a magnifying glass to inspect your work! All such mods are done at your own risk. If you're not used to such equipment, it's best to gain some experience first, by building some simple SMT projects.

Above: nothing startling here, just the usual sound discriminator and Scout reaction tune mods in evidence with the 2.5mm sockets

Above: What have we here? Four more side panel buttons! The top two are used for the sound recorder, the next is for NFM bandwidth toggle. The bottom one is currently unused.

 

Sound Recorder
An essential item for capturing all kinds of interesting bits of info, surprisingly there hasn't been a module produced to fit into the AR8000. AOR UK was working on a design, which they then abandoned. Implementations on other receivers has often left a bit to be desired, whereby the record mode has to be set up, before it can be invoked. What is needed is a single key-press for instant record and playback.
All such devices seem to use the ISD1000A chip series, intended for use in memo-recorders, and various novelty items that require cheap and cheerful audio facilities. This is a great device, with non-volatile memory (message retention is 100 years!), up to 20 seconds capacity, and it requires very few extra components. To integrate one into the AR8000 seemed a difficult task at first, but it is actually quite easy. I opted to use an existing memo-recorder board (Memokey 320, sold by Maplin Electronics, board type MKP-05), but if you can't find one there are plenty of others using the same technology. Check it's fully working before delving inside. The important thing is that it should use the die version of the chip, if you look on the board you should see it-a small black blob! Any other type may not be possible to squeeze in. Even this board had to be pruned, there was extra circuitry including a microphone, which was removed, and the top 5mm had to be sawn off for it to fit in the only suitable spot I could find. As can be seen from the photo (right) this area is just above the LCD display, on the logic board, with a small sticky pad allowing it to rest on the speaker.
Carefully analyse the track layout from the die chip, and the connections should be obvious. Discard any extra bits and pieces no longer required on the board, including the switches and LED. Remove the two electrolytic caps near the top of the board.
At the bottom of the board are the supply and audio out connections, left to right 0V, AF out, AF ground, and +5V. Just above the +5V pad is a surface mount cap, remove it, the left pad is the line level audio in, which should be DC isolated with an external cap. Audio from the AR8000 comes from J6-3, a connection can be found on the logic board (see the external sockets photo at bottom). The only snag with that is that the audio fed to the recorder is always unmuted, but this is not a major problem in my opinion.
The record and playback switches can be mounted wherever you like, personally I prefer the right side panel. Two press-to-make switches are added which obviously connect to the pads vacated by the original switches. I used a spare left panel (from a broken AR8000), which is perfect for the job (and also gives the option of two more switches), but sadly AOR do not supply this separately.

Sound recorder board
This is the memo-recorder board squeezed into the area above the LCD display. On the LCD back plate rests a 4013 flip-flop which operates the IF bandwidth toggle.

 

NAM/NFM IF Bandwidth Switching
A popular mod, which is commercially available and the DIY version has been doing the rounds for years. The idea is very simple, to allow the selection of the narrow SSB/CW IF filter while in AM and NFM modes, and entails swapping the two control voltages from U2. My way to accomplish this is a bit different from the mods I've seen. It requires a flip-flop IC, two diodes and one Supersot FET, the NDC7001C dual FET (one is N-channel, the other P-channel). The latter device is extremely small (see image right lower), even by SMD standards, so you may prefer to use two discrete FETs instead. As can be seen (photo right), I did just that after over-heating the original!
The two drains are joined together and connect to the cathode of a diode; the gates are also connected together, and connect to the Q/NOT Q of a 4013 flip-flop IC via a 10k resistor. The 4013 is in toggle mode and uses a spare momentary push-to-make switch from the mod mentioned above. The source of one FET connects to the junction of R22/C30, the other source connects to the junction of C32/R25/R26.
Two tracks on the IF board need to be cut, I recommend studying the service manual and the board very carefully before doing this. Look to the right of the top row of pins of U6, you'll see three horizontal tracks, the top one and the middle one need to be cut, and the track exposed to create four connection pads. For the top track you need to bridge the connections with a diode (1N914), the cathode (banded end) soldered to the right side pad, which is also connected to a source of the NDC7001C. The middle track left pad connects to the anode of the diode that goes to the gates of the NDC7001C, the right pad connects to the remaining source of the NDC7001C.
I would stress that the PCB track cutting is a slightly tricky procedure, take your time while attempting this, and triple check to make sure you're cutting the right tracks! Do a continuity check to confirm the tracks are actually cut and when you've installed the mod, confirm all connections are correct.
I recommend this mod, it will improve the SNR when listening to weak signals on AM, or those subject to adjacent channel splatter, and it's also very useful to use when listening to low-deviation NFM signals (i.e. those of a covert nature).

Bandwidth switching mod
NDC7001C dual FET board

Mode Audio Balance
I've always found the variation in audio levels between different modes irritating, especially between AM and NFM, which will often be scanned within the same bank. Although audio levels will depend on modulation levels, the AM was always too high. Switching to SSB/CW also resulted in an ear-splitting din.
The remedy was to simply add series resistors in the relevant audio path. U6, a 4066 is the audio multiplexer used and is located on the top left of the IF board.

U6 pin-outs:
Pin 1: NFM audio in
Pins 2 and 3: Audio out to C85
Pin 4: SSB audio in
Pin 8: Audio out to C85
Pin 9: AM/WFM audio in

Trace the tracks from pins 4 and 9, I recommend obtaining the service manual and looking at the PCB layout. Break the tracks at a convenient point using a craft knife. Scrape off each side of the tracks to reveal the bare track. The distance between the two break points should be suitable for a surface mount resistor. Lightly tin one of the track edges, then carefully position and solder in the resistor. Perform a continuity check to ensure you've made the connections. The actual values of resistors is a case of AOT, but I found that for the input of pin 4 (SSB level) a value of 82k gave good results, and for pin 9 (AM and WFM) I used 33k. The latter reduces the WFM level, which isn't desired, but I prefer to have the lower AM level.

 

Audio Limiter
Although the previous mod reduces the difference in audio level between modes, the fact is that there's still a large dynamic range within transmissions of the same mode. Obviously the wide deviation NFM of cellular phone transmissions will be a lot louder than 12.5kHz PMR, but even with the latter there can be big differences. The most likely reason is that the transmissions are of a covert nature, and the person operating cannot talk beyond a whisper. When out and about I always listen on in-ear headphones, and I found I was always having to readjust the volume to avoid discomfort, as well as to avoid detection, by operators within ear-shot.
This mod uses a small PCB and SMD components (shown right), and is fitted in the space on the right side of the IF board. The circuit is very simple, with a low-current op-amp IC, the ICL7611 used as an amp to feed audio to a diode rectifier. The resultant voltage is fed to a VN10KM FET, which attenuates the audio. I initially added an NDC7001 dual FET for control and gating (and toggled by a flip-flop), but found this was superfluous, as I found it was best left on all the time.
The mute point (which connects to the VN10 via a 2k2 resistor) is the junction of R73/C88, and the op-amp is fed from the AF (J6-3) line, pin 7 of U5B. Pin 8 of the op-amp is tied to +5V for minimum quiescent current.
This mod does increase the distortion level, which makes WFM reception sound a bit grotty, if that's a problem, then you'll need to be able to switch it off. If you're interested in listening to security/covert stuff on NFM, then you'll find it a very worthwhile addition.

Audio limiter board

 

Improved WFM Performance 
The AR8000 uses two crystal filters for IF roofing purposes in all modes except for WFM. This is necessary as the bandwidth would be far too narrow, but the consequence is that performance isn't too good, being very prone to overloading from high-powered transmissions. The WFM mode uses a tank L/C configuration to provide some bandpass filtering at the 45MHz IF, but this isn't really up to the job. The answer is to fit a SAW filter, in fact if you look at the board, there seems to have been space allocated for one, but AOR probably dropped this from the final design. There's a big problem however, I've yet to locate a 45MHz SAW filter, and bear in mind it needs to be pretty small, to fit in the available space. If you do know of a source for such a filter, please email me!

 

Other Stuff...

Antipip board detector

The "AntiPip" mod is mentioned elsewhere on this site. Sadly, this circuit couldn't be made to work on the AR8000 in this form. It did work fine on an old Uniden Bearcat 200XLT scanner however. On the left is the tone detector, to the right is the "scan advance" and mode enable circuit.

Antipip trigger board

FX118 board

Left is a prototype spectrum shift encoder/decoder, which I experimented with.
I never fitted this into the AR8000, but would be easy to add if required.

Logic board mods

Above shows the bottom of the logic board, with two sockets added: one for Reaction tune with an Opto Scout, the other is raw unfiltered audio out for use with data decoders. You can also see the connection made for the sound recorder audio source (left centre of the board) and the change of crystal to eliminate the 'wandering birdies' problem.

FX224 board

Left is a variable split-band decoder using an FX224, which fitted into the existing socket on the IF board. This caused a PLL error upon switch on, an annoying problem that could not be solved.
The original board design has since been hacked around with, so now the 4049 IC has been removed, the frequency being controlled manually by hex and DIP switches on a separate board.

©2004 The Wave

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