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Hardware Assembly Manual P13361

HARDWARE ASSEMBLY MANUALP13361: System Dynamics Filtering Laboratory

Release Date: February 17, 2013 Revision: B

PURPOSE

The purpose of this document is to outline the procedures to be used in order to properly assemble the printed circuit board (PCB) and hardware module portion of the System Dynamics Filtering Laboratory.

TABLE OF CONTENTS

PURPOSE..........................................................................................................................................................1

TABLE OF CONTENTS........................................................................................................................................1

MASTER LIST OF PRODUCT COMPONENTS........................................................................................................2

MASTER LIST OF ASSEMBLY EQUIPMENT..........................................................................................................5

PRINTED CIRCUIT BOARD (PCB) ASSEMBLY..........................................................................................................6

PRODUCT COMPONENTS............................................................................................................................................6

ASSEMBLY EQUIPMENT..............................................................................................................................................7

PROCEDURE.............................................................................................................................................................7

Power Section...................................................................................................................................................7

HARDWARE MODULE ASSEMBLY....................................................................................................................11

PRODUCT COMPONENTS..........................................................................................................................................11

ASSEMBLY EQUIPMENT............................................................................................................................................12

PROCEDURE...........................................................................................................................................................13

INTERFACE PANEL PREPARATION................................................................................................................................13

PRINTED CIRCUIT BOARD PREPARATION......................................................................................................................14

UNDER WIRE CONNECTION.......................................................................................................................................14

February 17, 2013 1 Rev B


MOUNTING OF COMPONENTS...................................................................................................................................15

MOUNTING OF COMPONENTS...................................................................................................................................15

VERIFICATION OF OPERATION........................................................................................................................16

APPENDIX.......................................................................................................................................................17



MASTER LIST OF PRODUCT COMPONENTS

The following is a master list of product components used to assemble the printed circuit board (PCB) and hardware module. See the Bill of Materials for more information.



P/N PART NAME DESCRIPTION QTY

A3A01 JACK_BANANA_F_WHT 1

A3A02 JACK_BANANA_F_YLW 1

A3A03 JACK_BANANA_F_BLK 2

A3A04 JACK_BANANA_F_RED 2

A3A05 JACK_3.5mm_FEMALE Female mono headphone jack, 3.5mm, 2

A3A06 HEADPHONES 1

A3A07 ADAPTER_BANANA_M_BNC_F 2

A3A08 CNCTR_BANANA_MM_WHT 1

A3A09 CNCTR_BANANA_MM_YLW 1

A3A10 CNCTR_LINE_IN_3.5mm 1

A3A11 CNCTR_SOCKET_WIRE_5_IN 4


A3A14 INTERFACE_PANEL 1

A3A15 CNCTR_24AWG_WIRE_RED 1

A3A16 CNCTR_24AWG_WIRE_BLK 1

A3B01 PCB_BLANK 1

A3B02 U1 1

A3B03 R1 1

Female banana jack, surface mount, white (for reference PS connection)Female banana jack, surface mount, yellow (for +9V PS connection)Female banana jack, surface mount, black (for Ground)Female banana jack, surface mount, red (for FCN/DAQ connection)

Headphones to be included with hardware, connect to line out jack, mono/stereo capableAdapter male pos/gnd banana to male BNC (oscilloscope)Male banana to male banana patch cord, 24", white (for ground PS connection)Male banana to male banana patch cord, 24", yellow (for +9V PS connection)Mono 2' 3.5mm phone plugs (male-male), for connection between audio player and line in/mic jackFemale-female socket wire connector used between boards and jacks, 5" long, sold in packs of 1007" Female Jumpers and 40 Headers 28AWG, UL1007, 80 deg C, 300V.

Plexi-glass plate used for input/output jack support, 4"X1.7"X0.25" used, comes in 6"X12"

24AWG wire used between signal in/out (+) and audio jacks (red); also used for breadboard connections, sold in 100ft spools24AWG wire used between signal in/out (-) and audio jacks (black); also used for breadboard connections, sold in 100ft spoolsPrinted circuit board (no attached components), 4" x 3.3"X0.062", 13.2 sq. inchesIntegrated Circuit, LM7805, through hole, 3 pin, voltage regulatorResistor, through hole, 5% tol., 1W, (100 Ohm)




A3B04 R2 1

A3B05 R3,R4 2

A3B06 R5 1

A3B07 R6 1

A3B08 D1,D2,D3,D4 1N4001 diode, general purpose 4

A3B09 D5 1

A3B10 C1,C2,C3,C4 4

A3B11 C5,C6 2

A3B12 C7 1

A3B13 SW1 1

A3B14 JP1,JP2,J1,J2,J3,J5 28

A3B15 J4 4

A3B16 T1 Test point, yellow 2A3B17 T2_Signal_OUT, T2_Signal_IN Test point, blue 2A3B18 T2_+5V, T3_+ Test point, red 2A3B19 T2_GND, T3_- Test point, black 2

A3B20 VOLTAGE_REG_SCREW 1

A3B21 VOLTAGE_REG_WASHER 1

A3B22 VOLTAGE_REG_NUT 1

A301 BREADBOARD 1

A302 RUBBER_SUPPORT 1

A303 VOICE_REC_BOARD 1

A304 STAND_OFF 15

Resistor, through hole, 5% tol., 1/4W, (330 Ohm)Resistor, through hole, 5% tol., 1/4W, (1.6K -Ohm)Resistor, through hole, 1% tol., 1/4W, (1 kilo-Ohm)Resistor, through hole, 5% tol., 1/4W, (100 Ohm)

Red LED panel indicator light, through hole, 635nm, 1.8VCapacitor, through hole, aluminum, radial, 50V rating, 20% tol., (1 micro-F) Capacitor, through hole, tantilum, radial, 6.3V rating, 10% tol., (100 micro-Farrad)Capacitor, through hole, tantilum, radial, 50V rating, 10% tol., (0.1 micro-Farrad)Slider switch, SPDT 2 position, 0.4VA@20V AC/DC, 0.098" pin spacingConnector to PCB, JP1 JP2 filter select/out select, J1, J2, J3, J5 connectors to interface panel and voice recorder board, sold in pack of 80Connector to PCB, J4 connector to breadboard, socket strip, sold in pack of 36

Slotted screw used to fasten U1 to board, 4-40x3/8" screw, stainless steel, solld in pack of 100Washer to fasten U1 on board, for 4-40 screw, stainless steel, sold in pack of 100Nut to fasten U1 on board, for 4-40 screw, zinc-plated steel, sold in pack of 100Breadboard, 1 terminal strip, 2 bus strips, 270 contacts, 3.3" x 1.8", screw fastenedRubber sheet used to support Voice Recording Board, adhesive back, comes in 1/2" X 1/8" X 36" barsSeparated PCB that contains the voice recorder circuit and various attachments ISD-COBPCB stand off, 1.5" long, 4-40 threaded, aluminum




A305 MOUNTING_PLATE 1

A306 FILTER_MODULE_ENCLOSURE 1

A307 STAND_OFF_SCREW 30

A308 MOUNTING_PLATE_SCREW 4

A309 IC_LM741_AUDIO_AMPLIFIER 2

A309 SPACER_PCB 4

A310 JUMPER 3

Plexi-glass plate used to mount hardware in enclosureFilter module activitiy enclosure, ABS plastic, hinged lid with padlock option, 7.87"X5.9"X3.93"Slotted screw used to components to mounting plate, 4-40x1/2" screw, stainless steel, solld in pack of 100Torx screw for mounting mounting plate to enclosure, thread forming, M4x10mm, stainless steel, sold in pack of 25Integrated Circuit LM741 through hole, 8 pin, audio amplifier, for use in breadboardRubber grommet used between PCB and standoffs in order to raise the PCB to the same height as the interface panel, 1/8" ID x 7/32 high, sold in pack of 1002 position female-female jumper, 3A, .100 5GOLD, used for signal rounting on PCB and voice recorder board



MASTER LIST OF ASSEMBLY EQUIPMENT

The following is a master list of equipment used to assemble the printed circuit board (PCB) and hardware module.

ID QTY DESCRIPTION SUGGESTED MODEL1 1 Electronics laboratory studio classroom System Dynamics classroom (GLE-2120)

2 1 DC 12V Power Supply GW Instek Laboratory DC Power Supply (GPS-3303)

3 1 Oscilloscope

4 1 Arbitrary Function Generator Agilent Technologies 33210A5 2 BNC Female-Female Patch Cable Pamona 48" BNC F-F Patch Cable (4277-C-48)6 1 BNC to Aligator Adapter Pamona Test Clip, BNC (2631)

7 1 Digital Multimeter

8 2 Banana to Aligator Patch Cable

9 1 Soldering Iron Pace 120V PS-90 Soldering Iron (8007-0528)10 1 Lead Free Solder Multicore 28 Gauge Solder (796065)11 1 Needle Nose Pliers Stanley 5" Needle Nose Pliers (84-096)

12 1 Wire Cutters Craftsman Wire Cutter-Stripper and Crimper (76575)

13 1 Wire Strippers / Crimpers Craftsman Wire Cutter-Stripper and Crimper (76575)

14 1 Torx Screwdriver Craftsman 6-in-1 LED Screwdriver (35722)15 1 Slotted Screwdriver Craftsman 6-in-1 LED Screwdriver (35722)16 1 CA Glue Super Glue 2g (15109)17 1 Hot Glue Gun Stanley GR20K Heavy Duty Hot Melt Glue Gun18 1 Hot Glue Sticks 10" Surebonder Glue Stick

19 1 1/4" Rachet

20 1 7/16" Scocket

21 1 3/32" Socket

22 1 Utility Knife Craftsman Twin Blade Lockback Knife (#95013)

Agilent Technologies 60MHz Digital Storage Oscilloscope (DSO3062S)

7 Function Auto Ranging Digital Multimeter (19015146)Pamona 36" Aligator to M Banana Patch Cable (1166-36-0)

Craftsman 1/4 in Drive Quick Release Teardrop Rachet (#44807)Craftsman 9 pc. Universal 1/4 in Dr. Socket Set, Inch (#38209)Craftsman 9 pc. Universal 1/4 in Dr. Socket Set, Inch (#38209)



PRINTED CIRCUIT BOARD (PCB) ASSEMBLY

This section outlines how to assemble the custom printed circuit board (PCB). See the Appendix of this document to view the PCB Assembly Schematic.

PRODUCT COMPONENTS




A3B01 PCB_BLANK 1

A3B02 U1 1

A3B03 R1 Resistor, through hole, 5% tol., 1W, (100 Ohm) 1A3B04 R2 Resistor, through hole, 5% tol., 1/4W, (330 Ohm) 1

A3B05 R3,R4 Resistor, through hole, 5% tol., 1/4W, (1.6K -Ohm) 2

A3B06 R5 Resistor, through hole, 1% tol., 1/4W, (1 kilo-Ohm) 1

A3B07 R6 Resistor, through hole, 5% tol., 1/4W, (100 Ohm) 1A3B08 D1,D2,D3,D4 1N4001 diode, general purpose 4

A3B09 D5 1

A3B10 C1,C2,C3,C4 4

A3B11 C5,C6 2

A3B12 C7 1

A3B13 SW1 1

A3B14 JP1,JP2,J1,J2,J3,J5 28

A3B15 J4 4

A3B16 T1 Test point, yellow 2A3B17 T2_Signal_OUT, T2_Signal_IN Test point, blue 2A3B18 T2_+5V, T3_+ Test point, red 2A3B19 T2_GND, T3_- Test point, black 2

A3B20 VOLTAGE_REG_SCREW 1

A3B21 VOLTAGE_REG_WASHER 1

A3B22 VOLTAGE_REG_NUT 1

A310 JUMPER 3

Printed circuit board (no attached components), 4" x 3.3"X0.062", 13.2 sq. inchesIntegrated Circuit, LM7805, through hole, 3 pin, voltage regulator

Red LED panel indicator light, through hole, 635nm, 1.8VCapacitor, through hole, aluminum, radial, 50V rating, 20% tol., (1 micro-F) Capacitor, through hole, tantilum, radial, 6.3V rating, 10% tol., (100 micro-Farrad)Capacitor, through hole, tantilum, radial, 50V rating, 10% tol., (0.1 micro-Farrad)Slider switch, SPDT 2 position, 0.4VA@20V AC/DC, 0.098" pin spacing

Connector to PCB, JP1 JP2 filter select/out select, J1, J2, J3, J5 connectors to interface panel and voice recorder board, sold in pack of 80

Connector to PCB, J4 connector to breadboard, socket strip, sold in pack of 36

Slotted screw used to fasten U1 to board, 4-40x3/8" screw, stainless steel, solld in pack of 100

Washer to fasten U1 on board, for 4-40 screw, stainless steel, sold in pack of 100Nut to fasten U1 on board, for 4-40 screw, zinc-plated steel, sold in pack of 1002 position female-female jumper, 3A, .100 5GOLD, used for signal rounting on PCB and voice recorder board

ASSEMBLY EQUIPMENT





3 1 Oscilloscope

4 1 Arbitrary Function Generator Agilent Technologies 33210A5 2 BNC Female-Female Patch Cable Pamona 48" BNC F-F Patch Cable (4277-C-48)6 1 BNC to Aligator Adapter Pamona Test Clip, BNC (2631)

7 1 Digital Multimeter 7 Function Auto Ranging Digital Multimeter (19015146)

8 2 Banana to Aligator Patch Cable

9 1 Soldering Iron Pace 120V PS-90 Soldering Iron (8007-0528)10 1 Lead Free Solder Multicore 28 Gauge Solder (796065)11 1 Needle Nose Pliers Stanley 5" Needle Nose Pliers (84-096)


15 1 Slotted Screwdriver Craftsman 6-in-1 LED Screwdriver (35722)18 1 Hot Glue Gun Stanley GR20K Heavy Duty Hot Melt Glue Gun19 1 Hot Glue Sticks 10" Surebonder Glue Stick


Pamona 36" Aligator to M Banana Patch Cable (1166-36-0)

PROCEDURE

Power Section

1. U1 Regulator

Bend the leads to the appropriate length to fit in the PCB holes

Screw the hole of the regulator into the board with a 4-40 screw

Solder and clip the leads from the bottom of the board

2. SW1 Switch

Solder into SW1 position

Can be soldered in either orientation

3. LED

Solder into D5 position on the board

Ensure that the housing for the LED is oriented appropriately; connect the anode to the square pad and the cathode to the circular pad

4. D1, D2, D3, D4 Diodes

Solder diodes into the respective board positions



Observe polarity; connect the anode to the square pad and the cathode to the circular pad

5. R5

Solder into board and clip leads

6. C5, C6, C7


Apply a dab of hot glue at the base of each capacitor to secure it

Capacitors are non-polarized; polarity is irrelevant

Built-in Filter Section

1. R1, R2, R3, R4, R6


2. C1, C2, C3, C4


Apply a dab of hot glue at the base of each capacitor to secure it

Observe polarity; the ground side should be connected to the circular pad

Headers and Connection Points

1. TP1, TP2, TP3, TP4

Insert both leads into the given holes wedge outwards

Solder and clip

2. JP1 JP2 Headers

Use wire cutters to clip a section from double row header strip (A3B14) into five pairs (5x2 configuration)

Solder into JP1

Repeat for JP2



3. J1, J2 Headers

Use wire cutters to clip a section from single row header strip (A3B14) into a 2x1 configuration

Solder into J1

Repeat for J2

4. J3, J5 Headers

Use wire cutters to clip a section from single row header strip (A3B14) into a 3x1 configuration

Remove the middle pin from the housing with pliers

Solder into J3

Repeat for J5

5. J4 Female SL Header

Use wire cutters to clip a section of socket strip (A3B15) into a 4x1 configuration

Insert in J4 in PCB and solder



Test PCB Operation

Procedure to verify that the PCB has been assembled properly

1. Test voltage regulator circuit

On the Instek power supply, set the voltage knob (6) to approximately 10 o’clock (for 9V) and set current knob (8) to approximately 12 o’clock (for adequate current supply)

Set the tracking to series by pushing in the left button (16) and pushing out the right button (15)

Turn on the power supply to fine tune the voltage (knob 6) to 9V

Turn off the power supply

Connect one alligator to banana patch cable to the positive master output (17) with the banana end

Connect another alligator to banana patch cable to the negative (ground) output (21) with the banana end

Connect the alligator end of the power alligator to banana patch cable to the T3 positive (+) test point

Connect the alligator end of the power alligator to banana patch cable to the T3 negative (-) test point

Make sure the PCB power switch (SW1) is off

Turn on the power supply (and turn its output on)

Turn the PCB power switch (SW1) on

Verify that the PCB LED is on

Use multimeter to test the voltage at J3

Verify the output at J3 is 9V

Use multimeter to test the voltage at T2 between ‘+5V’ and ‘GND’

Verify the output at T2 between ‘+5V’ and ‘GND’ is approximately 5V’

Turn off the PCB power switch (SW1)

2. Test signal filtering circuits



a. Set up the board in the same way as for the voltage regulator circuit test above

b. Connect a function generator to the PCB at J1 (red at SP+, black at SP-) with the alligator end of a BNC to alligator adapter connected to a female-female BNC patch cable that connects to the function generator output. Take care to make sure the alligator clips are isolated from each other

c. Set the function generator to a sinusoidal 1 VP-P (0V offset) at a frequency of 200 Hz, make sure the output is off

d. Place header jumpers (A310) to select breadboard (‘BB’) output on JP1 and JP2 on the PCB

e. Connect an oscilloscope to the PCB at T2 (red at Signal OUT, black at GND) with the alligator end of a BNC to alligator adapter connected to a female-female BNC patch cable that connects to the oscilloscope. Take care to make sure the alligator clips are isolated from each other

f. Turn the PCB power switch (SW1) on

g. Turn the output of the function generator on

h. Verify that an output from the board is registered on the oscilloscope

i. Turn the output of the function generator off

j. Turn off the board power switch (SW1)

k. Move the oscilloscope connection to the board to T1 (red on SPK+, black on SPK-)

l. Replace the header jumpers on JP1 and JP2 to select unfiltered output (‘UF’)

m. Turn on the output of the function generator and the board power switch (SW1) on

n. Verify that an output is registered on the oscilloscope

o. Repeat steps I through n for the high-pass (‘HPF’), low-pass (‘LPF’), and band-pass (‘BPF’) selections of JP1 and JP2

3. Troubleshooting

Check over each resistor and capacitor on the board and make sure the proper resistor/capacitor has been soldered into each place

Check to make sure the polarized capacitors (C1, C2, C3, and C4) and diodes (D1, D2, D3, D4) have been soldered into each place in the proper polarity alignment

Check over each solder joint on the board and make sure the joint is complete and clean

Check over the board to verify all of the traces are intact





HARDWARE MODULE ASSEMBLY

This section outlines how to assemble the hardware module (see Appendix for the hardware assembly schematic).

Product Components




A3A01 JACK_BANANA_F_WHT 1

A3A02 JACK_BANANA_F_YLW 1

A3A03 JACK_BANANA_F_BLK 2

A3A04 JACK_BANANA_F_RED 2

A3A05 JACK_3.5mm_FEMALE Female mono headphone jack, 3.5mm, 2

A3A06 HEADPHONES 1

A3A07 ADAPTER_BANANA_M_BNC_F 2

A3A08 CNCTR_BANANA_MM_WHT 1

A3A09 CNCTR_BANANA_MM_YLW 1

A3A10 CNCTR_LINE_IN_3.5mm 1



A3A14 INTERFACE_PANEL 1

A3A15 CNCTR_24AWG_WIRE_RED 1

A3A16 CNCTR_24AWG_WIRE_BLK 1

A301 BREADBOARD 1

A302 RUBBER_SUPPORT 1

Female banana jack, surface mount, white (for reference PS connection)Female banana jack, surface mount, yellow (for +9V PS connection)Female banana jack, surface mount, black (for Ground)Female banana jack, surface mount, red (for FCN/DAQ connection)

Headphones to be included with hardware, connect to line out jack, mono/stereo capableAdapter male pos/gnd banana to male BNC (oscilloscope)Male banana to male banana patch cord, 24", white (for ground PS connection)Male banana to male banana patch cord, 24", yellow (for +9V PS connection)Mono 2' 3.5mm phone plugs (male-male), for connection between audio player and line in/mic jackFemale-female socket wire connector used between boards and jacks, 5" long, sold in packs of 1007" Female Jumpers and 40 Headers 28AWG, UL1007, 80 deg C, 300V.

Plexi-glass plate used for input/output jack support, 4"X1.7"X0.25" used, comes in 6"X12"

24AWG wire used between signal in/out (+) and audio jacks (red); also used for breadboard connections, sold in 100ft spools24AWG wire used between signal in/out (-) and audio jacks (black); also used for breadboard connections, sold in 100ft spoolsBreadboard, 1 terminal strip, 2 bus strips, 270 contacts, 3.3" x 1.8", screw fastenedRubber sheet used to support Voice Recording Board, adhesive back, comes in 1/2" X 1/8" X 36" bars




A303 VOICE_REC_BOARD 1

A304 STAND_OFF 15

A305 MOUNTING_PLATE 1

A306 FILTER_MODULE_ENCLOSURE 1

A307 STAND_OFF_SCREW 30

A308 MOUNTING_PLATE_SCREW 4

A309 IC_LM741_AUDIO_AMPLIFIER 2

A309 SPACER_PCB 4

Separated PCB that contains the voice recorder circuit and various attachments ISD-COBPCB stand off, 1.5" long, 4-40 threaded, aluminumPlexi-glass plate used to mount hardware in enclosureFilter module activitiy enclosure, ABS plastic, hinged lid with padlock option, 7.87"X5.9"X3.93"Slotted screw used to components to mounting plate, 4-40x1/2" screw, stainless steel, solld in pack of 100Torx screw for mounting mounting plate to enclosure, thread forming, M4x10mm, stainless steel, sold in pack of 25Integrated Circuit LM741 through hole, 8 pin, audio amplifier, for use in breadboardRubber grommet used between PCB and standoffs in order to raise the PCB to the same height as the interface panel, 1/8" ID x 7/32 high, sold in pack of 100

ASSEMBLY EQUIPMENT



3 1 Oscilloscope

4 1 Arbitrary Function Generator Agilent Technologies 33210A5 2 BNC Female-Female Patch Cable Pamona 48" BNC F-F Patch Cable (4277-C-48)9 1 Soldering Iron Pace 120V PS-90 Soldering Iron (8007-0528)10 1 Lead Free Solder Multicore 28 Gauge Solder (796065)11 1 Needle Nose Pliers Stanley 5" Needle Nose Pliers (84-096)


13 1 Wire Strippers / Crimpers Craftsman Wire Cutter-Stripper and Crimper (76575)

14 1 Torx Screwdriver Craftsman 6-in-1 LED Screwdriver (35722)15 1 Slotted Screwdriver Craftsman 6-in-1 LED Screwdriver (35722)16 1 CA Glue Super Glue 2g (15109)

19 1 1/4" Rachet

20 1 7/16" Scocket


Craftsman 1/4 in Drive Quick Release Teardrop Rachet (#44807)Craftsman 9 pc. Universal 1/4 in Dr. Socket Set, Inch (#38209)



ID QTY DESCRIPTION SUGGESTED MODEL

21 1 3/32" Socket

22 1 Utility Knife Craftsman Twin Blade Lockback Knife (#95013)

Craftsman 9 pc. Universal 1/4 in Dr. Socket Set, Inch (#38209)

PROCEDURE

INTERFACE PANEL PREPARATION

This section describes the pre-assembly procedure for the interface panel and its attached components in preparation of wiring.

1. Attach Voice Recorder Board

a. Using the utility blade, cut 3 sections of the 1/2” rubber support (A202) that span the long end of the voice recorder board (A303) (about 2 inches)

b. Make sure the cut rubber is enough to adequately cover the bottom of the voice recorder board

c. Apply CA glue to the first section of cut rubber on the non adhesive side, be sure to not apply too much glue. Use the nozzle to spread out the glue into an even layer

d. Working quickly, place the glue covered cut rubber to the bottom of the voice recorder board, make sure it is as close to the edge of the voice recorder board as possible

e. Repeat steps c & d for the remaining 2 cut rubber pieces, fully covering the bottom of the board

f. Remove the adhesive backing of the attached rubber pieces and attach the rubber backed board to the labeled interface panel, take care to not cover the screw holes on the interface panel (See Figure 1)



Figure 1: Voice Recorder Board Location on Interface Panel

2. Thread the yellow (A3A02), white (A3A01), red x 2 (A3A04), and black x 2 (A3A03) banana jacks, and the mono audio jacks (A3A05) into the interface panel per the following:

a. Yellow into the +9V hole

b. White into the REF. hole

c. Red into the VIN and VOUT holes

d. Black into the 0V holes

e. Mono audio jacks into the LINE IN and LINE OUT holes, make sure the jacks terminals are directed towards the bottom edge of the interface panel (closest to where the PCB will be in the final assembly)

3. Use the ¼” ratchet and the 7⁄16” socket to tighten down the banana jacks

4. Use the ¼” ratchet and the 3⁄32” socket to tighten down the audio jacks

5. Use the slotted screwdriver to attach a standoff (A304) to the bottom of the interface panel at each of the 7 support holes with 4-40 x 1⁄2” slotted screws (A307)

PRINTED CIRCUIT BOARD PREPARATION

This section describes the pre-assembly procedure for the printed circuit board and its attached components in preparation of wiring.

1. Use the slotted screwdriver to attach a standoff (A304) to the bottom of the assembled PCB at each of the 4 support holes with 4-40 x 1⁄2” slotted screws (A307), threading a spacer (A309)



between the PCB and each standoff

UNDER WIRE CONNECTION

This section describes the procedure to connect the under wires between the completed PCB (A3B) and preassembled interface panel (see above section).

1. Cut four 2” sections of red 24AWG wire (A3A15)

2. Cut four 4” section of black 24AWG wire (A3A16)

3. Strip approximately ¼’ of insulation off of each wire end

4. Cut off one end of two blue (7”) (A3A12) and two yellow (5”) (A3!11) socket wires

5. Strip approximately ¼ ” of insulation off of each wire end

6. Solder the prepared wires in the following arrangement onto each jack (see Appendix of this document to view the Harness Schematic and a Audio Jack Detail for wiring guidance):

a. 1st Red 24AWG wire: 1st end on VOUT terminal, 2nd end on LINE OUT positive (+) terminal

b. 2nd Red 24AWG wire: 1st end on VIN terminal, 2nd end on LINE IN positive (+) terminal

c. 1st Black 24AWG wire: 1st end on 0V terminal (under VIN) , 2nd end on LINE IN negative (–) terminal

d. 2nd Black 24AWG wire: 1st end on 0V terminal (under VOUT), 2nd end on LINE OUT negative (–) terminal

e. 1st Blue Socket wire: Stripped end on LINE IN negative (–) terminal

f. 2nd Blue Socket wire: Stripped end on LINE IN positive (+) terminal

g. 3rd Blue Socket wire: Stripped end on VOUT terminal

h. 4th Blue Socket wire: Stripped end on 0V terminal (under VIN)

i. 1st Yellow Socket wire: Stripped end on +9V terminal

j. 2nd Yellow socket wire: Stripped end on REF. terminal

7. Once the soldering is complete attach the socket ends of the wires per the following:

a. +9V yellow socket wire: attach to J3+ header on PCB

b. REF. yellow socket wire: attach to J3 – header on PCB

c. VOUT blue socket wire: attach to J2+ header on PCB



d. 0V (under VOUT jack) blue socket wire: attach to J2– header on PCB

e. LINE IN positive (+) blue socket wire: attach to GND header (next to Anain) on voice recorder board, thread the wire through the hole in the interface panel next to the voice recorder board

f. LINE IN negative(–) blue socket wire: attach to Anain header on voice recorder board, thread the wire through the hole in the interface panel next to the voice recorder board

8. Wire the remaining unstrapped socket wires (2 blue and 2 yellow) per the following:

a. 1st blue socket wire: attach 1st end to VCC on the voice recorder board to J5+ on PCB, thread the wire through the hole in the interface panel next to the voice recorder board

b. 2nd blue socket wire: attach 1st end to GND (next to VCC) on the voice recorder board to J5– on the PCB, thread the wire through the hole in the interface panel next to the voice recorder board

c. 1st yellow socket wire: attach 1st end to SP+ on the voice recorder board to J1 (SP+) on the PCB

d. 2nd yellow socket wire: attach 1st end to SP- on the voice recorder board to J1 (SP–) on the PCB

MOUNTING OF COMPONENTS

This section describes the procedure to mount the assembled PCB, interface panel, and breadboard to the mounting plate (A308).

1. Use the slotted screwdriver to attach a standoff (A304) to the bottom of the breadboard at each of the 4 support holes with 4-40 x 1⁄2” slotted screws (A307)

2. Attach the standoffs of the interface panel to the mounting plate with 4-40 x 1⁄2” slotted screws

3. Attach the standoffs of the assembled PCB to the mounting plate with 4-40 x 1⁄2” slotted screws

4. Attach the standoffs of the breadboard to the mounting plate with 4-40 x 1⁄2” slotted screws

5. Make sure everything is properly mounted to the mounting plate and all wires are still connected

6. Place the LM741 chips (A309) across the chip rail on the breadboard

MOUNTING OF COMPONENTS

This section describes the procedure to mount the assembled mounting plate into the enclosure (A306).



1. Place the assembled mounting plate into the enclosure and line up the mounting holes near the corners with the holes in the corners of the bottom of the enclosure

2. Use a Torx screwdriver to drive the self-tapping screws into each hole of the enclosure, taking care to drive the screw in perpendicular to the mounting plate. Use firm but careful pressure to drive the screws

3. Verify that the mounting plate assembly is firmly attached to the enclosure

4. Place yellow (A3A09) and white(A3A08) banana patch cables and banana to BNC adapters (A3A07) into the enclosure

5. Close enclosure

VERIFICATION OF OPERATION

To verify the operation of the hardware activity kit, please see the Hardware Operations Manual.



APPENDIX

APPENDIX

AUDIO JACK DETAIL............................................................................................................................20

HARDWARE ASSEMBLY SCHEMATIC (BLACK & WHITE)...............................................................21

HARDWARE ASSEMBLY SCHEMATIC (FULL COLOR).....................................................................22

HARNESS SCHEMATIC.........................................................................................................................19

PCB ASSEMBLY SCHEMATIC.............................................................................................................18



PCB ASSEMBLY SCHEMATIC



HARNESS SCHEMATIC





AUDIO JACK DETAIL




POSITIVE (+)NEGATIVE (–)

UNUSED


HARDWARE ASSEMBLY SCHEMATIC (BLACK & WHITE)





HARDWARE ASSEMBLY SCHEMATIC (FULL COLOR)


Documents

Outline Template (Microsoft Word)edge.rit.edu/content/P13361/public/BuildTest/Assembly Manual/P1336… · Web viewTABLE OF CONTENTS. PURPOSE1. ... The following is a master list of