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Description
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Place the 16 MHz Crystal into the circuit board as shown.
Bend the wires sticking through the back outwards a little to
hold it in place. Flip the board over and solder it into
place. Then use wire cutters to clip off the extra wires
sticking out the back; cut close to the end of the solder
joint.
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Place the two 22 pF capacitors into the circuit board as
shown. Bend the wires sticking through the back outwards a
little to hold them in place. Flip the board over and solder
them into place. Then use wire cutters to clip off the extra
wires sticking out the back; cut close to the end of the
solder joint.
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Place the three 0.1 uF capacitors into the circuit board as
shown. Bend the wires sticking through the back outwards a
little to hold them in place. Flip the board over and solder
them into place. Then use wire cutters to clip off the extra
wires sticking out the back; cut close to the end of the
solder joint.
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Put the 16 pin socket into the circuit board as shown.
There's a notch in the socket which should line up with the
notch in the image of the socket. The notch will help you
align the microchip when you install it later. Turn the board
over and hold the socket in with a finger, tack two corners
pins to keep it in place then solder the rest of the pins.
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Put the 28 pin socket into the circuit board as shown.
There's a notch in the socket which should line up with the
notch in the image of the socket. The notch will help you
align the microchip when you install it later. Turn the board
over and hold the socket in with a finger, tack two corners
pins to keep it in place then solder the rest of the pins.
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Put the BC0919 microchip into the circuit board
as shown. Make sure it is the
BC0919 and NOT the LTV847.
There
is no need for a socket here since this chip is just a bunch
of resistors and won't be easily damaged by static or heat.
There is a notch in this chip which should line up with the
notch in the image of the socket. Once
you are sure the notch is aligned correctly and you have the
BC0919 chip,
turn the board over and hold the socket in with a finger, tack
two corners pins to keep it in place then solder the rest of
the pins.
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Install the mini push button into the circuit board as
shown. It will snap into place when it is properly installed.
Flip the board over and solder it into place.
(Note this button is used to reset the microcontroller and
unless you are programming the device you probably won't use
this button.)
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Place the 10K ohm resistor into the circuit board as shown.
Bend the wires sticking through the back outwards a little to
hold it in place while soldering. Flip the board over and
solder it into place. Then use wire cutters to clip off the
extra wires sticking out the back; cut close to the end of the
solder joint.
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Put the SIP8 47 Ohm Resistor Array into the
circuit board as shown. Make sure
the dot on the chip is near the “1” on the board
image.
Turn
the board over and hold the this resistor array in with a
finger, tack the two pins on the end to keep it in place then
solder the rest of the pins.
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Put the 3.5 mm jacks into the circuit board as shown.
Flip the board over and solder them into place. Make
sure these are soldered flush against the circuit board or
they won't fit into the case design.
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Place the two 10 uF capacitors into the circuit board as
shown. These are polarized
capacitors which means you must solder them in with the
correct orientation. The longer wire should go into the hole
marked with a plus sign. Bend the wires
sticking through the back outwards a little to hold them in
place. Flip the board over and solder them into place. Then
use wire cutters to clip off the extra wires sticking out the
back; cut close to the end of the solder joint.
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Put the break away header into the circuit board
as shown. Turn
the board over and hold it in with a finger, tack the two pins
on the end to keep it in place then solder the rest of the
pins.
(Note this is only used to when
programming the microcontroller.)
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Place the 2 and 3 hole 3.5 mm screw terminal headers into
the circuit board as shown. Turn the board over and solder
them into place.
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Place the two NPN 2222 transistors into the circuit board
as shown. Make sure the flat
sides of the transistors match the image on the board.
(Note: The rightmost transistor in the image is installed
backwards so don't let that confuse you. The pictures at the
end show this transistor installed correctly.) Bend the wires
sticking through the back outwards a little to hold them in
place. Flip the board over and solder them into place. Then
use wire cutters to clip off the extra wires sticking out the
back; cut close to the end of the solder joint.
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Place the 5V regulator into the circuit board as shown.
Make sure the metal heat sink is
facing towards the inside of the board as shown in the
picture. Bend the wires sticking through the
back outwards a little to hold them in place. Flip the board
over and solder them into place. Then use wire cutters to
clip off the extra wires sticking out the back; cut close to
the end of the solder joint.
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Install the LTV847 optoisolater into the 16 pin socket you
previously soldered onto the board and the ATMega168 into the
28 pin socket you previously soldered onto the board. These
chips have a dot and/or notch in them. This must line up with
the notch in the sockets.
Press
firmly until they don't go in any more. Look
carefully to make sure all the pins went into the socket and
didn't get bent to the side while pressing them into the
socket.
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Note that these buttons are
soldered to the back of the circuit board. Make sure you flip
the board before putting them into the circuit board as show
in the picture. On the back of the board put
the six high quality push buttons into the circuit board as
shown. Press them firmly until they are all the way in their
holes. Flip the board over and solder them into place.
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Compare the board to the pictures below to make sure
everything looks correct.
Look at the solder joints to make sure they look good.
Use flux remover spray or rubbing alcohol/toothbrush
to take the flux off the board.
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Here are some images of the finished circuit board.
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Description
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If you ordered the kit all the button holes and a large
rectangular hole have been cut into the case via a CNC
machine. If you are building it without the kit use a Dremel
and drill to make these holes (note the drill guide in the
next step has all the holes marked).
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Cut out the “Drill Guide” sticker. Leave it as
one piece that wraps around the case as shown in the picture.
Test putting it on the case before removing the sticker
backing. Peel of the sticker backing and stick the sticker to
the case. Make sure everything is lined up or you will have
problems later when installing the circuit board.
If you don't have the kit and want to print your own label,
you can get the pdf here.
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Use a center punch on the following holes on the “Drill
Guide”:
4x “3.5 mm Jack” holes
1x “Power” hole
If you don't have a center punch you can skip to the next
step, but be extra careful to drill on the hole centers.
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Drill a pilot 1/16 inch hole for all holes.
Then drill the holes to the correct size as marked on the
drill guide sticker. Optionally you can use other drills
between 1/16 and the final sized hole to make it easier. As
the drill guide says, all the “3.5 mm Jack” holes
should be 1/4 inch. The power hole should be 1/2 or 5/8 inch
depending on which power switch you are using.
Then remove the “Drill Guide” sticker.
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Make sure all the hex nuts are removed from the buttons on
the circuit board or the buttons won't fit through the holes
in the case. Now install the circuit board. You will need to
flex out the sides of the case a little to get the the sides
in. Be gentle and take your time. It goes in without much
force once you have everything in the correct place.
You don't want to put the board in diagonally and then push
the other side down. This won't work because the buttons
won't go in correctly. The circuit board must be eased into
position while keeping it parallel to the bottom of the case.
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This is what the top will look like after the circuit board
has been installed.
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Now take the 3 longer wires and solder put them into the
LCD screen holes on the picture and then flip the board over
and solder them. Make sure you keep the wires angles in the
direction they are on this picture so they reach main circuit
board. Use this picture as a guide on which color wire goes
where.
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Now slide the LCD screen into it's hole. Make sure it is
not upside down. Then when the screen in flush with the case
use a hot glue gun (or thick glue) to tack down the four
corners of the LCD screen. If you don't know whether your
glue is conductive or not make sure you don't glue anything
that could cause a short. The easiest way to do this is using
a small amount of glue on the four corners of the LCD screen.
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Now use a small Philips screwdriver to hold the LCD wires
on to the main circuit board. The red wire should go to
“+5V”, black to “GND”, and green to
“TX0”.
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Solder the short red wire to the center pin on the power
switch.
(Note these switches are sensitive to excessive heat when
soldering so be careful to use use as little heating as
possible when soldering them.)
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Install the switch into the case and screw the switch's nut
tight as shown in the picture. Next solder the red wire from
the 9V plug to the other pin on the power switch.
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Use a Philips screwdriver to attach the black wire from the
9V battery plug into GND on the board and short red wire
that's solder to the power plug into the +9V spot on the
circuit board.
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If the corners of your foam aren't cut off do that and any
other trimming needed so that foam fits into the bottom of the
case. Then peel the covering off the sticky tape on the foam.
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When sticking the foam on to the case put the 9V battery
wire under the sticky tape as you stick it down. This helps
keep the plug from wiggling around too much and possibly over
stressing the solder joint of the red wire on the power plug.
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Install the battery.
If you haven't tested it yet connect the 9V battery and
make sure the screen turns on when you turn on the power
switch.
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Cut out the “Final Label” sticker. Make sure
you also cut out the 6 button holes. Test putting it on
before removing the sticker backing. Once your are sure it
will fit properly remove the sticker backing and stick it on
as shown in the picture.
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Last step is installing the 6 hex nuts for the buttons. Use
a pliers or wrench to get them snug, but don't make them over
tight or you will damage the label.
You are done!
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