7/28/2019 Construction_ Con Resitencias

1/3

ID Value Type Identification Polarised

D1 1N4148 Diode 4148, small, orange Yes - line up black bandon diode with white band on PCBR1 15K Resistor br/grn/blk/red/br NoR2,R3 1K Resistor br/br/blk/blk/br NoR4 4K7 Resistor yel/pur/blk/br/br NoR5/R6 680R ResistorR7 180R Resistor br/yel/blk/pur/br NoR8 10M Resistor br/grn/blk/blk/br No

C1-C5 1uF Capacitor 1uF or 1u 35 Yes - positive lead is longerC6 1nF Capacitor 102 NoC7 10uF Capacitor 10uF or 10u 25 Yes - positive lead is longerC8,C9 0.1uF Capacitor 104 NoC10/C11 27/33nF Capacitor 27 or 33 No

U1 16pin RS232 Driver MAX232 YesU2 3 pin Voltage Reg 78L05 YesU3 16pin binary counter 4060 (74HC4060) YesQ1 3 pin NPN Transistor BC549 Yes

Y1 2.45mhz Crystal large silver thing No

J1,J2 5 pin 90deg Header gold pins with plastic No (need to get pins facing outwards though)

DS1 Red LED red... Yes - positive lead is longerDS2 Green LED green... Yes - positive lead is longerDS3 Yellow LED yellow... Yes - positive lead is longer

Suggestion construction

1. Place the diode, D1. Bend leads down at right angles, close to body

2. Place the resistors, R1,R2,R3,R4,R8. Bend leads down at right angles, close to body

3. Place capacitors in middle of board, C9, C6, C11, C10.

4. Place the two ICs, U1 and U3. The small semicircle on one end of the ic should match the orientation on PCB. The dot one on corner of the chip should also match the square pad on the PCB (only one of the 16 pins hs a square pad. Bend thepins inwards slightly using a flat object, such as the side of a table to makeit fit easier.

5. Place capacitor C8, voltage reg U2, transistor Q1 at top left of board. Bendthe transistors legs so theyre straight and close together (like the voltage reg) if they are not already. Solder carefully as the legs are very close. Make sure the voltage reg and transistor match the silkscreen overlay on the board, withtheir flat side to the right.

6. Place the 2 x 5 pin Headers, so they face outwards on either side of board. Gently push into holes, theyll fit, just need to be done carefully (dont mash itin basically, just push firmly)

7/28/2019 Construction_ Con Resitencias

2/3

7. Place the crystal, Y1. This is tricky, as the crystal needs to be suspended in the air. To do this, press down on the ends (rather than close to crystal body) of the two leads until the leads are facing down at 90 degrees - ensure the leads DO NOT touch the crystal body. Place into the PCB, and allow the crystal tosite parallel to the pcb, about 4-5mm above it (so its above the top of the plastic on the headers, and away from contacting anything. Crystal will hang over the edge a bit if u have done this correctly (if it doesnt, then the leads may betouching the crystal body.

8. Place the capacitors, C7,C1,C2,C3,C4,C5. Note the longer leg is the + and shorter leg -. Also, one of the legs may be marked - (for eletrolytic) or + (for tantalum).

9. Put the two serial connectors on to the end of the board - the Female connector on the left (near capacitors), the Male connector on the right (near crystal). The outside pins will bend out slightly to get all 5 pins in the 5 cups. Oncethe pins from both sides are in the cups, put the board into the plastic connector housing, and adjust how far the pins are in the connector cups so that the connectors sit nicely in the grooves in the housing. Solder whilst the connectorsand PCB remain in the housing is the safest way to ensure the connectors fit nicely. Dont let too much solder flow into the cups (as it may be drawn into the connector, stopping the male serial port of a laptop from inserting all the way in.

10. Place the 3 LEDs. The LEDs are the two holes on the left or rightmost edgesof the board (for Red and Green/Yellow LEDS respectively). The holes next in arefor the resistors that go in after. This part is too hard to explain, so youllhave to use your own common sense to get the led in. The LED is intended to pokethrough the holes in the serial connectors, so that it can be seen with the plastic connector sealed. The longer led is the positive one (the side with the slide of plastic cut out of the LED is the negative). The Red LED goes top left ofboard, on the outermost two holes on the left. The positive hole is the BOTTOM hole. The Green LED goes to the top right of the board, with positive hole beingthe TOP hole. The Yellow LED goes to the bottom right of the board, with the positive hole being the TOP hole.

11. Place the resistors for the LED's, R5,R6,R7. These resistors go in standingup, meaning one lead of the resistor is bend down alongside the resistor body. R7 is 180R and goes in the holes second from the left of the board (the left mosttwo are for LED). R5 is 680R and goes in the bottom right, second from the right, and R6 is 680R and goes in the top right, second from the right.

PCB Complete! Dont seal it in the housing yet though, wait till it's tested first!

12. Strip 20mm of the outer sheath from the 2M cable. Any more and the serial plug we're putting on one end will not have the outer sheath to clamp (and thus eventually the inner wires could be exposed). The the green wire away at the baseof the sheath (as we dont need this one). Strip the remaining 5 wires about 5 mm

.

13. Locate the second female solder cup connector, and the plastic connector housing (grey). When looking at the back of the connector, the top row pins are labelled 1 to 5, left to right. The following wires should go in each cup:1 - White (CLK)2 - Black (GND)3 - Red (IGN/12V)4 - Blue (RX)5 - Yellow (TX)

7/28/2019 Construction_ Con Resitencias

3/3

Solder wires into cups. Locate 2 clamps, 2 shortest screws from connector shellpacket. Optionally put a few layers of Place clamp on, with screws on lightly. Put connector into shell to determine position to tighten clamp. Remove and tighten clamp, then place back in, put shell together, and secure with 2 hex nuts and2 screws (with half thread).

14. Locate the consult plug, 5 consult pins, and the other end of the cable youjust put a serial connector on. Strip about 40mm of outer sheath from the cable.Cut the green wire off again. Strip the remaining 5 wires about 5mm. At the endof each pin (the crimp/top side of pin, not blade) there will be two sections that would normally be crimped in somehow. As most of us will not have a crimpingtool for this, then the following can be performed:* Cut the bottom (longer, but shorter) tabs on both side (want to roughly half the height of them so pins go in connector.* Bend each side of the top tab in with some pliers. Just bend at 90 degrees will suffice. Once both are bent in, may need to pinch it sideways/top to bottom inorder to make that section a bit smaller/squarer so it fits into the consult plug.* Insert the stripped wire into the pin for soldering. Only insert it so far aswhere the second tab finishes - we dont want any solder past this point (as partof the plastic consult connector inserts past here).* Solder wires into pins. Solder the Blue, Yellow and Red wires, then flip cableover and solder the White and Black (this is because those two sets of pins fac

e opposite ways since they are on opposite rows in connector).

15. Now pins are ready to be inserted into consult connector. Get the consult connector, and look of the back of it, turning it around so the flat side is to the right, and the rounded side to the left. From here, we insert 2 wires in the top leftmost two positions, 2 in the bottom leftmost two positions, and one in the top rightmost position.

Back of connector (B = Blue, Y = Yellow, R = Red, K = Black, W = White)___________________/ || B Y - - - - R || |

| K W - - - - - |\__________________|

Insert the wires into their positions as show. The top of the pins (the side with the line thru middle, side that was soldered) goes towards the outside of theconnector (both top and bottom, so top row faces up, bottom faces down). Push all the connectors half way in, then push them as far as u can in with your fingernail on the pin (dont try push in via the wire, it will just bend as not strongenough). Once in about 3/4, you can pull it all the way through with a pair of needle nose pliers. Grip the pin firmly and draw in.

16. With pins now in the consult connector, we (attempt) to seal them in with the plastic tabs that are hanging off the connector. Push them in, then the tiny t

abs should lock in. You may have trouble locking them in if too much solder wasapplied to the wire/pin. Do you best, then take some electrical tape and start wrapping from the connector (around the sealing tabs) and up until you pass wherethe sheath was cut off at.