PWM-TOOLS tester electronic component assembly manual for DIY assembly.This universal manual was developed by PWM Company http://pwm.company & http://pwm.su and is intendedfor the assembly of chip testers of any models produced by the company. The document contains the recommended sequence of groups of elements for installation on a printed circuit board for self-assembly DIY electronic devices. When installing most components, consider the polarity of the inclusion of the part. Neither polarity has only these parts: resistors, ceramic and film capacitors, two-sided suppressors. PPTC fuses.

Group number

The name of the elements Appearance

1 0.25 watt power resistors

Axial diodes to 1 watt inclusive

Zener to 1 watt inclusive.

2 Ceramic Capacitors MLCC

Axial diodes power up to 2 watts

TVS suppressor (not present on all devices)

Group number

The name of the elements Appearance

3 LEDs. The color of the PCB is on the back side

TO-92 package transistors, TL431, linear stabilizers

PPTC fuse 0.3A(Not present on all devices)

4 TO-220 packege MOSFET

TO-220 package Schottky diodes(Not present on all devices)

5 Round Hole 2.54MM DIP IC Sockets Adaptor. Plastic panel(Not present on all devices)

Optocouplers(Not present on all devices)

High power resistors(Not present on all devices)

Group number

The name of the elements Appearance

Fuse PPTC 4A in a bent position

Plastic connectors JST XH 3P / 2P(Not present on all devices)

6 Voltmeters(Not present on all devices)

Chokes and inductors horizontally(Not present on all devices)

Power connectors DC-005 Jack

Mylar film capacitor(Not present on all devices)

7 Electrolytic capacitors

Group number

The name of the elements Appearance

8 Pushbutton switches fixed 8.5 x 8.5 mm

9 All other electronics elements

Potentiometers (variable resistors)

ZIF socket for the audited components

BNC connectors

10 Final preparation for the first launch of the assembled board and testing its operability

Install plastic buttons on the switchesInstall DIP chips in the socket socket panels on the board (not available on all devices)Install the test chip into the main ZIF test socketFinal inspection of assembled PCB

11 Removal of flux residues

Remove solder flux from the underside of the PCB withalcohol, a brush, cotton wool or a cloth to give a neat look and prevent dust from sticking to the flux

Group number

The name of the elements Appearance

12 Testing device prior to assembly into the housing

All devices can test the chip without using an oscilloscope. Serviceability of chips is determined by the glow of the LED.In the presence of an oscilloscope, you can check the output signal by means of it, but in this manual consideronly checked through the LEDs.

Depending on your model, the tester and the tested ICs are two kinds of visual inspection of IC1. The test chip at a low oscillation frequency. FOR MODELS: TEST494, TEST3525, TEST2113, TEST2153, TEST3843, TEST555, TESTOPAM1For tester models with a generation button at low frequency “LOW FREQUENCY”, set the switch in this position. The microcircuit will operate at a low frequency and its work can be visually traced by the luminescence of the LEDs. LED blinking means - turning on the blue LED - this is PLUS (+), and the white LED means MINUS (-) at the output of the chip. According to the logic of the microcircuit, we can determine the basic performance of the microcircuit by pulses. Use adjustment potentiometers and function buttons for a more detailed test of the operation of the chip.2. Chip test for generating the output voltage of a given level. FOR MODELS: TESTTNY, TEST22This test is designed to test the power chips with built-inpower key. This test is a reference output voltage, which gives a pulse generator circuit. Green LED indicates the right voltage at the output of the chip. Also, this test is used to check the reference voltage generated by the tested chips in MODELS: TEST494, TEST3525, TEST2153, TEST3843.

Tester setup & adjustmentIf the parts are correctly installed, any model of testers starts working right after switching on. If during the assembly no errors were made and the parts were not damaged by static electricity, the device does not need additional adjustment and adjustment.If the tester tool does not work properly, first check that all components are installed correctly and with right polarity. Correct the mistakes.If, in this case, the device cannot be started, the assembled device should be checked in blocks, starting from the power input circuit of the device.Tester models with built-in voltage converter should be checked starting from this block. The voltage adjustment should work rotating potentiometer.In more detail, all the problems in the operation of the device, it is not possible to describe in this manual. The version for self-assembly of the device (DIY) implies

Further, you can read more detailed instructions on the installation of radio components on a printed circuit board with illustrations of the instrument assembly. In detail, set out the sequence of installation of electronic components and the recommended sequence of groups of elements for installation on a printed circuit board. The process of final assembly of the device into the body is described in a separate document.

Component mounting sequence

First install temporary racks for easy installation.

Fix the plastic spacers and M3 35mm screws in the form of a table, with a distance at the bottom of the printed circuit board for the conclusions of the axial components and their convenient installation. This order of installation of components allows you to quickly and conveniently mount components on the circuit board of the device. The basic idea of convenient installation is to place components in height from lower to higher.

PWM recommends placing the components in groups, followed by soldering all the leads of the components into a group. Components are soldered after all the components of the group are installed, the PCB is turned over with the leads pointing upwards. Soldering is carried out from the bottom of the board. After soldering the components of the group, the elements are cut off and the next group of elements is established.This type of mounting is called mounting into holes with manual placement and manual soldering of elements. Despite the complexity of installation, this type of installation is more reliable than SMD installation, and the boards made in this way are more resistant to bends, deformations and temperature changes. Therefore, lead mounting is used not only by DIY electronics enthusiasts, but also in extreme space conditions and where strength, power and good maintainability are needed.

Components installation and convenient rotation of the circuit board 180 degrees

Let's proceed to the installation. Mount parts in groups performing such operations:Arrange a group of components of the same height through the holes until it stops.Cover the top with cardboard (paperback or advertising booklet) and flip the board. Place the circuit board with the cardboard on the table. Cardboard is needed for easy turning - so that the components do not fall out of the holes when turning.

Apply flux with a brush to the terminals of the radio elements and to the pads onthe back side of the board.

Use only neutral flux without activators and acids. PWM recommends the classic alcohol-rosin flux.

Carefully solder all elements of the group

Cut all the conclusions of a group of components with small clippers, visually checking the soldering quality

Turn the circuit board over and place the next group of items.

For small radio-electronic elements of groups 1-4, it is advisable to install and solder for the group as a whole. This will be the fastest option. Larger parts of groups 5-9 it is desirable to install individually.

Recommended sequence of groups of elements to be mounted on a printed circuit board

1. Group

0.25 watt power resistorsAxial diodes to 1 watt inclusiveZener to 1 watt inclusive.

2. Group

Ceramic Capacitors MLCCAxial diodes power up to 2 watts TVS suppressor

3. Group

LEDs LEDAll components in the TO-92 package: transistors, TL431, linear regulatorsPPTC fuse 0.3A

4. Group

All components in the TO-220 package are mounted with fastening them through an insulating gasket to the screw connection. Soldering is performed only after fixing such components with a screw nut. All transistors in the TO-220 package are mounted horizontally. To do this, you must first (before installation in the holes on the board) with pliers bend the legs of the transistor 90 degrees. The place of the fold - the transition of the thick part of the conclusions of the element in the thin.

5. Group

Install plastic collet DIP chip connectors, if there are any on board. This does not apply to the central socket ZIF, for the tested components.Install optocouplers.Install high power resistorsInstall a 4A PPTC fuse, pre-bending the pins 90 degrees. The 4A PPTC fuse is always installed over the P-channel MOSFET.Install plastic connectors JST XH 3P / 2P

6. Group

Install and fix voltmeters if they are present in your device. Installation is done on M2 screws. Use small stainless steel distance meters. The leads of the voltmeter to shorten the wires to 35-50mm, clean and tin.Install chokes and inductors horizontally if present in your device. To do this, bend the pins by 90 degrees with pliers.Install DC-005 Jack Power ConnectorsInstall mylar film capacitors (green) and ceramic capacitors (blue)

7. Group

Install all electrolytic capacitors, observing the correct polarity.

8. Group

Install pushbutton switches. The correct position of the button installation is determined by the coincidence of the rectangle in the image on the printed circuit board and the rectangular cut-out on the switch itself from the side of its conclusions.

9. Group

Install all other electronic elementsSet potentiometers (variable resistors) strictly perpendicular to the board axesInstall ZIF connector for tested componentsInstall BNC connectors

10. Group

Install plastic buttons on the switches. Attention! These buttons keep on the switches due to friction force, therefore for installation it is necessary to insert them neatly and with a little effort. If the plastic tip is not included in the fastening of the button - use a knife or file to slightly expand the hole.Install DIP chips in the socket socket panels on the board (not available on all devices)Install the test chip into the main ZIF test socketMake a final check of the board for the quality of installation and for the absence of parasitic jumpers from solder.

11. Group

Removal of flux residuesPassive alcohol-rosin flux does not interfere with the operation of the device, does not conduct electrical currentand does not cause corrosion of the printed circuit board. Rosin even protects soldering sites from oxidation. However, we recommend that you always remove the flux using ethyl or isopropyl alcohol. Remove flux in several stages. At the first stage it is desirable to use a small brush dipped in alcohol.

12. Group

Testing the device before assembly into the bodyCheck the device for operation before installing it with the case. Use only safe power supplies that are not electrically connected to the electrical city network to prevent electrical shock.

More schematically, groups of elements for assembly are presented in the table “Recommended sequence of groups of elements for installation on a printed circuit board by PWM for self-assembly of DIY electronic devices” at the beginning of this document. Also, this table will be useful to beginners, radio amateurs in the fascinating world of radio electronics. All the details of the device as much as possible are marked and signed on the PCB itself. If you have any questions with the installation of elements, please refer to the assembly instructions, drawings and drawings of the device. If you did not find the answer in PWM’s official instructions for assembling and setting up the device, look in the PWM user forum or the Internet. If you cannot find the answer to your question and in this case, please contact PWM support service.

The process of final assembly of the device into the body is described in a separate document.

Document Version 1.0. http://PWM.COMPANY