Z80 Microprocessor KitConstruction Manual

Z80 MICROPROCESSOR KIT CONSTRUCTION MANUAL

CONTENTS

INTRODUCTION.....................................................................................3

COMPLETE ASSEMBLED KIT...............................................................4

PREPARING FOR ASSEMBLY...............................................................5

ASSEMBLY STEPS................................................................................6

TROUBLESHOOTING...........................................................................25

PARTS LIST............................................................................................27

2

INTRODUCTION

This construction manual provides steps to assemble the Z80 microprocessor kit.

Preprogrammed IC chips are 1) monitor ROM 27C256, 2) Programmable Logic Device, PLD GAL16V8 and 3) AT89C2051 microcontroller.

Be advised, 95% that causes not working circuit is from soldering! Good soldering point makes the current flow easily. Bad soldering points may causes high impedance path, consequences the distorted pulse signal! The Z80 will not functioning properly!

When pick the PCB, do not touch the soldering pad! Pick it with the board border only!

For those who live in dry and cold area, electrostatic discharge may zaps the CMOS chips. Keep them at the low impedance sheet, like aluminum foil.

3

COMPLETE ASSEMBLED KIT

4

RS232C connector, DB9 male

32kB Static RAMDC jack +9V

Preprogrammed monitor ROM

Z80 CPU

SW4, slide switch selects between INTR key or 10ms tick

LCDContrast adj.

Homemade keypad sticker using Inkjet printer (vector file is available for download)

Preprogrammed microcontroller

Preprogrammed PLD

PREPARING FOR ASSEMBLY

Tools

1. The example of soldering tools is shown below. Main tools are soldering iron, solder lead,wire cutter. Voltmeter is for checking +5V power supply.

Author also has the logic probe, it can check the oscillator running easily. No need the expensive oscilloscope.

5

ASSEMBLY STEPS

□ 1.Check the PCB, no wire or conductive parts on both sides. Remember do not touch

the PCB pad with finger. Pick it at the board border. The board comes with presoldered transient voltage suppressor, D2.

6

□ 2.Check the transient voltage suppressor, D2 on the PCB. The gray line on the chip is

cathode pin! It must be soldered as shown below.

□ 3.We begin with low profile devices. Insert Y1, XTAL 3.579MHz. To prevent the Xtal

case touch the PCB, we may use two pieces of tick paper insert at the bottom. Use one finger press it while soldering at the soldered side.

7

□ 4. Insert C1, 100pF ceramic disc capacitor then followed with resistors. Place them in

axial direction.

For resistors and capacitors, we can bend the legs to make it in place. So we can solder it easily.

8

Finished soldering point should look like this.

Remember, place the soldering iron's tip to touch to the pad and leg for 1-2 seconds, then put the solder wire at the tip, count one, two three, then take them out.

Do not lift the tip up and down! Enough solder will make the finished work like PAGODA and looks shine!

Cut the legs, we can insert another parts.

9

□ 5. Now insert multilayer capacitors, 100nF and R12, R PACK. Solder it.

□ 6. Insert R16, R PACK. Pin 1 of R pack is a dot point! Soldering R pack many need

your finger to press it.

Then insert and solder electrolytic capacitors, 10uF. All electrolytic capacitors has polarity. Longer leg is positive, put it to the square footprint (with + indicator)!

10

□ 7. The voltage regulator, 7805 is TO220 package, we can bend the legs like this.

The TAP pin is GND for heatsink. We can solder it to the pad directly. The ground plan will be heatsink of the voltage regulator. You can tighten the TAP to the PCB with M3 nut and washer as well.

11

□ 8. We can insert the IC socket and the rest parts.

For seven segment LED, we may solder only one pin beforehand. Then check the position, both should be line up on the same level.

We can adjust them by putting the solder tip, to make it slightly movable. Use finger to move it, make it in position.

12

□ 9. The dot LED has polarity!, the flat side is CATHODE pin! The footprint for LED

has square one for ANODE pin! Solder it only one pin beforehand, so we can adjust it in position easily. When it was in good position, finish the rest pins.

Again SW4 is not easy to stand, just solder one pin, then adjust the position with finger while soldering.

D14 also has polarity. Cathode pin has black line!

Q1 and Q2 are PNP transistors. Place them in position the same as symbol on the PCB!

13

□ 10. Insert DC jack, the positive pin will need a saw files for trimming.

Insert D4, protection diode. Insert C6, it has polarity! Recheck before solder them.

14

C4 can be placed axially to make it looks good.

15

VB1 is DB9 male type connector.

16

□ 11. Insert TACT switches, 36 keys. Key must be pressed until locked with clicking

sound!

Then solder it. To make sure that all keys are in placed, turn the board back, recheck all keysare the same level! Some key may springs back, press it until click!

17

□ 12. Small speaker can be placed at the bottom layer and have hot glue to fix it.

18

□ 13. Before insert the IC chips, check +5V by powering the board with AC adapter.

The DC input accepts from +9VDC to +12VDC. The 7805 needs at least +2V dropped voltage. Use a volt meter check at test points TP1+5V and TP2 for GND pin. If it was nearly+5V, it works fine. Then remove the power.

Insert the IC chips carefully. Recheck the pin position. See the example below picture.

19

Pin 1 has indicator on the IC chips. Shown Zilog Z80 CPU and monitor EPROM, 27C256.

The quartz window of the EPROM can be opened for showing student to see the silicon chip.

However if you like to close it with small sticker, then you can make it. The normal light or even sunshine can not kick the charge that stored in the floating gate of the FET in the CMOS structure. To kick it, you will need strong UV with wavelength about 253.7 nm.

Read more at http://en.wikipedia.org/wiki/EPROM

20

Text LCD with 16-pin socket for plugging to the 16-header on the board.

Remember, plugging/removing the LCD must be done when the board is powered off!

21

Your first computer shall look like this when powers it on. For LCD, adjust R18 to make thefirst line appears.

Building the computer is easy and fun!

Let us test the Z80 to execute our program by entering the Z80 instructions in hex code.

Press key PC, 3E, +, 01,+, D3,+, 40,+ , 76, PC, GO.

Did you see the binary number 0000 0001 on the GPIO1 LED? We program the Z80 to write the accumulator contents to the 8-bit GPIO1. This brings the internal data to outside realworld!

The program is simple. It has only three instructions. The hex code is only five bytes.

1800 3E 01 LD A, 1 ; load accumulator with 11802 D3 40 OUT (40H),A ; write to port 40H1804 76 HALT ; Halt the CPU

22

You can change the value to be loaded easily at the 2nd byte located at address 1801. Then see the change when press key GO again. How easy it is!

Another example of displaying text on LCD. After the LCD initialized, we can use built-in LCD drivers to print text or ASCII letter on screen. We will learn how to use LCD with the Z80 programming lab book.

23

Before take a rest after completed assembly, let us enter the hex code for running LED.

line addr hex code label instruction comment---- ---- -------- ----- –------------ –-------------- 0001 1800 .ORG 1800H0002 1800 0003 1800 GPIO1 .EQU 40H 0004 1800 0005 1800 3E 01 MAIN LD A,10006 1802 0007 1802 D3 40 LOOP OUT (GPIO1),A0008 1804 CD 0C 18 CALL DELAY0009 1807 CB 07 RLC A0010 1809 C3 02 18 JP LOOP0011 180C 0012 180C 0013 180C 11 FF FF DELAY LD DE,-1 0014 180F 21 00 10 LD HL,1000H 0015 1812 19 LOOP2 ADD HL,DE 0016 1813 38 FD JR C,LOOP2 0017 1815 C9 RET 0018 1816 0019 1816 .END0020 1816 tasm: Number of errors = 0.

The program is simple forever loop writing the accumulator contents to the GPIO1 LED.

Let us entering the hex code with hex key and + key now.

Started at 1800, 3E, 01, D3, 40, CD, 0C, 18,..... until 38, FD and last byte C9. Then press PC, GO. What is happening?

Then take a rest and have your time to learn more how to program the Z80 with the lab book.

Have fun!

24

TROUBLESHOOTING

PROBLEM CAUSE ACTION

No display, no power LED 1. no power from AC adapter2. wrong polarity jack3.wrong direction of protection diode, D4

1. Check AC outlet2. correct the jack polarity, use new adapter3. correct diode direction

No display, power LED lit 1. wrong IC chip insertion2. wrong monitor program3. wrong PLD code4. oscillator is not running5. CPU is not reset

1. correct chip position2. reprogram the monitor EPROM3. reprogram PLD4. check XTAL soldering, R1and R2 must be 1k, C1 must be 100pF5.wrong C2 polarity, check TP4 with logic probe, press RESET key will make it logic “low”.

No display on GPIO1 LED 1. wrong direction of D142. wrong direction of LED

1. correct the direction2. correct Cathode/Anode pins

No beep when press key 1. no speaker2. wrong position of Q2

1. solder the speaker2. correct the position of Q2

Heat up at voltage regulator, U9 7805

1. DC input is much higher than +7V

1. Lower input DC voltage

No display on LCD 1. wrong insertion position 1. correct the position

No back-light on LCD 1. no R17 installed2. R17 is higher resistant3. LCD module has no back-light4. back-light pins is not the same as schematic

1. install R172. use 5-10 Ohms for R173. use LCD module with back-light4. use LCD module with correct back-light pins

Load/Send hex file problem 1. terminal is not set correct format2. Z80 kit stops loading

3.RS232 cable is not cross cable.

1. set terminal for 2400 bit/s, 8-data bit, no parity, one stop bit, no flow control.2. File is not Intel HEX file.Ensure the file is Intel HEX file.3. check the cable, it must be

25

4. Send hex file displays unreadable letters

cross cable

4. correct terminal settings.

10ms tick LED, D15 is not blinking

1. wrong polarity of D152. AT89C2051 is not programmed

1. correct the polarity2. reprogram the microcontroller

Some key has no response 1.not yet solder it 1. check and solder it

26

PARTS LIST

Semiconductors

U1 Z80 40-pin DIP microprocessorU2 27C64 or 27C256 EPROMU3 HM62256B 32kB SRAMU4 74LS14 inverterU5 74HC74 Dual D-type flip-flopU6 GAL16V8B programmable logic deviceU7 74LS90 decade counterU8 AT89C2051 20-pin microcontrollerU9 LM7805/TO voltage regulatorU11,U10 LTC-4727JR 4-digit 7-segment LEDU12,U14,U16 74HC573 8-bit latchU13 CD4001 quad NOR gateU15 74HC541 tri-state bufferU17 MAX232A rs232 converterD1,D6,D7,D8,D9,D10,D11, 3mm LEDD12,D13,D15D2 TVS5V_SOD123 transient voltage

suppressorD4 1N4007 rectifying diodeD14 1N5226A +3.3V zener 500mW Q2,Q1 BC557 PNP transistorD3 POWER 3mm LEDD5 TONE 3mm LED

Resistors (all resistors are 1/8W +/-5%)

R1,R2,R9 1kR3,R4,R5,R6,R8,R1810KR7,R19 680 OhmsR10 2kR16,R12 10k RESISTOR SIP 9R13 4.7kR14 330 OhmsR17,R15 10 Ohms

Capacitors

C1 100pF ceramicC2,C3,C15,C16,C17 10uF electrolyticC4 100uF electrolyticC5 10uF 16V electrolyticC6 1000uF 16V electrolyticC7,C8,C9,C10,C11 0.1uF multi layerC12,C13 0.1uF multilayerC14 10uF 10V electrolyticC18 0.1uF multilayer

Additional parts

JP1 HEADER 20X2JR1 CONN RECT 16 pinsJ1 DC input JACKJ2 HEADER 3 pinsLS1 8 Ohms SPEAKER

SW1 RESET 12mm tact switchSW2 INTR 12mm tact switchSW3 MONITOR 12mm tact switch SW4 slide switch-SPDT

S1,S2,S3,S4,S5,S6,S7,S8, 12mm TACT switchS9,S10,S11,S12,S13,S14,S15,S16,S17,S18,S19,S20,S21,S22,S23,S24,S25,S26,S27,S28,S29,S30,S31,S32,S33

VB1 DB 9, Male connectorY1 XTAL 3.579MHzPCB double side plate through holeLED cover Clear RED color acrylic plasticKeyboard sticker printable SVG file

27

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