Assembly Manual - Rochester Institute of Technologyedge.rit.edu/edge/P13321/public/MSD II/P13321-DOC-ASSMW... · Web viewLevitation Clock Assembly Manual P13321-DOC-ASSMW It is assumed

Rochester Institute of Technology

Assembly Manual

P13321 – Levitation Clock

Kevin Fronczak, Trong Duong, Holden Sandlar

3/12/2013

It is assumed that the user of this manual has basic soldering skills as well as the ability to differentiate components (ie. The user is able to tell the difference between a diode and a resistor).

Levitation Clock Assembly Manual P13321-DOC-ASSMW

Table of Contents

Main Control Board..........................................................................................................................................3

Required Parts......................................................................................................................................................3

Populating the Board............................................................................................................................................4

Main Control Board Cable Assembly....................................................................................................................6

Power Cable.........................................................................................................................................................6

Solenoid Cable......................................................................................................................................................7

User Interface Board........................................................................................................................................7

Required Parts......................................................................................................................................................7

Populating the Board............................................................................................................................................8

User Interface Board Cable Assembly................................................................................................................13

Power Cable.......................................................................................................................................................13

Data Cable..........................................................................................................................................................14

Solenoid Assembly.........................................................................................................................................15

Required Parts....................................................................................................................................................15

Winding Counter Construction...........................................................................................................................16

Winding Solenoids..............................................................................................................................................18

Frame Assembly.............................................................................................................................................18

Required Parts....................................................................................................................................................18

Assembling Frame..............................................................................................................................................18

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Main Control BoardMain Control Board schematic can be found in document P13321-SCH-MCBRE.pdf with the relevant Eagle files found under P13321-EGS-MCBRE.sch (for the schematic) and P13321-BRD-MCBRE.brd (for the PCB file).

Required PartsThe full Bill of Materials can be found in P13321_BOM.xlsx or P13321-BOM-MCBRX.pdf for the Main Control Board specifically.

Name Part Number Quantity0.01 μF Capacitor FK18C0G1H103J 50.1 μF Capacitor EEA-GA1HR10B 50.33 μF Capacitor 647-UVK2AR33MDD 11 MΩ Resistor CF1/4LT52R105J 11 μF Capacitor EEA-GA1H1R0 410 μF Capacitor FK24X5R1C106K 2100 Ω Resistor CF1/2C101J 310 kΩ Resistor CF1/2CT52R103J 310 kΩ Trimmer Potentiometer 3362P-1-103TLF 410-pin Molex Connector (Male) 22-23-2101 116 MHz Crystal Oscillator 9B-16.000MAAJ-B 118 pF Capacitor FK18C0G1H180J 11 kΩ resistor CF1/2CT52R102J 12.2 μF Ceramic Capacitor 810-FK14Y5V1H225Z 128-pin Dip Socket 4828-3004-CP 12-pin Molex Connector (Male) 571-6404562 52-pin MTA-100 Connector (Female) 571-3-640440-2 53 V CMOS Battery CR2032 132.768 kHz Oscillator ECS-.327-12.5-13X 1330 μF Electrolytic Cap 80-ESK337M050AH4AA 13-pin Molex Connector (Male) 571-6404563 1Adjustable Voltage Regulator LM317KCSE3 4CMOS Battery Connector S8421-45R 1DC/DC Converter 595-PTN78020WAH 1Diode Main Controller 1N4001 4Linear Regulator 863-MC7805CDTRKG 1Micro-Controller ATMEGA328P-PU 1PCB Stand-Offs 1590-2 6Power MOSFET STP16NF06 4RGB LED WP154A4SUREPBGVGAW 1RSET Resistor (6 kΩ ±0.01%) 71-PTF566K0000BYEK 1RTC DS1307 1

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Name Part Number QuantityThermal Paste Artic Silver 5 1TO-220 Heatsink (for Driver) FA-T220-25E 4Wire Red – 22AWG 5x 20”Wire Black – 22AWG 5x 20”PCBA Drawing P13321-PCB-MPCBA.pdf 1Test Documentation P13321-DOC-TESTW.pdf 1Tuning Procedure P13321-DOC-TUNEW.pdf 1HP 19V; 4A ACDC Converter 394224-101 1

Populating the BoardBefore placing any components on the Main Control PCB, it is crucially important to follow the steps outlined in the Test Procedures document, P13321-DOC-TESTW.pdf to ensure the board is electrically sound after fabrication. Neglecting to do so can result in a non-working board and may require re-ordering parts due to shorts or other etching-related problems.

Figure 1, below, shows a black-and-white image of the main control board layout. Throughout this section various areas will be highlighted to illustrate where the components are located on the board to aid in the placement of devices as well as the importance of the order in which components are soldered to the board.

Figure 1. Main Control PCB layout (top)

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1) Begin by soldering the 5V Regulator (863-MC7805CDTRKG), shown below. It is important to start with this component due to the surface-mount solder tab. Otherwise it may be very hard to access it with a soldering iron if other components around it are in the way.

Figure 2. Location of LM7805

2) Next, all through-hole components (bar the Power MOSFETs [STP16NF06], Adjustable Voltage Regulators [LM317KCSE3], and Heatsinks [FA-T220-25E]) can be soldered to the board. Note that the ATMEGA328P-PU has a 28-pin DIP socket (IC1 on the PCB). DO NOT SOLDER THE ATMEGA TO THE MAIN CONTROL BOARD. The DIP Socket should be soldered so that the ATMEGA can easily be removed and replaced as needed. As a final note, leave enough space on the RGB LED so that it can be bent at a 90° angle with a 3 mm space between the bottom of the LED and the top of the PCB.

3) Next, solder the Power MOSFETs [STP16NF06] to the PCB. Bend the device so that the hole on the tab lines up with the hole on the board. Using the #4 Machine Screw and Nut pair, fasten the Power MOSFETs to the board.

4) Now in order to properly secure the adjustable regulators [LM317KCSE3], the hole on its tab must be aligned with the hole on the heatsink [FA-T220-25E]. In order to do this, place a heatsink in the area next to the corresponding regulator being soldered. When both devices are in place, align the holes as best as possible (slight adjustments can be made later). When the holes are aligned, bend the left-most and right-most pins away from each other at the bottom of the board. These pins should be bent so that they are parallel with the bottom of the PCB. Now the heatsink can be removed and the regulator can be soldered. Repeat this process for each of the four regulators.

5) At this point, all electrical components should be properly soldered to the board. If this is the case, the heatsinks [FA-T220-25E] may be soldered to the board. Since there are no electrical connections to the heatsinks, the solder is just serving the purpose of securing them to the PCB.

6) Once the heatsinks are in place and secured, take a small dot of thermal paste and place it on the back of the tab of the regulator [LM317KCSE3] (note that this device may need to be bent slightly in order to access this area). Once this is done, slowly press the regulator to be flush with the heatsink. Then take the #4 Machine Screw and Nut and fasten them through the regulator and heatsink and tighten so that the components are secure against the face of the heatsink.

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Main Control Board Cable AssemblyThis section outlines the creation of the Main Control Board Power Cable and the Solenoid Cables.

Power CableRequires 571-3-640440-2 (x1) , 20” Red 22 AWG Wire (x1), and 20” Black 22 AWG Wire (x1).

1) Take Red Wire and strip 0.25” off each end, as shown below.

2) Take Black Wire and strip 0.25” off each end.3) Take MTA-100 2-pin Female Connector and place red wire and black wire so that when the

connector is pointing towards you and the wires are coming out of the bottom , the red wire is located on the right and the black wire is located on the left, as shown below.

4) Once the wire is inside the terminal, bend the wire at a 90° angle and use an MTA-100 Crimp Tool to secure the wires in the connector.

5) Once secure, place a dab of epoxy or hot glue to the area where the wires and connector meet, as shown below.

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6) Take the ACDC Power Supply and solder the positive (interior of cable) to the red cable wire. Take the negative Power Supply wire (the cable shielding) and solder it to the black cable wire. Apply epoxy or hot glue to secure.

Solenoid CableRequires 571-3-640440-2 (x4) , 20” Red 22 AWG Wire (x4), and 20” Black 22 AWG Wire (x4).

1) Follow steps (1) through (5) in the Power Cable section above.2) Take non-terminated end of red wire and solder to top magnet wire on coil so that there is 1” of

space between solder joint and coil. In order to ensure a tight connection, take 1” of the magnet wire and wrap it around the 0.25” of stripped red wire as shown below:

3) Take non-terminated end of black wire and solder to bottom magnet wire on coil so that there is 1” of space between solder joint and coil. In order to ensure a tight connection, take 1” of the magnet wire and wrap it around the 0.25” of stripped black wire as shown above.

User Interface BoardUser Interface Board schematic can be found in document P13321-SCH-UICTE.pdf with the relevant Eagle files found under P13321-EGS-UICTE.sch (for the schematic) and P13321-BRD-UICTE.brd (for the PCB file).

Required PartsThe full Bill of Materials can be found in P13321_BOM.xlsx or P13321-BOM-UICTX.pdffor the User Interface board specifically.

Name Part Number Quantity0.1 uF Capacitor EEA-GA1HR10B 110.33 uF Capacitor 647-UVK2AR33MDD 11 uF Capacitor EEA-GA1H1R0 1100 ohm Resistor CF1/2C101J 3

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Name Part Number Quantity10k Resistor CF1/2CT52R103J 310k Trimmer 3362P-1-103TLF 10-pin Molex Connector (Male) 571-6404562 110-pin Molex KK Connector (Female) 571-3-640440-2 21k ohm resistor CF1/2CT52R102J 12-pin MTA-100 Connector (Female) 571-3-640440-2 12-pin Molex Connector (Male) 571-6404562 18-bit Shift Register SN74HC164D 43-pin MTA-100 Connector (Female) 571-3-640440-3 1Cat Ear KK Crimp Terminal 08-50-0030 20Diode 1n4148 3Dual 7-Segment Display DC56-11GWA 2Line Driver 74LVC244ADB,118 4Linear Regulator 863-MC7805CDTRKG 1Resistor Array 4816P-1-221LF 4Tactile Switch B3F-1000 3TO-220 Heatsink 577102B04000G 1Wire Red – 22AWG 1x 20”Wire Black – 22AWG 1x 20”Wire Green – 22AWG 9x 20”Wire Yellow – 22AWG 1x 20”PCBA Drawing P13321-PCB-UPCBA.pdf 1Test Documentation P13321-DOC-TESTW.pdf 1

Populating the BoardBefore placing any components on the User Interface PCB, it is crucially important to follow the steps outlined in the Test Procedures document, P13321-DOC-TESTW.pdf to ensure the board is electrically sound after fabrication. Neglecting to do so can result in a non-working board and may require re-ordering parts due to shorts or other etching-related problems.

Figure 3, below, shows a black-and-white image of the User Interface board layout. Throughout this section various areas will be highlighted to illustrate where the components are located on the board to aid in the placement of devices as well as the importance of the order in which components are soldered to the board.

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Figure 3: User Interface PCB layout

Figure 4: Fully Assembled PCB (Back)

1) Begin by soldering the 4 resistor array (4816P-1-221LF) shown below. These 4 components are labeled as R33, R34, R35, and R36. It is important to start with these components due to the surface-mount soldering leads. These are the 4 surface-mount components that have leads closest apart, which is why it is absolutely necessary to be soldered first. Otherwise it may be

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very hard to access it with a soldering iron if other components around it are in the way. The four resistor arrays are shown in Figure 5.

Figure 5: Location of resistor array

2) Next, solder the 4 line drivers (74LVC244ADB,118). These are being soldered next instead of the shift registers because it is right below the resistor arrays. It is best to solder it now rather than after the shift registers because it has enough bottom room for easier access of the bottom pins. Make sure to leave enough room between U3 and U4 to solder the 0.1 uF capacitor C14 as shown below. Be careful when soldering the pins that are facing toward the resistor arrays (in step 1) as the area in between is very hard to access. Slowly solder each pin and inspect for shorts/bad connection from not having enough solder. The location of the capacitor can be denoted in Figure 6 and shown clearly in Figure 7.

Figure 6: Capactior Location

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Figure 7: Capacitor location on fully assembled board

3) Next, solder the 4x 8-bit shift registers (SN74HC164D) shown below in Figures 8 and 9. Figure 8 is the black and white version of the PCB layout and the Figure 9 is the location of the shift registers on a fully assembled board. Please note the location and make sure to not mistake it with other IC chips.

Figure 8: Black and White layout of Shift registers

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Figure 9: Shift Registers on fully assembled board

4) Next, solder the last surface-mount component, which is the 3.3 V regulator5) Next, solder all the through-hole components including : capacitors, resistors, and diodes6) Next, solder on the 10-pin (22-23-2101) and the 2-pin molex (571-6404562) connectors.7) Then finally, flip the board over and solder the three buttons and the two displays. The display

can be shown in Figure 4.

Figure 10: Fully Assembled PCB (Front)

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8) Note that a wire is used to jump a connection between the last pin of the 10-pin molex to the left pin of the 2-pin molex. This was caused by missing a layout trace connection between the two pins. Carefully solder those two connections and make sure to use a decent size wire to be able to carry the maximum amount of current possibly going to that pin.

User Interface Board Cable AssemblyThis section outlines the creation of the User Interface Data Cable (P13321-DRW-UIDCV.pdf) and the User Interface Power Cable (P13321-DRW-UIPCV.pdf).

Power CableRequires 571-3-640440-2 (x1) , 571-3-640440-3 (x1), 20” Red 22 AWG Wire (x1), and 20” Black 22 AWG Wire (x1).

1) Take Red Wire and strip 0.25” off each end, as shown below.

2) Take Black Wire and strip 0.25” off each end.3) Take MTA-100 2-pin Female Connector and place red wire and black wire so that when the

connector is pointing towards you and the wires are coming out of the bottom , the red wire is located on the right and the black wire is located on the left, as shown below.

4) Once the wire is inside the terminal, bend the wire at a 90° angle and use an MTA-100 Crimp Tool to secure the wires in the connector.

5) Once secure, place a dab of epoxy or hot glue to the area where the wires and connector meet, as shown below.

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6) Repeat steps 1-5 using the 3-pin connector. The extra terminal will be on the left, as shown below:

Data CableRequires 571-3-640440-2 (x2) , 08-50-0030 (x20), 20” Green 22 AWG Wire (x9), and 20” Yellow 22 AWG Wire (x9).

1) Strip 0.25” off of each end of Green and Yellow wire, as shown below

2) Take KK Crimp Terminal (08-50-0030) and place wire so that the bottom “flaps” wrap around insulation and the rest around the wire itself. Using the Molex KK Crimp tool, secure the crimps to the wire, as shown below:

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3) With the 10-pin Female Molex Connector’s locking tabs facing towards you, insert the wires so that they progress as G-G-Y-G-G-G-G-G-G-G from left to right as shown:

Solenoid AssemblyThis section covers the process of creating the custom solenoids used for the Levitation Clock, as well as the creation of a custom winding-counter.

Required PartsName Part Number QuantityMagnet Wire 24 AWG 1200’3/8” Diameter Hex Bolt – 3.5” long 4Metal Washer 1.5” OD 4Metal Washer 1” OD 43/8” Hex Nut 4Electrical Tape 1 rollPower Drill 1Photoresistor 619-350-00009 1Microcontroller Arduino UNO 1470 Ω Resistor 660-CF1/2CT52R471J 21 kΩ Resistor CF1/2CT52R102J 1White LED 941-C503CWANCBADB152 2

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Winding Counter ConstructionIn order to guarantee an accurate winding count, a optical counter can be constructed using a Photoresistor (619-350-00009), two LEDs, two 470 Ω Resistors, one 1 kΩ resistor, and a microcontroller such as an Arduino UNO. Simply follow the schematic below, and upload the Arduino code (or modify it for the microcontroller being used). A small strip of black electrical tape (1/8” wide) should be placed on the 1 ½” washer radially/ The Sense_LED and Photoresistor should be placed so that they are pointing at the edge of the washer at all times (shown in Figure 12). Once the counter reaches a pre-determined count value, the LED_Indicate will turn on indicating to stop winding.

Figure 11. Optical Counter Circuit Schematic

Figure 12. Optical Counter Orientation

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Figure 13. Optical Counter Arduino Code

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Winding Solenoids1) Place 1 ½” washer flush to top of 3/8” hex bolt2) Place 1” washer loosely at opposite end of 3/8” hex bolt3) Insert non-terminated end of hex bolt into power drill.4) With a small piece of electrical tape, secure magnet wire to hex bolt leaving 2-3” freely hanging at top

of bolt near hex head.5) Orient optical counter as described in previous section.6) Begin winding- DO NOT use drill at full power as this can cause damage to the magnet wire due to the

rotational speed.7) When LED_Indicate on Optical Counter lights up, stop winding.8) Remove Hex bolt from drill.9) Take Hex Nut and apply to Hex Bolt, securing the bottom 1” Washer which was previously freely

hanging.10) Repeat process for each solenoid being constructed.

Frame AssemblyThis section covers assembling the PCBs and Solenoids into the frame.

Required PartsName Part Number QuantityAssembly Drawing P13321-DRW-ASSMS 1Full Clock Drawing P13321-DRW-FULLS 1Base P13321-DRW-BASES 1Top P13321-DRW-FLIDS 1Shell P13321-DRW-SHLLS 1Glass Tube P13321-DRW-GLASV 4Ring P13321-DRW-RINGS 4Solenoid P13321-DRW-SLNDV 4Levitation Object P13321-DRW-LOBJV 4#6 3/8” Wood Screw 3069920881 8#10 2” Wood Screw 3069921201 4#4 ¼” Wood Screw HFA44040GR 4Main Control Board P13321-PCB-MPCBA 1User Interface Board P13321-PCB-UPCBA 1

Assembling Frame1) The clock should come from the manufacturing in two pieces: shell with top (P13321-DRW-SHLLS

plus P13321-DRW-FLIDS already secured to shell), and the base (P13321-DRW-BASES).2) Place the User Interface board at the back of the shell and align the mounting points so that the

seven-segment display faces outward. Secure the board with the #4 wood screws, as shown.

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3) Once the UI Board is secured, place the main control board such that it is aligned to the bottom of the frame with the marking provided by the manufacturer of the frame (there should be four holes which fit the #4 screws securing the MOSFETs to the main board. These holes are spaced with two holes 2.25” from the front of the frame at 9.75” from the right side of the frame and 11.5” from the right side of the frame. The other two have the same spacing with respect to the right-hand of the frame but are at 4.75” from the front of the frame). Make sure the RGB LED faces towards the FRONT of the frame (that is, it should be pointing opposite of the UI board as shown below).

4) After the Main Control Board is secured, slide each solenoid into their respective slots on the top of the frame and hook them to the main board. Note that each cable should hook up to its respective position on the main board. That is, the left-most solenoid connects to the left-most connector (looking at the board from the front) and so on.

5) After the solenoids and all other cables are secure (data cable, power cable), it is important to zip-tie as much loose cabling as possible as well as use the cable holders supplied in order to permanently secure all cables. This is shown below.

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Documents

Assembly Manual - Rochester Institute of Technologyedge.rit.edu/edge/P13321/public/MSD II/P13321-DOC-ASSMW... · Web viewLevitation Clock Assembly Manual P13321-DOC-ASSMW It is assumed