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Zeppelin Design Labs MACCHIATO Assembly Manual

Mini digital synthesizer
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MACCHIATo
Assembly Manual
MINI DIGITAL SYNTHESIZER

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Summary of Contents for Zeppelin Design Labs MACCHIATO

  • Page 1 MACCHIATo Assembly Manual MINI DIGITAL SYNTHESIZER...

  • Page 2: Table Of Contents

    SCHEMATIC ......................46 © 2017 ZEPPELIN DESIGN LABS. NO PART OF THIS DOCUMENT MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION FROM THE AUTHOR. ZEPPELIN DESIGN LABS TAKES NO RESPONSIBILITY FOR ANY DAMAGE OR HARM THAT MAY COME TO ANYONE OR ANYTHING THROUGH THEIR PRODUCTS. THE MACCHIATO SOFTWARE IS COVERED BY THE CREATIVE COMMONS SHARE-ALIKE LICENSE, WHICH MEANS YOU ARE FREE TO ADD OR BUILD UPON THE CIRCUIT IDEA AND THE SOFTWARE IN ANY WAY YOUR CREATIVITY ALLOWS, BUT ANY DERIVATIVES MUST BE SHARED USING THE SAME LICENSE.

  • Page 3: Introduction

    Today, the Macchiato Mini-Synth combines the best of low-cost microcontroller technology, the Arduino development environment, and the Mozzi Synthesis Library (developed and curated by Tim Barass). The Macchiato emulates many of the best features and sounds of the original beloved analog synths in a tiny, low-cost, lightweight package.

  • Page 4: How It Works

    Design Labs. Feel free to edit and tweak the code any way you’d like, and then re-program your synth using the ISP header on the main board. The Macchiato is the perfect platform for exploring the sounds that Mozzi offers. You will find detailed instructions for doing this in the Macchiato Mini-Synth Quick...

  • Page 5: What You Will Need

    WHAT YOU WILL NEED Here’s everything you will need to build The Macchiato Mini-Synth kit as shown below. Tools and supplies needed for various cabinet options are discussed in the section “MAKING A CABINET” on page 26. TOOLS 1. Digital multimeter 2.

  • Page 6: What's In The Box

    WHAT’S IN THE BOX Table 1: The Macchiato Mini-Synth Bill Of Materials (BOM) is a complete parts list of everything that should be present in your kit, followed by photos of each part. Print the BOM and carefully go through the kit, identifying every part.
  • Page 7 Table 1: The Macchiato Mini-Synth Bill Of Materials Part # Description Notes CB-90-11 Heat Shrink Tubing 1/8” x 5/8” (2mm x 15mm) CP-10-03 Capacitor Electrolytic 50V 1uF CP-10-08 Capacitor Electrolytic 16V 220uF C11, C12 CP-20-07 Capacitor Film 100V 22nF CP-20-11 Capacitor Film 100V 4.7nF...
  • Page 8 CB-90-11 C11, C12 C1 - C5, C14 D1, D2 FA-60-37 FA-90-25 HD-05-03 PC-70-02 PL-10-70 PL-10-90 VR1 - VR9 R18, R21 R1, R13 R3, R5 - R10, R12 R2, R4, R11 R15, R16 ST-10-23...

  • Page 9: Populating The Printed Circuit Board

    EVERY USE. Your Macchiato Mini-Synth is built entirely onto one printed circuit board (PCB). The PCB even includes a built-in capacitive touch keyboard! All of the components will be installed on the “component side”...
  • Page 10 (mostly) surface mounted, which are a little more difficult to solder. The square chip in the middle of the board has been pre-programed with the software your Macchiato needs to run. If you are interested in changing the way your Macchiato operates then you may want to look into modifying this software and re-programing the chip.
  • Page 11 2. Resistors: The values of resistors are given by a series of colored stripes. There are several tutorials online describing how to decode these stripes, but we will identify each resistor for you by simply naming the stripe colors, and giving you the value and the part number. “Figure 3: Component Values And Locations”...
  • Page 12 b. Install the 1K resistors (R18,R21). These resistors are labeled BROWN, BLACK, BLACK, BROWN, BROWN. Don’t be dismayed that R18 and R21 are not labeled “1K” on the PCB. These values were changed after the PCB’s were made. Figure 3 has the correct values listed for reference.
  • Page 13 Now clip each lead with your flush cutters at the solder joint (9). Before installing any more components on the circuit board, double-check the resistance values of each of the installed resistors (10). Set your digital multimeter to the “ohms” or “resistance” setting, and measure across all of the resistors.
  • Page 14 4. Capacitors: There are three different types of capacitors in the kit: ceramic (15), film (16) and electrolytic (17). We will place them in the PCB one type at a time, and then solder them all in at once. a. Ceramic Caps: There are six 100nF yellow ceramic caps (C1,C2,C3,C4,C5,C14). We will install five of them now and one of them toward the end of the assembly process.
  • Page 15 b. Film Capacitors: There are 3 green film caps and all of them have different values. The 4.7nF cap (C13) is smaller than the other two and is marked “2A 472 J” (21). The 22nF cap (C8) is marked “2A 223 J” (22).The 47nF cap (C9) is marked “2A 473 J” (23). These caps are not polarized;...
  • Page 16 c. Electrolytic Capacitors: There is one 1uF cap (C10) and two 220uF caps (C11,C12). You can read their values on their casings. Electrolytic capacitors ARE POLARIZED: there is a right way and a wrong way to install them. If you get it wrong, your synth will not work and the cap might burst.
  • Page 17 5. Diodes (D1,D2): Diodes are polarized: it matters which lead goes in which hole. You will notice one end of the diode body has a white stripe around it (27). It goes like this: WHITE STRIPE = SQUARE PAD NO STRIPE = ROUND PAD Gently bend the leads like you did for the resistors (27).
  • Page 18 6. Header (P2): By installing a 2x3 header array, you create an ISP (in-system programming) port. This is a little socket that enables you to plug a cable into your synthesizer and upload (or “flash”) new software onto the control chip. This is covered in detail in the Macchiato Reference Manual.
  • Page 19 IC’s have a specific orientation. If you install them wrong, your synth will not work and you could damage or destroy the IC. Each IC has a dot, divot, or a flat side at one corner or end. These features have a corresponding graphic on Figure 3 to show you how to orient the IC. a.
  • Page 20 c. Voltage Regulator (U2): This component is shaped like a three-quarter moon. Notice the PCB graphic at U2 has a similar shape to show you the correct orientation. Thread the three leads through the PCB and press this component into place (40). Bend the leads out on the other side of the board.
  • Page 21 9. DC Power Jack (P1): Press it snug to the board and solder in the pins on the solder side. Double check to make sure it’s sitting flush to the board before you solder it (45,46). 10. Input Filter Capacitor (C14): We will now install the other 100nF ceramic capacitor. This component will be attached to the solder side of the board, across the DC power jack.
  • Page 22 11. MIDI IN Jack (P3): Press it snug to the board. Double check it is flat against the board and then solder it in (52,53). 12. Power Switch (S1): Before you place the power switch on the board, push the little red button onto the switch (54).
  • Page 23 14. Battery Holder (BT1): Before we install the battery holder we need to slightly modify the screw holes to allow them to better accept the screws. a. Use the tip of your X-Acto knife to gently flare out the ends of the screw holes just a little bit (before and after photo).
  • Page 24 b. Cut the wire leads to 1-1/4“ (30mm) (Fig 63). Strip 1/8” (3mm) insulation off the ends. Gently twist the tiny strands of copper wire together. Now gently twist the red and black wires together (64). Tin the ends of the wires with your soldering iron (65). c.
  • Page 25 Congratulations! Your Macchiato Mini-Synth is complete, except for the cabinet. I know you are eager to hear cool sounds, so open up the “Macchiato Quick-Start Guide” and make some noise. Keep the label sheet handy so you can keep track of the many knobs. When you are ready to protect your...

  • Page 26: Making A Cabinet

    MAKING A CABINET Your Macchiato wants a cabinet and you have some options: make a cabinet from a cereal box or cardstock from the craft store, or get a plastic cabinet kit from Zeppelin Design Labs. In the future we will publish CAD models that you can download and use to 3D-print your own case.
  • Page 27 2. Flatten your cereal box, if that is what you are using. (Use a large box.) Cut the box open along its glued seam (4). 3. Glue the template temporarily to the BACK of your material (the INSIDE of your cabinet.) Use rubber cement (5, 6).
  • Page 28 4. Cut out the template. a. Using sharp scissors, or a metal ruler and an X-Acto knife, carefully cut out the whole perimeter of the template (9,11). Additionally, snip along every solid line near tabs G through L (10). b. Cut slits in Tabs C & D. Carefully cut along the solid lines with the tip of your blade (12). 5.
  • Page 29 6. Score the fold lines. Use your ruler and the tip of a butter knife to carefully score every dotted fold line (17, 18). Skip Tabs C & D; they will fold neatly without scoring. Be as accurate as you can.
  • Page 30 9. Fold and glue the hems. Tabs A & B are hems, meaning they are to be folded over flat and glued down. Pre-crease them sharply (21). Apply rubber cement, following directions on the jar for the strongest bond (22). Fold the tabs flat and clamp them down with large paper clips or small binder clips (23).
  • Page 31 d. Push two pins up through the two pinholes in the cabinet, from the inside to the outside (27) e. With the backing still on, fit the label down over the pins in the cabinet (28). When you have the label neatly settled on the cabinet, hold down one end with binder clips (29).
  • Page 32 h. Remove the binder clips; remove the last of the backing (32); stick the label onto the cabinet (33). If your cardstock has a textured surface, you may need to warm the sticker with a hair dryer and burnish it down thoroughly. 11.
  • Page 33 12. Crease the Folds: Crease along each scored fold line, one by one, until each fold more or less stands up at 90 degrees on its own (38), with the following special notes: a. Crease Tabs E & F flat as hems. b.
  • Page 34 14. Install the Synth. a. If desired, pop a 9V DC battery into the battery holder. Now fit the synth into the cabinet, tight to the front (44). b. Fold up the back, carefully fitting the red ON/OFF button through its hole (45). c.
  • Page 35 (49). Add some custom labels, if you wish. The remaining stickers can adorn your Macchiato Mini-Synth in a variety of ways. They look good on the refrigerator, too.

  • Page 36: Building The Plastic Cabinet Kit

    An exception is the Bottom. Be VERY CAREFUL to orient the Bottom correctly! Place your Macchiato over it to verify the center standoff lines up with the center hole. The Bottom may show either the shiny or dull side up.
  • Page 37 2. Prep the parts. a. If any parts in your kit are attached to each other, do not break them apart; slice or chop them with your knife. Shave off and sand down all the tabs, flash and machining ripples from all parts (2, 3).
  • Page 38 3. Glue the Sides to the Bottom. a. Dry fit the Sides to the Bottom (8a). Note how the Bottom sits flush to the slots in the Side, both toward the front and the rear (9b). Run a tiny bead of glue inside the slot along the bottom edge of one Side (8b).
  • Page 39 Press the Back into place and hold for about a minute (12). If necessary, add a small bead of glue to the inside of the joint between Back and Bottom (13). 5. Install the Front in exactly the same manner as the Back (14, 15) 6.
  • Page 40 b. Pick up one magnet on the tip of your knife (17). Dry fit it into each one of the pits on the cabinet Sides. If necessary, clean up the bottom of the pits so that the magnet sits flat at the bottom (18).
  • Page 41 7. Install the synth. a. Remove the two front standoffs from your Macchiato PCB (23). Install them in the front two holes in your cabinet, using the tiny plastic washers under the cabinet Bottom (24,25). b. Point the ON/OFF switch at its hole in the cabinet Back and slide the synth into place (26).
  • Page 42 8. Apply the Label. a. Cut out the label around the outside edge of the white border (31). b. Cut out the five speaker slits, staying just inside the white border lines (32). c. Cut out the nine pot holes and one LED hole. Cut away all of the black dots, staying just inside the white borders.
  • Page 43 d. Place the Top onto the completed PCB so all nine pots and the LED stick through (34). Place the label down over the pots as well. When you like how it lines up, use binder clips or tape to secure one end of the label (35). e.
  • Page 44 9. Assemble the Lid a. Pop the Console and Top onto the cabinet (40, 41). Looks pretty neat, huh? If needed, touch up the Console or the Sides with fine sandpaper to achieve the nicest-looking fit you can. b. Remove the Top and carefully apply a tiny, continuous bead of glue to the top edge of the Console (42).
  • Page 45 That’s it! Apply extra stickers for a custom finish and you are ready for the concert hall. Please see the Macchiato Quick Start Guide and Reference Manual to get the most out of your new Mini-Synth.

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