DIY-Thermocam V2 Assembly Manual

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DIY-Thermocam V2 Assembly Guide

Revision 5 from 12.09.2017

• To assemble the device, you need the following tools: A soldering iron, some

solder, a cutting pliers, a nippers, a screwdriver and a multimeter

• At the moment, the following versions of the FLIR Lepton sensor are supported:

2.0 (80x60), 2.5 (80x60 radiometric) & 3.0 (160x120)

• If you have the choice between multiple soldering tips, use the smallest one

• In case you have a soldering station with adjustable temperature, use around 400

- 450 degree celcius

• Catch the PCB, the microcontroller and one of the two pin header strips

• Cut the header strip with a cutting pliers into the following pieces: 2 x 15, 1 x 5 and

3 x 1

DIY-Thermocam V2 Assembly Guide

Page 1

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Summary of Contents for DIY-Thermocam V2

Page 1 DIY-Thermocam V2 Assembly Guide Revision 5 from 12.09.2017 • To assemble the device, you need the following tools: A soldering iron, some solder, a cutting pliers, a nippers, a screwdriver and a multimeter • At the moment, the following versions of the FLIR Lepton sensor are supported: 2.0 (80x60), 2.5 (80x60 radiometric) &...
Page 2 DIY-Thermocam V2 Assembly Guide • Plug the microcontroller into the header pieces • One of the three single header should be placed in the hole labeled VUSB, do not forget it • Put the microcontroller with the headers into the PCB and make sure they sit tight •...
Page 3 DIY-Thermocam V2 Assembly Guide • Turn the PCB around, make sure the microcontroller still sits tight • Solder the pins on the bottom • Cut the pins short with cutting pliers, right above the solder points you just made • Re-solder the pins to make sure they are really connected well to the PCB...
Page 4 DIY-Thermocam V2 Assembly Guide • Attach the SD card slot to the PCB by soldering the four points on the edges first, then the data pins on the bottom side • Put the 8GB micro SD card into the SD adapter •...
Page 5 DIY-Thermocam V2 Assembly Guide • Remove the wifi shield from the backside of the visual camera module • Push the two female sockets on the two sides alternating to the left and right, until they drop off • It's required to break those pieces off, otherwise the module will not fit later •...
Page 6 DIY-Thermocam V2 Assembly Guide • Use two of the M2 x 10 bolts and put them though the holes in the PCB • On the left bolt, put one of the M2 x 3.5mm distance spacers, on the right bolt one of the M2 x 3.0mm spacer, take care you choose the right length...
Page 7 DIY-Thermocam V2 Assembly Guide • Remove the plastic part from the angled male pins with your hand or a nippers • Bend the 2-pin header alternating to the left and the right, until it drops off DIY-Thermocam V2 Assembly Guide...
Page 8 DIY-Thermocam V2 Assembly Guide • Grab the 8-pin right-angle female header and put it into the PCB • Use two M2x10 bolts and put one of the 3.0mm black spacers on top of each • Plug the Lepton board into the socket and through the two bolts, then save it with two plastic nuts •...
Page 9 DIY-Thermocam V2 Assembly Guide • Solder the step-up converter to the PCB by using a 3 pin strip • Solder the four 4.7k resistors (the smaller ones) to their position on the PCB • Solder the two 10k resistors (bigger ones) to their position right to the spot sensor •...
Page 10 DIY-Thermocam V2 Assembly Guide • Check your FLIR Lepton version: Lepton2.0 (80x60, non-radiometric), Lepton2.5 (80x60, radiometric), Lepton3.0 (160x120, non-radiometric) and skip this step 10 if you have the Lepton2.5 • Catch the MLX90614 single-point infrared sensor and plug it into the board, make sure the little indicator matches the mark on the PCB •...
Page 11 DIY-Thermocam V2 Assembly Guide • Put the charging LED to the place labeled CHG-LED with the short leg in the hole • You can put it all the way in, then bend the LED to the top as shown on the image and solder it •...
Page 12 DIY-Thermocam V2 Assembly Guide • Grab the the six side panels from the enclosure and remove the protection foil from both sides • For all enclosure parts, the shiny side goes inside, whereas the matted side goes to the outside •...
Page 13 DIY-Thermocam V2 Assembly Guide • Take the push button, the power switch and the external USB switch together with the shrink tubes and the cable pieces • Solder the cable pieces to the components • It is good to put some solder on the components pins first, then on the cables, and afterwards put those two together •...
Page 14 DIY-Thermocam V2 Assembly Guide • Put the position of the power switch to OFF (O) and push it through the hole in the panel • Secure the USB power switch with two M2 x 8 bolts and two nuts, then switch it to the upper position as shown on the image •...
Page 15 DIY-Thermocam V2 Assembly Guide • Pick the display module and screw the four smaller distance bolts into the four bigger ones DIY-Thermocam V2 Assembly Guide Page 15...
Page 16 DIY-Thermocam V2 Assembly Guide • Put the lithium battery in place like shown on the image, but do not connect it so • Solder the wires of the push button to the two pins labeled BUTTON, the direction does not matter. It is good to put some solder on the pins first, then on the cables, and afterwards put those two together •...
Page 17 DIY-Thermocam V2 Assembly Guide • Make sure the power switch is still in the off-position, then connect the battery cable to the red terminal marked • Put the two sideplates to their position and bend the wires, so that they do not put...
Page 18 DIY-Thermocam V2 Assembly Guide • Put the display module on top of the PCB and safe it with the four remaining distance bolts • Screw them into the PCB as shown on the image and tighten them • Insert the Lepton 2.0, 2.5 or 3.0 into the module, make sure you hear a click when it snaps in •...
Page 19 DIY-Thermocam V2 Assembly Guide • Install the display panel (top side) and afterwards the right and bottom sidepanel • It makes a difference how they are inserted, so take care the matted side is on the outside and they are rotated right to fit •...
Page 20 DIY-Thermocam V2 Assembly Guide • Put the backpanel on top of the four sidepanels and secure it with four of the black screws • It may be a little bit tricky to make it fit the first time, do not use more pressure than...
Page 21 DIY-Thermocam V2 Assembly Guide • Use the remaining four black screws and put them into the holes on the front plate, then tighten them • Connect the device to a wall charger or your computer, make sure the external USB switch above the power switch is on the top position...
Page 22 DIY-Thermocam V2 Assembly Guide • Flash the newest firmware to the device by following the firmware update guide in the document section • Fully charge the device, so that the charging LED turns green • Turn the device on and complete the first start procedure •...