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Qube Solutions PiXtend V1.3 Full Construction Manual

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PiXtend
Construction manual:
PiXtend V1.3 Full
Kit Assembly
Construction manual
PiXtend V1.3 Full Kit Assembly
Stand 15.08.2016, V1.03
Qube Solutions UG (limited liability)
Arbachtalstr. 6, 72800 Eningen, GERMANY
http://www.qube-solutions.de/
http://www.pixtend.de
www.pixtend.de
1 / 75
Copyright by Qube Solutions UG (limited liability)

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Summary of Contents for Qube Solutions PiXtend V1.3 Full

  • Page 1 Construction manual: PiXtend V1.3 Full Kit Assembly Construction manual PiXtend V1.3 Full Kit Assembly Stand 15.08.2016, V1.03 Qube Solutions UG (limited liability) Arbachtalstr. 6, 72800 Eningen, GERMANY http://www.qube-solutions.de/ http://www.pixtend.de www.pixtend.de 1 / 75 Copyright by Qube Solutions UG (limited liability)
  • Page 2 Another possibility is that you send your device back to us and we take care about the correct disposal for you. www.pixtend.de 2 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 3: Table Of Contents

    2.13 Plug connectors and clamping strips...............59 2.14 Relays........................60 2.15 Assembly of the integrated circuits (ICs)..............62 2.16 Rotation axes......................64 2.17 Battery........................65 2.18 Spacers and screw joints..................67 2.19 Jumper........................68 3. Connecting PiXtend and Raspberry Pi................71 www.pixtend.de 3 / 75 Copyright by Qube Solutions UG (limited liability)
  • Page 4 Construction manual: PiXtend V1.3 Full Kit Assembly Table of Figures Figure 1: Components of the PiXtend V1.3 Full assembly kit.................15 Figure 2: Technical aids and tools........................17 Figure 3: Usable soldering heads........................18 Figure 4: Mounting direction of the IC-Sockets....................22 Figure 5: Fixing the IC-Sockets before the soldering..................23...
  • Page 5 Figure 79: PiXtend mounted on Raspberry Pi....................72 Figure 80: Flat ribbon cable connected to the Raspberry Pi................73 Figure 81: PiXtend with Raspberry Pi Model 2 B – Assembly finished............74 www.pixtend.de 5 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 6: Introduction & Common

    We recommend to print the overview of all components in tabulator form (incl. Numbering) from side 7 and the placement plan on side 13. All mentioned sides will be needed several times while assembling. www.pixtend.de 6 / 75 Copyright by Qube Solutions UG (limited liability)
  • Page 7 Poly fuse / Multi fuse, RM 5.08 mm 50 mA Lithium-Battery CR2025, standing 170 mAh, 3 Pin Atmel ATmega32A-PU, Microcontroller 40 Pin, DIP LM2576T-5, Switching regulator TO220-5 MAX485-CPA, Transceiver, RS485 8 Pin, DIP www.pixtend.de 7 / 75 Copyright by Qube Solutions UG (limited liability)
  • Page 8 100 μH Fastron 09HCP LED1, LED2, LED3, LED4, LED5, LED6, LED7, LED8, LED9, LED10, LED11, Standard-LED, 2.54 mm 3 mm, green LED12, LED13, LED14, LED15, LED16, LED17, LED18, LED19 www.pixtend.de 8 / 75 Copyright by Qube Solutions UG (limited liability)
  • Page 9 Metal layer-resistor 1/4 W, 0207 120 Ω, 1 % R56, R57, R58, R59 Metal layer-resistor 1/4 W, 0207 47 Ω, 1 % R110, R111 Metal layer-resistor 1/4 W, 0207 20 Ω, 0.1 % www.pixtend.de 9 / 75 Copyright by Qube Solutions UG (limited liability)
  • Page 10 Post connector 40 Pole for AWG28 / RM 1.27 mm Flat ribbon cable Quick-release axle for Potentiometer Spacers M2.5 x 25 mm Spacers with external thread M2.5 x 5 mm www.pixtend.de 10 / 75 Copyright by Qube Solutions UG (limited liability)
  • Page 11 Kit Assembly Labelling Count Description Value (on the board) Spacers with external thread M3x5 mm Spacers M3x15 mm Screw, cross recess M2.5x6 mm Screw, spacers M3x6 mm Heat-conducting paste www.pixtend.de 11 / 75 Copyright by Qube Solutions UG (limited liability)
  • Page 12 PiXtend Construction manual: PiXtend V1.3 Full Kit Assembly www.pixtend.de 12 / 75 Copyright by Qube Solutions UG (limited liability)
  • Page 13 PiXtend Construction manual: PiXtend V1.3 Full Kit Assembly www.pixtend.de 13 / 75 Copyright by Qube Solutions UG (limited liability)
  • Page 14 Please do not send back the whole PiXtend kit, if only one part is missing. This will only delay your project and causes expenses and costs for us. Thank you! www.pixtend.de 14 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 15: Component Overview

    PiXtend V1.3 Full Kit Assembly 1.2 Component overview Figure 1: Components of the PiXtend V1.3 Full assembly kit Figure 1 gives an overview over all components included in the assembly kit. Labelling, values and quantities are shown in the previous list.
  • Page 16 If available, the components can be tested and measured with a multimeter. If you don't have a multimeter and you are not sure with a component so we will help you with pleasure. E-Mail to: support@pixtend.de www.pixtend.de 16 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 17: Technical Aids And Tools

    Usable soldering heads are shown in Figure 3. A common multimeter is not urgently needed, but helpful. Especially at finding failures and differentiate the components (for example resistors). www.pixtend.de 17 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 18: Figure 3: Usable Soldering Heads

    PiXtend Construction manual: PiXtend V1.3 Full Kit Assembly Figure 3: Usable soldering heads www.pixtend.de 18 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 19: Important Information

    • respected, the approval for the European economic area (CE-conformity) is lost. Please adhere to the instructions and read all provided information before you put the PiXtend in operation. www.pixtend.de 19 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 20: Assembling And Soldering

    12. Voltage regulators and cooling elements 13. Plug connectors and clamping strips 14. Relays 15. Assembly of the integrated circuits (ICs) 16. Rotation axes 17. Battery 18. Spacers and fittings 19. Setting jumper www.pixtend.de 20 / 75 Copyright by Qube Solutions UG (limited liability)
  • Page 21 PDFs it is possible to search for components. Part list and placement plan you can find in our download area: http://www.pixtend.de/downloads/ www.pixtend.de 21 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 22: Ic-Socket

    The paperboard is lying on the table. Hold the circuit board and pull out the paperboard carefully. This procedure needs sensitiveness, but it make the bending of the pins unnecessary and leads to a faster result. www.pixtend.de 22 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 23: Figure 5: Fixing The Ic-Sockets Before The Soldering

    Figure 5: Fixing the IC-Sockets before the soldering The bending of the opposing pins can be done with the fingernails or with a screwdriver. Figure 6 shows the circuit board with all sockets. www.pixtend.de 23 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 24: Figure 6: All Ic-Sockets Fixed

    Start the soldering iron now. Begin with soldering of the already bent pins of every socket. It is not to recommend to solder all pins immediately! Figure 7: IC-Sockets overlie flat www.pixtend.de 24 / 75 Copyright by Qube Solutions UG (limited liability)
  • Page 25 Now all Sockets should lie flat, so all other pins can be soldered. You built a good and solid base for the integrated circuits that will pay off later. www.pixtend.de 25 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 26: Light Emitting Diodes (Leds)

    The light emitting diodes are put in the board one after another. For the fixing before the soldering it is enough to bend the two connection wires on the bottom side of the circuit board. www.pixtend.de 26 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 27: Figure 9: Led-Connection Wires Bent

    Figure 10: LEDs crooked soldered Use the same method as with the IC-Sockets and press the LED on the board, then heat the bottom side of the soldering joint for short time. www.pixtend.de 27 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 28: Figure 11: Aligning Of The Leds

    If it is not important for you if the LEDs are straight or not, so you sure can solder all pins at once and go on with the next step. Figure 12: LEDs straight aligned www.pixtend.de 28 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 29: Figure 13: Shorten The Connection Wires

    To complete the assembly of the LEDs it's only to shorten the connection wires with a cutter (Figure 13). Figure 13: Shorten the connection wires Cut the wires near the soldering joint. Then short circuits between the connection can be avoided best. www.pixtend.de 29 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 30: Figure 14: Sockets And Leds Mounted

    PiXtend Construction manual: PiXtend V1.3 Full Kit Assembly Your PiXtend-board should look now as following: Figure 14: Sockets and LEDs mounted www.pixtend.de 30 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 31: Resistors And Potentiometer

    M3x15 mm bottom) get screwed as in Figure 15. Figure 15: "Jacking up" the circuit board Before assembling and soldering of the resistors can be prepared more: Figure 16: Preparing the resistors www.pixtend.de 31 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 32: Figure 17: Resistors Mounted

    Which resistor values have to be placed on which position you can see on the placement plan and the part list from side 7. www.pixtend.de 32 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 33: Figure 18: 47 Kω - Yellow, Violet, Black, Rot, Brown

    Figure 20: 10 kΩ – brown, black, black, rot, brown Figure 21: 3,3 kΩ - orange, orange, black, brown, brown Figure 22: 1,21 kΩ - brown, rot, brown, brown, brown www.pixtend.de 33 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 34: Figure 23: 680 Ω - Blue, Grey, Black, Black, Brown

    Figure 26: 120 Ω - brown, red, black, black, brown Figure 27: 47 Ω - yellow, violet, black, gold, brown Figure 28: 20 Ω 0.1% - red, black, black, gold, violet www.pixtend.de 34 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 35: Figure 29: Fixing Of The Resistors

    Figure 30 is shown a place like that. If all four resistors would be placed in the row first, so it would be hard to solder the resistors in the middle. www.pixtend.de 35 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 36: Figure 30: Placing Resistors

    If not the soldering point can be heated again and feed with more solder if necessary. Figure 31: Good soldering joints (Solder cone on the pad ) The connection wires of the resistors get cut again with the cutter. www.pixtend.de 36 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 37: Figure 32: Placement Of The Potentiometers

    Figure 32: Placement of the Potentiometers The spacers are getting removed again and put aside through the final assembly. Figure 33: PiXtend – Resistors and potentiometers mounted www.pixtend.de 37 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 38: Pin Header For Jumper

    A certain percentage buffer for failures we indeed have inserted. So some pins will remain. www.pixtend.de 38 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 39: Figure 35: Needed Jumper Blocks

    That the loose put pin header doesn't fall out something has to be laid under. We use the bending aid for that. Figure 36: Bending aid as help for soldering the pin headers www.pixtend.de 39 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 40: Figure 37: Correct Resting Pin Header

    (24-pole). Figure 37: Correct resting pin header After the positioning all other pin can be soldered. This process is getting repeated for all other pin header pieces. www.pixtend.de 40 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 41: Diodes

    The bending can be done without bending aid too, by hand (sense of proportion). The preparation and soldering of the LM4040-diode is explained more detailed in the following. www.pixtend.de 41 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 42: Figure 39: Bending Of The Diodes With Bending Aid

    With the diodes it is the same procedure as with the LEDs: Insert, bend connection wires, soldering and if necessary positioning, cutting long connection wires at the bottom side near the soldering joint. www.pixtend.de 42 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 43: Figure 41: Help At Placing The Diodes

    42. Figure 42: LM4040-diode preparation The next step is to mount the LM4040-diode. Then bend the connection wires on the bottom side and solder them. www.pixtend.de 43 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 44: Crystals

    16 MHz. The round clock crystal is giving the time for the real time clock. Figure 43: Clock crystal XTAL3 Figure 44: 16 MHz XTAL1 for the PiXtend- Controller www.pixtend.de 44 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 45: Capacitors

    At electrolyte capacitors it must be cared for the polarity. The longer connection wire is the plus pole. The minus pole is marked by a white stripe as shown in Figure 46. Figure 46: Polarity of the electrolyte capacitors www.pixtend.de 45 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 46: Figure 47: Preparation Of The Electrolyte Capacitor C9

    Please here too take care of the polarity. Additional to the marking of the plus pole on the printing of circuit board, there is a white stripe printed on the board which is marking the minus pole: Figure 48: Electrolyte capacitors C9 mounted www.pixtend.de 46 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 47: Figure 49: Ceramic Capacitors In Overview

    The colours and forms of the capacitors can variate. The ceramic capacitors can be differentiated by the different quantity in the assembly kit or by the printing on each component. www.pixtend.de 47 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 48: Figure 50: Avoiding Of Tilting Movement

    The placement of the board is gone far already. If you are not sure that you have done all steps well, so you can compare it with picture 51. www.pixtend.de 48 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 49: Poly Fuse

    Or they will collide with the housing later. The correct position shows figure 55 in section 2.10. www.pixtend.de 49 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 50: Small Transistors

    ESD- shoes or ESD- straps are helpful here. The plastic housing can be touched without problems. If the pins have to be bent, a pliers with plastic handle should be used. www.pixtend.de 50 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 51: Figure 54: Orientation Of The Small Transistors

    The transistor have a predetermined mounting direction which is marked by a round and a flat side of the plastic housing. The form of the housing is printed on the circuit board and easy to recognize. Figure 54: Orientation of the small transistors www.pixtend.de 51 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 52: Big Transistors

    This side is marked on the circuit board (white stripe - Figure 55). Direct touching of the connection wires with the hands should be avoided. By electrostatic load the transistors can be damaged. ESD-shoes or ESD-straps are helpful here. www.pixtend.de 52 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 53: Figure 56: Bending The Connection Wires Of The Transistors

    After that the rest of the connection wires are getting soldered and cut with the cutter. The transistors should be aligned and positioned like that: Figure 57: Positioning of the big transistors www.pixtend.de 53 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 54: Ferrite / Inductance

    The coil can have different construction forms, that's why there are different drills for the different grid dimensions. It only must be soldered this pads which through which your component fits best. Figure 59: Assembly of the coil www.pixtend.de 54 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 55: Figure 60: Coil Mounted Correct

    (flat lying on the circuit board – Figure 60). Figure 60: Coil mounted correct It mustn't be cared of the polarity at ferrite and coils. www.pixtend.de 55 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 56: Voltage Regulator And Cooling Element

    The connection wires are getting bend at 90° near the housing with the plat pliers. Figure 61: Bending the connection wires The completely bent component shows Figure 62. Figure 62: Connection wires bent www.pixtend.de 56 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 57: Figure 63: Applying The Heat-Conducting Paste

    In the assembly kit is included a M3x6 mm screw. With this one the voltage regulator is getting screwed on the cooling element (tighten it hard). The connectors are looking through the opening of the cooling element. www.pixtend.de 57 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 58: Figure 64: Voltage Regulator With Cooling Element

    As last step the pre-mounted voltage regulator with cooling element has to be placed on the circuit board. The cooling element should lie flat on the circuit board. www.pixtend.de 58 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 59: Figure 65: Voltage Regulator Mounted

    Check here again if the connection wires have no connection to the cooling element of the voltage regulator. www.pixtend.de 59 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 60: Plug Connectors And Clamping Strips

    If later wires are getting connected here occurring powers can be absorbed best from the circuit board. If the strips are “hovering” over the board so the soldering points are burdened, which should be avoided! www.pixtend.de 60 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 61: Relays

    We recommend to solder only two opposing pins of each relay that it is possible to adjust the position again. Or the relay can be mounted crooked on the board, what optical makes a bad impression. www.pixtend.de 61 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 62: Figure 68: Pixtend - Nearly Ready

    Now you have your assembly kit on the level of a ARTC-assembly kit (Almost Ready To Control) and with big steps you come near to the completion of the PiXtend-board! Figure 68: PiXtend – nearly ready www.pixtend.de 62 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 63: Assembly Of The Integrated Circuits (Ics)

    The notch of the IC, IC socket and the printing on the board have to match. If the ICs are getting mounted wrong it can lead to malfunction and defects! www.pixtend.de 63 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 64: Figure 70: Correct Positioning Of An Ic With Notch

    Figure 70: Correct positioning of an IC with notch Some Chips have no notch, they have a point. Picture 71 shows the correct positioning. Figure 71: Correct positioning of an IC with point www.pixtend.de 64 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 65: Rotation Axes

    Even when it functionally makes no different do we recommend to put the “arrows” in the rotation axes in the same orientation. That helps at adjusting the analogue outputs later. www.pixtend.de 65 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 66: Battery

    → if necessary shorten it with the cutter – Are soldering joints near to each other connected unwanted? → if necessary cut the unwanted connections (desoldering wick) Figure 73: Check of the soldering joints www.pixtend.de 66 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 67: Figure 74: Battery Mounted

    If you are pleased with the soldering joints and the position of all components, the battery can be soldered. The battery has three connection pins and can be mounted only in one direction. The result shows Figure 74. Figure 74: Battery mounted www.pixtend.de 67 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 68: Spacers And Screw Joints

    Hold the Raspberry Pi over the board before the montage, so it is easier to see which drills are the right ones. The order here is the same as with the M3- spacers: M2,5x5 mm – circuit board – M2,5x25 mm spacers www.pixtend.de 68 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 69: Jumper

    → The position of this jumper will be important when the interfaces are getting used. More information you can find in the datasheet of PiXtend. For now set the jumper to the position “OFF”. – Jumper „DO-PWM“ near DO4 and DO5: www.pixtend.de 69 / 75 Copyright by Qube Solutions UG (limited liability)
  • Page 70 – If you are not sure at setting the jumpers, so it is always the safest to not set the jumper. More information to the jumpers and there effects you can find in the PiXtend- datasheet. www.pixtend.de 70 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 71: Figure 77: Pixtend Ready For The Marriage

    PiXtend now is ready for the “marriage” with the Raspberry Pi Model 2 B. Figure 77: PiXtend ready for the marriage The following steps are valid equally to the model 3B / B+. www.pixtend.de 71 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 72: Connecting Pixtend And Raspberry Pi

    Therefore is needed a little cross recess screw driver. On the following page you will find a picture with correct aligned Raspberry Pi and a mark of the four screws. www.pixtend.de 72 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 73: Figure 79: Pixtend Mounted On Raspberry Pi

    As last step now the 40-pole side of the cable can be connected to the Raspberry Pi. Take care that the connector is pushed down straightly to avoid bending of the pins. www.pixtend.de 73 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 74: Figure 80: Flat Ribbon Cable Connected To The Raspberry Pi

    PiXtend Construction manual: PiXtend V1.3 Full Kit Assembly Figure 80: Flat ribbon cable connected to the Raspberry Pi www.pixtend.de 74 / 75 Copyright by Qube Solutions UG (limited liability)

  • Page 75: Figure 81: Pixtend With Raspberry Pi Model 2 B - Assembly Finished

    Do you need help at any point of this manual or do you have questions about the usage or initial operation? → Gladly you can contact us over our Forum or per E-Mail. www.pixtend.de 75 / 75 Copyright by Qube Solutions UG (limited liability)

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