General guidelines for assembly, safety and
Contents
1. 21 Switch K6000 22 Relay 23 Crystal 24 Transformator 25 Screw connector General guidelines for power supply and any shielding Preferably use an approved AC adapter or batteries If this is not possible because the kit has to be connected directly to the AC outlet then carefully follow the guidelines below Mount the kit in a suitable plastic housing If a metal housing is needed for screening purposes then the housing must be grounded Use a mains switch if the device consumes more than 10W Power consumption Mains voltage x Current If applicable use a isolated transformer Use a double pole AC outlet switch for kits that are connected to the AC outlet without a transformer Use a robust AC outlet lead with clamp or use a AC outlet input connector Use well insulated cable for AC outlet voltage cabling with a minimum area of cross section of 0 75mm Attach the sticker supplied 26 to the housing and fill in the AC outlet voltage frequency power consumption or current and the value of the fuse 6 RS MICRO PROCESSOR CONTROLLER TIMER In addition to the features of an ordinary week day switching clock this jewel of a controller allows controlling independant temperatures through one or all four of its outputs For every temperature to be measured up to 4 a separate sensor K6001 or K6003 is required which allows to install the controller itself distant from the measuring point When a se2. component leads leads in place sufficiently O This solder joint results in Trim the excess wires up to a bad connection the level of the solder Careless assembly will certainly lead to problems Insert the part oriented correctly into its correct holes in the PCB Mount the components in the correct order as stated in the manual Use the boxes O to check off your progress amp Before starting to build read also the general guidelines K6000 3 RS wa 44 see fp Hi Ip be al de mm St E q UR gt Sys v te VE parte 49 SET SICH Ca E NIT ai Oo lo S gt co RS K6000 K6000 5 RS General guidelines for assembly safety and electromagnetic compatibility Soldering 1 Mount the components against the PCB surface and carefully solder the leads in place 2 Obtain cone shaped shiny soldered joints by heating up the component leads sufficiently 3 This solder joint gives a bad connection 4 Snip off the excess lead up to the level of the solder Components Resistor Potentiometer Trimmer potentiometer Coil Capacitor Trimmer capacitor Electrolytic capacitor Diode Rectifier bridge 10 Zener diode 11 LED light emitting diode 12 IC socket 13 IC integrated circuit 14 Transistor 15 Voltage regulator cO 0 O Q G N 16 Triac 17 Diac 18 PCB pin 19 Fuse holder 20 Pushbutton
3. push buttons The controller is now ready for use K6000 15 RS REN Ense POS Nas HS NSS N olzeu jo 291 LI O O O O 0 0x0 O UND oo 000000 00000 BIS 99 1sva ndolg isnray 9 co AVTASIO 310010 A OL deia drop sb Ku deb A a O O O T ic MO god H r Id 7 80009d TR NVAJTIJA 299999 We ANNNDN dzp dt LOJSNVEL es DOOOOOOOOG G 9 0 oo o00 AYALLVE PO IN SOI HAT cXc dO A8 tXL I gt 31ngow adi O NAJLIVA LIOA 6 JDHITITITITITITITITITTIC RS K6000 R32 IC2 yi DIVIDER Cv T Te 0SC1 R26 I RA0 SENSOR1 SENSOR2 V SENSOR4 c5 RTCC OSC2 F NNN N QA 0 912 20 21 9V BATTERY D10 T6 ZD2 MOUNTED D26 D27 JC NOT MOUTED 4 8V Ni Cd BATTERY D26 D27 JC MOUNTED D10 T6 ZD2 NOT MOUNTED ZD1 R30 E R6 vCo 44 Vx TS 01 RS 7 1 K6000
4. the best one but as only few of us possess a frequency counter the second method will be the most frequently used one Turn the trimming capacitor CV1 to its centre position the fixed and movable plates must overlap by about half their surfaces Should in course of time the clock go wrong then you would have to readjust the trimming capacitor CV1 a little To that end the front panel contains a hole through which the clock can be adjusted FIXING THE FRONT PANEL M3 BOLT P6000B Nadi FS LJ LJ 8mm THREAD TUBE SOLDERSIDE 5mm THREAD TUBE HH Fi JA It M3 BEVELLED HEAD BOLT ALU FRONT PANEL Fit each of the six sunk holes with an 8mm and 10mm spacer using an M3 bevelled head bolt ATTENTION Fix these screws WELL because with the foil sticked they will no longer be accessible Before sticking the self adhesive foil to the aluminium front pate check that the surface contains no wire edges dirt or other obstacles Position the foil onto the front panel pay attention to the LED windows OUT1 Provisionally adhere one half of the foil using adhesive tape Remove the protective sheet from the other half and stick this side then remove the adhesive tape and the protective sheet from the first half and stick this half to the aluminium front plate too Fit the basic module onto the thread tubes using six M3 bolts and check that the indication LED s and LCD display are well positioned also check the operation of the
5. HIGH Q f vellemanki General guidelines for assembly safety and electromagnetic compatibility For more info about all our kits please visit our Web site http www velleman be K6000 1 RS While the soldering iron is heating read this first You want to enjoy your Velleman Kit as quick as possible these hints will assist you First take your time Hasty jobs often result in disappointments Make sure your workspace is wide clean and well lit Collect all the necessary tools you might need for the assembly Take care while unpacking that nothing is left in the wrapping or boxes such as small parts manuals and leaflets Please check if all components are present Use the supplied partlist as a guide In case there is something missing or damaged return the Kit to your dealer Read all supplied manuals and notes carefully before you start constructing The Velleman Kit Warranty Please read this carefully In most cases you can easily solve problems yourself This text tells you all about The Kit you have built or intend to build was design by a team of highly skilled design engineers Before their design reaches the customer it has been tested and re tested over and over again This procedure guarantees you that every design actually works when it is put together in the right way But what if something does go wrong Avoid unnecessary expenses and loss of time Examine the whole circuit closely An even bett
6. See that the pcb is perfectly parallel with the basic pcb because only then you can solder and cut the connections at the component side of the basic pcb Fitting the display onto the basic module LCD MODULE M2 5 BOLT INSULATING SLEEVE IT IN NANANANANSNAANSA 5mm SPACER M2 5 NUT P6000B Check that where the display has to be fitted the solder points on the basic pcb are cut short BE SHURE TO CUT the solder points from SW6 Fit the dislay at the solder side of the basic pcb using four M2 5 bolts together with four 5mm spacers and an additional insulation ring Fix the display using four M2 5 nuts at the component side of the basic pcb and check that the display is at right angles to the basic pcb Now connect by means of uninsulated wires the display with the base PCB see fig LCD TYPEA LCD TYPE B Insert the following IC s LJ IC1 VK6000 or PIC16C57 type with its notch towards the transformer LJ IC2 HCT4060 type or equivalent with its notch towards IC3 K6000 11 RS LJ IC3 74HC373 type or equivalent with its notch towards the pcb edge LI IC4 74HC373 type or equivalent with its notch towards SW6 LJ IC5 6116 type or equivalent with its notch towards IC3 LJ Fit IC6 through IC9 TIL111 or 4N27 type opto couplers or equivalent with their notches towards C8 Before fitting the front panel and the battery we will first test the circuit TEST AND CONNECTION a Test without temperature s
7. and fit it with a 0 4A fuse LJ Fit the 4 six pole connectors J1 through J4 U Fit the relays RY1 through RY4 Assembly of the noise suppressing networks for the outputs 2 2 O LI Fit the capacitors C10 through C13 100nF 400V or higher Fit these capacitors vertically and with only one lead connected for the present LI Fit the following 220 ohm 1 2W resistors also vertically and with only one lead connected for the present When using the normally closed NC contact of the relay fit resistor R37 R39 R41 R43 for output 1 2 3 4 respectively When however using the normally open NO contact fit resistor R36 R38 R40 R42 for output 1 2 3 4 respectively Then connect the free extremities of each capacitor resistor pair together and cut them K6000 9 RS LJ Apply an extra layer of solder to the soldered copper traces LJ Connect the 9V battery holder when not using a NiCd battery to the points black wire and to one of the two holes red wire of E1 L Fit the 12V 100mA transformer TRANSFO 2 LJ Fit the 2X6V 12V 300mA transformer TRANSFO 1 Check the position of the 12V output Fit the following components on the solder side Do this very carefully because afterwards some of these components will have to fit under or to pass through the front panel Be also careful when soldering because for some of the components you have to heat close by the component body LJ RV1 4K7 5K trimming pot
8. ensors Connect the mains voltage to the points MAINS ATTENTION CERTAIN POINTS OF THE PCB NOW CARRY DANGEROUS MAINS VOLTAGE Normally the display should show the text 1 OFF Mo 00 00 now Should this not be the case just turn the contrast trimming potentiometer Using the push buttons SW2 and SW3 second and third from the left you now should be able to select among the four outputs the output number is the first digit on the display ATTENTION Should the controller not work then try to unblock by just pressing the RESET push button next to IC4 This RESET button may be used every time the controller locks up Attention pressing the RESET button erases the memory content b Test with temperature sensors K6001 or K6003 Before doing the following test first disconnect the mains voltage Connect one or more sensors to the points SENSOR1 through SENSOR4 and branch off the power supply for the K6001 type sensors from the points Vsensor and see fig 6 0 The power supply for the K6003 type sensors has to be made separately or replace TRANSFO 2 by a 2X6V 1A type see fig 6 1 Now switch the power back on Normally for these outputs eguipped with a sensor the display should indicate a temperature now instead of OFF selection of the outputs is again done using the buttons SW2 and SWS The display indicating SENSOR ERROR or simply keeping indicating OFF for a certain output means that this sensor is defective
9. entiometer LJ CV1 30pF trimming capacitor Ql the LED s LD1 through LD5 LD5 red with their tops at a height of 14mm above the pcb surface To do so first solder one lead of the LED then correct its position and finally solder its second lead Pay attention to the polarity the shortest lead should correspond with the flat side of the circle on the pcb overprint At this point before proceeding check the whole mounting once more thoroughly as well as the solder side for soldering mistakes Fitting the keyboard module onto the basic module ca 7mm P6000S P6000S mue ue qu mim NSSSSSSSSSSAS SS NSSSSSSSSSSAS SS 10mm SPACER SOLDE P6000S P6000S SOLDERSIDE SOLDERSIDE SNSS ASSASSIN SNS SN NSN SSS SIISISISISTISISISIITIIIIIISICCS CD ID mi II gt 2 2 gt g A A g A P6000B 5 5 P6000B 5 STEP 1 STEP 2 STEP 3 STEP 4 Solder six uninsulated wires to the points KB S1 through S5 at the solder side of the keyboard pcb These wires will serve afterwards to make the connections with the basic module REMARK Cut the superfluous extremities of these wires FLUSH with the pcb surface at the component side K6000 10 RS Fit the keyboard pcb into the four holes at the solder side of the basic pcb See that the connection wires KB S1 S5 pass through the basic pcb too and that the connection point KB corresponds with the hole marked 1 at the solder side of the basic pcb Fix the keyboard pcb using four M2 5 nuts
10. er procedure is to let someone else do this for you Every tiny detail is important Are all components put in the right place and correctly oriented Watch out for bad or forgotten solder joints and short circuits What about the power supply Is it correct and present Does the Kit require special calibration or adjustment Do the possible external devices such as computers audio sources or power circuits match the Kit specifications When all the above did not bring you any closer to a solution start thinking of a defective part or parts Semiconductors like transistors FET s IC s and processors although very reliable do not support abuse You can send us suspect semiconductors for inspection and eventual exchange but keep in mind Our experienced technicians can tell the difference between a defective and a fried transistor and in several cases a stamp is much more expensive than a replacement semiconductor bought at the local store Any Velleman Kit if defective will be repaired or replaced at our option within 30 days of purchase Simply return it to the place of purchase with proof of purchase K6000 2 RS ASSEMBLY STEPS Required tools to assemble the kit Use a small soldering iron of max 40W Use thin 1mm solder do not use any flux Use a small cutter to trim excess wires A Mount the components Obtain cone shaped shiny against the PCB surface soldered joints by heating and carefully solder the up the
11. nsions front panel 235X120mm Building in depth min 50mm Modifications reserved K6000 7 RS ASSEMBLY A Assembly of the keyboard module P6000S LJ Fit D5 through D9 1N4148 type small signal diodes or equivalent Pay attention to the polarity LJ Fit the push buttons SW1 through SW5 with their bodies AGAINST the pcb REMARK Don t warm up the terminals of the push buttons too long because this might damage the push buttons irreparably B Assembly of the basic module P6000B LJ Fit the wire jumpers marked J on the pcb U The wire jumper between IC3 and IC5 dotted lined and marked WRITE PROTECT must be fitted in the first instance If afterwards you want to prevent the established program from getting overwritten then you ll have to cut this wire jumper Wire jumper JC should not be fitted for the present Fit the following components when using a 9V battery for memory backup LJ D10 diode from the 1N4148 series or equivalent Pay attention to the polarity U ZD2 3 3V zener diode Pay attention to the polarity J T6 BC557C type transistor or equivalent Fit the following components when using a NiCd battery for memory backup LJ Wire jumper JC LJ D27 diode from the 1N4148 series or equivalent Pay attention to the polarity LJ D26 diode from the 1N4000 series or equivalent Pay attention to the polarity Fit the following resistors LJ R1 through R6 1K brown black red LJ R7 4K7 yellow viole
12. nsor becomes defective the controller outputs a message on the screen and switches the corresponding output off Any relevant information like output number temperature or on off day and time is displayed through an illuminated LC display Programming the device up to 200 steps is done through a clear menu structure Just like with an ordinary thermostat you can readjust the preprogrammed settings temporarily and set a hysteresis per output In order to save programming work in the case of a mains voltage drop the print has been designed such that it can be fitted with a NiCd or ordinary 9V battery TECHNICAL DATA 4noisefree relay outputs max 5A 4 opto coupler inputs for temperature sensors K6001 or K6003 Allows to supply up to four sensors type K6001 Detection of the presence and operation of temperature sensors 16 character LCD screen illuminated 50 program steps per output 200 in total Allows either week or day program Programming resolution 1 minute and 0 1 Hysteresis adjustable from 0 to 25 0 1 per step separately per output Accuracy 0 1 Measuring range 40 to 150 Sampling frequency 1 sec 24 hour clock with day indication LED indication of the output states Standard version intended for building in Separately obtainable housing B6000 for building up Supply voltage mains Memory back up 24 hours with 9V battery 8 hours with 4 8V NiCd battery Dime
13. or wrongly connected See USER MANUAL if you want to test all the functions before fixing the front panel After a successful test you may fit a 9V battery Fix the battery with a binder or with a piece of two sided adhesive tape When using a NiCd battery you may fit two 2 4V batteries or one 4 8V battery in the place marked E1 REMARK With a NiCd battery the memory back up will not work until the controller will have been powered on for a few weeks this is the time needed to charge the NiCd battery K6000 12 RS K6000 K6000 K6010 Vsensor SENSOR4 SENSOR3 SENSOR2 SENSOR1 MAINS G G G e e SENSOR OUT 13 RS 5 K6000 K6010 TRANSFO2 Q Q Vsensor SENSOR4 SENSOR3 SENSOR2 SENSOR1 3 SENSOROUT K6003 K6000 14 RS ADJUSTMENT ATTENTION WHEN THE CIRCUIT IS POWERED ON A LOT OF POINTS CARRY DANGEROUS MAINS VOLTAGE As the clock of the controller must continue working during a power failure we opted for an oscillator based clock built round a crystal and a devider If you don t adjust the clock it may go wrong after a certain period of time Adjusting can be done in two different ways 1 Using a frequency counter Connect the counter to the points GND earth and TP The frequency measured must be of 256KHz i e a period of 3 90625mS The time base can be adjusted using trimming capacitor CV1 2 at sight Of course the first method is
14. t red LJ R8 through R12 47K yellow violet orange LJ R22 through R31 4K7 yellow violet red LJ R32 10M brown black blue J R33 1K brown black red LJ R34 680 ohm blue grey brown LJ R35 1 2W 220 ohm red red brown white Fit the following diodes pay attention to the polarity Ll D1 through D4 diode from the 1N4148 series or equivalent J D11 through D15 diode from the 1N4148 series or equivalent Ll D16 through D25 diode from the 1N4000 series Q ZD1 7 5V zener diode LJ Fit the IC sockets for IC1 through IC9 LJ Fit push button SW6 see also REMARK above in point A K6000 8 RS LI Fit the 4K7 resistor network RA1 Such a network consists of nine resistors connected together at one end and accomodated in one single housing The common is marked with a notch a dot or a stripe and must correspond with the hole marked C LI Fit 2 pcb pins for GND and TP LJ T1 through T5 BC547 type or equivalent Transistors LJ Fit the 4 1943MHz crystal X1 Crystal LJ Fit the 7806 type voltage regulator VR1 with its metal back towards D26 Fit the following capacitors LJ C1 5pF ceramic sometimes marked 4 7 LJ C2 39pF ceramic LJ C3 through C5 100nF sometimes marked u1 or 104 LJ C6 10uF electrolytic capacitor Pay attention to the polarity LJ C7 2200uF electrolytic capacitor Pay attention to the polarity LJ C8 and C9 470uF Pay attention to the polarity LJ Fit the fuse holder F1
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