Assembling the FCC4 Fast Clock Controller Kit
Contents
1. Assembling the FCC4 Fast Clock Controller Kit Excerpted from the FCC4 User Manual by Mike Dodd mike mdodd com April 13 2014 This manual and the firmware programmed into the microprocessor are copyright 2014 Michael M Dodd All rights reserved KIT ASSEMBLY The fast clock controller is built on a high quality printed circuit board PCB with plated through holes Plated through holes have metal walls so the solder readily flows into the hole and out onto the soldering pad on the opposite side of the PCB What you ll need you will need these basic electronics tools to assemble and test the FCC4 kit Needle nose pliers All Electronincs PLR 55 http www allelectronics com make a store item plr 55 5 mini long nose pliers 1 html Wire cutters All Electronics FC 14 http www allelectronics com make a store item fc 14 5 flush cutter 1 html Soldering iron 30 45 watts tip temperature of 700 to 800 I strongly recommend a temperature controlled soldering station such as one of these You can adjust the tip temperature and the tip is isolated from the power plug to prevent household voltage from destroying sensitive electronics components as you solder them to the PCB O Weller WTCPT HMC Electronics http www hmcelectronics com cgi bin scripts product 1980 0217 gclid CPaA2vaMuZ4CFchn5QodJ210pg All Electronics IR 361 http www allelectronics com make a store item ir 361 60w te2. 2 terminals C Install the four pin header in the J5 location marked on the PCB Place the short pins into the holes and solder them The long leads protrude from the top of the header There is no header for J5 See the yellow sidebar below to learn why C Install S1 the six position speed selector switch in the location marked on the PCB Check that the switch is oriented as shown here before soldering unsoldering this switch later could damage it or the PCB FCC4 Fast Clock Controller User Manual Page 6 O If the switch has protective plastic covering the switches use a hobby knife or other sharp blade to snag a corner then peel it Speed selection switch off Refer to user manual f aat e a Op a Y l 123456 Aj i Fig 4 Speed switch orientation Why is the pin header for J4 missing A pin header for J4 is not included with the FCC4 so the six holes within the J4 outline remain empty These holes are intended for possible future enhancements and are not used at this time Do not fill the J4 holes with solder might need these holes empty if you send me your FCC4 for troubleshooting These holes must remain empty when you complete the assembly Please resist any temptation to mess around with the J4 pads They are connected directly to the microprocessor without protective resistors so it is possible to destroy this important chip by improper use of these points If these points coul
3. Solder cool procedure Some components can be damaged or ruined by excessive heat so follow this two step procedure for each lead wherever you see solder cool in the instructions 1 Solder one lead Solder quickly to not overheat the component 2 After soldering blow gently on the solder joint for one or two seconds to cool it then turn the board over and blow gently on the component itself for one or two seconds Repeat steps 1 and 2 for each lead on the component Solder and cool each lead Do not solder all the leads at once without cooling Don t overheat other components Even if the instructions don t say solder cool you can employ a soldering technique that minimizes heat damage to components such as resistors capacitors and plastic components such as sockets plastic switches and terminal blocks Similar components usually are installed together Insert all components listed in a single step into their holes then begin soldering Solder one lead one each component in turn then come back and solder another lead This gives each component time to cool before you come back to solder the next lead Take care to solder every lead They are easy to overlook when using this round robin technique Double check your work FCC4 Fast Clock Controller User Manual Page 2 Refer to this component layout and the printed circuit board PCB itself while assembling the FCC4 fast clock controller The front side of the PCB is show
4. avoid confusion disregard the flat on the PCB outline and on the LED if present and always place the longer lead into the hole with the square pad LEDs can be installed flush with the PCB or left standing about 1 4 to 1 above it C Install the two LEDs in the locations marked on the PCB Insert solder cool each lead and trim the leads Remember to place the longer lead into the hole with the square pad O LED1 O LED2 Terminal blocks pin header and speed switch Press these components flat against the PCB and solder on the back side This can be tricky but once you solder one pin the component will stay in place Nevertheless continue to press it until you have two pins soldered Otherwise the component might tilt which looks sloppy and increases the chance of damage during use since the its body is not supported by the PCB Remember you will be tightening screws against wires in the terminal blocks and moving switches on S1 to set the clock speed These components need to be resting flat on the PCB for support C Install the three terminal blocks in the locations marked on the PCB with their side holes facing outward away from the PCB If due to parts availability your terminal blocks have the wire holes on top and the screws on the side install these with the screws facing outward away from the PCB Insert press flat against the PCB solder but do not trim the leads O J1 2 terminals O J2 4 terminals O J3
5. the pins to remove the socket and FCC4 Fast Clock Controller User Manual Page 4 straighten the pin Unsoldering a socket is difficult and risks damaging the PCB Check carefully then solder all pins on the back of the PCB There is no need to trim socket pins after soldering C Install the three DIP sockets in the locations marked on the PCB Insert solder but do not trim the leads Do not insert the integrated circuits into the sockets at this time O U1 18 pins 9 on each row O CD1 14 pins 7 on each row O CD2 14 pins 7 on each row Capacitors C Install the seven 0 1 uF capacitors reddish brown body labeled 104 in the locations marked on the PCB Insert solder and trim the leads O C2 C3 C4 C6 C7 C8 O C9 C Install electrolytic capacitor C1 round black labeled 47 uF in the location marked on the PCB Insert the longer lead in the hole in the square pad marked with a sign Insert solder and trim the leads C Install electrolytic capacitor C5 tiny round black labeled 1 uF in the location marked on the PCB Insert the longer lead in the hole in the square pad marked with a sign Insert solder and trim the leads OOO O O Voltage regulators and transistors These five devices have a semi circular body with three leads on the bottom Install them oriented so the flat side matches the outline printed on the PCB Be sure the orientation is correct before soldering Spread the leads slightly
6. to match the hole spacing and gently press the device into the holes until you feel slight resistance Stop at this point leaving the device standing about 1 4 above the PCB Do not attempt to press the device against the PCB Doing so will break the leads where they enter the body The holes are spaced wide to allow the device to stand above the PCB Shining light at an oblique angle on the flat surface of a component makes the markings more visible Compare the straight on view of a 78L05 voltage regulator on the left with the oblique lighting on the right C Install the two voltage regulators U2 and U4 marked 78L05 in the locations marked on the PCB Insert solder cool each lead and trim the leads 6 8 O U2 O U4 Fig 3 Lighting comparison FCC4 Fast Clock Controller User Manual Page 5 C Install voltage regulator U3 marked LM317 in the location marked on the PCB Insert solder cool each lead and trim the leads LC Install the two transistors Q1 and Q2 marked 2N3904 in the locations marked on the PCB Insert solder cool each lead and trim the leads O Q1 O Q2 LEDs An LED has a yellow or green transparent body with two leads on the bottom One lead is longer than the other and the body might have a flat surface on the bottom flange see the yellow sidebar below Flats on LEDs Sadly not all LEDs have a flat or sometimes the flat does not match the outline on the FCC4 circuit board To
7. FCC4 Soldering electronic components requires the use of a low wattage soldering iron about 35 to 45 watts Ideally use a temperature controlled soldering station as listed above Use only rosin core solder on electronic circuits Never use acid core solder and never use flux of any kind Not paste flux Not liquid flux Not rosin flux No flux Remember Rosin core solder only and no flux FCC4 Fast Clock Controller User Manual Page 1 Getting started You may solder components such as resistors and diodes from the front side of the PCB This eases assembly because you can press the component against against the PCB while soldering Some components such as capacitors terminal blocks and integrated circuit sockets can be soldered only from the back side Bend the leads of capacitors slightly to hold them against the front side and press sockets and terminal blocks firmly against the front side while soldering on the back side Resistors and diodes used on the fast clock controller PCB have 0 4 hole spacing It is helpful to buy or make a lead bending jig to avoid measuring each time such a component must be installed This photo shows a commercial jig and a resistor with its leads bent downward 90 at the correct 0 4 spacing A similar jig could be easily fabricated from styrene Refer to Fig 2 FCC4 Component Layout on page 3 as you install the components in each step Fig 1 Component lead bending jig
8. Pin 4 is outside the socket and is not in its socket Remove the chip bend the pin inward slightly and re insert into the socket Pin 5 of the socket is bent under the socket and is not soldered in its hole on the PCB Fig 5 Chip and socket pins that can go wrong Bent under socket pins pose a serious problem because it might involve unsoldering all the socket pins then removing the socket Doing this can damage the PCB First remove the chip and try to solder the socket pin on the top of the PCB leaving it bent under the socket This works if your soldering iron tip is small enough to touch the hole and the pin simultaneously If you can t solder the pin use desoldering braid to remove the solder from all socket pin pads remove the socket straighten the pin and re install soldering all pins Be sure to remove the chip before unsoldering or soldering the socket pins Needless to say it is far better to discover a bent under socket pin during assembly before soldering L First you need to choose a power supply and check that the FCC4 s power system is working properly as described in the FCC4 User Manual Turn off power to the FCC4 C Insert U1 into its 18 pin socket This chip is painted orange on the end with the notch that must match the notch in the socket Orient the notch as shown on the component layout on page 3 Check that it is oriented correctly and that all pins are in the socket not bent under the c
9. d have been at all useful to you I would have included the connector and protective resistors Ignore J4 entirely except when instructed during the system checkout Assembly complete Congratulations Your FCC4 controller circuit board is completely assembled Hold the PCB up to a light and verify that the only empty holes are the 10 holes at the J4 and J5 outlines plus the large mounting holes in three corners Inspect the PCB for poor or missed solder joints or untrimmed leads Correct any problems Check also for solder bridges between adjacent pins To remove a solder bridge place the end of desoldering braid All Electronics SWK http www allelectronics com make a store item swk de soldering wick 1 html or Radio Shack 64 2090 http www radioshack com product index jsp productiId 2062744 on the offending solder and heat with your iron to wick up the excess Installing the chips The final step in assembling the FCC4 kit is to install the three chips in their sockets It is vital that these chips be inserted correctly into the sockets If the rows of pins are spread too wide for the socket contacts gently press them against a flat surface to bend them closer together FCC4 Fast Clock Controller User Manual Page 7 Fig 5 shows three things that can go wrong with chip pins and sockets Pin 3 is bent under the chip and is not in its socket Remove the chip straighten the pin and re insert into the socket
10. hip C Insert CD1 and CD1 the clock drivers into their 14 pin sockets These resemble U1 with two rows of pins The center three pins in each row are absent These chips are painted red on the end with the notch that must match the notch in the socket Orient the notch as shown on the component layout on page 3 Check that each is oriented correctly and that all pins are in the socket not bent under the chip L With the FCC4 s power supply checked out and the three chips in their sockets perform the initial testing procedure described in the FCC4 User Manual FCC4 Fast Clock Controller User Manual Page 8
11. ll the three diodes oriented to match the outlines on the PCB with the lead from the banded end in the hole in the square pad Bend the leads at 0 4 spacing insert solder cool and trim the leads O D1 O D2 O D3 Resistors C Install the two 240 ohm resistors red yellow brown in the locations marked on the PCB O R1 O R3 C Install resistor R2 47 ohms yellow violet black in the location marked on the PCB LJ Install the five 1K resistors brown black red in the locations marked on the PCB Take care to read the color code correctly and not confuse these with the brown black orange resistors Bend the leads at 0 4 spacing insert solder and trim the leads O R4 O R5 O R6 O R7 O RQ C Install the two 10K resistors brown black orange in the locations marked on the PCB Take care to read the color code correctly Bend the leads at 0 4 spacing insert solder and trim the leads O R8 O R10 Sockets Installing the sockets before taller components are installed allows you to turn over the PCB on your workbench and press it against the bottom of the sockets while soldering the socket pins Orient each socket so that its notch matches the outline on the PCB Bend corner pins slightly to hold the sockets in place while you turn over the PCB Check carefully that there is a socket pin in each hole It is easy for a pin to bend under the socket If you discover this after soldering the socket you will need to unsolder all
12. mperature controlled solder station 1 html All Electronics IR 50 http www allelectronics com make a store item ir 50 temperature controlled solder station 50w 1 html 60 40 rosin core solder All Electronics TS 110 7 in dispenser http www allelectronics com make a store item ts 110 60 40 solder 1 htm or SOL564 42 pound spool http www allelectronics com make a store item sol 564 60 40 solder imm 1 2 b roll 1 html Do not use flux of any kind when assembling the FCC4 or soldering any electronics circuit The rosin core solder listed above is intended for electronics use and needs no additional flux You will void your warranty if you use flux You will need a voltmeter capable of reading up to 10 volts DC to check out your power supply before connecting it to the FCC4 and for troubleshooting if the FCC4 does not operate properly An inexpensive multimeter such as All Electronics DVM 810 http www allelectronics com make a store item dvm 810 economy digital multimeter 1 html is suitable About soldering You need to know how to solder electronic circuits to assemble the kit If you are unfamiliar with soldering techniques you can find a good tutorial on the Web such as this one at http www aaroncake net electronics solder htm You can purchase a solder practice kit such as this one www makershed com ProductDetails asp ProductCode MKEL2 It definitely is a good idea to hone your skills before assembling the
13. n here the reverse side is referred to as the back side in the assembly instructions on the following pages re FCC4 Fast Clock Controller v1 3 3 2014 Michael M Dodd Speed selection switch Refer to user manual Te for settings Vdd Com 123456 TP2 Com Vck a ine ES 8V 10V 78L05 LM317 ITO 9 9 00 00000 8 Fig 2 FCC4 Component Layout FCC4 Fast Clock Controller User Manual Page 3 Assembling the circuit board The FCC4 is built on a professional quality fiberglass printed circuit board PCB with copper traces on both sides and a silk screened component diagram on the front side Refer to Fig 2 FCC4 Component Layout for locations of the components when assembling the PCB The speed selector switch is near the upper left with J1 power near the lower left J3 external control switches connector and J2 clock connector are located near the upper right corner The following steps are organized for easiest assembly with the smaller parts installed first After soldering a component in place cut off the leads on the back of the PCB just above the solder Do not trim the leads on sockets terminal blocks and the speed selector switch Bend the leads of all resistors and diodes at 0 4 spacing to fit the holes in the PCB This goes faster if you buy or make a simple jig Fig 1 to get the same 0 4 spacing for all 11 resistors and three diodes Let s begin Diodes C Insta
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