Assembly Manual
Contents
1. 14 Figure 6 Assembled Controller Board Rear View 15 Figure 7 Daughter Board Connection to 4x20 LCD 16 Figures LCD Daughter Board Dip Switch8 a a ani EV euros 17 Pitre 9 DPIC Board One tit dUOli s uu ER 19 Figure 10 PIC Processor R5 252 Connections casi E ed eie tunaqa beo ete tub Uus 20 Figure 11 LCD Ribbon Cable Orientation uuu sus poaae a u aus ue dus 21 Fisure 12s Crossneedle Meter Winni nase ea u R 24 Fisure L5 esR bbon Cable Connection ar iz 28 Figure 14 Display Switch Board Component Placement 51 Figure 15 Control Board Component Placement 22 TABLES Table 1 Ribbon Cable Wiring to CrossneedleMeter and Front Panel Pot 23 Table 2 SwitchiDisplay Board Parts List ann buco nai EP Sd 3l Table gt Controller Board Parts Eis ca seers u id 34 Tablet hscellaneods Parts Lit uu u ee ee 43 Tale gt Hardware 2 2 Ekel 47 Table 6 Optional Expansion Kit Parts LlIst 48 Table 7 Large 7 Segment Display Option Parts Llist2. 50 1 Addendum 1 The R59 value is incorrectly marked as 1K on the silkscreen of the main Controller Board The correct value 1s 2 7K R59 is incorrectly marked as 1K on the silkscreen is listed correctly in the schematic and Parts List 2 Your MB 1 is shipped with a grey switch for the top right position Display Set Up function in place of the black switch shown in the figure above Your MB 1 is shipped with a Blue internal 7 segment LEDs These by far have been the most popular color choice 2 Introduction Thank you for purchasing the MeterBuilder MB 1 Power Meter This manual describes the steps for assembling the kit The operating instructions and calibration procedures are described fully in the MB User Manual MB 1 consists of the following assemblies Display Switch Board Controller Board High Performance PIC Processor Board already assembled 4x20 LCD and LCD driver Daughter Board Crossneedle Analog Meter The PIC processor 1s a high performance Microchip PIC18F8722 processor mounted on a fully assembled and tested circuit board This board plugs into the Controller Board in a daughter board arrangement using 40 pin headers The PIC processor board the LCD and LCD driver daughter board contain surface mounted components but these units are shipped fully assembled There are no user installed surface mount components in this kit Please check the Parts List before star
3. of the 40 pin headers 19 Figure 10 PIC Processor R5 232 Connections pins on this white connector are used Dialer lt e eo aia lt N h E 1 from Left to Next to last Pin on Header Connect Second Pin from Right to last Pin on Header Connect the LCD Display module to the JLCD connector on the Controller Board Use the ribbon cable that has a white marking on one of the connectors 20 Figure 11 LCD Ribbon Cable Orientation B NEN CHE Bei PO NES MAS gt S w EIN LE 0o Da o SS y A _ E O IR A Eoer Prc STAMP 10700 a gt o a i v o a m b ya Z1 wy 23 49 LJ YC wr WE gt 3 rar gt lt A TW a e i 42121131324 F1 4 d QT l a ss hub fab he Tiaia g a 58 E 4 3 4 orca en i J LCD Cable White Marking on Ribbon Cable Connector must face top of case TT Connect the JPWR JSW and JLED IDC connectors on the Controller Board to the corresponding IDC connectors on the Switch Display Board using the 10 pin and 14 pin grey ribbon cable assemblies The shorter 10 pin cable assemblies should be used The longer 10 pin cable assemblies if provided are part of the Expansion Kit and are used to connect the hi visibility external displays Plug a 12 V DC source into the Controller Board power connector Press the Power Switch The Power Relay should operate and a startup message should appear on t
4. 2 U7 74HCT04 Hex Inverter IC and associated 14 pin IC socket 1 Install components in the following order RF chokes L1 L3 Small Components ceramic capacitors and resistors transistors MCP1541 regulator TO 92 package looks like a transistor and small 1N4001 diodes You may wish to install the 47 ohm resistor R48 that is in series with the sound transducer so that it is raised slightly from the board If you decide that you want to reduce the volume of the sounder this will allow you to easily clip off the resistor and tack solder in a larger value Note that R48 a 47 ohm resistor marked 47R and R50 a 47K ohm resistor marked 47K both get installed on the Controller Board Be careful not to confuse the two Relays IC Sockets position the slot on the IC sockets as shown on silkscreen pin tab mounted toward left when viewing the board from the front If you did not order the Expansion Kit do not install any IC sockets at the U1 U3 and U7 locations Sound Transducer polarity sensitive Remove paper covering or leave it on if you want to operate at reduced volume All IDC Connectors Note on the Controller Board all of the IDC Connectors are mounted on the component side of the board IMPORTANT For the IDC connectors the slots should be positioned facing toward the FRONT of the board see Figure 4 and Figure 15 silkscreen layout This does not apply to the right angle IDC connect
5. position slot on IC socket as shown on silkscreen pin 1 tab mounted toward left when viewing the board from the front Important Do not solder the 7 segment LEDS directly to the PCB You must install the 40 pin sockets even if you do not plan to swap LEDs in the future since the sockets are required to position the LEDs properly with respect to the bezel IDC Connectors Note on the Display Board IDC Connectors are mounted on the non component REAR side of the PCB with the slots facing toward the TOP of the board see Figure 2 and Figure 14 silkscreen layout Electrolytic Capacitors observing polarity Note The two 10 uF electrolytic capacitors on the Display Board are low profile capacitors Front Panel Switches It is recommended that you install the switches last to prevent accidental marring of the switch faces during assembly You can temporarily apply a piece of masking tape to the face of each switch to keep the switch LEDs inserted until they are soldered into place If an LED comes out of the switch while handling it 1s easily re inserted but you will have to make sure that the LED is oriented correctly with respect its anode and cathode leads IMPORTANT Make sure that you position the switches taking into account the text marking on the switch and the LED configurations of the switch LEDs as shown in Figure 7 The switches will seat in the Display PCB more easily if you let the LEDs fl
6. Trim Pot Coupler Trimmer Pot Shorting pin for 3 pin headers 2 extra case screws Notes Some of the External Seven Segment Display Modules and the External Bar Graph modules are packaged with a demo board and a ribbon cable assembly The 4x20 LCD is may also be packaged with a demo board and a ribbon cable assembly These demo boards and cable assemblies if provided are not used with the kit 50 Figure 14 Display Switch Board Component Placement uaal2syIs woyog qaa BEE 1TED Hans DH aM aM ON or OM 2 3 J 3 2 J 1037 2947 1031 1331 1037 1937 1437 2057 1037 4s ad37 1 HE 3 1 Z 95 937 4s ad37 1 H 0 37 1 ms 0d371 T Hz um i z d d J 2 a d d J Jl 2 d d d J 10371 eda 1031 12371 7037 1937 14371 10371 Ma3 g3d T MS 4237 2 MB d3 l I Ma gadg T ME USI T MB I31 T m3 d37 1T d 10Hn JANNAH TIHAH Z ENM AMM Crmn3aid Wa TOH SHH HATANIN l i l l l l l l MEME TA plueog e dsir Jap 159158131 51 Figure 15 Control Board Component Placement L rs amal 3 lf zea Or Ma o 5 lc AR Lt ABLOH Z ure 4n TE 3 m c s HJH H Ua j H 1047 4818 MED Dm od 8 A A A D 2n D DD LET ESSE ES D REESE ES PRESE zb 4 E pu ie m D ix X EM c3 D L r D ml T M Z Io gd 1 tod l Em E uw Im pod 10 0 tag p3 MIR AT EEEH 2o ow u 223 aw w Krim ad E c 32 z SES m7 T a 9 yap I EICH LC ee Phara U ZA peaH A
7. White Pot Rear Terminal 23 Figure 12 Crossneedle Meter Wiring Purple Blue Green Yellow A Red AD Orange Brown Que E a M Wire all LED cathodes together and connect to Yellow wire on REFL coil Forward Needle Coil Reflected Needle Coil 9 Final Checkout It is recommended that final checkout be performed prior to mounting the circuit boards in the case This will make troubleshooting easier if a problem is detected For normal operation the white pushbutton on the PIC processor daughter board must be in the UP position and the white shorting pins on the PIC board must be connected as shown in Figure 9 When power is turned on you will see one illuminated green LED and one illuminated red LED on the PIC board when this switch is in the correct position Two illuminated red LEDS on the PIC board indicate that this switch is in the incorrect down position Plug the Connector end of the colored ribbon cable assembly that is connected to the front panel pot and analog meter into the JMTR POT ICD Jack on the Controller Board 24 Using the ribbon cable assembly with the white marking on one of the end connectors connect the LCD Display module to the JLCD ICD connector on the Controller Board maintaining the orientation of the white marking as shown in Figure 11 white marking faces toward top of LCD Please double check this Connect the JSW JLED and JPWR connectors on the Cont
8. the left side of the board when viewing the board from the front in its normal orientation Install the 7 Segnent LEDs in the 40 pin sockets on the Display Board Position each 7 segment LED so that the decimal point 1s oriented toward the bottom of the board Controller Board Insert all remaining ICs on the Controller Board making sure to properly position pin 1 When viewing the board from the front pinl is positioned toward the left side of the board for IC s oriented left right Pin 1 is positioned toward the op of the board for IC s oriented up down Mount the processor daughter board as shown below in Figure 9 Make sure to observe orientation of the processor board as well as positioning of the board into the proper slots on the 40 pin headers 6 pins on each 40 pin header are unused by the PIC processor board on the side of the board opposite to the heat sinks Install the two jumper wires from the PIC processor daughter board to the 40 pin header pins as shown in Figure 10 the colors of the jumper leads may differ from those shown in the photo Just make sure to interconnect the leads as shown These leads connect the RS232 transmit and receive signals from the PIC daughter board to the DB 9 connector for communication to a PC 18 Figure 9 PIC Board Orientation Shorting Plugs must o 3 sb nm 49 QD be in position shown Position Pic Board as shown leaving 6 empty slots in each
9. MeterBuilder MB 1 PROGRAMMABLE RF POWER METER ASSEMBLY MANUAL Version 1 01 Updated May 2014 A qe Patent and Copyright Notices Patent Applied For Copyright Material in this document copyrighted 2011 FullWave LLC All firmware and software used in the MB 1 copyrighted 2011 FullWave LLC FCC Notice This equipment has been tested and found to comply with the limits for a Class B digital device pursuant to part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference in a residential installation This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instructions may cause harmful interference to radio communications However there is no guarantee that interference will not occur in a particular installation If this equipment does cause harmful interference to radio or television reception which can be determined by turning the equipment off and on the user is encouraged to try to correct the interference by one or more of the following measures Reorient or relocate the receiving antenna Increase the separation between the equipment and receiver Connect the equipment into an outlet on a circuit different from that to which the receiver is connected Consult the dealer or an experienced radio TV technician for help Changes or modifications to this device not expressly approve
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11. ard at this time 12 Figure 4 Assembled Controller Board Front View Ad mm TT d BP 1 q f h i ba If not installing the Expansion Kit leave these slots empty TNT Orientation Left or Top all ICs Rear of Board ue A Vea IC Pin 1 E v A d A ue DADAS E NEM WMENMU D LUN XM UO D JN R es aM wu UN me Position Slots on IDC Connectors Facing of Board Li E A W im Front of Board Single Low Leave these 6 pins empty Profile 10uf Cap when plugging in PIC Board Shown with all components installed 13 Figure 5 Assembled Controller Board IDC Cable Designations J SW A 1 me LE i TUN NIIT N zu Vue gt gas ss d Y ere m 74HCTO4N das OPS 9722 B o Meter Bu der E E Board di t pl ape a LIFE Front of Board of Board J MTRPOT J LED J PWR J LCD Figure 6 Assembled Controller Board Rear View 3 Pin Headers with shorting pins installed selecting External Display 5 volt option Front two pins shorted Shown with all components installed 15 5 3 Mounting the LCD Daughter Board to the LCD The LCD Daughter Board must be soldered to the 4x20 LCD as shown below Before mounting the daughter board first make sure that the two dip switches on the daughter board are in the position shown in Figure 8 Tack solder one pin first making sure that t
12. d by the Manufacturer could void the user s authority to operate this equipment 1 ADDENDUM sin a 4 2 INTRODUCTION Pr A 5 3 GENERAL ASSEMBLY NOTES 2 2 20 Ei 5 4 FRONT PANEL S WITCHES rom 7 5 CIRCUIT BOARD ASSEMBLIES AND LCD MODUILE 7 IE DISIPLAYDPO ip 7 3 22 CONTROLLER BOARD sense dada 10 5 3 MOUNTING THE LCD DAUGHTER BOARD TO THE LCD eese nennen eene eene 16 6 CHECKOUT STEDP T iiie nee ERU It Bee 17 7 CHECKOUT STER uuu ee 18 8 FRONT PANEL POT AND ANALOG METER WIRING 22 9 PUNAL CHECK OU Lo A A AA 24 10 EINABASSEMBETY esee 25 IL JINEHALIZING THE SOFTWARE 2 520 28 12 EXPANSION KIT OPTION sauna 29 13 LARGE 7 SEGMENT DISPLAY OPTION u u 2 a aee aucune aus ee a e eaa cu ua a s 29 14 WARRANTY essentiellen Biss 29 15 PARISLIST erre H M H PR 30 FIGURES Figure 1 Assembled Display Board Component SIde 8 Figure 2 Assembled Display Board Non Component Side IDC Cable Designations 9 Figure 5 Installation of Power DIOU6S ento u u eee nappe ariel 11 Figure 4 Assembled Controller Board Front ViIew 13 Figure 5 Assembled Controller Board IDC Cable Desienations
13. d to the case Just make sure to connect them to the correct IDC jacks Before installing any of the boards sand the four areas on the inside of the case front where spacers from the Display Board will contact the case to ensure good grounding Also sand the five areas on the inside of the case bottom where the spacers from the Controller Board will contact the case 25 Mount the boards and other components to the case using the hardware specified below Install the 4 case feet on the bottom of the case This will keep the bottom of the case form getting marred Display Board 4 40x 7 8 in Panel Screws 4 4 spacers 3 8 length 6 4 washers 18 4 nuts 6 Place the 4 panel screws the ones with the hex heads through the 4 holes on the plastic bezel The beveled edge of the bezel faces toward the front Then insert the screws through the case front Temporarily tape the 4 screw heads in place to the front of the case with masking tape Then turn the case on its front face so that the screws face upward Use a cloth to prevent scratching the case and bezel Before placing the spacers over the 6 fasteners insert 2 lock washers on each of the 4 panel screws and on each of the 2 blind studs located on the side of the case opposite the bezel These lock washers are used to build out the spacer length Install 6 4 spacers 3 8 inch length on the 4 screws and 2 studs Place the Display Board in place Secure the Display Board w
14. e that the heat sink assemblies are mounted perpendicular to the Controller board Tack solder the 7805 pins first checking alignment Then tack solder one of the heat sink tabs while ensuring that the heat sink assembly is mounted squarely on the circuit board and perpendicular to the board s surface Finish soldering the heat sink assemblies and 7805 leads 11 Coupler and Panel Meter Trim Pots Preset the Panel Meter Trim Pots single turn pots at approximately 50 of full travel This will guarantee a readable output at the Panel Meter output ports during the self test sequence without risk of severely overdriving the internal panel meter or any externally connected analog meters Preset the Coupler Trim Pots blue multi turn pots to at least 50 of full CW travel 7 Ya turns CW or more This will guarantee a detectable output during the self test sequence of the coupler ports Note that the coupler trim pots have no mechanical stops Plug in the HCF4069 Hex Inverter IC U6 This IC is required to operate the Power Relay on the Controller Board during initial checkout As with all ICs observe proper positioning of pin 1 on the IC with respect to the socket When viewing the board from the front pin 1 is positioned toward the left of the board for IC s oriented left right Pin 1 is positioned toward the top of the board for IC s oriented up down Do NOT install the other ICs at this time Also do not install the PIC processor bo
15. erived buffer signals for bad solder connections or solder bridges Also examine the IC that buffers these signals 8 Front Panel Pot and Analog Meter Wiring Remove the previously connected power connection and ribbon cable assemblies One of the pre assembled ribbon cables uses a colored ribbon cable Remove a small amount of insulation from all 10 leads from the side with no connector Connect these leads to the crossneedle meter and front panel potentiometer as shown in Table 1 and Figure 12 Note the brown and yellow leads of the ribbon cable are connected to ground on the Controller Board These leads get connected to the FWD and REFL coil common leads of the crossneedle meter as well as to the cathode side of all three illumination LEDs on the crossneedle meter housing The left lead from each LED is the cathode lead when looking at the meter from the rear housing side The anode lead of each LED gets wired to its own ribbon cable lead as shown in the table below and in Figure 12 22 Table 1 Ribbon Cable Wiring to CrossneedleMeter and Front Panel Pot Wire Color Connection Crossneedle FWD coil Wiring Brown FWD Needle Orange FWD Needle Crossneedle REFL coil Wiring Red REFL Needle Yellow REFL Needle and to cathode side of all LEDs Crossneedle LED Wiring Purple LED 1 Anode side Blue LED 2 Anode side Green LED 3 Anode side Potentiometer Wiring Black Pot Front Terminal Grey Pot Center Terminal
16. he LCD followed by the normal LCD display If you do not see the startup message verify 5 volts on the Display Board and Controller Board power busses If power is present verify power at each of the ICs the LCD and the PIC processor board If you hear a two second beep during power up read the paragraph below Two Second Beep Fault Indication This section applies only if you hear a two second beep during power up 2 During power up a number of self tests are performed One of these tests checks the serial I O bus between the processor and the peripherals the Serial Peripheral Interface SPI bus by doing a handshake between the PIC processor and the LCD module If this check fails first check that the ribbon cable that connects the main controller board to the LCD An unconnected or improperly connected LCD cable will cause the 2 second beep If the cable is connected properly this indicates that a board problem exists that is preventing the SPI bus leads from propagating to or from the processor The leads that are involved are the SPI OUT SPI IN and SPI CLK leads as well as the buffered signals derived to and from these leads see schematic Check that pulses are appearing on the SPI OUT and SPI CLK leads at the PIC daughter board as well as the buffered leads Also determine if pulses are present at the SPI IN lead at the at the PIC daughter board If you find a problem with these leads examine the related traces including the d
17. he daughter board is parallel to the main LCD board Make sure no pins or paths on the daughter board touch or are close to the paths or pins on the LCD It is acceptable to angle the bottom of the daughter board upward slightly to provide additional clearance if necessary After assuring adequate clearance solder the remaining 15 pins Note the Demo board and other components that come packaged with the 4x20 LCD are not used with MB 1 Figure 7 Daughter Board Connection to 4x20 LCD Tack solder one pin while confirming that daughter board is parallel to LCD board Wrong Boards not Parallel Correct Boards Parallel 16 Figure 8 LCD Daughter Board Dip Switches LCD Daughter Board Make sure these two switches are in the position shown toward ON designation 6 Checkout Step 1 Connect a 10 pin IDC ribbon cable assembly between the JPWR Connector on the Display Board and the JPWR Connector on the Controller Board Also connect a 14 pin IDC ribbon cable assembly between the JLED Connector on the Display Board and the JLED Connector on the Controller Board Make sure the fuse is installed Connect the 12 volt DC supply to the power connector barrel connector on the Controller Board You must operate the power relay on the Controller Board to check for power on the two 5 volt Controller Board busses Do this by pressing the POWER button bottom right button on the Display Switch Board The above ribbon cable co
18. in the case 3 Pin Headers Install both 3 pin headers as shown in Figure 6 Install shorting plugs on each of these headers for the 5 volt connection as shown These jumpers select either 5 volts or 12 volt power for each of the two external displays The external display devices that are included with the Expansion kit are powered from 5 volts 40 Pin Headers These connect the PIC processor daughter board to the Controller PCB To ensure proper alignment first plug the PIC processor board into them two 40 pin headers 6 pins are unused on the ends of each header The orientation of the processor board is not critical at this point since no power is being applied you are just using the PIC board for spacing Mount the daughter board header assembly by tack soldering the four diagonal corners on the 40 pin headers Make sure the headers are flush and square with the PCB before soldering the remaining pins Remove the PIC processor board after all header pins are soldered Heat Sinks and LM7805 Regulators Install a small amount of heat sink compound provided on the back of each 7805 voltage regulator before attaching it to the heat sink Install the 7805 to the heat sink with a 4 40 x 1 4 screw lockwasher and nut using the middle hole on the heat sink Make sure the 7805 is positioned squarely on the heat sink before tightening the mounting screw since the heat sink 7805 will be soldered to the board as a single assembly Make sur
19. ith a lock washer and nut on each of the 6 fasteners Tighten the nuts being careful not to over tighten especially on the bezel side When tightening make sure that any tools you are using do not damage the PCB surface LCD 2 spacers 5 16 in 4 2 nuts 4 2 washers 12 Place two washers on each of the 4 LCD mounting studs before placing the spacer on each of the studs These lock washers are used to build out the spacer length Then mount the LCD display board securing it with a washer and nut on each stud Do not over tighten When tightening make sure that any tools you are using do not damage the PCB surface Main Controller Board 4 40x 1 in screws 5 4 spacers x 5 8 in 5 4 nuts 5 4 washers 5 Remove the PIC Board and RS232 jumper leads before installing the Main Controller Board so that you can gain access to the center mounting screw hole To aid in installing place the two rear screws and center screw in place from the bottom of the case Temporarily place masking tape on the screw heads on the bottom of the case to hold them in position while installing the board Install spacers on each of the 3 screws in the interior of the case Tilt screws and spacers toward the front of the case while positioning board at an angle so that screws will engage the holes in the board Once in place attach the lock washers and nuts very loosely on these 3 screws You can then slide in the front two remaining mounting sc
20. luded with Expansion Kit which includes power cube Feet MoterBuilder MB t OU 46 Description 2 Hardware 2 spacer 5 16 in length 2 nuts 2 lock washers 1 5mm hex wrench for knob 4 Hardware 4 40 screw 7 8 in Panel Screws 4 40 screw 1 in 4 40 screw 1 4 1n 4 spacer 3 8 in length 4 spacer 5 8 in length 4 nuts 4 lock washers 4 Fender Washers Large Front Panel Pot Washers Large Front Panel Pot Nuts Case Screws including spares Case shipped with 8 screws installed Table 5 Hardware 47 Component ID Table 6 Optional Expansion Kit Parts List Description Oty Polarity Sensitive 1 5 inch 7 Segment External Hi Visibility Module 4 Inch 40 Bar External Hi Visibility Bar Graph TE 10 Lead Ribbon 2 Cable Assembly 20 inches with Connectors 48 49 Table 7 Large 7 Segment Display Option Parts List Component Description Oty Polarity ID Sensitive UII Pre Programmed Replacement for 25AA256 25AA128 256 K 32KB Serial Bus EEPROM Pre Programmed with Expansion Kit Option and Large External Display Option Spare Components The kit is shipped with the following spare components 1 6 amp Fuse Choke The RF chokes will pop if they encounter even a brief short on the output side as could happen if you plug in IC in upside down so check for continuity across the chokes if you encounter a problem Panel Meter
21. ngle 10 Pin ICD Connector 14 Pin ICD Connector Qty Polarity Sensitive 42 Component ID LCDI Description LCD Daughter Board 4x20 LCD Oty Table 4 Miscellaneous Parts List Polarity Sensitive Yes Position Connector with white marking on ribbon cable facing TOP of LCD ONIS SEV P o ze dis mnm i A S Top of Case White Marking facing top of LCD and top of case 43 Component Description Qty Polarity ID Sensitive MI Crossneedle Yes Meter MB HF1 Yes Coupler 196 Vols EIS Shielded RCA Cable for Coupler Connection 10 Lead 1 Ribbon Cable Assembly Colored Cable with Connector on one end 10 Lead 1 Ribbon Cable Assembly Grey Cable with Connectors Component ID Oty Polarity Description Sensitive 10 Lead 1 Ribbon Cable Assembly Grey Cable with Connectors White Mark Mount on LCD 2x5 connector white with white mark facing top of case marking for LCD connection 14 Lead 2 Ribbon Cable Assemblies Grey cable with Connectors 4 7K 10 Turn Hi Resolution Pot R100 Knob Bezel Controller PCB Circuit Board oO 900 0009 o o o a o o o 45 Component Description Qty Polarity ID Sensitive Enclosure 12 volt Power cord 2 5 mm tip Not inc
22. nnections route power from the Controller Board to the Display Board and also connect the switch contacts from the PWR switch on the Display Board to the power relay circuit on the Controller Board through leads ON OFF SW1 and ON OFF SW2 17 Each push of the Power switch should toggle the power relay RLY 1 on off If you do not hear the relay click and see the LED on the PWR switch light up troubleshoot the power on circuit which consists of a simple flip flop 4069 IC and the Power Switch Once the power relay is operated verify 5 volts on the display board and 5 volts on each of the two 5 volt busses 5V and 5V AUX on the Controller board The measured voltages should be within 1 volts of 5 volts The following are convenient locations to check for 5 volt power Display Switch Board Pads of Electrolytic Capacitor C4 Controller Board o 5V Bus Pads of Electrolytic Capacitor C15 o 5V AUX Bus Pads of Electrolytic Capacitor C14 If you are not reading the correct voltage do not proceed until you troubleshoot the voltage problem The Circuit Description document contains the complete schematic of the meter 7 Checkout Step 2 If the 5 volt busses check out remove the power cable from the Controller Board barrel connector and remove the interconnecting ribbon cables Then install the remaining components as described below Display Board Insert the two 7219 7221 IC drivers positioning pin l on each IC toward
23. nob on the shaft of the front panel pot If you are installing the chrome knob that comes with the Expansion Kit use a 1 5 mm hex wrench to tighten the screw Install handle on rear of case Expansion Kit only Carefully reconnect all cables with particular care of the cable that connects the LCD to the main controller board Make sure the white marking on the ribbon cable end that connects to the LCD faces the top of the case As shown in the figure below when viewing the case from the rear the connector designations on the Switch Display Board when read from left to right are JSW 14 pin JLED 14 pin JPWR 10 pin f you ordered the Expansion Kit 2 blank RCA male plugs are included Plug these blanks into the two 5 volt auxiliary power jacks on the rear panel labeled 5v to prevent unintentional connections to these jacks Note that all ribbon cable assemblies in shipped units are grey except the cable assembly that connects to the front panel pot and internal crossneedle meter to the Controller Board JMTRPOT 27 Figure 13 Ribbon Cable Connections vr ERA q 11 Initializing the Software Before you can use MB 1 for normal operation you must perform a one time initialization of the software This will load in the default meter settings including the coupler calibration tables It will also load the LCD module with a special character set used by the software for generating the Bar Graph This operati
24. oat out slightly above the top of the switch while inserting Once you have fully inserted the contact leads and the two locating tabs on each switch the LEDs should line up with their mounting holes and you should be able to press them into place You may find it easier to install the top row of switches first Note The PCB pads for the switches are snug intentionally to help maintain the alignment of the switches However you may want to apply pressure to the front of each switch when soldering the first two connections to ensure that the switch is fully seated Do not install the ICs or 7 Segment LEDs on the Display Board at this time Figure 1 Assembled Display Board Component Side AT 40 Pin IC Sockets Pin 1 Oriented toward y left side of board Green Green Green Decimal Points l Yell face down Shown with all components inserted Note Your MB 1 is shipped with a grey switch for the top right position Display Set Up switch in place of the black switch shown above Figure 2 Assembled Display Board Non Component Side IDC Cable Designations Y Position Slots on IDC Connectors Facing Top of Board Top of Board e 5 2 Controller Board Note the following components are included with the Expansion Kit If you are not installing the Expansion Kit leave the corresponding slots on the Controller Board empty U1 U3 MCP 9922 D to A converter IC and associated 14 pin IC sockets
25. om any defects in this product are excluded including damage to other equipment used with the MB 1 Meter This warranty also does not cover damages or inconvenience resulting from changes or availability in the third party accessories that the 29 MB 1 meter is capable of operating with 15 Parts List All Resistors are 1 8 watt unless otherwise specified 30 Table 2 Switch Display Board Parts List 3l _ DOWN Component Description Oty Polarity ID Sensitive SWPANMTR Black Front 2 SWALARM Panel Sw Dual LED Green Yellow No Text SWMINMAX Black Front 2 SWCOUPLR Panel Sw Single LED Yellow No Text SWPOWER Red Front 2 Panel Sw Single LED Green No Text SWDISP Grey Front 2 Panel Sw Single LED Green No Text PCB Switch 1 Display Circuit Board Latest version has 6 mounting holes 33 Table 3 Controller Board Parts List Note the components listed in red font below are not included if the optional Expansion Kit was not ordered Component ID Fuse Ext7Segl Ext7Segl Header Header2 JCOUP JPM JHVI JHV2 JLCD JMTRPOT JPWR JLED JSW Description 1 6 amp quick blow Fuse Size 5mm x 20mm 3 pin Header Supplies 5 volt or 12 volt power to External Display devices Shorting pins for 3 pin headers 40 Pin Header Female for PIC Board Installation 12 port RCA Jack 10 Pin ICD Connector Right A
26. on needs to be performed only once Perform this operation after you have successfully run the self test routines as described above The initialization step is a simple operation and is accomplished by Powering down the meter Pressing both M1 and M2 keys two left most menu buttons Applying Power while holding in both MI and M2 Keep the buttons pressed until you see SYS RESET PLS WAIT message The initialization operation takes a few seconds You will see a completion message when the initialization process is done The initialization is now complete 28 Note that the trim pots for your Panel Meter and Coupler are not yet adjusted The procedures for making these adjustments are given in the User Manual Congratulations Before proceeding if you have not done so already first spend a few minutes reading the Programming MB 1 link on the MeterBuilder website It is essentially a high level summary of the information covered in this walkthrough in the Quick Start Guide in the User s manual You then have two options You can proceed to the Quick Start walkthrough sections 1 and 2 in the MB 1 User Manual Or if you want to skip some of the details at this point jump to the no nonsense version of the Quick Start Guide authored by AD5X They are both on the documentation page 12 Expansion Kit Option The expansion kit option includes a number of accessories The parts list for the Expansion Kit is shown in Table 6 The E
27. ors mounted on the rear of the board DB 9 Connector 12 volt DC Power Connector Fuse clips Insert fuse into fuse clips first before soldering fuse clips to board to ensure proper alignment Electrolytic Capacitors observing polarity Note one of the electrolytics on the Controller Board is a low profile device that gets installed under the PIC daughter board see Figure 4 Install this first High Current Diodes 1N540x Mount these diodes vertically with the cathode face down toward the board and the anode face up Wrap the anode lead back around the body of the diode and connect it to the PCB The Cathode side of the diode band on cathode side gets 10 connected to the circle part of the silkscreen legend as shown below There are four of these diodes Make sure that you raise these diodes approximately 4 inch off the board exposing 14 inch of lead between the board and the diode This extra lead length provides some additional heat sinking for the diodes reducing their operating temperature Figure 3 Installation of Power Diodes ee athode band side o diode gets inserted face down on circle RCA Jacks Very important Be careful to ensure that the RCA jacks are mounted perpendicular to the board and fully seated Tack solder the diagonal corner pins first and check alignment before soldering the remaining pins Proper alignment of these connectors is required for the Controller Board to mount properly
28. ou to check for shorts on both the filtered and non filtered sides of the power busses this applies to the Controller Board only Polarity Sensitive Components Some components such as the electrolytic capacitors and sound transducer are polarity sensitive A symbol is printed on the PCB and should be connected to the lead of the component Polarity sensitive components are identified in the Polarity Sensitive column in the parts list Of course all diodes transistors voltage regulators and ICs must be oriented correctly as well For the 1N4001 match the band end of the component cathode with the band end on the silkscreen Note there are two ways of identifying the polarity on electrolytic capacitors If the leads on the capacitor are different sizes the larger lead is the positive lead Electrolytic capacitors also have a band on the body of the capacitor that identifies the negative lead Resistance Values Resistors are marked with an R or K to indicate their value e g 47R 47 ohms 47K 47 000 ohms 4 Front Panel Switches Most of the front panel switches are black The power switch is red The four Menu switches and the Display Set Up switch top right switch are grey so that they can be easily recognized 5 Circuit Board Assemblies and LCD Module It is recommended that you install components in the following order 5 1 Display Board Small Components ceramic capacitors and resistors IC Sockets
29. r tray e g 33 ohms 100 ohms etc you will find that it is easier to identify an empty slot for a resistor on the PCB read its value off the silkscreen and then select that value from the correct bin as contrasted with installing all of the 33 ohm resistors installing all of the 100 ohm resistors etc The same applies for the capacitors One of the 10uf capacitor for the Controller Board is a low profile device Install that electrolytic first as shown in Figure 4 You may want to insert multiple components on the front of the board before soldering them You will have to bend the leads slightly after inserting each component to hold them in place Four to six components at a time seems to be a good number A circuit board vise shown in the picture below is a handy tool for circuit board assembly If you are not familiar with these do a Google search for Weller circuit board vise NEQU rm One more suggestion after soldering each group of components before clipping off the excess leads take a quick look at the soldered connections with a magnifying glass or loop The fact that the unclipped leads are sticking out makes these newly soldered connections easy to spot for examination This only adds a few seconds to each group of components and is worth the extra effort RF Chokes Install all of the RF chokes L1 L3 on the Controller Board before installing any other components since this will allow y
30. rews and spacers on the front of the board Attach a lock washer and nut loosely on each of the 2 front screws RCA Connector Blocks 4 40x 1 in screws 2 4 washers 2 4 nuts 2 Secure the RCA connectors to the rear of the case Do not tighten at this time Tighten gradually and in sequence the five Controller Board mounting screws and the two screws securing the RCA jacks When the board is positioned properly left to right the DB 26 9 connector will be centered in its cutout Do not over tighten When tightening make sure that any tools you are using do not come in contact with the PCB surface Reinstall the previously removed PIC Board and RS232 jumper leads on the Main Controller Board as shown in Figure 10 Panel Meter 2 Fender washers 4 40 screws x In 2 4 washers 4 Locate the Panel Meter in its cutout Insert each screw through a fender washer Then place 2 lock washers on each screw before screwing them to the Panel Meter standoffs Do not over tighten or the Panel Meter case will crack Front Panel Potentiometer 2 nuts 2 washers Before inserting the pot install nut and washer on the pot threads so that the threads from the pot will extend only slightly through the front of the case Secure the pot with the other washer and nut from the front of the case Make sure that the wires connected to the pot are positioned toward the bottom of the case to avoid any shorts Install the k
31. roller Board to the corresponding connectors on the Switch Display Board using the appropriate size 10 pin and 14 pin grey ribbon cable assemblies The Jack designations appear on the silkscreen of both the Display Board and Controller Board Isolate all subassemblies to prevent shorts while testing The pink static control bubble wrap is useful for this Connect the 12 volt power cable to the power barrel connector on the Controller PCB Power up the unit with the front panel Power Switch bottom right switch Press the UP or DOWN menu buttons on the front panel until the SELF TEST Menu is displayed on the bottom line line 4 of the LCD as shown below Then push the leftmost menu button short press of M1 to start the self test The self test sequence 1s described fully in the MB 1 User Manual If any failures are detected the self test procedure that failed together with the schematics and Circuit Description should aid you in localizing the problem You will also find additional troubleshooting procedures here Self Test Menu 10 Final Assembly Important Note Be careful when tightening the nuts to not over tighten Avoid contacting the circuit board surface with any tools Remove the power cable If your DB 9 connector came equipped with standoffs remove them from the DB 9 connector You will find it easier to mount the boards in the case if you first unplug the ribbon cables and reconnect them after the circuit boards are secure
32. ting assembly The Parts List starts in Table 2 3 General Assembly Notes It is recommended that you use a standard 60 40 solder formula and a soldering iron of no more than 30 watts All components should be mounted flush on the board unless otherwise noted Because power to ground shorts are usually the most difficult to isolate after installing each group of components such as the switches the sockets or connectors you may want to verify that no shorts have been introduced between ground and the 5 volt bus on the Display Board or between ground and either of the two 5 volt busses on the Controller Board If you use this approach if a short is detected on a power bus you will only have to backtrack to the last installed group of components to isolate the problem You can check for shorts by doing a simple continuity check across the 5 volt busses periodically during assembly If you decide to follow this suggestion locations where you can perform these checks are given below Convenient Capacitor Locations to check for power bus shorts The Display Board has a single 5 volt bus The Controller Board has two 5 volt busses 5V and 5V AUX Display Switch Board Pads of Electrolytic Capacitor C4 Controller Board o 3V Pads of Electrolytic Capacitor C15 o 5V AUX Pads of Electrolytic Capacitor C14 Reducing Assembly Time The capacitors and resistors are the most numerous parts If you put each resistor value in its own bin o
33. xpansion Kit is required if you wish to install additional external analog panel meters It is also required to use the external 7 Segment Display and external Bar Graph module with MB The standard MB 1 without the Expansion kit is supplied with a pre programmed 25AA128 16 KB external EEProm The Expansion kit is supplied with a pre programmed 25AA256 32KB external EEProm If you ordered the optional expansion kit you will receive the 25AA256 EEProm memory chip only 13 Large 7 Segment Display Option This option is currently included at no additional cost with the Expansion Kit It allows you to configure MB 1 to operate with the very large family of SURE Electronics External 7 segment display modules 1 8 inches to 7 inches in height See http stores ebay com Sure Electronics and search for Information Boards 14 Warranty The original purchaser of MeterBuilder MB 1 Kit is covered by a 12 month limited warranty from the date of purchase from FullWave L L C The warranty covers defects in components and materials for one year The warranty does not cover defects due to improper assembly or components damaged during assembly The sole obligation of FullWave L L C under this warranty is to replace defective components within the one year warranty period Defects attributable to abuse misuse improper installation or accidental damage are not covered by this warranty Any incidental or consequential damages resulting fr
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