assembly instructions the renard ss24 - do it yourself christmas

From doityourselfchristmas.com

1 Board Assembly2 Triac Heat Sink3 Parts Listing (BOM)4 Related Links

The following sequence of steps is by no means the only way to assemble the Renard SS24. It is simply a suggestedorder of events to achieve the desired goal.

NOTE: The part numbers referenced in the following instructions are those taken from the Renard SS24 BOM.

1 - Start by checking the PCB over forany obvious production faults. Checkfor traces that end abruptly or havecracks/breaks in them. Also check thatall holes are clear.

2 - Install four diodes D1 thru D4 (PN#625-1N5817-E3). The diodes will havea silver/grey stripe on a black body.Make sure that this stripe lines up withthe stripe on the PCB silk screen (to theleft).

Assembly Instructions The Renard SS24 - doityourselfchristmas.com http://www.doityourselfchristmas.com/wiki/index.php?title=Assembly_In...

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3 - Install two 750 ohm resistors R1 &R2 (PN# 291-750-RC). Make sure thatthe resistors have a value of 750 ohms(violet/green/brown/gold stripes). Theseresistors have no polarity to worryabout.

4 - Install the 120 ohm resistor R3 (PN#291-120-RC). Make sure that theresistor has a value of 120 ohms(brown/red/brown/gold stripes). Thisresistor have no polarity to worry about.

5 - Install two 1K ohm resistors R4, R7(PN# 299-1K-RC). Make sure that theresistors have a value of 1K ohm(brown/black/red/gold stripes). Theseresistors have no polarity to worryabout.

6 - Install three 27K ohm resistors R5,R8, R9 (PN# 299-27K-RC). Make surethat the resistors have a value of 27Kohms (red/violet/orange/gold stripes).These resistors have no polarity toworry about.


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7 - Install zener diode D5 (PN#78-1N5229B). The diode must beinstalled correctly. The diode shouldhave a black stripe on the orange/redbody. Make sure that this stripe lines upwith the stripe on the PCB silkscreen (tothe left).

8 - Install zener diode D6 (PN#78-1N5239B). The diode must beinstalled correctly. The diode shouldhave a black stripe on the orange/redbody. Make sure that this stripe lines upwith the stripe on the PCB silkscreen (tothe right).

9 - Install 25 680 ohm resistors R6, R10thru R33 (PN# 299-680-RC). Make surethat the resistors have a value of 680ohms (blue/grey/brown/gold stripes).These resistors have no polarity toworry about.

10 - Install 24 180 ohm resistors R34thru R57 (PN# 291-180-RC). Make surethat the resistors have a value of 180ohms (brown/grey/brown/gold stripes).These resistors have no polarity toworry about.

11 - Install three 0.1uF capacitors C3,C4 & C5 (PN# 80-C322C104K5R).These capacitors have no polarity toworry about.

INSTALLATION NOTE:

The following resistor network isa "bussed" type resistor network.


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This means that the five resistorcomponents (pins 2-6) are allconnected in a common buss topin 1. Installing the resistornetwork backwards will cause amultitude of malfunctions. Soplease take the time to make sureit is installed correctly.

12 - Install the 330 ohm resistornetwork RN1 (PN# 264-330-RC). Theresistor network should have a dot on itto indicate pin 1. Insert pin 1 of theresistor network into the square solderpad (to the left).

13a - Install four green LEDs PWR(D7), HB, ZC & SD (PN#604-WP7104GT). The LEDs arepolarized and must be installedcorrectly. The short lead is the cathodeand must be placed in the square solderpad.

13b - Install two red LEDs FE & OE(PN# 604-WP7104IT). The LEDs arepolarized and must be installedcorrectly. The short lead is the cathodeand must be placed in the square solderpad.

14 - Install three 2-pin vertical headersJP1, JP2 & JP3 (PN# 538-22-03-2021).These headers have no polarity to worryabout.

15 - Install the clock oscillator U3 (PN#520-TCH1843-X). The oscillator mustbe installed in the correct orientation.The oscillator has three rounded cornersand one squared corner, make sure thatthe squared corner is positioned tomatch the PCB silkscreen (upper left


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corner).

16 - Install the voltage regulator U1(PN# 511-LF50CV). The voltageregulator must be installed correctly.The voltage regulators tab/heat sinkmust be aligned with wider line of thePCB silkscreen outline (facing towardsthe PCB top edge).

17 - Install the 2200uF capacitor C1(PN# 647-UVR1C222MHD1TO). Thiscapacitor is polarized and must beinstalled correctly. The capacitor shouldhave a black stripe on the body toindicate which lead is negative. Thepositive lead of the capacitor will be thelonger lead. Make sure that the positivelead is placed in the square solder pad.

18 - Install the 47uF capacitor C2 (PN#647-UVR1C470MDD1TD). Thiscapacitor is polarized and must beinstalled correctly. The capacitor shouldhave a silver/grey stripe on the body toindicate which lead is negative. Thepositive lead of the capacitor will be thelonger lead. Make sure that the positivelead is placed in the square solder pad.

19 - Install four fuse clips (PN#534-3517) Note: they are directionalfor proper fit of the fuse. A helpfulinstallation tip here would be to put afuse in the clips when you position themin their mounting holes. This will helpkeep them correctly aligned so that thefuse will fit properly.

INSTALLATION NOTE:

Pin 1 of the following IC socketsmust be aligned with the squaresolder pad. Another way to verify


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that you installed them correctlyis to make sure that the notch onthe socket is aligned with thenotch on the PCB silkscreenoutline.

20 - Install two 8-pin IC sockets for U4& U5 (PN# 571-1-390261-2).

21 - Install three 14-pin IC sockets forU6, U7 & U8 (PN# 571-1-390261-3).

22 - Install 25 6-pin IC sockets for U2,M1 thru M24 (PN# 571-1-390261-1).

23 - Install 24 triacs T1 thru T24 (PN#511-BTA04-700T). The triacs must beinstalled correctly. The triac tab/heatsink must be aligned with wider line ofthe PCB silkscreen outline. The tab/heatsink of the odd numbered triacs willfacing the even numbered triacs andvice versa.

24 - Install 24 terminal blocks for Ch1thru Ch24 (PN# 571-2828372). Theseterminal blocks have a smallinterlocking tab that allows theterminals to be "stacked" together tocreate a larger terminal block. It iseasier to go ahead and "stack" twelveterminal blocks together first and thenmount them on the PCB.

25 - Install two terminal blocks for120V input (PN# 571-7969492).


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26 - Install the transformer TF1 (PN#838-3FS-312).

27 - Install two RJ45 modular jacks J1& J2 (PN# 571-5556416-1). Due tominor variations in manufacturing,some RJ45 jacks are a tighter fit thanothers. Care should be taken to ensurethat the pins are aligned first beforeapplying too much pressure to seat thelocking lugs through the board.

28 - Install the DE9 connector JDP1(PN# 152-3409).

If you are unsure about your ability to build this board, then youshould go to The Beginner's Setup Guide at this point. TheBeginner's Setup Guide will walk you thru some initial tests to makesure that everything is working correctly before inserting the ICchips.

INSTALLATION NOTE:

Pin 1 of each IC must be alignedwith pin 1 of the correspondingsocket. This can be verified bynoting that the notch on the IC isaligned with the notch on thesocket.

29 - Install the H11AA1 optocoupler U2(PN# 782-H11AA1).


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30 - Install three PIC microcontrollersU6, U7 & U8 (PN#579-PIC16F688-I/P). The PICs need tobe programmed with the appropriatefirmware before installation. More infoon programming PICs can be foundhere.(http://www.doityourselfchristmas.com/forums/showpost.php?p=3346&postcount=1)

31 - Install two RS232/RS485 InterfaceICs U4 & U5 (PN# 511-ST485BN).

32 - Install 24 optoisolators M1 thruM24 (PN# 859-MOC3023).

33 - Install the heat sink (PN#532-577102B00) on voltage regulatorU1. The mounting hardware and heattransfer compound are not included inthe BOM since any common hardwarecan be used to attach the heat sink. Ifyou don't have any heat transfercompound handy, you can use PN#532-249. In the picture the heat sink isattached using a #8 x 3/8" metal screwfound at home depot.

34 - Install two fuses (PN#504-GMA-10) and two fuse covers(PN# 534-3527C).


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Completed Renard SS24

Congratulations! You have finished building your Renard SS24!

A simple heat sink can be fabricated from .5"x.5"x.060" (1/16”) angle aluminum available at your local homeimprovement store. You can use a larger size angle if desired, but you have to keep with the 1/16" thickness. Atemplate for the hole pattern can be found here. The triac listed in the BOM has an isolated tab, so no isolators areneeded.

A small amount of heat transfer compound should be applied between the heat sink and the tab of the triacs. You canuse the same compounds that are used on computer CPU chips and their heat sinks. If you don't have any availablelocally, you can always use something like Mouser PN# 532-249.

IMPORTANT BOM INFORMATION:

Mouser part numbers are listed (unless otherwise noted) as a means of simplifying the listing. Mouser is not theonly place to get these parts, they are used as the reference since they tend to have all the parts needed tocomplete the project. However, the parts can be procured from any electronics parts source that you prefer.

In the event that any of the following parts are not in stock at Mouser when you decide to order them, you cancheck the Part Substitutions wiki page and see if there any suggestions for alternative parts.

PART NUMBER(Mouser PN# unless noted)

QTY REF NOMENCLATURE

511-LF50CV 1 U1 5 VDC Voltage Regulator


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532-577102B00 1 Heatsink for Voltage Regulator

782-H11AA1 1 U2 Optocoupler, Bi-Directional Input

520-TCH1843-X 1 U3 Crystal Clock Oscillator, 18.432 MHz

511-ST485BN 2 U4, U5 Differential Bus Transceivers

571-1-390261-2 2 IC Socket, 8 pin (for U4 & U5)

579-PIC16F688-I/P 3 U6-U8 PIC Microcontroller

571-1-390261-3 3 IC Socket, 14 pin (for U6-U8)

859-MOC3023 24 M1-M24 Optoisolator, Triac Driver

571-1-390261-1 25 IC Socket, 6 pin (for U2, M1-M24)

511-BTA04-700T 24 T1-T24 Triac, 4A 700V

291-750-RC 2 R1, R2 Resistor, Carbon Film 750 ohms 1/4W 5%

291-120-RC 1 R3 Resistor, Carbon Film 120 ohms 1/4W 5%

299-1K-RC 2 R4, R7 Resistor, Carbon Film 1K ohms 1/8W 5%

299-27K-RC 3 R5, R8, R9 Resistor, Carbon Film 27K ohms 1/8W 5%

299-680-RC 25 R6, R10-R33 Resistor, Carbon Film 680 ohms 1/8W 5%

291-180-RC 24 R34-R57 Resistor, Carbon Film 180 ohms 1/4W 5%

264-330-RC 1 RN1 Resistor Network, 6 pin, 330ohms 2%

625-1N5817-E3 4 D1-D4 Diode

78-1N5239B 1 D6 Diode, Zener 9.1V .5W

78-1N5229B 1 D5 Diode, Zener 4.3V .5W

604-WP7104IT 2 FE, OE LED, 3mm Red

604-WP7104GT 4PWR, HB, ZC,

SDLED, 3mm Green

647-UVR1C222MHD1TO 1 C1 Radial Electrolytic Capacitor 16V 2200uF 20%

647-UVR1C470MDD1TD 1 C2 Radial Electrolytic Capacitor 16V 47uF 20%


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80-C322C104K5R 3 C3-C5 Capacitor, Radial Ceramic 50V 0.1uF

571-2828372 24Channel

TerminalsTerminal Block, 2 Pos 5.08 mm

571-7969492 2Power

TerminalsTerminal Block, 2 Pos 5.08 mm

152-3409 1 JDP1 D-Sub Connectors, Right Angle DE9

571-5556416-1 2 J1, J2 Jack, Modular RJ45 PCB Mount Top Entry

538-22-03-2021 3 JP1-JP3 Header, 2 Pin

151-8000 3 Shunt

504-GMA-10 2 F1, F2 Fuse, Fast Acting 10A

534-3517 4 Holder, Fuse Clip PCB mount 5mm

534-3527C 2 Cover, Fuse

838-3FS-312 1 TF1Power Transformers [email protected] [email protected] SinglePrimary

Below is the same parts list as above but it is formatted for direct importing into the Mouser BOM feature. Just copy andpaste the list as is.

511-LF50CV|1532-577102B00|1782-H11AA1|1520-TCH1843-X|1511-ST485BN|2571-1-390261-2|2579-PIC16F688-I/P|3571-1-390261-3|3859-MOC3023|24571-1-390261-1|25511-BTA04-700T|24291-750-RC|2291-120-RC|1299-1K-RC|2299-27K-RC|3299-680-RC|25291-180-RC|24264-330-RC|1625-1N5817-E3|478-1N5239B|178-1N5229B|1604-WP7104IT|2604-WP7104GT|4647-UVR1C222MHD1TO|1647-UVR1C470MDD1TD|180-C322C104K5R|3571-2828372|24571-7969492|2152-3409|1571-5556416-1|2


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538-22-03-2021|3151-8000|3504-GMA-10|2534-3517|4534-3527C|2838-3FS-312|1

The Renard SS24 Controller Board

Beginners Setup Guide The Renard SS24

Troubleshooting Guide The Renard SS24

Board Availability Information (http://doityourselfchristmas.com/forums/showthread.php?6664-The-Renard-SS-24-is-now-available!-(first-post-is-current-2-19-2011))

Renard Main Page

Renard Firmware

Part Substitutions

VIXEN

Glossary of DIYC Terms

Electronic Symbols (http://en.wikipedia.org/wiki/Electronic_symbol)

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This page was last modified on 27 May 2011, at 21:30.


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assembly instructions the renard ss24 - do it yourself christmas

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