Step
*=Orientation
!=Static Sensitive | Part | Qty | Location | Done | Description |
| 1*! | 1n5817-e3
Diode | 4 | D1-D4 | | Install four diodes D1 thru D4 (PN# 625-1N5817-E3). The diodes will have a silver/grey stripe on a black body. Make sure that this stripe lines up with the stripe on the PCB silk screen (to the left). |
| 2 | 750 ohm
Resistor | 2 | R1,R2 | | Install two 750 ohm resistors R1 & R2 (PN# 291-750-RC). Make sure that the resistors have a value of 750 ohms (violet/green/brown/gold stripes). These resistors have no polarity to worry about |
| 3 | 120 ohm
Resistor | 1 | R3 | | Install the 120 ohm resistor R3 (PN# 291-120-RC). Make sure that the resistor has a value of 120 ohms (brown/red/brown/gold stripes). This resistor have no polarity to worry about. |
| 4 | 1K ohm
Resistor | 2 | R4, R7 | | Install two 1K ohm resistors R4, R7 (PN# 299-1K-RC). Make sure that the resistors have a value of 1K ohm (brown/black/red/gold stripes). These resistors have no polarity to worry about. |
| 5 | 27K ohm
Resistor | 3 | R5, R8, R9 | | Install three 27K ohm resistors R5, R8, R9 (PN# 299-27K-RC). Make sure that the resistors have a value of 27K ohms (red/violet/orange/gold stripes). These resistors have no polarity to worry about. |
| 6*! | 4.3V
Zener | 1 | D5 | | Install zener diode D5 (PN# 78-1N5229B). The diode must be installed correctly. The diode should have a black stripe on the orange/red body. Make sure that this stripe lines up with the stripe on the PCB silkscreen (to the left). *Beware that this part and D6 may be mislabeled. The initial instructions had them swapped. When in doubt, use the actual part numbers shown here. |
| 7*! | 9.1V
Zener | 1 | D6 | | Install zener diode D6 (PN# 78-1N5239B). The diode must be installed correctly. The diode should have a black stripe on the orange/red body. Make sure that this stripe lines up with the stripe on the PCB silkscreen (to the right). *Beware that this part and D5 may be mislabeled. The initial instructions had them swapped. When in doubt, use the actual part numbers shown here. |
| 8 | 680 ohm
Resistor | 17 | R6, R10-R25 | | Install 17 680 ohm resistors R6, R10 thru R25 (PN# 299-680-RC). Make sure that the resistors have a value of 680 ohms (blue/grey/brown/gold stripes). These resistors have no polarity to worry about. |
| 9 | 180 ohm
Resistor | 16 | R26-R41 | | Install 16 180 ohm resistors R26 thru R41 (PN# 291-180-RC). Make sure that the resistors have a value of 180 ohms (brown/grey/brown/gold stripes). These resistors have no polarity to worry about. |
| 10 | 0.1 uF
Cap | 2 | C3,C4 | | Install two 0.1uF capacitors C3,C4(PN# 80-C322C104K5R). This capacitor has no polarity to worry about. |
| 11* | 330 ohm
Res Network | 1 | RN1 | | Install the 330 ohm resistor network RN1 (PN# 264-330-RC). The resistor network should have a dot on it to indicate pin 1. Insert pin 1 of the resistor network into the square solder pad (to the left). |
| 12* | Green
LED | 4 | PWR, HB, ZC, SD | | Install four green LEDs PWR, HB, ZC & SD (PN# 604-WP7104GT). The LEDs are polarized and must be installed correctly. The short lead is the cathode and must be placed in the square solder pad. |
| 13* | Red
LED | 2 | FE, OE | | Install two red LEDs FE & OE (PN# 604-WP7104IT). The LEDs are polarized and must be installed correctly. The short lead is the cathode and must be placed in the square solder pad. |
| 14 | 2 Pin
Header & Jumper | 3 | JP1-JP3 | | Install three 2-pin vertical headers JP1, JP2 & JP3 (PN# 538-22-03-2021). These headers have no polarity to worry about. Add 1 jumper to each. |
| 15* | Clock
Oscillator | 1 | U3 | | Install the clock oscillator U3 (PN# 520-TCH1843-X). The oscillator must be installed in the correct orientation. The oscillator has three rounded corners and one squared corner, make sure that the squared corner is positioned to match the PCB silkscreen (upper left corner). |
| 16* | Voltage
Regulator | 1 | U1 | | Install the voltage regulator U1 (PN# 511-LF50CV). The voltage regulator must be installed correctly. The voltage regulators tab/heat sink must be aligned with wider line of the PCB silkscreen outline (facing toward the PCB top edge). |
| 17* | 2200uF
Elec Cap | 1 | C1 | | Install the 2200uF capacitor C1 (PN# 140-XRL16V2200-RC). This capacitor is polarized and must be installed correctly. The capacitor should have a black stripe on the body to indicate which lead is negative. The positive lead of the capacitor will be the longer lead. Make sure that the positive lead is placed in the square solder pad. |
| 18* | 47uF
Elec Cap | 1 | C2 | | Install the 47uF capacitor C2 (PN# 647-UVR1C470MDD). This capacitor is polarized and must be installed correctly. The capacitor should have a silver/grey stripe on the body to indicate which lead is negative. The positive lead of the capacitor will be the longer lead. Make sure that the positive lead is placed in the square solder pad. |
| 19 | Fuse
Clips | 4 | F1, F2 | | Install four fuse clips (PN# 534-3517). |
| 20* | 8 Pin
Socket | 2 | U4, U5 | | Pin 1 of the following IC sockets must be aligned with the square solder pad. Another way to verify that you installed them correctly is to make sure that the notch on the socket is aligned with the notch on the PCB silkscreen outline. Install two 8-pin IC sockets for U4 & U5 (PN# 571-1-390261-2). |
| 21* | 14 Pin
Socket | 2 | U6,U7 | | Install two 14-pin IC sockets for U6, U7 (PN# 571-1-390261-3). |
| 22* | 6 Pin
Socket | 17 | U2, M1-M16 | | Install 17 6-pin IC sockets for U2, M1 thru M16 (PN# 571-1-390261-1). |
| 23*! | 4A
Triac | 16 | T1-T16 | | Install 16 triacs T1 thru T16 (PN# 511-BTA04-700T). The triacs must be installed correctly. The triac tab/heat sink must be aligned with wider line of the PCB silkscreen outline. The Tab/heat sink of the odd numbered triacs will be facing the even numbered triacs and vice versa. |
| 24 | Green
Terminal | 16 | CH1-CH8, CH9-CH16 | | Install 16 terminal blocks for Ch1 thru Ch16 (PN# 571-2828372). These terminal blocks have a small interlocking tab that allows the terminals to be "stacked" together to create a larger terminal block. It is easier to go ahead and "stack" 8 terminal blocks together first and then mount them on the PCB. |
| 25 | Black
Terminal | 2 | 2*N 120V | | Install two terminal blocks for 120V input (PN# 571-7969492). |
| 26 | 120V
Transformer | 1 | TF1 | | Install the transformer TF1 (PN# 838-3FS-316). |
| 27 | RJ45
Jacks | 2 | J1, J2 | | Install two RJ45 modular jacks J1 & J2 (PN# 571-5556416-1). Due to minor variations in manufacturing, some RJ45 jacks are a tighter fit than others. Care should be taken to ensure that the pins are aligned first before applying too much pressure to seat the locking lugs through the board. |
| 28 | DB9
Jack | 1 | JDP1 | | Install the DB9 connector JDP1 (PN# 152-3409). |
**STOP** - Test the board NOW, before inserting any chips!!!!
|
**STOP** - Program PICs NOW, before installation
|
| 29*! | Bi-Directional
Optocoupler | 1 | U2 | | Pin 1 of each IC must be aligned with pin 1 of the corresponding socket. This can be verified by noting that the notch on the IC is aligned with the notch on the socket. Install the H11AA1 optocoupler U2 (PN# 782-H11AA1). |
| 30*! | 16F688
PIC | 2 | U6,U7 | | Install two PIC microcontrollers U6, U7 (PN# 579-PIC16F688-I/P). |
| 31*! | RS485
Interface | 2 | U4, U5 | | Install two RS232/RS485 Interface ICs U4 & U5 (PN# 511-ST485BN). |
| 32*! | MOC3023
OptoIsolator | 16 | M1-M16 | | Install 16 optoisolators M1 thru M16 (PN# 859-MOC3023). |
| 33 | Heat
Sink | 1 | U1 | | Install the heat sink (PN# 532-577102B00) on voltage regulator U1. The mounting hardware and heat transfer compound are not included in the BOM since any common hardware can be used to attach the heat sink. If you don't have any heat transfer compound handy, you can use PN# 532-249. In the picture the heat sink is attached using a #8 x 3/8" metal screw found at home depot. |
| 34 | Fuses &
Covers | 2 | F1 | | Install two fuses (PN# 504-GMA-10) and two fuse covers (PN# 534-3527C). |
