Qube Solutions PiXtend V1.3 Full Instructions for use

PiXtend
Construction manual: PiXtend V1.3 Full
Kit Assembly
Construction manual
PiXtend V1.3 Full Kit Assembly
Qube Solutions UG (limited liability)
Arbachtalstr. 6, 72800 ningen, G RMANY
http://www.qube-solutions.de/
http://www.pixtend.de
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Stand 15.08.2016, V1.03

PiXtend
Construction manual: PiXtend V1.3 Full
Kit Assembly
This product was developed and produced in accordance with the uropean directives on
the subject and therefore carries the C sign. The authorized use of the product is
described in this data sheet and the belonging assembly- and operating manuals.
Warning:
Changes or modifications of the product, as well as the non-compliance of the statements
from the mentioned data sheets and operating manuals leads to loss of the approval for
the uropean economic area.
The symbol with the crossed out waste bin means, that the product should be recycled
separated to the domestic waste as electronic waste. Where you find the next free
acceptance place, will tell you your local administration.
Another possibility is that you send your device back to us and we take care about the
correct disposal for you.
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PiXtend
Construction manual: PiXtend V1.3 Full
Kit Assembly
Table of contents
1. Introduction & Common.....................................................................................................6
1.1 Scope of delivery.........................................................................................................6
1.2 Component overview.................................................................................................15
1.3 Technical aids and tools.............................................................................................17
1.4 Important information!................................................................................................19
2. Assembling and soldering................................................................................................20
2.1 IC-Socket...................................................................................................................22
2.2 Light emitting diodes (L Ds).....................................................................................25
2.3 Resistors and Potentiometer.....................................................................................30
2.4 Pin header for Jumper...............................................................................................37
2.5 Diodes........................................................................................................................40
2.6 Crystals......................................................................................................................43
2.7 Capacitors..................................................................................................................44
2.8 Poly fuse....................................................................................................................48
2.9 Small Transistors.......................................................................................................49
2.10 Big Transistors.........................................................................................................51
2.11 Ferrite / Inductance..................................................................................................53
2.12 Voltage regulator and cooling element....................................................................55
2.13 Plug connectors and clamping strips.......................................................................59
2.14 Relays......................................................................................................................60
2.15 Assembly of the integrated circuits (ICs).................................................................62
2.16 Rotation axes...........................................................................................................64
2.17 Battery......................................................................................................................65
2.18 Spacers and screw joints.........................................................................................67
2.19 Jumper.....................................................................................................................68
3. Connecting PiXtend and Raspberry Pi............................................................................71
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PiXtend
Construction manual: PiXtend V1.3 Full
Kit Assembly
Table of Figures
Figure 1: Components of the PiXtend V1.3 Full assembly kit.........................................................................15
Figure 2: Technical aids and tools................................................................................................................... 17
Figure 3: Usable soldering heads................................................................................................................... 18
Figure 4: Mounting direction of the IC-Sockets............................................................................................... 22
Figure 5: Fixing the IC-Sockets before the soldering......................................................................................23
Figure 6: All IC-Sockets fixed.......................................................................................................................... 23
Figure 7: IC-Sockets overlie flat...................................................................................................................... 24
Figure 8: Alignment of the L Ds..................................................................................................................... 25
Figure 9: L D-connection wires bent.............................................................................................................. 26
Figure 10: L Ds crooked soldered................................................................................................................. 26
Figure 11: Aligning of the L Ds....................................................................................................................... 27
Figure 12: L Ds straight aligned..................................................................................................................... 27
Figure 13: Shorten the connection wires.........................................................................................................28
Figure 14: Sockets and L Ds mounted..........................................................................................................29
Figure 15: "Jacking up" the circuit board......................................................................................................... 30
Figure 16: Preparing the resistors................................................................................................................... 30
Figure 17: Resistors mounted......................................................................................................................... 31
Figure 18: 47 kΩ - yellow, violet, black, rot, brown.......................................................................................... 32
Figure 19: 30 kΩ – orange, black, black, rot, brown........................................................................................32
Figure 20: 10 kΩ – brown, black, black, rot, brown.........................................................................................32
Figure 21: 3,3 kΩ - orange, orange, black, brown, brown...............................................................................32
Figure 22: 1,21 kΩ - brown, rot, brown, brown, brown....................................................................................32
Figure 23: 680 Ω - blue, grey, black, black, brown..........................................................................................33
Figure 24: 470 Ω – yellow, violet, black, black, brown.....................................................................................33
Figure 25: 270 Ω - red, violet, black, black, brown.......................................................................................... 33
Figure 26: 120 Ω - brown, red, black, black, brown.........................................................................................33
Figure 27: 47 Ω - yellow, violet, black, gold, brown......................................................................................... 33
Figure 28: 20 Ω 0.1% - red, black, black, gold, violet......................................................................................33
Figure 29: Fixing of the resistors..................................................................................................................... 34
Figure 30: Placing resistors............................................................................................................................ 35
Figure 31: Good soldering joints..................................................................................................................... 35
Figure 32: Placement of the Potentiometers................................................................................................... 36
Figure 33: PiXtend – Resistors and potentiometers mounted.........................................................................36
Figure 34: 36-pole pin header and flat pliers................................................................................................... 37
Figure 35: Needed Jumper blocks.................................................................................................................. 38
Figure 36: Bending aid as help for soldering the pin headers.........................................................................38
Figure 37: Correct resting pin header............................................................................................................. 39
Figure 38: Diodes in overview......................................................................................................................... 40
Figure 39: Bending of the diodes with bending aid.........................................................................................41
Figure 40: Right mounting direction of a diode............................................................................................... 41
Figure 41: Help at placing the diodes............................................................................................................. 42
Figure 42: LM4040-diode preparation............................................................................................................. 42
Figure 43: Clock crystal XTAL3....................................................................................................................... 43
Figure 44: 16 MHz XTAL1 for the PiXtend- Controller....................................................................................43
Figure 45: lectrolyte capacitors in overview.................................................................................................. 44
Figure 46: Polarity of the electrolyte capacitors.............................................................................................. 44
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PiXtend
Construction manual: PiXtend V1.3 Full
Kit Assembly
Figure 47: Preparation of the lectrolyte capacitor C9...................................................................................45
Figure 48: lectrolyte capacitors C9 mounted................................................................................................45
Figure 49: Ceramic capacitors in overview..................................................................................................... 46
Figure 50: Avoiding of tilting movement.......................................................................................................... 47
Figure 51: Progress of the circuit board.......................................................................................................... 47
Figure 52: Poly fuses in overview................................................................................................................... 48
Figure 53: Variants of the TO92-housing........................................................................................................49
Figure 54: Orientation of the small transistors................................................................................................ 50
Figure 55: Big Transistors............................................................................................................................... 51
Figure 56: Bending the connection wires of the transistors.............................................................................52
Figure 57: Positioning of the big transistors.................................................................................................... 52
Figure 58: Montage of the Ferrite................................................................................................................... 53
Figure 59: Assembly of the coil....................................................................................................................... 53
Figure 60: Coil mounted correct...................................................................................................................... 54
Figure 61: Bending the connection wires........................................................................................................ 55
Figure 62: Connection wires bent................................................................................................................... 55
Figure 63: Applying the heat-conducting paste............................................................................................... 56
Figure 64: Voltage regulator with cooling element..........................................................................................57
Figure 65: Voltage regulator mounted............................................................................................................. 58
Figure 66: Montage of the clamping strips...................................................................................................... 59
Figure 67: Position of the Relays.................................................................................................................... 60
Figure 68: PiXtend – nearly ready.................................................................................................................. 61
Figure 69: Preparation of the ICs.................................................................................................................... 62
Figure 70: Correct positioning of an IC with notch.......................................................................................... 63
Figure 71: Correct positioning of an IC with point........................................................................................... 63
Figure 72: Montage of the rotation axes......................................................................................................... 64
Figure 73: Check of the soldering joints..........................................................................................................65
Figure 74: Battery mounted............................................................................................................................ 66
Figure 75: Montage of the spacers................................................................................................................. 67
Figure 76: Jumper "SPI_ N".......................................................................................................................... 68
Figure 77: PiXtend ready for the marriage...................................................................................................... 70
Figure 78: Plugging the flat ribbon cable to the PiXtend.................................................................................71
Figure 79: PiXtend mounted on Raspberry Pi................................................................................................. 72
Figure 80: Flat ribbon cable connected to the Raspberry Pi...........................................................................73
Figure 81: PiXtend with Raspberry Pi Model 2 B – Assembly finished...........................................................74
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PiXtend
Construction manual: PiXtend V1.3 Full
Kit Assembly
1. Introduction & Common
We are appy t at you decided for PiXtend!
The available construction instruction guides you, step by step, from the assembly kit to
the complete device. We wish you a lot of fun for the assembly and the usage of your own
controlling platform.
1.1 Scope of delivery
Once the assembly kit arrives, please check if all components of the following list are
included. Please mind that it is only the components for the PiXtend assembly kit and not
the optional accessories.
Information to optional accessories (manuals, part lists, …) you can find in our download
area on our homepage:http://www.pixtend.de/downloads/
A optical overview over all included components and therefore a help for the a check for
completeness gives figure 1.
We recommend to print the overview of all components in tabulator form (incl.
Numbering from side 7 and the placement plan on side 13. All mentioned sides will
be needed several times while assembling.
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PiXtend
Construction manual: PiXtend V1.3 Full
Kit Assembly
Labelling
(on the board Count Description Value
C1, C4, C6, C10, C12, C13,
C16, C20, C23, C24, C27,
C41
12 Ceramic capacitor, RM 5.08 mm 100 nF
C5, C33, C34, C35, C36,
C37, C38, C39, C40, C44,
C45, C46, C47, C48, C49
15 Ceramic capacitor, RM 5.08 mm 33 nF
C15, C28, C29, C31, C32,
C42, C43 7 Ceramic capacitor, RM 2.54 mm 1 nF
C2, C3, C7, C8, C21, C22 6 Ceramic capacitor, RM 5.08 mm 22 pF
C9 1 lectrolyte capacitor radial
RM 5.08 mm 1000 μF / 35 V
C14, C17 2 lectrolyte capacitor radial
RM 5.08 mm 1000 μF / 10 V
C30 1 lectrolyte capacitor radial
RM 3.5 mm 100 μF / 35 V
C11, C18, C19, C25, C26 5 lectrolyte capacitor radial
RM 2.54 mm 1 μF / 50 V
D1 1 Precision-Z-Diode LM4040CIZ, TO92 5 V, 0.1%
D2 1 Transil diode P6K 36CA, RM 12.7
mm 36 V
D3, D4 2 Schottky-Diode SB340 / 1N5822
RM 15.24 mm 3 A
D5, D6, D7, D8, D9, D10,
D11, D12, D13, D14, D15,
D16
12 Diode 1N4004, RM 10.16 mm 1 A
D17, D18, D19, D20, D21,
D22 6 Schottky-Diode BAT41, RM 7.62 mm 0,25 A
F1, F2, F3, F4, F5, F6 6 Poly fuse / Multi fuse, RM 5.08 mm 3 A
F7, F8 2 Poly fuse / Multi fuse, RM 5.08 mm 100 mA
F9, F10 2 Poly fuse / Multi fuse, RM 5.08 mm 50 mA
G1 1 Lithium-Battery CR2025, standing 170 mAh, 3 Pin
IC1 1 Atmel ATmega32A-PU, Microcontroller 40 Pin, DIP
IC2 1 LM2576T-5, Switching regulator TO220-5
IC3 1 MAX485-CPA, Transceiver, RS485 8 Pin, DIP
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PiXtend
Construction manual: PiXtend V1.3 Full
Kit Assembly
Labelling
(on the board Count Description Value
IC4 1 MAX232-CP , Level Converter RS232 16 Pin, DIP
IC5 1 DS1307(+), RTC 8 Pin, DIP
IC6 1 74HC157, Quad 2 Channel Multiplexer 16 Pin, DIP
IC7 1
Microchip
MCP4812- /P, Dual- DAC
Digital- Analogue- Converter
8 Pin, DIP
IC8, IC9 2 LM358A, Dual- Operational amplifier 8 Pin, DIP
KK1 1 Fischer lectronic
U-Cooling element, SK 13/35 35x17x13 mm
U1 1 Microchip
MCP2515-I/P, CAN-Controller 18 Pin, DIP
U2 1 Microchip
MCP2551-I/P, CAN-Transceiver 8 Pin, DIP
V1, V2 2 74HCT126N, CMOS Quad Buffer 14 Pin, DIP
JP1 1 Female connector, dual-rowed, 2,54
mm 2x4 Pole
JP2 1 Pin header, dual-rowed, 2.54 mm 2x13 Pole
JP10, J11, J12, J13, J14,
J15, J16, J17 1Pin header, 2.54 mm Note:
there are 2x36pol
pin headers
included, which
get cut in two
pieces at
assembly!
1x24 Pole
JP18, JP19 1 Pin header, 2.54
mm 1x6 Pole
JP4, JP5, JP6, JP7, JP8,
JP9 6Pin header, 2.54 mm 1x3 Pole
JP3 1 Pin header, 2.54
mm 1x2 Pole
K1, K2, K3, K4 4 Fujitsu FTR-K1CK005W, Relay 1x Changer (SPDT)
L1 1 Ferrite core, inductance, axial 10 μH
L2 1
Standing Inductance, Storage choke
Würth 7447480101
Fastron 09HCP
100 μH
L D1, L D2, L D3, L D4,
L D5, L D6, L D7, L D8,
L D9, L D10, L D11,
L D12, L D13, L D14,
L D15, L D16, L D17,
L D18, L D19
19 Standard-L D, 2.54 mm 3 mm, green
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PiXtend
Construction manual: PiXtend V1.3 Full
Kit Assembly
Labelling
(on the board Count Description Value
Q1, Q2, Q3, Q4, Q5, Q8,
Q9, Q12, Q13 9
Small Signal- MOSF T- Transistor,
TO92
2N7000(A)
N-Channel
0.2 A, 60V
Q6, Q7, Q10, Q11, Q14, Q15 6
Power- MOSF T- Transistor, TO220
International Rectifier IRFZ44N,
55 V, 41 A
N-Channel
R60, R62 2 Potentiometer, lying, 9 mm 25 kΩ
R4 1 Metal layer-resistor 1/4 W, 0207 47 kΩ, 1 %
R2, R64 R65, R66, R67,
R84, R85, R86, R87, R102,
R104
11 Metal layer-resistor 1/4 W, 0207 30 kΩ, 1 %
R1, R3, R10, R20, R21,
R22, R25, R26, R27, R28,
R29, R30, R31, R32, R33,
R38, R39, R40, R41, R46,
R47, R48, R49, R52, R53,
R61, R63, R106, R107,
R108, R109, R112, R113,
R114, R115
35 Metal layer-resistor 1/4 W, 0207 10 kΩ, 1 %
R103, R105 2 Metal layer-resistor 1/4 W, 0207 3.3 kΩ, 1 %
R15, R16, R17, R18, R19,
R23, R24, R72, R73, R74,
R75, R76, R77, R78, R79,
R92, R93, R94, R95, R96,
R97, R98, R99
23 Metal layer-resistor 1/4 W, 0207 1.21 kΩ, 1 %
R6, R7, R11, R12, R13, R14,
R100, R101 8 Metal layer-resistor 1/4 W, 0207 680 Ω, 1 %
R8, R34, R35, R36, R37,
R42, R43, R44, R45, R50,
R51, R68, R69, R70, R71,
R88, R89, R90, R91
19 Metal layer-resistor 1/4 W, 0207 470 Ω, 1 %
R54, R55, R80, R81, R82,
R83 6 Metal layer-resistor 1/4 W, 0207 270 Ω, 1 %
R5, R9 2 Metal layer-resistor 1/4 W, 0207 120 Ω, 1 %
R56, R57, R58, R59 4 Metal layer-resistor 1/4 W, 0207 47 Ω, 1 %
R110, R111 2 Metal layer-resistor 1/4 W, 0207 20 Ω, 0.1 %
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PiXtend
Construction manual: PiXtend V1.3 Full
Kit Assembly
Labelling
(on the board Count Description Value
SV1 1 Tub connector, standing 26 Pole
SV2 1 Tub connector, standing 10 Pole
X1 1 Clamping strip RM 5.0 mm, 250-502 2-pole
X2, X7, X8, X10 4 Clamping strip RM 3.5 mm, 250-206 6-pole
X3 1 Clamping strip RM 3.5 mm, 250-203 3-pole
X4 1 Clamping strip RM 5.0 mm, 250-510 10-pole
X5, X6 2 Clamping strip RM 5.0 mm, 250-506 6-pole
X9 1 Clamping strip RM 3.5 mm, 250-208 8-pole
XTAL1 1 Piezoelectric crystal, HC49U-S 16 MHz
XTAL2 1 Piezoelectric crystal, HC49U-S 20 MHz
XTAL3 1 Piezoelectric crystal, Clock crystal,
TC38 32.768 kHz
1 IC-Socket for IC1 40 Pole
1 IC-Socket for U1 18 Pole
2 IC-Socket for IC4, IC6 16 Pole
2 IC-Socket for V1, V2 14 Pole
6IC-Socket for
U2, IC3, IC5, IC7, IC8, IC9 8 Pole
1 PiXtend V1.3 Circuit board 231.5 x 107.5 x 1.6 mm
16 Jumper with handle, 2.54 mm black
1Flat ribbon cable 26 Pole,
AWG28 / RM 1.27 mm, 4.5 cm
pre-assembled!
1
Post connector 26 Pole for
AWG28 / RM 1.27 mm Flat ribbon
cable
1
Post connector 40 Pole for
AWG28 / RM 1.27 mm Flat ribbon
cable
2 Quick-release axle for Potentiometer
4 Spacers M2.5 x 25 mm
4Spacers with external thread M2.5 x 5 mm
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PiXtend
Construction manual: PiXtend V1.3 Full
Kit Assembly
Labelling
(on the board Count Description Value
8Spacers with external thread M3x5 mm
8 Spacers M3x15 mm
4 Screw, cross recess M2.5x6 mm
1 Screw, spacers M3x6 mm
1 Heat-conducting paste 1 g
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PiXtend
Construction manual: PiXtend V1.3 Full
Kit Assembly
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PiXtend
Construction manual: PiXtend V1.3 Full
Kit Assembly
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PiXtend
Construction manual: PiXtend V1.3 Full
Kit Assembly
We check every assembly kit before delivery (visual inspection, weight check). If
nevertheless a part should be missing so write us an email (i[email protected]) and we look
immediately that you get a free forwarding.
Please do not send back the whole PiXtend kit, if only one part is missing. This will only
delay your project and causes expenses and costs for us. Thank you!
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PiXtend
Construction manual: PiXtend V1.3 Full
Kit Assembly
1.2 Component overview
Figure 1 gives an overview over all components included in the assembly kit. Labelling,
values and quantities are shown in the previous list.
1. lectrolyte capacitors
2. Poly fuses
3. Ceramic capacitors
4. Resistors
5. Potentiometer & rotation axes
6. Heat- conducting paste
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Figure 1: Components of the PiXtend V1.3 Full assembly kit
1
2
3
4
5
6
7
8
9
10 11 12
13
14
15 16
17 18
19 20
21 22 23

PiXtend
Construction manual: PiXtend V1.3 Full
Kit Assembly
7. Lithium- Battery
8. Pin headers and tub connectors
9. PiXtend- board
10.Power transistors
11. Integrated circuits (ICs) and IC-Sockets
12.Diodes and light emitting diodes (L Ds)
13.Cooling elements
14.Pre-assembled flat ribbon cable with 26/40-pole connectors
15.Clamping strips
16.Relays
17.Voltage regulators
18.Ferrite (looks like a oversized resistor) and coil
19.Metal- spacers
20.Screws
21.Jumper
22.Small signal- transistors
23.crystals
Please consider:
The colour and form of small parts can change. We can't guarantee that the components
will always look the same as in the overview picture or in the following pictures of the
manual.
But the components can be separated by the includes count of pieces or the labelling of
the components. If available, the components can be tested and measured with a
multimeter.
If you don't have a multimeter and you are not sure with a component so we will help you
with pleasure. -Mail to: [email protected]
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PiXtend
Construction manual: PiXtend V1.3 Full
Kit Assembly
1.3 Tec nical aids and tools
1. Cutter (small)
2. Needle-nosed pliers / Flat nose pliers (small)
3. Bending aid (for resistors, capacitors etc.) (optional)
4. Cross recess screw driver
5. Slotted screwdriver
6. Desoldering wick
7. Solder (Ø 0,5 mm – 1 mm)
Furt ermore it is needed a soldering iron wit a ead w ic is t in enoug to
solder circuit boards. Usable soldering eads are s own in Figure 3.
A common multimeter is not urgently needed, but helpful. specially at finding failures and
differentiate the components (for example resistors).
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Figure 2: Technical aids and tools
1 2
345
67

PiXtend
Construction manual: PiXtend V1.3 Full
Kit Assembly
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Figure 3: Usable soldering heads

PiXtend
Construction manual: PiXtend V1.3 Full
Kit Assembly
1.4 Important information!
Please consider always the assembly- and safety instructions of the
manual in further process, which are signed with the yellow
warnings sign.
•Always use the the recommended tools and technical aids for the preparation- and
assembly steps.
•Before you are forming, soldering, assembling or changing the components in any
other way, please be sure that the steps of the construction manual are completely
read and understood. If the components once are changed or soldered an
exchange or return is impossible.
•Please do all soldering, forming and wiring conscientiously. The result will pay your
effort!
•And please read too the safety information in the PiXtend- datasheet and the
printed safety instructions, which are included in the assembly kit.
•If the assembly- and operation manuals as well as the technical datasheet are not
respected, the approval for the uropean economic area (C -conformity) is lost.
Please adhere to the instructions and read all provided information before you put
the PiXtend in operation.
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PiXtend
Construction manual: PiXtend V1.3 Full
Kit Assembly
2. Assembling and soldering
If you have read the safety- and assembly instructions and checked the completeness of
the components with help of the part list and the overview picture, then it can be started
with the assembly.
For the soldering and assembly works, depending on the manual dexterity, about 4 hours
will be needed. Take enough time to avoid careless mistakes and the consequential
rework.
We recommend the following order at placing and soldering.
1. IC-Socket
2. Light emitting diodes (L Ds)
3. Resistors and Potentiometer
4. Pin headers for Jumper
5. Diodes
6. Crystals
7. Capacitors
8. Poly fuses
9. Small Transistors
10.Big Transistors
11. Ferrite and coil
12.Voltage regulators and cooling elements
13.Plug connectors and clamping strips
14.Relays
15.Assembly of the integrated circuits (ICs)
16.Rotation axes
17.Battery
18.Spacers and fittings
19.Setting jumper
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