There were two boards made for this counter. Note the location of the 220 ohm resistors and click the picture of your board for instructions. |
Soldering TipsThe best soldering tip is use is a very narrow one. Check for pictures of some tips. A temperature regulated iron is the best to use. Plated Through HolesThis PCB uses plated through holes. It is very difficult to remove parts from plated through holes unless you can remove one lead at a time. This means double checking all multiple pin parts (ICs, oscillator, voltage regulator, transistors) BEFORE soldering! If you solder a part and realize it is in wrong, you have to cut all the pins off the part to get it out, which means getting a new replacement. Email and I will help with a new part. Fitting/Soldering The ICsThe ICs have their pins flared out slightly. They will not fit into the board without a little adjustment. The pins need to be gently pushed in so they are straight down. This can be done with your fingers on each side of the IC pushing inward toward the middle of the IC. Go slow, check until they fit. Hold the IC against the board with one finger, get some solder on the solder tip, then tack one lead of the IC to the board. Next, set the board down and solder another pin to the board feeding solder to the tip and pin and get a good solder joint. With your finger against the top of the IC, holding it against the board, reheat both soldered pins to get the IC firmly against the board. Finally, solder the rest of the pins. Large Soldering TipsWhen using a solder tip larger than what is recommended, the best way to make it work is to start by placing the solder tip ABOVE the hole on the lead, get solder to flow on the lead adding some solder to the soldering tip and lead. Then move the tip down to the hole, keeping the tip against the lead, add a little more solder. The solder should be seen going into hole. If you have a small round blob on top of the hole, try again, and check the top of the board to see if the solder has flowed through the hole. To Cut or Not to Cut the BoardThe board can be cut into two boards through the rows of holes in the middle of the PCB. See below. Tin snips work well for cutting the board. It is recommended to start cutting as shown on the right side, as shown above, (when the board is populated) to prevent damaging the 6.8K resistor near the holes on the right side.Cutting the board now, before populating the board, is a lot easier. However, you can change your mind later. If tin snips are not available, a straight edge (i.e., a ruler) and a utility knife can be used to score both sides of the board through the holes. Go as deeply as you have patience for, then break apart. If you are planning to mount the frequency counter between Board 1 and the bottom unetched PCB the boards need to be cut. If you plan on building a case for the receiver and mounting the frequency counter on the front face, then you may not need to cut the boards depending on your design. Also, other projects may not require the boards to be cut. |
Check Fix on the PCBIt is so hard to make the perfect board; this one is no exception. Line "G" on the PIC board was extended so it shorted the 220 ohm resistor taking it out of the circuit. Two problems resulted, a very bright "G" segment and it blew out the 4077 IC chip. The fix is to cut the "G" segment line just above the bottom connection to the 220 resistor. This fix will be done before the boards are shipped, but it is a good idea to double check this fix before stuffing the board. With a DVM on ohms, check for no connection between the "G" line resistor pads. Arrows show where the leads of the DVM go to check fix.
Picture showing the fix on the bottom side of the board and pads to place the DVM leads to check the fix.
If you do get a connection between the two points, use a sharp knife, razor blade, or some appropriate instrument to make sure there is no connection between the pads of the 220 ohm resistor. The location of the cut is important. The hole in the upper right of the small copper square of the fix must remained connected to the upper lead of the 220 resistor. If you get a board without the cut, make the cut in the same place as shown in the above picture. Step 1 - ResistorsThe footprints for the resistors have the value printed inside the footprint. Double check the value when inserting a resistor. Bend the leads of the 1/8 watt resistors about 1/16" from the body of the resistor to fit into the footprint. The leads of the 1/4 watt resistors are bent right against the body of the resistor. 1 - 10K, 1/8 watt, bend leads 1/16" from body 3 - 1K, 1/8 watt, bend leads 1/16" from body 4 - 100K, 1/8 watt, bend leads 1/16" from body 2 - 6.8K, 1/4 watt, gently bend leads against body 8 - 220 ohm, 1/4 watt, gently bend leads against body
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Step 2 - Diodes4 - 1N4148 diodes, bend leads 1/16" from body Make sure the black band on the diode is inserted the correct way. The wide white band on the footprint is where the black band should go on the diode. To double check, the bands should be opposite each other at each pair. Step 3 - Capacitors1 - .1 8 - .01, Note: Some kits may contain large .01 disc capacitors. Start on the left side of the board and work around the top edge to the left side to get them all.2 - .01 bottom side of board - Do not solder now! This picture shows the location on the top of the board where two .01s are soldered underneath the board.These will be put on the board in Step 8 after the ICs and 10 MHz oscillator have been soldered on the board. Step 4 - 2N3906 TransistorsThe kits have 7 - 2N3904s with straight leads for the LED cathode drivers and one flared (on a small piece of cardboard) for the crystal oscillator switch. It is not necessary to push the transistors against the PCB. The footprint for the transistors was necessary because of the tight fit between the traces for the LED readout. As a result, a slight offset of the center lead is needed to fit the transistors in the footprint. 7 - 2N3906 straight leads Insert 3 2N3906 in the top row. Notice the flat side of the transistor and match it to the footprint flat. Solder the lower row of pins first. Then clip those leads so there is better access to the top row of leads. Solder the remaining leads. Insert 4 2N3904 in the lower row. Match the flat of the transistor to the flat of the footprint. Solder the lower row of pins first. Then clip those leads so there is better access to the top row of leads. Solder the remaining leads.Check for solder bridges and bent wires shorting against adjacent pins after soldering and clipping all the transistor leads. Solder bridges can be easily removed by wiping the tip of the soldering gun between the pins. 1 - 2N3906 flared leads Cut the transistor from the cardboard and insert in the place indicated above by the yellow arrow. Step 5 - 7805 and 10MHz OscillatorThe 10 MHz oscillator can must have the dot in one corner at the lower left hand side as shown above in the picture. The dot is in the footprint and just outside so you can double check after the part is in place. The 7805 voltage regulator must have the front of the part toward the outside of the board. Also, the front side of the part should be pointed to the part number "7805". The metal heat sink for the 7805 is the back of the part and should be toward the center of the board. See picture above. Step 6 - PIC IC socket 28 pinThe one on the bottom left can easily be overlooked as there are other holes very close by. Step 7 - Solder 5 ICsThere are 2 ICs that require special attention. The first one is the 74AC151:Pin 5 on the 74AC151 is cut off. Pull the pin out from the IC as shown above and cut it off. Pay particular attention to the location of the notch on the IC. The picture above shows the location of the IC and the location where the pin is cut for. After the pin is cut insert into the board and solder.The second one is the 4077:It was a surprise to see this dot on the part at the wrong location! Insert this part according to the notch only! Ignore the dot.Next, insert and solder the 2 74HC4046 and the 4066:Be sure you have it right BEFORE you solder. Removing parts from plated through holes is very difficult.Step 8 - Solder two .01 capsIf you received large .01 disc capacitors with your kit, please click here for instructions. Click "Back" on your browser to return here. The leads of two .01 caps are cut to 1/8". Insert the caps into the pads and solder. May take a little effort. To make it easier, be sure the width of the leads match the holes before cutting them short.The Crystal Oscillator sets 1/8" above the PCB, enough to see if the leads of the cap are not touching the bottom of the oscillator. Double check to make sure the leads are clear of the oscillator. There is little worry with the PIC cap as it is all plastic above where the .01 cap goes.Step 9 - Solder the 7 LED displays |