Controller Kit 5We will install the 2n3704 transistors next.
The transistors do not sit right against the board, and have a flat side for ease of orientation.
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Installing the 2N3906 transistors
Same as above, just watch the orientation. |
Install the 1Uf caps.
The 1 uf caps sit right against the board, and will need to be soldered one at a time. Make then straight, or your board will not look very cool.I am sure you can do better than this. |
Installing the 4.7Uf caps, and the 100Uf cap
These caps are polarized, so make sure that the + and - leads are correct.The caps show a white band with an arrow pointing the the - end, and the board has a + next to the + pad. |
Installing the connectors
The lead spacing on the connectors is pretty close, so care must be taked to make good sound connections, without any shorts between the pins. The orientation of the connector is also important, so use the photo as a guide, by placing the notch the same as the photo.The MIMA disable connector with only two sockets, is pretty flimsy even when installed, so hot melt the connector after soldering, but do not get the hot melt into the relat sockets. It is ok to get hotmelt on the transistors. |
Installing the TIP 120 power transistors
Orient the transistors as shown, then add a little hot melt glue to help support them as shown. |
Installing the voltage regulator and heat sink.
The voltage regulator and heat sink will get warm during normal operation, so we will enhance the thermal conduction by making a heat sink grease sandwitch.First bend the LM7805 leads as shown, and make sure that when the leads are in the circuit board holes, that the mounting hole in the part lines up with the hole in the board. Spread a thin coating of the heat sink grease on the back side of the heat sink, and press it in position on the board. Spread more heat sink grease on the back of the LM 7805 regulators metal tab. Push the bent leads through the appropriate holes in the board, and fasten the whole assembly to the board with the supplied 6-32 screw and nut. Tighten firmly, while keeping the heat sink within the rectangular silk screen area.
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doing the etch cuts and board fix
The new boards have one error that will need to be fixed. The 21.5K and 30.9K resistors were forgotten in the schematic, so the board must be modified as detailed on this PDF.
board fix
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Cleaning the board, and Pluging in the rest of the parts
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To clean the MIMA card of excess soldering flux, wash the board completely with an old toothbrush and some alcohol. Get some denatured grain 100%, the good stuff.
Pull the relays and the fuse. Go easy with the alcohol around the little connector between the relay sockets, and don't wet the adjustment pot very much.
Wash the rear and front of your board by dipping the toothbrush into the alcohol, and washing all flux off of BOTH sides of the board.
The back side can be brushed until the alcohol does not turn dark. It will wash the flux off quickly, so you don't need much alcohol.
Let the boards dry thoroughly out in the sun.When dry, plug in the relays, towards the bottom of the socket as shown with the white contact area to the top.(there are two unused socket pins)
Plug in the fuse, and the microprocessor. |
Final test
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You are finished!
What you do next is up to your confidence level that you have completed the assembly correctly.
If you are a master solderer, and was careful to put all parts in the correct place and orientation, you could start your harness, joystick, or display construction.Not so confident? If you want me to fire up the board for the first time, calibrate it, and check all operations, then you will have to send it back to me, with a check for $50. I will first inspect the soldering under a stereo zoom microscope to look for any shaky, cold, or solder bridged connections, which I will repair. Next I will connect it to my Insight simulator test fixture where I will run the board through a through test procedure to confirm that it is operating properly. Finally, I will burn in the latest software, put the card in my car, and go for a short test ride. If all is well, I will pack it up, and send it right back to you. If I find any problems that cannot be repaired in 1/2 hour,I will contact you and discuss our options. |
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